BRAKE MASTER CYLINDER(for RHD) INSTALLATION

PROCEDURE

  1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Note:

    When installing a new brake master cylinder sub-assembly, remove the protectors from the master cylinder piston and outlet ports.

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

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

      20 N*m

      204 kgf*cm

      15 ft.*lbf

      Note:

      • The brake master cylinder sub-assembly requires careful handling. Do not allow the brake master cylinder sub-assembly to receive any impact, such as from being dropped. Do not reuse a brake master cylinder sub-assembly that has been dropped.

      • Do not hold the brake master cylinder sub-assembly by the master cylinder piston. Hold the brake master cylinder sub-assembly by its body or its reservoir when carrying it.

      • Do not pull out the master cylinder piston.

      • Do not strike or pinch the master cylinder piston, or cause any damage to the master cylinder piston by any other means.

      • When installing the brake master cylinder sub-assembly to the brake booster assembly, or when removing the brake master cylinder sub-assembly from the brake booster assembly, make sure that the brake master cylinder sub-assembly is kept horizontal or with its tip facing downward (the master cylinder piston is facing upward) to prevent the master cylinder piston from falling out.

      • Do not allow any foreign matter to contaminate the master cylinder piston. If any foreign matter gets on the master cylinder 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 master cylinder piston.

      • Do not kink or damage the brake lines.

      • Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

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

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

      w/o VSC

      15.2 N*m

      155 kgf*cm

      11 ft.*lbf

      w/ VSC

      19.5 N*m

      199 kgf*cm

      14 ft.*lbf

      Note:

      • Do not kink or damage the brake lines.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

        Click hereClick here

    4. Engage the clamp to secure the 2 brake lines to the No. 3 brake tube clamp.

    5. Connect the reservoir level switch connector.

  2. BLEED BRAKE SYSTEM

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  3. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1KR-FE)

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  4. INSTALL OUTER COWL TOP PANEL

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

      9.2 N*m

      94 kgf*cm

      81 in.*lbf

    2. Engage the 2 clamps to install the wire harness.

  5. INSTALL FRONT AIR SHUTTER SEAL RH

    1. Install the front air shutter seal RH with the 2 clips.

  6. INSTALL FRONT NO. 1 VENTILATOR SEAL

    1. Engage the clamp to install the front No. 1 ventilator seal.

  7. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY

    Tip:

    Use the same procedure as for LHD.

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