BRAKE MASTER CYLINDER (w/ VSC) INSTALLATION


  1. CHECK AND ADJUST BRAKE BOOSTER PUSH ROD

    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. A01DUXNE05

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

      SST
      09737-00013

      Tech Tips

      SST 09797-00012 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. A01DVX6E01

      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


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

    2. A01DZ73E01

      Install the master cylinder and brake tube way to the booster with the 2 nuts.

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

    3. Using a union nut wrench, connect the 4 brake lines to the brake master cylinder and brake tube way.

      A01DYISE01
      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 to the master cylinder.

    5. for Manual Transmission:

      Connect the clutch reservoir tube to the master cylinder reservoir.

  3. FILL RESERVOIR WITH BRAKE FLUID

    Fluid
    Item Specified Condition
    except TSAM Made SAE J1703 or FMVSS No. 116 DOT 3
    for TSAM Made SAE J1704 or FMVSS No. 116 DOT 4

  4. 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. A01DYWH

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

    2. Slowly depress and hold the brake pedal.

    3. A01DXKZ

      Block the tube holes with your fingers, and then release the brake pedal.

    4. Remove the your fingers, slowly depress and hold the brake pedal, block the tube holes with your fingers again, and then release the brake pedal. Repeat this step 3 or 4 times.

    5. Using a union nut wrench, connect the 2 brake tubes to the brake 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.

  5. BLEED AIR FROM BRAKE LINE


    1. Remove the bleeder plug cap.

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

    7. Install the cap.

    8. A01E31B

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

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

    A01E1RYE01

    1. Remove the bleeder plug cap.

    2. Connect the vinyl tube to the bleeder plug.

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

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

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

    6. Tighten the bleeder plug.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    7. Install the bleeder plug cap.

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

  7. CHECK BRAKE FLUID LEVEL IN RESERVOIR


    1. A01E2XS

      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.

      Fluid
      Item Specified Condition
      except TSAM Made SAE J1703 or FMVSS No. 116 DOT 3
      for TSAM Made SAE J1704 or FMVSS No. 116 DOT 4

  8. CHECK FOR BRAKE FLUID LEAKAGE

  9. CHECK SRS WARNING LIGHT


    1. w/ Airbag System:

      Check the SRS warning light Click here.