BRAKE MASTER CYLINDER(w/o ABS) INSTALLATION

PROCEDURE


  1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

    Click here

  2. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (for 1TR-FE, 2TR-FE)

    Note


    • The master cylinder and piston are designed so that the piston can easily fall out. Prevent this by making sure the tip of the master cylinder points downward when handling the master cylinder.

    • Make sure foreign matter does not adhere to the piston of the master cylinder. If foreign matter adheres, clean it off with a cloth. Then apply lithium soap base glycol grease to the entire outer circumference contact surface area of the piston.


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

    2. Install the brake master cylinder sub-assembly, brake booster tube clamp bracket (with 4-way) and reservoir hose bracket to the brake booster assembly with the 3 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    3. Install the booster vacuum tube to the brake booster tube clamp bracket with the bolt.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }
    4. B0068F6C03
      *a Torque Wrench Fulcrum Length

      Using a union nut wrench, connect the 6 brake lines to the brake master cylinder and 4-way.

      Torque:
      Specified tightening torque
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      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 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

      Note


      • Do not damage or deform the brake lines.

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

    5. Connect the brake fluid level warning switch connector to the brake master cylinder sub-assembly.

    6. Connect the clutch reservoir tube, and slide the clamp to secure it.

  3. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (for 2KD-FTV)

    Note


    • The master cylinder and piston are designed so that the piston can easily fall out. Prevent this by making sure the tip of the master cylinder points downward when handling the master cylinder.

    • Make sure foreign matter does not adhere to the piston of the master cylinder. If foreign matter adheres, clean it off with a cloth. Then apply lithium soap base glycol grease to the entire outer circumference contact surface area of the piston.


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

    2. Install the brake master cylinder sub-assembly and brake booster tube clamp bracket (with 4-way) to the brake booster assembly with the 2 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    3. B0068F6C03
      *a Wrench Fulcrum Length

      Using a union nut wrench, connect the 6 brake lines to the brake master cylinder and 4-way.

      Torque:
      Specified tightening torque
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      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 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

      Note


      • Do not damage or deform the brake lines.

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

    4. Connect the brake fluid level warning switch connector to the brake master cylinder sub-assembly.

    5. Connect the clutch reservoir tube, and slide the clamp to secure it.

  4. BLEED BRAKE SYSTEM

    Click here

  5. BLEED CLUTCH LINE

    Click here