BRAKE MASTER CYLINDER(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. Install the brake master cylinder sub-assembly to the brake stroke simulator cylinder sub-assembly.

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  2. INSTALL BRAKE STROKE SIMULATOR TUBE

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  3. INSTALL BRAKE BOOSTER GASKET


    1. Install a new brake booster gasket to the brake master with stroke simulator cylinder assembly.

  4. INSTALL BRAKE MASTER WITH STROKE SIMULATOR CYLINDER ASSEMBLY


    1. Set the brake master with stroke simulator cylinder assembly, No. 1 brake actuator tube and No. 2 brake actuator tube to the installation position.

      Note

      Do not kink or damage the brake lines.

    2. Install the brake master with stroke simulator cylinder assembly with the 4 nuts.

      Torque:
      12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }
    3. B004F3NC02
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Using a union nut wrench, connect the No. 1 brake actuator tube and No. 2 brake actuator tube to the brake master cylinder sub-assembly and brake stroke simulator cylinder sub-assembly.

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

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      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        13.38 N*m (136 kgf*cm, 10 ft.*lbf)

    4. Connect the connector to the brake master cylinder sub-assembly.

    5. B004G70C01
      *a Stopper

      Install the wire harness clamp bracket to the brake stroke simulator cylinder sub-assembly with the bolt.

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

    6. Engage the wire harness clamp to the wire harness clamp bracket.

      Note

      Securely install the wire harness clamp bracket so that its stopper contacts the brake stroke simulator cylinder sub-assembly as shown in the illustration.

  5. 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.

  6. INSTALL PUSH ROD PIN

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  7. INSTALL BRAKE PEDAL RETURN SPRING


    1. Install the brake pedal return spring to the push rod pin and steering column assembly.

  8. INSTALL BRAKE ACTUATOR WITH BRACKET

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  9. CONNECT NO. 1 RESERVOIR HOSE

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  10. INSTALL SKID CONTROL ECU BRACKET ASSEMBLY

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  11. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK

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  12. INSTALL SKID CONTROL ECU ASSEMBLY

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  13. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

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  14. BLEED BRAKE SYSTEM

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  15. INSTALL FRONT WHEEL LH

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  16. INSPECT AND ADJUST BRAKE PEDAL

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