BRAKE MASTER CYLINDER(for RHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Note

    When installing a new brake master cylinder sub-assembly, remove the protectors from the master cylinder piston and outlet ports.


    1. A012M2IC01
      *a More than 22 mm (0.866 in.)

      for Manual Transaxle:

      When installing a new brake master cylinder reservoir assembly or a new brake master cylinder sub-assembly, cut off the clutch tube tip of the brake master cylinder reservoir assembly as shown in the illustration.

      CAUTION:

      Be careful not to cut your finger on the cut surface.

      Note


      • Do not allow any foreign matter to enter the brake master cylinder reservoir assembly.

      • Make sure that fluid supply is not affected by cutting the tube.

    2. Install a new brake master cylinder O-ring to the brake master cylinder sub-assembly.

    3. Install the brake master cylinder sub-assembly to the brake booster assembly with the 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note


      • Do not hold the brake master cylinder sub-assembly by the master cylinder piston. Hold the brake master cylinder sub-assembly by its body or its reservoir when carrying it.

      • Do not pull out the master cylinder piston.

      • Do not strike or pinch the master cylinder piston and do not cause any damage to the master cylinder piston by any other means.

      • When installing the brake master cylinder sub-assembly to the brake booster assembly, or when removing the brake master cylinder sub-assembly from the brake booster assembly, make sure that the brake master cylinder sub-assembly is kept horizontal or with its tip facing downward (the master cylinder piston is facing upward) to prevent the master cylinder piston from falling out.

      • Do not allow any foreign matter to contaminate the master cylinder piston. If any foreign matter gets on the master cylinder piston, remove it by using a piece of cloth and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the master cylinder piston.

      • Do not kink or damage the brake lines.

      • Do not allow the brake lines to twist and interfere with other parts or vehicle body during tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines.

    4. Using a union nut wrench, connect the 2 brake lines to the brake master cylinder sub-assembly.

      Torque:
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note


      • Do not kink or damage the brake lines.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines.

      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

        Click here

    5. Connect the reservoir level switch connector and engage the clamp.

  2. CONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle)


    1. Connect the clutch reservoir tube to the brake master cylinder sub-assembly and slide the clip to secure it.

  3. BLEED BRAKE SYSTEM

    Click here

  4. BLEED CLUTCH LINE (for Manual Transaxle)

    for EC60: Click here

    for EC61: Click here

    for EC69: Click here

  5. INSTALL OUTER COWL TOP PANEL (for Sedan)


    1. Install the outer cowl top panel with the 11 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  6. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for Sedan)


    1. Engage the clamp to install the No. 2 heater air duct splash shield seal to the outer cowl top panel.

  7. INSTALL WATER GUARD PLATE LH (for Sedan)


    1. Engage the clamp to install the water guard plate LH to the outer cowl top panel.

  8. INSTALL OUTER COWL TOP PANEL (for Hatchback, Wagon)


    1. Install the outer cowl top panel with the 11 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  9. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for Hatchback, Wagon)


    1. Engage the clamp to install the No. 2 heater air duct splash shield seal to the outer cowl top panel.

  10. INSTALL WATER GUARD PLATE LH (for Hatchback, Wagon)


    1. Engage the clamp to install the water guard plate LH to the outer cowl top panel.

  11. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Tech Tips

    Use the same procedure as for LHD.

    Click here