BRAKE MASTER CYLINDER(for RHD) INSTALLATION

PROCEDURE


  1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

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  2. INSTALL BRAKE MASTER CYLINDER O-RING


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

  3. 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. B0076T0C09
      *1 Front No. 2 Brake Tube
      *a Claw

      Install the brake master cylinder sub-assembly and wire harness clamp bracket to the brake booster assembly with the 2 nuts.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

      Note


      • Install the wire harness clamp bracket so that its claw contacts the brake master cylinder sub-assembly securely.

      • The brake master cylinder sub-assembly requires careful handling. Do not subject the brake master cylinder sub-assembly to any impact, such as from being dropped. 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 new and dry cloth. Do not use water or detergent. 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 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.

      Tech Tips

      Install the brake master cylinder sub-assembly while avoiding the front No. 2 brake tube.

    2. B0075PEC04
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      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 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.

      Tech Tips


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

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      • 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)

    3. Connect the connector and engage the clamp to the brake master cylinder sub-assembly.

  4. INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the wiring harness clamp bracket with the bolt and nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  5. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK ASSEMBLY


    1. Engage the claw and clamp to install the No. 3 engine room relay block assembly to the wiring harness clamp bracket.

  6. BLEED BRAKE SYSTEM

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