BRAKE MASTER CYLINDER (for RHD) INSTALLATION


  1. INSTALL BRAKE MASTER CYLINDER O-RING


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

  2. 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. B000LPD

      Apply a light layer of a grease enclosed with a new brake master cylinder sub-assembly or lithium soap base glycol grease to the circumference of the brake master cylinder sub-assembly and inner surface of the brake booster assembly as shown in the illustration.

      Text in Illustration
      B000I6M Apply Grease
    2. B000N02E01
      Text in Illustration
      *1 Master Cylinder Piston

      Install the brake master cylinder sub-assembly and vacuum check valve bracket to the brake booster assembly with the 2 nuts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 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 its tip faces downward (the master cylinder piston faces 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 use any other types of grease.

      • Do not kink or damage the brake lines.

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

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

    3. B000HATE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

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

      Torque:
      Specified tightening torque
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note


      • Do not kink or damage the brake lines.

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

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

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 250 mm (9.84 in.)):

        18 N*m (184 kgf*cm, 13 ft.*lbf)

    4. Connect the reservoir level switch connector.

  3. BLEED BRAKE SYSTEM

    Click here

  4. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. Install the front outer cowl top panel sub-assembly with the 10 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.

  5. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here