BRAKE MASTER CYLINDER(for LHD) 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. Install a new brake master cylinder O-ring to the brake master cylinder sub-assembly.

    2. B006PSHC01
      B006PCE Apply Grease

      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.

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

      Torque:
      12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }

      Note


      • The brake master cylinder sub-assembly requires careful handling. Do not drop or subject the brake master cylinder sub-assembly to any impact. Do not reuse a brake master cylinder sub-assembly that has been dropped.

      • 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, or 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 or interfere with other parts or the vehicle body during tightening.

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

      • Do not use any other type of grease or fluid.

    4. B006Q3WC01
      *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
      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 from the connecting parts.

      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 162 mm (6.38 in.)):

        17.36 N*m (177 kgf*cm, 13 ft.*lbf)

  2. CONNECT NO. 1 RESERVOIR TUBE


    1. Connect the No. 1 reservoir tube to the brake master cylinder sub-assembly and slide the clip to secure it.

    2. B006LEPC01
      *a Paint Mark

      Install the No. 1 reservoir tube to the hose clamp bracket.

      Note

      Install the No. 1 reservoir tube so that the paint mark on the No. 1 reservoir tube is positioned as shown in the illustration.

  3. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  4. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  5. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  6. INSTALL BATTERY

    Click here

  7. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. B006NZ8C01
      *1 Outer Cowl Top Panel Sub-assembly
      *a Outer Cowl Top Panel Sub-assembly Bracket
      *b Vehicle Body
      *c Align contact surfaces

      Install the outer cowl top panel sub-assembly to the vehicle body.

      Note


      • Make sure to fully insert the outer cowl top panel sub-assembly so that the outer cowl top panel sub-assembly fully contacts the vehicle body in the shaded area shown in the illustration.

      • Check that there are no gaps between the contact surfaces of the outer cowl top panel sub-assembly bracket and vehicle body.

    2. B006OL8N01

      Install the 10 bolts in the order shown in the illustration.

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

      Tech Tips

      Tighten the bolts of the same number in any order.

    3. B006OEC

      Engage the clamp to install the wire harness to the outer cowl top panel sub-assembly.

    4. B006PQK

      Engage the clamp to install the wire harness to the outer cowl top panel sub-assembly.

    5. B006PXON01

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

    6. w/ Wiper Deicer System:


      1. Engage the clamp (A) to install the wire harness to the outer cowl top panel sub-assembly.

      2. Connect the connector.

  8. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL


    1. Engage the 2 claws to install the No. 1 heater air duct splash shield seal to the outer cowl top panel sub-assembly.

  9. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL


    1. Engage the 2 claws to install the No. 2 heater air duct splash shield seal to the outer cowl top panel sub-assembly.

  10. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. Install the brake master cylinder reservoir assembly to the outer cowl top panel sub-assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. Connect the connector to the brake master cylinder reservoir assembly.

  11. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  12. INSPECT WASHER NOZZLE

    Click here

  13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  14. BLEED BRAKE SYSTEM

    Click here