BRAKE MASTER CYLINDER (for LHD) INSTALLATION

INSTALL BRAKE BOOSTER GASKET
1. Install a new brake booster gasket to the brake master with simulator cylinder assembly.

INSTALL BRAKE MASTER WITH SIMULATOR CYLINDER ASSEMBLY

Install the brake master with simulator cylinder assembly with the 4 nuts.

Torque:

13 N*m { 130 kgf*cm, 9 ft.*lbf }

Text in Illustration
*1	No. 6 Front Brake Tube
*2	No. 7 Front Brake Tube

Using a union nut wrench, connect the No. 6 front brake tube and No. 7 front brake tube to the brake master with simulator cylinder assembly.

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

Note

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

Engage the clamp and connect the connector.

CONNECT MASTER CYLINDER PUSH ROD CLEVIS
1. Apply lithium soap base glycol grease to the push rod pin.
2. Connect the master cylinder push rod clevis to the brake pedal with the push rod pin, and install a new clip as shown in the illustration.
INSTALL BRAKE PEDAL RETURN SPRING
1. Install the brake pedal return spring between the brake pedal support sub-assembly and push rod pin.
CONNECT NO. 2 RESERVOIR HOSE
1. Connect the No. 2 reservoir hose to the brake master cylinder sub-assembly with the clips.
CONNECT NO. 1 RESERVOIR HOSE
1. Connect the No. 1 reservoir hose to the brake master cylinder sub-assembly with the clips.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
CONNECT BRAKE BOOSTER PUMP CONNECTOR
1. Add brake fluid into the reservoir between MAX and MIN line on the brake fluid reservoir.
  
  Brake fluid
  
  SAE J1703 or FMVSS No. 116 DOT3
2. With the power switch off, connect the 2 brake booster pump connectors.
3. Turn the power switch on (IG) and check that the brake booster pump motor operates and stops.
4. Turn the power switch off.
BLEED BRAKE MASTER CYLINDER
1. Bleed brake master cylinder.
  1. Remove the brake master cylinder reservoir filler cap assembly.
  2. Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.
    
    Brake fluid
    
    SAE J1703 or FMVSS No. 116 DOT3
  3. Connect the intelligent tester to the DLC3 and turn the power switch on (IG).
  4. Turn the intelligent tester on and enter the following menus: Chassis / ABS/VSC/TRC / Utility / Air Bleeding.
  5. Select the "Master Cylinder or Stroke Simulator has been removed" and bleed brake master cylinder according to the intelligent tester display.
  6. After air bleeding, tighten each bleeder plug.
    
    Torque:
    
    front bleeder plug
    
    8.3 N*m { 85 kgf*cm, 73 in.*lbf }
    
    rear bleeder plug
    
    11 N*m { 110 kgf*cm, 8 ft.*lbf }
2. Clear the DTCs Click here.
3. Turn the intelligent tester off and turn the power switch off.
4. Inspect for brake fluid leaks.
5. Adjust the brake fluid level in the reservoir Click here.
INSPECT AND ADJUST BRAKE PEDAL

Tech Tips

Click here
CHECK BRAKE MASTER CYLINDER WITH INTELLIGENT TESTER
1. Check the brake master cylinder and stroke simulator Click here.
INSPECT MASTER CYLINDER PRESSURE SENSOR SIGNAL
1. Check the pressure sensor signal Click here.
CHECK FOR DTC
1. Check for DTCs. If any DTC is output, perform troubleshooting for that DTC Click here.
INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
1. Engage each clamp.
2. Connect each connector.
3. Engage the claw and 2 guides.
4. Install the No. 1 instrument panel under cover sub- assembly with the 2 screws <D>.
INSTALL AIR CLEANER ASSEMBLY WITH HOSE
1. Install the air cleaner assembly with hose with the 2 bolts.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
2. Install the air cleaner hose with the band.
3. Install the No. 1 fuel vapor feed hose to the air cleaner hose.
4. Connect the air flow meter connector and harness clamp.
INSTALL NO. 1 AIR CLEANER INLET
1. Install the inlet No. 1 air cleaner with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Connect the No. 1 fuel vapor feed hose to the clamp.
INSTALL NO. 2 AIR CLEANER INLET
1. Install the inlet No. 2 air cleaner with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY
1. Install the intake air resonator sub-assembly with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Connect the 3 water hose clamps to the intake air resonator sub-assembly.
INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY
1. Install the outer cowl top panel sub-assembly with the 4 bolts, 4 nuts*1 and 2 nuts*2.
  
  Torque:
  
  Nut*1
  
  85 N*m { 867 kgf*cm, 63 ft.*lbf }
  
  Nut*2
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
  
  Bolt
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
2. Engage the grommet and clamp.
3. Connect the connector (w/ Windshield Deicer).
INSTALL FRONT SHOCK ABSORBER CAP LH (w/ Air Suspension)
1. Install the front shock absorber cap with the 3 nuts.
  
  Torque:
  
  14 N*m { 143 kgf*cm, 10 ft.*lbf }
INSTALL FRONT SHOCK ABSORBER CAP RH (w/ Air Suspension)

Tech Tips

Use the same procedure for the LH side and RH side.
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Tech Tips

Refer to the instructions for Installation of the windshield wiper motor and link assembly Click here.
INSTALL REAR DECK FLOOR BOX
1. Install the rear deck floor box with the 3 clips.