BRAKE MASTER CYLINDER > INSTALLATION

for Preparation Click here

1. Install the gasket and brake master cylinder assembly together with the brake simulator assembly with the 4 nuts.
   

   Torque:

   12.7 N*m{ 130 kgf*cm , 9 ft.*lbf }

2. Connect the connector, and engage the clamp.
   

3. Use the SST to fully tighten the 2 brake tubes.
   

   SST

   09023-00101  
   

   Torque:

   15 N*m{ 155 kgf*cm , 11 ft.*lbf }

1. Install the gasket and brake master cylinder assembly together with the brake simulator assembly with the 4 nuts.
   

   Torque:

   12.7 N*m{ 130 kgf*cm , 9 ft.*lbf }

2. Connect the connector, and engage the clamp.
   

3. Use the SST to fully tighten the 2 brake tubes.
   

   Torque:

   15 N*m{ 155 kgf*cm , 11 ft.*lbf }

1. Apply lithium soap base glycol grease to the push rod pin.
   

2. Install the push rod clevis to the brake pedal support assembly with the push rod pin and a new clip.
   

1. LHD:
   
   

   
   
   

   1. Install the reservoir tube No.2 with the clip.
      

2. RHD:
   
   

   
   
   

   1. Install the reservoir tube No.2 with the clip.
      

1. Install the reservoir tube No.1 with the clip.
   

2. LHD:
   
   

   
   
   

   1. Install the nut.
      

      Torque:

      5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

1. Install the brake master cylinder reservoir assembly with the 2 bolts.
   

   Torque:

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

2. Install the 2 reservoir tubes with the 2 clips.
   

3. Install the brake actuator hose with the 2 clips.
   

4. Install the brake actuator hose to the clamp.
   

   NOTICE:

   Install the brake actuator hose with the edges of the protector and clamp aligned.

5. Connect the warning switch connector.
   

1. Remove the 4 shock absorber nuts.
   

2. Install the 4 bolts, 2 nuts and cowl top panel sub-assembly.
   

   Torque:

   5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

3. Install the 4 shock absorber nuts (B).
   

   Torque:

   80 N*m{ 815 kgf*cm , 59 ft.*lbf }

4. Install the wire harness clamp and grommet (A).
   

1. Install the windshield wiper motor and link assembly with the 5 bolts.
   

   Torque:

   7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

2. Connect the connector.
   

1. Operate the front wiper, and stop the front wiper motor at the automatic stop position.
   

2. Clean the wiper arm serrations.
   

3. Clean the wiper pivot serrations with a wire brush (when reinstalling).
   

4. Install the front wiper arm and blade assembly LH with the nut at the position as shown in the illustration.
   

   Torque:

   24 N*m{ 245 kgf*cm , 18 ft.*lbf }

   HINT:

   Hold the arm hinge by hand to fasten the nut.

1. Clean the wiper arm serrations.
   

2. Clean the wiper pivot serrations with a wire brush (when reinstalling).
   

3. Install the front wiper arm and blade assembly RH with the 2 nuts at the position as shown in the illustration.
   

   Torque:

   24 N*m{ 245 kgf*cm , 18 ft.*lbf }

   HINT:

   Hold the arm hinge by hand to fasten the nut.

4. Operate the front wipers while spraying water or washer fluid on the windshield.
   

5. Make sure that the wipers function properly and there is no interference with the vehicle body.
   

1. Add brake fluid to the MAX line in the reservoir.
   

   Fluid:

   SAE J1703 or FMVSS No. 116 DOT3
   

   CAUTION:

   1. Add brake fluid carefully and check that the reservoir level remains between the MIN and MAX lines while bleeding the brakes.
      
   2. Do not stand the fluid can on the reservoir inlet when bleeding the brake actuator. Doing so will cause brake fluid to overflow.
      

1. Connect SST to the reservoir with the brake reservoir pressure adapter.
   

   SST

   09992-00242  
   09992-00350  
   

2. Using SST, loosen the bleeder plug of the actuator.
   

   SST

   09023-00101  
   

3. Connect a vinyl tube to the bleeder plug of the actuator.
   

4. Use the SST to boost pressure in the reservoir.
   

   Standard:

   50 to 80 kPa (0.5 to 0.8 kgf/cm², 7.3 to 11.6 psi)
   

5. Drain approximately 100 cc of fluid.
   

6. Tighten the bleeder plug and boost the pressure in the reservoir again (50 to 80 kPa (0.5 to 0.8 kgf/cm²)). Then, loosen the bleeder plug and bleed the brake actuator hose.
   

   NOTICE:

   Repeat this procedure at least 5 times.

7. When air is completely bled out from the hose between the reservoir and the actuator, tighten the bleeder plug.
   

   Torque:

   8.3 N*m{ 85 kgf*cm , 74 in.*lbf }

HINT:

Air can be easily bled from the front brake system if air has been bled from the master cylinder when replacing the brake master cylinder assembly.

NOTICE:

1. If brake fluid leaks onto any painted surface of the vehicle, wash or otherwise remove it completely.
   
2. Bleed the air by following the steps displayed on the intelligent tester.
   

1. Depress the brake pedal several times and bleed the front brake system from the bleeder plugs on the front brake cylinder RH and LH.
   

   HINT:

   Repeat the procedure until air is completely bled from the front brake system.

2. Tighten the bleeder plugs after bleeding.
   

   Torque:

   8.3 N*m{ 85 kgf*cm , 74 in.*lbf }

1. Install the 2 ABS motor relays.
   

CAUTION:

1. Never bleed air from the brake hydraulic system without using the intelligent tester. Failure to use the intelligent tester could cause serious injury or an accident.
   
2. Be sure to perform this procedure before replacement, removal, or installation of the actuator.
   

NOTICE:

Perform accumulator zero down by following the steps displayed on the intelligent tester.

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

2. Depressurize the accumulator.
   
   

   1. Check that the parking brake is applied and turn the ignition switch to the ON position.
      

   2. Turn on the intelligent tester and select "DIAGNOSTIC MENU" → "ABS/VSC" → "ECB UTILITY" → "ZERO DOWN" on the intelligent tester.
      

   3. When the buzzer sounds, turn the ignition switch off.
      

3. Circulate the fluid in the accumulator.
   
   

   1. Depressurize the accumulator 5 times.
      

      HINT:

      1. Accumulator pressure is released and accumulated repeatedly, which circulates the fluid inside the accumulator, when repeating accumulator zero down.
         
      2. The pump motor rotates and the accumulator is pressurized every time the ignition switch is turned from off to on.
         

1. After performing accumulator zero down (accumulator depressurizing), return the fluid in the accumulator back to the reservoir and then adjust the fluid level in the master cylinder reservoir to the MAX level.
   

   HINT:

   1. After performing accumulator zero down (accumulator depressurizing), fluid is built up in the accumulator by turning the ignition switch to the ON position and the fluid level of the reservoir lowers.
      
   2. If the fluid level is adjusted without performing accumulator zero down (accumulator depressurizing), fluid is sent from the accumulator to the reservoir. The fluid level may exceed the MAX level, but it is normal.
      

NOTICE:

Perform check and adjustment with the rug removed.

1. Check the brake pedal height.
   

   Pedal height from the silencer pad:

   LHD:

   144.7 to 154.7 mm (5.697 to 6.090 in.)
   

   RHD:

   154.9 to 164.9 mm (6.098 to 6.492 in.)
   

2. Adjust the brake pedal height.
   
   

   1. Disconnect the connector from the stop light switch assembly.
      

   2. Loosen the stop light switch lock nut. Turn the switch in order to give the pedal some free play.
      

   3. Loosen the clevis lock nut.
      

   4. Adjust the pedal height by turning the pedal push rod.
      

      Pedal height from the silencer pad:

      LHD:

      144.7 to 154.7 mm (5.697 to 6.090 in.)
      

      RHD:

      154.9 to 164.9 mm (6.098 to 6.492 in.)
      

   5. Tighten the clevis lock nut.
      

      Torque:

      26 N*m{ 265 kgf*cm , 19 ft.*lbf }

   6. Turn the stop light switch assembly so that the clearance between the nut end and the stop light switch cushion is between 0.5 and 2.4 mm (0.020 to 0.095 in.). Tighten the lock nut.
      

      Torque:

      16.7 N*m{ 170 kgf*cm , 12 ft.*lbf }

   7. Connect the connector to the stop light switch assembly.
      

1. Connect the intelligent tester to the DLC3.
   

2. Loosen the 2 bolts.
   

3. Turn the ignition switch to the ON position. Reading the stroke sensor 1 value shown on the intelligent tester screen, turn the stroke sensor slowly to the right and left to adjust it to the standard voltage.
   

   Standard voltage:

   0.8 to 1.2 V
   

4. Tighten the 2 bolts.
   

   Torque:

   9.3 N*m{ 95 kgf*cm , 82 in.*lbf }

   NOTICE:

   Do not depress the brake pedal after turning the ignition switch to the ON position.

5. Perform system initialization. (Click here)
   

1. Press the pedal until a slight resistance is felt. Measure the distance as shown in the illustration.
   

   Pedal free play:

   1 to 2 mm (0.039 to 0.079 in.)
   

   
   

   1. If the pedal free play is 1.0 mm (0.039 in.) or less, check the protrusion of the stop light switch assembly shaft.
      

      Protrusion of the stop light switch assembly shaft:

      0.5 to 2.4 mm (0.020 to 0.095 in.)
      

      HINT:

      1. Adjust if the protrusion is off the specified value.
         
      2. If the protrusion is within the specified value, it is normal though brake pedal free play is 1.0 mm (0.039 in.) or less.
         

1. Release the parking brake pedal.
   

2. With the engine running, depress the pedal and measure the pedal reserve distance as shown in the illustration.
   

   Pedal reserve distance from the dash panel at 490 N (50 kgf, 110 lbf):

   LHD:

   More than 90 mm (3.54 in.)
   

   RHD:

   More than 100 mm (3.94 in.)
   

1. Install the driver side knee airbag assembly with the 4 bolts.
   

   Torque:

   7.6 N*m{ 78 kgf*cm , 68 in.*lbf }

2. Connect the connector to the driver side knee airbag assembly.
   

   NOTICE:

   When handling the airbag connector, take care not to damage the airbag wire harness.

1. Connect the connectors.
   

2. Engage the 5 claws and the 4 clips.
   

3. Connect the hood lock control cable assembly.
   

4. Install the bolt <A>, the screw <C>, and the instrument panel finish panel sub-assembly lower.