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. A00OMNSE01
      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. A00OIF4E01

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

      Torque:
      without VSC
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      with VSC
      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. A00ON2KE01

      Attach the clamp and connect the connector.

  2. CONNECT CLUTCH TUBE (for Manual Transaxle)


    1. A00OIPSE01

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

  3. REMOVE BRAKE ACTUATOR ASSEMBLY


    1. w/ VSC:

      Install the brake actuator assembly Click here.

    2. w/o VSC:

      Install the brake actuator assembly Click here.

  4. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for 1AZ-FE)


    1. A00DSK0

      Install the outer cowl top panel with the 9 bolts.

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

  5. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for 1ZR-FAE)

    A010HPX

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

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

  6. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for 2ZR-FAE)

    A010HPX

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

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

  7. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for 3ZR-FE)

    A010HPX

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

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

  8. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for 3ZR-FAE)

    A010HPX

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

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

  9. INSTALL WINDSHIELD WIPER MOTOR AND LINK


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

  10. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for 1AZ-FE)


    1. A00DS8Z

      Install the cover with the 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  11. INSTALL NO. 2 CYLINDER HEAD COVER (for 1ZR-FAE)


    1. A005W8Q

      Attach the 4 clips to install the cover.

      Note


      • Be sure to attach the clips securely.

      • Do not apply excessive force or hit the cover to attach the clips. This may cause the cover to break.

  12. INSTALL NO. 2 CYLINDER HEAD COVER (for 2ZR-FAE)


    1. A005W8Q

      Attach the 4 clips to install the cover.

      Note


      • Be sure to attach the clips securely.

      • Do not apply excessive force or hit the cover to attach the clips. This may cause the cover to break.

  13. INSTALL NO. 2 CYLINDER HEAD COVER (for 3ZR-FE)


    1. A005VFG

      Attach the 4 clips to install the cover.

      Note


      • Be sure to attach the clips securely.

      • Do not apply excessive force or hit the cover to attach the clips. This may cause the cover to break.

  14. INSTALL NO. 2 CYLINDER HEAD COVER (for 3ZR-FAE)


    1. A005W8Q

      Attach the 4 clips to install the cover.

      Note


      • Be sure to attach the clips securely.

      • Do not apply excessive force or hit the cover to attach the clips. This may cause the cover to break.

  15. FILL RESERVOIR WITH BRAKE FLUID


    1. Fill the reservoir with brake fluid.

      Brake Fluid
      SAE 1704 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.

  16. 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. A005UWXE01

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

    2. A005TEX

      Slowly depress the brake pedal and hold it.*1

    3. A005T8P

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

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

    5. A005UWXE01

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

      Torque:
      without VSC
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      with VSC
      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.

  17. 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.

  18. BLEED BRAKE ACTUATOR (w/ VSC)

    Note

    After bleeding the brake system, if the specified height or feel of the brake pedal cannot be obtained, bleed the brake actuator assembly with the intelligent tester by following the procedure below.


    1. Depress the brake pedal more than 20 times with the ignition switch off.

    2. Connect the intelligent tester to the DLC3.

    3. Turn the ignition switch to ON.

      Note

      Do not start the engine.

    4. Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Air Bleeding.

      Tech Tips

      Refer to the intelligent tester operator's manual for further details.

    5. Bleed the front right brake line.

      Note


      • Make sure that the master cylinder reservoir tank does not run out of brake fluid.

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


      1. Select "FR Line" on the intelligent tester.

      2. Depress the brake pedal and hold it.

        Note

        The actuator operation stops automatically in 4 seconds.

      3. Tighten the bleeder plug completely.

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

      4. Wait 20 seconds.

      5. Repeat the steps above until there are no more air bubbles in the fluid.

    6. Bleed the front left brake line.

      Note


      • Make sure that the master cylinder reservoir tank does not run out of brake fluid.

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


      1. Select "FL Line" on the intelligent tester.

      2. Depress the brake pedal and hold it.

        Note

        The actuator operation stops automatically in 4 seconds.

      3. Tighten the bleeder plug completely.

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

      4. Wait 20 seconds.

      5. Repeat the steps above until there are no more air bubbles in the fluid.

    7. Bleed the rear right brake line.

      Note


      • Make sure that the master cylinder reservoir tank does not run out of brake fluid.

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

      • The actuator operation stops automatically in 4 seconds.


      1. Select "RR Line" on the intelligent tester.

      2. Depress the brake pedal and hold it.

      3. Tighten the bleeder plug completely.

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

      4. Wait 20 seconds.

      5. Repeat the steps above until there are no more air bubbles in the fluid.

    8. Bleed the rear left brake line.

      Note


      • Make sure that the master cylinder reservoir tank does not run out of brake fluid.

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

      • The actuator operation stops automatically in 4 seconds.


      1. Select "RL Line" on the intelligent tester.

      2. Depress the brake pedal and hold it.

      3. Tighten the bleeder plug completely.

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

      4. Wait 20 seconds.

      5. Repeat the steps above until there are no more air bubbles in the fluid.

    9. Disconnect the intelligent tester from the DLC3.

    10. Clear the DTCs Click here.

  19. BLEED CLUTCH LINE (for EB60)

    A005SXJE01
    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 5 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 both of the previous 2 steps 6 times.

    6. Tighten the bleeder plug.

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

    7. Depress the clutch pedal 10 times or more and confirm its operation.

      Note

      This must be performed before the engine is started.

    8. Install the bleeder plug cap.

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

  20. BLEED CLUTCH LINE (for EC60)

    A005RU3E01
    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 5 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 both of the previous 2 steps 6 times.

    6. Tighten the bleeder plug.

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

    7. Depress the clutch pedal 10 times or more and confirm its operation.

      Note

      This must be performed before the engine is started.

    8. Install the bleeder plug cap.

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

  21. INSPECT FOR BRAKE FLUID LEAK

  22. 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