BRAKE MASTER CYLINDER INSTALLATION


  1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY


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

    2. A00OU32E01
      Text in Illustration
      *1 Piston

      Install the brake master cylinder with the 2 nuts.

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

      Note


      • The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.

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

      • Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the 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 piston.

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

    3. A00OV3FE01

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

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

      Note

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

    4. A00OVUYE01

      Attach the clamp and connect the connector.

  2. CONNECT CLUTCH TUBE


    1. A00OR4SE01

      Connect the clutch tube to the brake master cylinder reservoir assembly with the clip.

  3. INSTALL BRAKE ACTUATOR ASSEMBLY (for LHD)


    1. Install the brake actuator assembly Click here.

  4. INSTALL INNER COWL TOP PANEL SUB-ASSEMBLY (for 1AD-FTV)


    1. Install the outer cowl top panel with the 9 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

    2. Attach the clamp and connect the connector.

  5. INSTALL INNER COWL TOP PANEL SUB-ASSEMBLY (for 2AD-FHV)


    1. Install the outer cowl top panel with the 9 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

    2. Attach the clamp and connect the connector.

  6. INSTALL INNER COWL TOP PANEL SUB-ASSEMBLY (for 2AD-FTV)


    1. Install the outer cowl top panel with the 9 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

    2. Attach the clamp and connect the connector.

  7. INSTALL WINDSHIELD WIPER MOTOR AND LINK


    1. Install the windshield wiper motor and link Click here.

  8. INSTALL FUEL FILTER ELEMENT ASSEMBLY


    1. for 1AD-FTV:

      Install the fuel filter element assembly Click here.

    2. for 2AD-FHV:

      Install the fuel filter element assembly Click here.

    3. for 2AD-FTV:

      Install the fuel filter element assembly Click here.

  9. FILL RESERVOIR WITH BRAKE FLUID


    1. Fill the reservoir with brake fluid.

      Brake Fluid
      SAE J1704 or FMVSS No. 116 DOT 4

      Note

      Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

  10. BLEED BRAKE MASTER CYLINDER

    Note


    • If the master cylinder is reinstalled or if the reservoir becomes empty, bleed the master cylinder.

    • To prevent brake fluid from damaging painted surfaces, cover any surrounding parts with a piece of cloth.


    1. A00OV3FE01

      Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.

    2. A00OQDUE01

      Slowly depress the brake pedal and hold it.*1

    3. A00OVHRE01

      Cover the 2 outer holes with fingers and release the brake pedal.*2

    4. Repeat *1 and *2 3 or 4 times.

    5. A00OV3FE01

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

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

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

  11. BLEED BRAKE LINE

    Note


    • Bleed the brake line of the wheel farthest from the master cylinder first.

    • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


    1. Connect a vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1

    3. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2

    4. Repeat *1 and *2 until all the air in the fluid is completely bled out.

    5. Tighten the bleeder plug completely.

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

    6. Repeat the above procedure for each wheel to bleed the brake line.

  12. BLEED CLUTCH LINE (for 1AD-FTV)

    A003B3WE01
    Text in Illustration
    *1 Bleeder Plug Cap
    *2 Bleeder Plug

    1. Remove the bleeder plug cap.

    2. Connect a vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

    4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled.

    6. Tighten the bleeder plug.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled from the clutch line.

  13. BLEED CLUTCH LINE (for 2AD-FHV)

    A003B3WE01
    Text in Illustration
    *1 Bleeder Plug Cap
    *2 Bleeder Plug

    1. Remove the bleeder plug cap.

    2. Connect a vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

    4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled.

    6. Tighten the bleeder plug.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled from the clutch line.

  14. BLEED CLUTCH LINE (for 2AD-FTV)

    A003B3WE01
    Text in Illustration
    *1 Bleeder Plug Cap
    *2 Bleeder Plug

    1. Remove the bleeder plug cap.

    2. Connect a vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

    4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled.

    6. Tighten the bleeder plug.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled from the clutch line.

  15. INSPECT FOR BRAKE FLUID LEAK

  16. INSPECT BRAKE FLUID LEVEL IN RESERVOIR


    1. A010LQYE01

      Check the fluid level.

      If the brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Brake Fluid
      SAE J1704 or FMVSS No. 116 DOT 4