BRAKE MASTER CYLINDER(for RHD) INSTALLATION

PROCEDURE


  1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

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  2. INSTALL BRAKE MASTER CYLINDER O-RING


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

  3. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY WITH WAY

    Note

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


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

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

      Note


      • The brake master cylinder sub-assembly requires careful handling. Do not drop or subject the brake master cylinder sub-assembly to any impact. 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 new and dry cloth. Do not use water or detergent. Then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the master cylinder piston.

      • Do not use any other types of grease.

      • 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.

    2. B005LRUC02
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

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

      Torque:
      Specified tightening torque
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note


      • 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.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        17.36 N*m (177 kgf*cm, 13 ft.*lbf)

  4. INSTALL RESERVOIR BRACKET


    1. Install the reservoir bracket with the 2 nuts.

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

    2. Engage the clamp to install the wire harness to the reservoir bracket.

  5. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. B005QA3C02
      *1 Brake Master Cylinder Reservoir Assembly
      *2 Reservoir Bracket

      Move the brake master cylinder reservoir assembly as shown in the illustration to engage the 2 claws.

    2. Connect the reservoir level switch connector and install the bolt.

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

  6. CONNECT NO. 1 RESERVOIR HOSE


    1. Connect the No. 1 reservoir hose to the brake master cylinder sub-assembly, and slide the clip to secure it.

  7. BLEED BRAKE SYSTEM

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  8. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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  9. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY

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