BRAKE MASTER CYLINDER INSTALLATION


  1. CHECK AND ADJUST BRAKE BOOSTER PUSH ROD

    Note

    The brake booster interior must not be a vacuum when adjusting the booster. Stop the engine and depress the brake pedal several times until there is no vacuum in the booster.

    Tech Tips

    Adjust the booster push rod when the master cylinder is replaced with a new one. Adjustment is not necessary when the master cylinder is reinstalled and the booster is replaced with a new one.


    1. A01J5OEE05

      Set SST on the master cylinder and lower the rod of SST until it just touches the piston.

      SST
      09737-00013

      Tech Tips

      SST 09737-00012 can also be used.

    2. Apply chalk to the flat tip of the rod of SST. Turn SST upside down and measure the clearance between the brake booster push rod and SST.

      Standard clearance
      0 mm (0 in.)

      If there is clearance between the main body of SST and the shell of the brake booster, the push rod is protruding too far. If the chalk does not stick to the tip of the brake booster push rod, the push rod protrusion is insufficient.

    3. A01J690E01

      If the clearance is not as specified, adjust the length by holding the rod using SST and turning the tip of the rod using a 7 mm socket driver.

      SST
      09737-00020

      Note

      Check the push rod clearance again after adjustment.

  2. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (w/o ABS)


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

    2. A01J4OR

      Install the master cylinder and bracket (with 4-way) to the booster with the 2 nuts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }
    3. A01J7AGE01

      Using a union nut wrench, connect the 6 brake lines labeled C to the brake master cylinder and 4-way.

      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.

    4. Connect the brake fluid level warning switch connector labeled B to the master cylinder.

    5. for Manual Transmission:

      Connect the clutch reservoir tube labeled A to the master cylinder.

  3. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (w/ ABS)


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

    2. A01J3RO

      Install the master cylinder and bracket (with 3-way) to the booster with the 2 nuts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }
    3. A01J5YNE01

      Using a union nut wrench, connect the 5 brake lines labeled C to the master cylinder and 3-way.

      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.

    4. Connect the brake fluid level warning switch connector labeled B to the master cylinder.

    5. for Manual transmission:

      Connect the clutch reservoir tube labeled A to the master cylinder.

  4. FILL RESERVOIR WITH BRAKE FLUID

    Fluid
    SAE J1703 or FMVSS No. 116 DOT3

  5. BLEED AIR FROM BRAKE MASTER CYLINDER

    Tech Tips

    If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.


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

    2. A01J701

      Slowly depress and hold the brake pedal.

    3. A01J5GH

      Cover the outer holes with your fingers, and release the pedal.

    4. Repeat the 2 previous steps 3 or 4 times.

    5. 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.

  6. BLEED AIR FROM BRAKE LINE

    A01J3W6

    1. Remove the bleeder plug cap.

    2. Connect the vinyl tube to the bleeder plugs.

    3. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.

    4. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

    5. Repeat the 2 previous steps until all the air in the brake fluid is gone.

    6. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf, for front brake }
      10 N*m  { 102 kgf*cm, 7 ft.*lbf, for rear brake }

    7. Install the cap.

    8. Bleed air from the brake line for each wheel by repeating the above procedures.

  7. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)


    1. Remove the brake master cylinder reservoir filler cap assembly.

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

      Fluid
      SAE J1703 or FMVSS No. 116 DOT3

    3. Remove the bleeder plug cap.

    4. A01J7CPE07

      Connect a vinyl tube to the bleeder plug.

    5. Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

    6. At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

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

    8. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    9. Install the bleeder plug cap.

    10. Check that all the air has been bled out of the clutch line.

    11. Check for brake fluid leaks.

    12. Check the brake fluid level in the reservoir Click here.

    13. Install the brake master cylinder reservoir filler cap assembly.

  8. CHECK BRAKE FLUID LEVEL IN RESERVOIR

    A01J74F

    1. Check the fluid level and add fluid if necessary.

      Fluid
      SAE J1703 or FMVSS No. 116 DOT3

      Tech Tips

      Add fluid to a level between the reservoir's MIN and MAX lines.

  9. CHECK FOR BRAKE FLUID LEAKAGE