RM35X0E _54 Brake _078668 BRAKE SYSTEM (OTHER) _0382364 BRAKE FLUID N

BRAKE SYSTEM (OTHER)  BRAKE FLUID  BLEEDING  


CAUTION / NOTICE / HINT

NOTICE:
·

for Automatic Transmission:

Move the shift lever to P and apply the parking brake before bleeding the brakes.

·

for Manual Transmission:

Move the shift lever to neutral and apply the parking brake before bleeding the brakes.

·

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

·

If brake fluid leaks onto any painted surface, immediately wash it off.

·

Do not operate the brake actuator assembly while air is in the brake system or in the brake master cylinder sub-assembly. Doing so may cause air to enter the brake actuator assembly.

·

If bleeding the brake actuator assembly is difficult due to air in the brake actuator assembly, replace it with a new one.

·

When bleeding air, select the suitable procedure listed below.

Replaced/Installed Item Work Procedure
Flexible hose (front/rear) Bleed brake line
Disc brake cylinder assembly (front/rear)
Rear wheel brake cylinder assembly
Brake actuator assembly Bleed brake system
Brake master cylinder sub-assembly
Brake master cylinder reservoir assembly
Brake booster assembly



HINT:

If any work is performed on the brake system or if air in the brake lines is suspected, bleed the air from the brake system.


PROCEDURE

Hide 1.BLEED BRAKE LINE (for LHD)

a.

Remove the center cowl top ventilator louver.

i.
C410840C01
2.802,3.177 2.708,3.177 2.708,3.177 2.458,2.729 true 1.594,3.146 1.5,3.146 1.5,3.146 1.177,2.719 true 1.646,3.052 1.958,3.208 0.313,0.156 10 false *a 2.865,3.094 3.177,3.25 0.313,0.156 10 false *a
*a Clip
V113147

Remove in this Direction


Disengage the 3 clips as shown in the illustration.


ii.

Disengage the clip and separate the hood to cowl top seal from the cowl top ventilator louver sub-assembly.


iii.
C410842

Disengage the 2 claws and 2 guides.


iv.
C410844C01
0,0 0,0 false
V113147

Separate in this Direction


Separate the center cowl top ventilator louver from the cowl top ventilator louver sub-assembly as shown in the illustration.



b.
C410846

Remove the brake master cylinder reservoir filler cap assembly.


c.

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

Brake Fluid:

SAE J1703 or FMVSS No. 116 DOT 3

SAE J1704 or FMVSS No. 116 DOT 4


NOTICE:
·

Make sure that there is sufficient brake fluid in the reservoir.

·

Do not remove the filter from the brake master cylinder reservoir assembly and be sure to fill the brake master cylinder reservoir assembly with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.




d.

Remove the bleeder plug cap.


e.

Connect a vinyl tube to the bleeder plug.


f.

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


g.

When fluid stops coming out, tighten the bleeder plug and release the brake pedal.*2


h.

Repeat steps *1 and *2 until all the air in the brake fluid is completely bled out and new brake fluid comes out.


i.

Tighten the bleeder plug completely.

Torque:
for Front Brake : 8.3 N*m (85 kgf*cm, 73 in.*lbf)
for Rear Brake (for Rear Disc Brake) : 8.3 N*m (85 kgf*cm, 73 in.*lbf)
for Rear Brake (for Rear Drum Brake) : 11 N*m (112 kgf*cm, 8 ft.*lbf)


j.

Install the bleeder plug cap.


k.

Repeat the above steps to bleed the brake fluid of the brake lines for each wheel.


l.

Inspect for brake fluid leaks.


m.

Inspect the brake fluid level in the reservoir.

Click hereBrake>BRAKE SYSTEM (OTHER)>BRAKE FLUID>ON-VEHICLE INSPECTION


n.

Install the brake master cylinder reservoir filler cap assembly.


o.

Install the center cowl top ventilator louver.

i.

Engage the 2 guides and 2 claws to install the center cowl top ventilator louver to the cowl top ventilator louver sub-assembly.


ii.
C410848C01
0.469,3.177 0.563,3.177 0.563,3.177 0.833,2.75 true 2.948,3.188 2.854,3.188 2.854,3.188 2.719,2.74 true 0.281,3.073 0.594,3.229 0.313,0.156 10 false *a 3.01,3.104 3.323,3.26 0.313,0.156 10 false *a
*a Clip
V113147

Install in this Direction


Engage the clip and install the hood to cowl top seal to the cowl top ventilator louver sub-assembly.


iii.

Engage the 3 clips as shown in the illustration.



Hide 2.BLEED BRAKE LINE (for RHD)

a.

Remove the center cowl top ventilator louver.

i.
C410841C01
2.302,3.135 2.385,3.135 2.385,3.135 2.552,2.719 true 0.656,2.635 0.885,2.281 0.885,2.281 0.969,2.281 true 2.094,3.031 2.406,3.229 0.313,0.198 10 false *a 1.021,2.208 1.333,2.406 0.313,0.198 10 true *a
*a Clip
V113147

Remove in this Direction


Disengage the 3 clips as shown in the illustration.


ii.

Disengage the clip and separate the hood to cowl top seal from the cowl top ventilator louver sub-assembly.


iii.
C410843

Disengage the 2 claws and 2 guides.


iv.
C410845C01
0,0 0,0 false
V113147

Separate in this Direction


Separate the center cowl top ventilator louver from the cowl top ventilator louver sub-assembly as shown in the illustration.



b.
C410847

Remove the brake master cylinder reservoir filler cap assembly.


c.

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

Brake Fluid:

SAE J1703 or FMVSS No. 116 DOT 3

SAE J1704 or FMVSS No. 116 DOT 4


NOTICE:
·

Make sure that there is sufficient brake fluid in the reservoir.

·

Do not remove the filter from the brake master cylinder reservoir assembly and be sure to fill the brake master cylinder reservoir assembly with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.




d.

Remove the bleeder plug cap.


e.

Connect a vinyl tube to the bleeder plug.


f.

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


g.

When fluid stops coming out, tighten the bleeder plug and release the brake pedal.*2


h.

Repeat steps *1 and *2 until all the air in the brake fluid is completely bled out and new brake fluid comes out.


i.

Tighten the bleeder plug completely.

Torque:
for Front Brake : 8.3 N*m (85 kgf*cm, 73 in.*lbf)
for Rear Brake (for Rear Disc Brake) : 8.3 N*m (85 kgf*cm, 73 in.*lbf)
for Rear Brake (for Rear Drum Brake) : 11 N*m (112 kgf*cm, 8 ft.*lbf)


j.

Install the bleeder plug cap.


k.

Repeat the above steps to bleed the brake fluid of the brake lines for each wheel.


l.

Inspect for brake fluid leaks.


m.

Inspect the brake fluid level in the reservoir.

Click hereBrake>BRAKE SYSTEM (OTHER)>BRAKE FLUID>ON-VEHICLE INSPECTION


n.

Install the brake master cylinder reservoir filler cap assembly.


o.

Install the center cowl top ventilator louver.

i.

Engage the 2 guides and 2 claws to install the center cowl top ventilator louver to the cowl top ventilator louver sub-assembly.


ii.
C410849C01
1.208,2.323 1.115,2.323 1.115,2.323 0.948,2.625 true 2.469,3.125 2.375,3.125 2.375,3.125 2.229,2.719 true 1.281,2.24 1.521,2.427 0.24,0.188 10 true *a 2.542,3.042 2.854,3.198 0.313,0.156 10 false *a
*a Clip
V113147

Install in this Direction


Engage the clip and install the hood to cowl top seal to the cowl top ventilator louver sub-assembly.


iii.

Engage the 3 clips as shown in the illustration.



Hide 3.BLEED BRAKE SYSTEM (for LHD)

NOTICE:
·

To prevent brake fluid from damaging painted surfaces, cover any surrounding parts with a piece of cloth.

·

Be sure to clean your hands before bleeding the brake master cylinder sub-assembly to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.



a.

for 7GR-FKS:

i.

Remove the V-bank cover sub-assembly.

Click hereEngine / Hybrid System>7GR-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>REMOVAL



b.

for 1GD-FTV:

i.

Remove the No. 1 engine cover sub-assembly.

Click hereEngine / Hybrid System>1GD-FTV (ENGINE CONTROL)>DIESEL THROTTLE BODY>REMOVAL



c.

Remove the center cowl top ventilator louver.

i.
C410840C01
2.802,3.177 2.708,3.177 2.708,3.177 2.458,2.729 true 1.594,3.146 1.5,3.146 1.5,3.146 1.177,2.719 true 1.646,3.052 1.958,3.208 0.313,0.156 10 false *a 2.865,3.094 3.177,3.25 0.313,0.156 10 false *a
*a Clip
V113147

Remove in this Direction


Disengage the 3 clips as shown in the illustration.


ii.

Disengage the clip and separate the hood to cowl top seal from the cowl top ventilator louver sub-assembly.


iii.
C410842

Disengage the 2 claws and 2 guides.


iv.
C410844C01
0,0 0,0 false
V113147

Separate in this Direction


Separate the center cowl top ventilator louver from the cowl top ventilator louver sub-assembly as shown in the illustration.



d.
C410846

Remove the brake master cylinder reservoir filler cap assembly.


e.

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

Brake Fluid:

SAE J1703 or FMVSS No. 116 DOT 3

SAE J1704 or FMVSS No. 116 DOT 4


NOTICE:
·

Make sure that there is sufficient brake fluid in the reservoir.

·

Do not remove the filter from the brake master cylinder reservoir and be sure to fill the brake master cylinder reservoir with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.




f.
C410850

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

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.




g.
C410852

Slowly depress the brake pedal and hold it.*1


h.
C410854

Cover the 2 outer holes with fingers, and release the brake pedal.*2


i.

Repeat steps *1 and *2, 3 or 4 times.


j.
C410856C01
2.729,2.646 2.854,3.031 2.854,3.031 2.938,3.031 false 1.781,2.938 2.094,3.094 0.313,0.156 10 false *a 2.99,2.948 3.302,3.104 0.313,0.156 10 false *b
*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 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.



HINT:
·

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

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

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)




k.

Remove the bleeder plug cap.


l.

Connect a vinyl tube to the bleeder plug.


m.

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


n.

When fluid stops coming out, tighten the bleeder plug and release the brake pedal.*2


o.

Repeat steps *1 and *2 until all the air in the brake fluid is completely bled out and new brake fluid comes out.


p.

Tighten the bleeder plug completely.

Torque:
for Front Brake : 8.3 N*m (85 kgf*cm, 73 in.*lbf)
for Rear Brake (for Rear Disc Brake) : 8.3 N*m (85 kgf*cm, 73 in.*lbf)
for Rear Brake (for Rear Drum Brake) : 11 N*m (112 kgf*cm, 8 ft.*lbf)


q.

Install the bleeder plug cap.


r.

Repeat the above steps to bleed the brake fluid of the brake lines for each wheel.


s.

Inspect for brake fluid leaks.


t.

Inspect the brake fluid level in the reservoir.

Click hereBrake>BRAKE SYSTEM (OTHER)>BRAKE FLUID>ON-VEHICLE INSPECTION


u.

Install the brake master cylinder reservoir filler cap assembly.


v.

Install the center cowl top ventilator louver.

i.

Engage the 2 guides and 2 claws to install the center cowl top ventilator louver to the cowl top ventilator louver sub-assembly.


ii.
C410848C01
0.469,3.177 0.563,3.177 0.563,3.177 0.833,2.75 true 2.948,3.188 2.854,3.188 2.854,3.188 2.719,2.74 true 0.281,3.073 0.594,3.229 0.313,0.156 10 false *a 3.01,3.104 3.323,3.26 0.313,0.156 10 false *a
*a Clip
V113147

Install in this Direction


Engage the clip and install the hood to cowl top seal to the cowl top ventilator louver sub-assembly.


iii.

Engage the 3 clips as shown in the illustration.



w.

for 7GR-FKS:

i.

Install the V-bank cover sub-assembly.

Click hereEngine / Hybrid System>7GR-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION



x.

for 1GD-FTV:

i.

Install the No. 1 engine cover sub-assembly.

Click hereEngine / Hybrid System>1GD-FTV (ENGINE CONTROL)>DIESEL THROTTLE BODY>INSTALLATION



Hide 4.BLEED BRAKE SYSTEM (for RHD)

NOTICE:
·

To prevent brake fluid from damaging painted surfaces, cover any surrounding parts with a piece of cloth.

·

Be sure to clean your hands before bleeding the brake master cylinder sub-assembly to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.



a.

for 7GR-FKS:

i.

Remove the V-bank cover sub-assembly.

Click hereEngine / Hybrid System>7GR-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>REMOVAL



b.

for 1GD-FTV:

i.

Remove the No. 1 engine cover sub-assembly.

Click hereEngine / Hybrid System>1GD-FTV (ENGINE CONTROL)>DIESEL THROTTLE BODY>REMOVAL



c.

Remove the center cowl top ventilator louver.

i.
C410841C01
2.302,3.135 2.385,3.135 2.385,3.135 2.552,2.719 true 0.656,2.635 0.885,2.281 0.885,2.281 0.969,2.281 true 2.094,3.031 2.406,3.229 0.313,0.198 10 false *a 1.021,2.208 1.333,2.406 0.313,0.198 10 true *a
*a Clip
V113147

Remove in this Direction


Disengage the 3 clips as shown in the illustration.


ii.

Disengage the clip and separate the hood to cowl top seal from the cowl top ventilator louver sub-assembly.


iii.
C410843

Disengage the 2 claws and 2 guides.


iv.
C410845C01
0,0 0,0 false
V113147

Separate in this Direction


Separate the center cowl top ventilator louver from the cowl top ventilator louver sub-assembly as shown in the illustration.



d.
C410847

Remove the brake master cylinder reservoir filler cap assembly.


e.

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

Brake Fluid:

SAE J1703 or FMVSS No. 116 DOT 3

SAE J1704 or FMVSS No. 116 DOT 4


NOTICE:
·

Make sure that there is sufficient brake fluid in the reservoir.

·

Do not remove the filter from the brake master cylinder reservoir and be sure to fill the brake master cylinder reservoir with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.




f.
C410851

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

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.




g.
C410853

Slowly depress the brake pedal and hold it.*1


h.
C410855

Cover the 2 outer holes with fingers, and release the brake pedal.*2


i.

Repeat steps *1 and *2, 3 or 4 times.


j.
C410857C01
2.729,2.635 2.833,3.052 2.833,3.052 2.906,3.052 false 1.771,2.938 2.083,3.094 0.313,0.156 10 false *a 2.948,2.969 3.26,3.125 0.313,0.156 10 false *b
*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 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.



HINT:
·

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

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

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)




k.

Remove the bleeder plug cap.


l.

Connect a vinyl tube to the bleeder plug.


m.

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


n.

When fluid stops coming out, tighten the bleeder plug and release the brake pedal.*2


o.

Repeat steps *1 and *2 until all the air in the brake fluid is completely bled out and new brake fluid comes out.


p.

Tighten the bleeder plug completely.

Torque:
for Front Brake : 8.3 N*m (85 kgf*cm, 73 in.*lbf)
for Rear Brake (for Rear Disc Brake) : 8.3 N*m (85 kgf*cm, 73 in.*lbf)
for Rear Brake (for Rear Drum Brake) : 11 N*m (112 kgf*cm, 8 ft.*lbf)


q.

Install the bleeder plug cap.


r.

Repeat the above steps to bleed the brake fluid of the brake lines for each wheel.


s.

Inspect for brake fluid leaks.


t.

Inspect the brake fluid level in the reservoir.

Click hereBrake>BRAKE SYSTEM (OTHER)>BRAKE FLUID>ON-VEHICLE INSPECTION


u.

Install the brake master cylinder reservoir filler cap assembly.


v.

Install the center cowl top ventilator louver.

i.

Engage the 2 guides and 2 claws to install the center cowl top ventilator louver to the cowl top ventilator louver sub-assembly.


ii.
C410849C01
1.208,2.323 1.115,2.323 1.115,2.323 0.948,2.625 true 2.469,3.125 2.375,3.125 2.375,3.125 2.229,2.719 true 1.281,2.24 1.521,2.427 0.24,0.188 10 true *a 2.542,3.042 2.854,3.198 0.313,0.156 10 false *a
*a Clip
V113147

Install in this Direction


Engage the clip and install the hood to cowl top seal to the cowl top ventilator louver sub-assembly.


iii.

Engage the 3 clips as shown in the illustration.



w.

for 7GR-FKS:

i.

Install the V-bank cover sub-assembly.

Click hereEngine / Hybrid System>7GR-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION



x.

for 1GD-FTV:

i.

Install the No. 1 engine cover sub-assembly.

Click hereEngine / Hybrid System>1GD-FTV (ENGINE CONTROL)>DIESEL THROTTLE BODY>INSTALLATION