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. A005ODJC01
      *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. Using a 13 mm deep socket wrench, install the brake master cylinder sub-assembly to the brake booster assembly with a new nut.

      Torque:
      20 N*m  { 204 kgf*cm, 15 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 brake master cylinder reservoir assembly 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 use any other type of grease or fluid.

      • Make sure to release vacuum from the brake booster assembly before removing the brake master cylinder sub-assembly from the brake booster assembly.

    4. Using a 13 mm deep socket wrench, install the wire harness bracket to the brake master cylinder sub- assembly with a new nut.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    5. A005OHGC01
      *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.)): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

    6. 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. INSTALL BATTERY

    Click here

  4. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  5. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

    Click here

  6. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  7. INSTALL WATER GUARD PLATE LH

    Click here

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

    Click here

  9. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  10. BLEED BRAKE SYSTEM

    Click here

  11. BLEED CLUTCH LINE (for Manual Transaxle)