BRAKE MASTER CYLINDER (for RHD) INSTALLATION


  1. INSTALL BRAKE BOOSTER GASKET


    1. Install a new brake booster gasket to the brake master cylinder bracket.

  2. INSTALL BRAKE MASTER CYLINDER BRACKET


    1. A01NEYV

      Install the brake master cylinder bracket to the body with the 4 nuts.

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

  3. INSTALL BRAKE STROKE SIMULATOR CYLINDER WITH BRACKET


    1. Install a new brake master cylinder gasket to the brake master cylinder bracket.

    2. Install the brake stroke simulator cylinder with bracket to the brake master cylinder bracket.

    3. A01NERG

      Using a union nut wrench, connect the No. 7 front brake tube to the brake stroke simulator cylinder sub-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.

    4. A01NF4G

      Connect the connector and engage the clamp.

  4. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. A01NEDI

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

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }
    2. A01NFCW

      Using a union nut wrench, connect the No. 6 front brake tube to the brake master cylinder sub-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.

  5. INSTALL BRAKE STROKE SIMULATOR TUBE


    1. A01NGPK

      Using a union nut wrench, tighten the 2 union nuts to install the brake stroke simulator tube to the brake master cylinder sub-assembly and brake stroke simulator cylinder sub-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.

  6. CONNECT MASTER CYLINDER PUSH ROD CLEVIS


    1. A01NCWHE01

      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.

  7. INSTALL BRAKE PEDAL RETURN SPRING


    1. A01NFGS

      Install the brake pedal return spring between the brake pedal support sub-assembly and push rod pin.

  8. CONNECT NO. 1 RESERVOIR HOSE


    1. A01NHJX

      Connect the No. 1 reservoir hose to the brake master cylinder sub-assembly with the clips.

  9. CONNECT NO. 2 RESERVOIR HOSE


    1. A01NFR6

      Connect the No. 2 reservoir hose to the brake master cylinder sub-assembly with the clips.

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  11. 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. A01NDJP

      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.

  12. BLEED BRAKE MASTER CYLINDER


    1. Bleed brake master cylinder.


      1. A01NHJO

        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.

  13. INSPECT AND ADJUST BRAKE PEDAL

    Tech Tips

    Click here

  14. CHECK BRAKE MASTER CYLINDER WITH INTELLIGENT TESTER


    1. Check the brake master cylinder and stroke simulator Click here.

  15. CHECK MASTER CYLINDER PRESSURE SENSOR SIGNAL


    1. Check the pressure sensor signal Click here.

  16. CHECK FOR DTC


    1. Check for DTCs. If any DTC is output, perform the troubleshooting for that DTC Click here.

  17. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY


    1. Engage each clamp.

    2. Connect each connector.

    3. A01NHAW

      Engage the claw and 2 guides.

    4. A01NF7E

      Install the No. 1 instrument panel under cover sub- assembly with the 2 screws <D>.

  18. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A01NF0QE01

      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. A01NDEN

      Engage the grommet.

    3. Connect the connector (w/ Windshield Deicer).

  19. INSTALL FRONT SHOCK ABSORBER CAP LH (w/ Air Suspension)


    1. A01NHTO

      Install the front shock absorber cap with the 3 nuts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  20. INSTALL FRONT SHOCK ABSORBER CAP RH (w/ Air Suspension)

    Tech Tips

    Use the same procedure for the LH side and RH side.

  21. 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.

  22. INSTALL REAR DECK FLOOR BOX


    1. A01NDSY

      Install the rear deck floor box with the 3 clips.