BRAKE MASTER CYLINDER (for RHD) INSTALLATION


  1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

    Note

    Make an adjustment with no vacuum in the brake booster assembly. (Depress the brake pedal several times with the engine stopped.)

    Tech Tips


    • Adjustment of the brake booster push rod is required when the brake master cylinder sub-assembly is replaced with a new one.


    • Adjustment is not necessary when the removed brake master cylinder sub-assembly is reused and the brake booster assembly is replaced with a new one.


    1. Apply chalk to the tip of an accessory tool.

      Tech Tips

      The accessory tool is enclosed with a new brake master cylinder sub-assembly.

    2. A019LJRE05
      Text in Illustration
      *1 Accessory Tool

      Place the accessory tool on the brake booster assembly.

    3. Measure the clearance between the brake booster push rod and accessory tool.

      Standard clearance
      0 mm (0 in.)

      Tech Tips

      Adjust the clearance in the following cases:


      • If there is a clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the push rod is protruding too far.

      • If the chalk does not stick on the tip of the brake booster push rod, the push rod protrusion is insufficient.

    4. A019MK3E01

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

      SST
      09737-00020

      Tech Tips

      Check the push rod clearance again after adjustment.

  2. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY


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

    2. A019JRE

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

      Torque:
      13 N*m  { 127 kgf*cm, 9 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 its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling out.

      • Do not allow any foreign matter to contaminate the master cylinder piston. If foreign matter gets on the piston, remove it by using a piece of cloth and then apply an even layer of lithium soap based glycol grease around the circumference (sliding part) of the piston.

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

  3. CONNECT BRAKE LINE


    1. A019L7T

      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 the union nut wrench is combined with a torque wrench Click here.

  4. CONNECT NO. 1 RESERVOIR TUBE


    1. A019OLH

      Connect the No. 1 reservoir tube to the brake master cylinder reservoir sub-assembly.

  5. BLEED BRAKE SYSTEM

    Click here

  6. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A019OF3E01

      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. A019N0P

      Engage the grommet and clamp to install the wire harness.

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

  7. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here