BRAKE MASTER CYLINDER (for LHD) > INSTALLATION

for Preparation Click here



1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

NOTICE:
Make the adjustment with no vacuum in the brake booster assembly. (Depress the brake pedal several times with the engine stopped.)

HINT:
  1. Adjustment of the brake booster push rod is required when the brake master cylinder sub-assembly is replaced with a new one.
  1. Adjustment is not necessary when the removed brake master cylinder sub-assembly is reused and the brake booster assembly is replaced with a new one.

  1. Apply chalk to the tip of the accessory tool.

    HINT:
    An accessory tool is enclosed with a new brake master cylinder sub-assembly.



    C132707E03

  1. Place the accessory tool on the brake booster assembly.
    Text in Illustration 
    *1
    		Accessory Tool

  1. Measure the clearance between the brake booster push rod and accessory tool.

    Standard clearance:
    0 mm (0 in.)

    HINT:
    Adjust the clearance in the following cases:

    1. If there is a clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the push rod is protruding too far.
    2. If the chalk does not stick on the tip of the brake booster push rod, the push rod protrusion is insufficient.



    C132720E01

  1. If the clearance is not as specified, adjust the push rod length by holding the rod using SST and turning the tip of the rod using a socket driver (7 mm).

    SST
    09737-00020  

    HINT:
    Check the push rod clearance again after adjustment.



2. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (w/o Stop and Start System)

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

  1. Install the brake master cylinder sub-assembly onto the brake booster.

    NOTICE:
    1. 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.
    2. Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.
    3. 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 its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling off.
    4. 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.
    5. Do not use any other type of grease or fluid.



    C199747

  1. Install the 2 nuts.

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



    C199745

  1. Using a union nut wrench (12 mm), connect the 2 brake tubes to the brake master cylinder sub-assembly.

    Torque:
    20 N*m{ 200 kgf*cm , 14 ft.*lbf }

    NOTICE:
    Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).



    C199744

  1. Engage the clamp and connect the brake fluid level warning switch connector.



3. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (w/ Stop and Start System)

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

  1. Install the brake master cylinder sub-assembly onto the brake booster.

    NOTICE:
    1. 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.
    2. Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.
    3. 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 its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling off.
    4. 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.
    5. Do not use any other type of grease or fluid.



    C211977

  1. Install the 2 nuts and vacuum sensor assembly.

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



    C211976

  1. Connect the vacuum hose.

  1. Engage the clamp to install the vacuum sensor wire harness to the brake master cylinder sub-assembly.



    C211975

  1. Using a union nut wrench (12 mm), connect the 2 brake tubes to the brake master cylinder sub-assembly.

    Torque:
    20 N*m{ 200 kgf*cm , 14 ft.*lbf }

    NOTICE:
    Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).



    C211974

  1. Engage the clamp and connect the brake fluid level warning switch connector and vacuum sensor wire connector.



4. CONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle)


    C199743

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



5. INSTALL FUEL FILTER ASSEMBLY (for 1ND-TV)


    A202865

  1. Install the fuel filter with the 2 nuts.

    Torque:
    19 N*m{ 189 kgf*cm , 14 ft.*lbf }



    A202864

  1. Connect the 2 fuel hose clamps to the fuel filter.

  1. Connect the 2 fuel hoses to the fuel filter.



    A202202

  1. Connect the 2 connectors.



    A202203

  1. Connect the 2 wire harness clamps.

  1. Connect the connector.



6. INSTALL BATTERY (for 1ND-TV)


7. INSTALL BATTERY CLAMP SUB-ASSEMBLY


A198368

  1. Install the battery clamp with the 2 nuts.

    Torque:
    3.5 N*m{ 36 kgf*cm , 31 in.*lbf }



8. FILL RESERVOIR WITH BRAKE FLUID


    C197231E02

  1. Fill the reservoir with brake fluid.
    Text in Illustration 
    *1
    		MAX Line
    *2
    		MIN Line

    Brake Fluid:
    SAE J1703 or FMVSS No. 116 DOT 3

    NOTICE:
    Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.



9. BLEED CLUTCH LINE (for EE65)


C195376E01

HINT:
In case of clutch fluid replacement, make sure that the old fluid is replaced in the clutch line between the reservoir and the bleeder before bleeding.

Text in Illustration 
*1
Bleeder plug cap
*2
Bleeder plug

  1. Remove the bleeder plug cap.

  1. Connect a vinyl tube to the bleeder plug.

  1. Depress the clutch pedal 5 times, and then loosen the bleeder plug while the pedal is depressed.

  1. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

  1. Repeat both of the previous 2 steps 6 times.

  1. Tighten the bleeder plug.

    Torque:
    8.4 N*m{ 86 kgf*cm , 74 in.*lbf }

  1. Depress the clutch pedal 10 times or more and confirm its operation.

    NOTICE:
    This must be performed before the engine is started.

  1. Install the bleeder plug cap.

  1. Check that all the air has been bled from the clutch line.



10. BLEED CLUTCH LINE (for EE53)


C195376E01

HINT:
In case of clutch fluid replacement, make sure that the old fluid is replaced in the clutch line between the reservoir and the bleeder before bleeding.

Text in Illustration 
*1
Bleeder plug cap
*2
Bleeder plug

  1. Remove the bleeder plug cap.

  1. Connect a vinyl tube to the bleeder plug.

  1. Depress the clutch pedal 5 times, and then loosen the bleeder plug while the pedal is depressed.

  1. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

  1. Repeat both of the previous 2 steps 6 times.

  1. Tighten the bleeder plug.

    Torque:
    8.4 N*m{ 86 kgf*cm , 74 in.*lbf }

  1. Depress the clutch pedal 10 times or more and confirm its operation.

    NOTICE:
    This must be performed before the engine is started.

  1. Install the bleeder plug cap.

  1. Check that all the air has been bled from the clutch line.



11. BLEED CLUTCH LINE (for EE63)


C195376E01

HINT:
In case of clutch fluid replacement, make sure that the old fluid is replaced in the clutch line between the reservoir and the bleeder before bleeding.

Text in Illustration 
*1
Bleeder plug cap
*2
Bleeder plug

  1. Remove the bleeder plug cap.

  1. Connect a vinyl tube to the bleeder plug.

  1. Depress the clutch pedal 5 times, and then loosen the bleeder plug while the pedal is depressed.

  1. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

  1. Repeat both of the previous 2 steps 6 times.

  1. Tighten the bleeder plug.

    Torque:
    8.4 N*m{ 86 kgf*cm , 74 in.*lbf }

  1. Depress the clutch pedal 10 times or more and confirm its operation.

    NOTICE:
    This must be performed before the engine is started.

  1. Install the bleeder plug cap.

  1. Check that all the air has been bled from the clutch line.



12. BLEED BRAKE MASTER CYLINDER


C197234E01

NOTICE:
  1. If the master cylinder is reinstalled or if the reservoir becomes empty, bleed the master cylinder.
  2. To prevent brake fluid from damaging painted surfaces, cover any surrounding parts with a piece of cloth.

  1. Using a union nut wrench (12 mm), disconnect the 2 brake tubes from the master cylinder.



    C197235E01

  1. Slowly depress the brake pedal and hold it (Procedure 1).



    C199773E01

  1. Cover the 2 outer holes with fingers, and release the brake pedal (Procedure 2).

  1. Repeat (Procedure 1) and (Procedure 2), 3 or 4 times.



    C197234E01

  1. Using a union nut wrench (12 mm), connect the 2 brake tubes to the master cylinder.

    Torque:
    20 N*m{ 200 kgf*cm , 14 ft.*lbf }

    NOTICE:
    Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).



13. BLEED BRAKE LINE

NOTICE:
  1. Bleed the brake line of the wheel farthest from the master cylinder first.
  2. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.



    C196629

  1. Connect a vinyl tube to the bleeder plug.

  1. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed (Procedure 1).

  1. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal (Procedure 2).

  1. Repeat steps (Procedure 1) and (Procedure 2) until the new brake fluid comes out.

  1. Tighten the bleeder plug completely.

    Torque:
    Front bleeder plug:
    8.3 N*m{ 85 kgf*cm , 73 in.*lbf }
    Rear bleeder plug (for Disc Brake):
    11 N*m{ 112 kgf*cm , 8 ft.*lbf }
    Rear bleeder plug (for Drum Brake):
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

  1. Repeat the above procedure for each wheel to bleed the brake line.



14. BLEED BRAKE ACTUATOR

NOTICE:
  1. After bleeding the air from the regular brake system, if the correct height or feel of the brake pedal cannot be obtained, perform air bleeding again by following the procedure below.
  2. Bleeding air without the intelligent tester may lead to an injury or accident. When performing this procedure, always bleed air using the intelligent tester.

  1. With the ignition switch off, depress the brake pedal several times to eliminate the vacuum pressure inside the booster.

  1. Connect the intelligent tester to the DLC3 with the ignition switch off.

  1. Turn the ignition switch to ON.

    NOTICE:
    Do not start the engine.

  1. Turn the intelligent tester on.

  1. Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Air Bleeding.

  1. Perform the bleeding at the right front wheel and left rear wheel (Procedure 1).

    1. Bleed the Decrease Line.

      1. Select "Decrease Line" on the intelligent tester menu display.
      2. Depress the brake pedal.
      3. Using the intelligent tester, operate the solenoid and at the same time, completely depress the brake pedal within 5 seconds.

        HINT:
        After operating the solenoid, the motor in the actuator operates for 5 seconds and during this time the brake pedal is pushed out.

      4. Loosen the bleeder plug at the right front wheel.

        NOTICE:
        1. Loosen the bleeder plug at only one place.
        2. Completely depress the brake pedal.

      5. Tighten the bleeder plug, and then release the brake pedal.

      Torque:
      Front bleeder plug:
      8.3 N*m{ 85 kgf*cm , 73 in.*lbf }

    2. Bleed the Increase Line.

      1. Perform brake line air bleeding at the right front wheel by depressing the brake pedal (Procedure 2).
      2. Repeat (Procedure 2) until all air is completely bled out.
      3. Perform the same procedure used at the right front wheel at the left rear wheel.

      Torque:
      Front bleeder plug:
      8.3 N*m{ 85 kgf*cm , 73 in.*lbf }
      Rear bleeder plug (for Disc Brake):
      11 N*m{ 112 kgf*cm , 8 ft.*lbf }
      Rear bleeder plug (for Drum Brake):
      8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

  1. Repeat (Procedure 1) until the air is completely bled out.

  1. Perform the same procedures for the left front wheel and right rear wheel line.

  1. Repeat the brake line air bleeding procedure by depressing the brake pedal.

    NOTICE:
    Repeat the brake line air bleeding procedure at each wheel until the air is bled out.



15. INSPECT FOR BRAKE FLUID LEAK


16. INSPECT BRAKE FLUID LEVEL


    C197231E01

  1. Check the brake fluid level.
    If brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

    Brake Fluid:
    SAE J1703 or FMVSS No. 116 DOT 3



17. BLEED AIR FROM FUEL SYSTEM (for 1ND-TV)

  1. Bleed the fuel line (Click here).



18. INSPECT FOR FUEL LEAK (for 1ND-TV)


19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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