BRAKE SYSTEM (OTHER)  BRAKE MASTER CYLINDER(for LHD)  INSTALLATION  

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Apply Grease

Apply a light layer of a grease enclosed with a new brake master cylinder sub-assembly or lithium soap base glycol grease to the circumference of the brake master cylinder sub-assembly and inner surface of the brake booster assembly as shown in the illustration.

Install the brake master cylinder sub-assembly and wiring harness clamp bracket to the brake booster assembly with the 2 nuts.

Torque:

12.7 N*m (130 kgf*cm, 9 ft.*lbf)

NOTICE:

·

The brake master cylinder sub-assembly requires careful handling. Do not drop or subject the brake master cylinder sub-assembly to any impact. Do not reuse a brake master cylinder sub-assembly that has been dropped.

·

Do not hold the brake master cylinder sub-assembly by the master cylinder piston. Hold the brake master cylinder sub-assembly by its body or its reservoir when carrying it.

·

Do not pull out the master cylinder piston.

·

Do not strike or pinch the master cylinder piston, or cause any damage to the master cylinder piston by any other means.

·

When installing the brake master cylinder sub-assembly to the brake booster assembly, or when removing the brake master cylinder sub-assembly from the brake booster assembly, make sure that the brake master cylinder sub-assembly is kept horizontal or with its tip facing downward (the master cylinder piston is facing upward) to prevent the master cylinder piston from falling out.

·

Do not allow any foreign matter to contaminate the master cylinder piston. If any foreign matter gets on the master cylinder 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 master cylinder piston.

·

Do not kink or damage the brake lines.

·

Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.

·

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

·

Do not use any other type of grease or fluid.

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*a	Torque Wrench Fulcrum Length
*b	Union Nut Wrench

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

Torque:

Specified tightening torque (w/ VSC) : 25 N*m (255 kgf*cm, 18 ft.*lbf)

Specified tightening torque (w/o VSC) : 15.2 N*m (155 kgf*cm, 11 ft.*lbf)

NOTICE:

·

Do not kink or damage the brake lines.

·

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

HINT:

·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION201902,999999,_V1,_078841,_0382392,RM100000001GTX7,

·

w/ VSC:

When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 180 mm (7.087 in.)):

22.5 N*m (229 kgf*cm, 17 ft.*lbf)

·

w/o VSC:

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

13.4 N*m (137 kgf*cm, 10 ft.*lbf)

Attach the clamp and connect the wire harness to the wiring harness clamp bracket.

2.177,0.865 2.49,0.292 2.49,0.292 2.656,0.292 true 2.719,0.208 2.917,0.396 0.198,0.188 10 true *a

*a	Paint Mark

Connect the No. 1 reservoir hose to the brake master cylinder sub-assembly and slide the clip to secure it.

NOTICE:

·

When connecting the No. 1 reservoir hose, face the paint mark up.

·

Make sure that the tabs of the clip are facing upward.

1.438,1.031 1.854,0.281 1.854,0.281 2.021,0.281 true 2.094,0.188 2.302,0.375 0.208,0.188 10 true *a

*a	Paint Mark

Connect the clutch reservoir tube to the brake master cylinder reservoir assembly and slide the clip to secure it.

NOTICE:

·

When connecting the clutch reservoir tube, face the paint mark up.

·

Make sure that the tabs of the clip are facing upward.

Install the outer cowl top panel sub-assembly with the 10 bolts.

Torque:

12 N*m (122 kgf*cm, 9 ft.*lbf)

Attach the 6 clamps and connect the wire harness to the outer cowl top panel sub-assembly.

Install the brake master cylinder reservoir assembly to the outer cowl top panel sub-assembly with the 2 bolts.

Torque:

8.5 N*m (87 kgf*cm, 75 in.*lbf)