BRAKE MASTER CYLINDER INSTALLATION

PROCEDURE

  1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

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

    2. C204970E01

      Install the brake master cylinder with the 2 new nuts.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

      Table 1. Text in Illustration

      *1

      Piston
      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. C200652E02

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

      20 N*m

      199 kgf*cm

      14 ft.*lbf

      Table 2. Text in Illustration

      *A

      for LHD

      *B

      for RHD
      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. C200635E02

      Attach the clamp and connect the connector.

      Table 3. Text in Illustration

      *A

      for LHD

      *B

      for RHD

  2. CONNECT CLUTCH TUBE (for Manual Transaxle)

    1. C200634E02

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

      Table 4. Text in Illustration

      *A

      for LHD

      *B

      for RHD

  3. INSTALL BRAKE ACTUATOR ASSEMBLY

    1. Install the brake actuator sub-assembly (Click here).

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

    Click here

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

    Click here

  6. INSTALL OUTER COWL TOP PANEL (for 1WW)

    Click here

  7. INSTALL WINDSHIELD WIPER MOTOR AND LINK

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

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

    Click here

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

    Click here

  10. INSTALL FUEL FILTER ELEMENT ASSEMBLY (for 1WW)

    1. Install the fuel filter element assembly (Click hereClick here).

  11. REMOVE CENTER COWL TOP VENTILATOR LOUVER

    Click here

  12. BLEED BRAKE SYSTEM

    Click here

  13. BLEED AIR FROM CLUTCH LINE (for 1ZR-FAE with Manual Transaxle)

    Click here

  14. BLEED AIR FROM CLUTCH LINE (for 2ZR-FAE with Manual Transaxle)

    Click here

  15. BLEED CLUTCH LINE (for 1WW)

    Click here

  16. INSTALL CENTER COWL TOP VENTILATOR LOUVER

    Click here