Removal and Replacement
BRAKE MASTER CYLINDERCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
REMOVAL
NOTICE: While the battery is connected, even if the engine switch is off, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal and open/close the doors while the battery is connected.
1. PRECAUTION
CAUTION: Be sure to read the "PRECAUTION" thoroughly before servicing.
2. REMOVE V-BANK COVER SUB-ASSEMBLY
3. REMOVE COWL TOP VENTILATOR LOUVER RH
4. REMOVE FRONT WIPER ARM LH
5. REMOVE FRONT WIPER ARM RH
6. REMOVE ENGINE ROOM SIDE COVER LH
7. REMOVE ENGINE ROOM SIDE COVER RH
8. REMOVE FRONT FENDER PROTECTOR UPPER LH
9. REMOVE FRONT FENDER PROTECTOR UPPER RH
10. REMOVE HOOD TO COWL TOP SEAL
11. REMOVE FRONT FENDER TO COWL SIDE SEAL LH
12. REMOVE FRONT FENDER TO COWL SIDE SEAL RH
13. REMOVE COWL TOP VENTILATOR LOUVER PROTECTOR LH
14. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY
15. PERFORM ACCUMULATOR ZERO DOWN
16. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
NOTICE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
17. REMOVE SKID CONTROL ECU
18. REMOVE SKID CONTROL ECU BRACKET
19. DISCONNECT ENGINE ROOM NO. 3 RELAY BLOCK
20. DRAIN BRAKE FLUID
NOTICE: If brake fluid leaks onto any painted surface, wash or otherwise remove it completely.
21. REMOVE BRAKE FLUID RESERVOIR
(a) Disconnect the wire harness clamp (labeled A) from the reservoir.
(b) Detach the connector clamp (labeled B) from the reservoir bracket, and then disconnect the brake fluid level warning switch connector (labeled C).
(c) Disconnect the No. 1 brake actuator hose (labeled D) from the reservoir.
(d) Release the locks of the reservoir connectors. Then disconnect the No. 2 brake actuator hose (labeled E) and No. 1 reservoir hose (labeled F) from the reservoir.
NOTICE:
^ Check for any dirt and foreign matter contamination in the reservoir and around the reservoir connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the reservoir and reservoir connector.
^ Do not use any tools to separate the reservoir and reservoir connector.
^ If the reservoir and reservoir connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.
^ Put the reservoir and reservoir connector ends in plastic bags to prevent damage and dirt contamination.
(e) Remove the 2 bolts and brake fluid reservoir.
22. REMOVE NO. 1 RESERVOIR HOSE
(a) Remove the hose clip (labeled A) and No. 1 reservoir hose (labeled B) from the master cylinder.
(b) Remove the hose clip (labeled C) and reservoir connector (labeled D) from the No. 1 reservoir hose (labeled B).
23. REMOVE RESERVOIR BRACKET
(a) Remove the 3 bolts and reservoir bracket.
24. REMOVE FRONT WHEEL
25. DISCONNECT BRAKE TUBE
26. REMOVE BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY
27. REMOVE INSTRUMENT PANEL FINISH PANEL END LH
28. REMOVE INSTRUMENT SIDE PANEL LH
29. REMOVE NO. 1 INSTRUMENT CLUSTER MOULDING
30. REMOVE STEERING COLUMN COVER
31. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY
32. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY
33. REMOVE NO. 1 INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY
34. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
35. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY
36. REMOVE BRAKE PEDAL RETURN SPRING
37. REMOVE PUSH ROD PIN
38. REMOVE BRAKE MASTER CYLINDER WITH SIMULATOR ASSEMBLY
(a) Disconnect the brake stroke simulator connector.
(b) Remove the 4 nuts and brake master cylinder with simulator.
39. REMOVE BRAKE BOOSTER GASKET
(a) Remove the brake booster gasket from the brake master cylinder with simulator.
INSTALLATION
NOTICE: While the battery is connected, even if the engine switch is off, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal and open/close the doors while the battery is connected.
1. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake master cylinder with simulator.
2. INSTALL BRAKE MASTER CYLINDER WITH SIMULATOR ASSEMBLY
(a) Install the brake master cylinder with simulator with the 4 nuts.
Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
(b) Connect the brake stroke simulator connector.
3. INSTALL PUSH ROD PIN
4. INSTALL BRAKE PEDAL RETURN SPRING
5. INSTALL BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY
6. CONNECT BRAKE TUBE
7. INSTALL RESERVOIR BRACKET
(a) Install the reservoir bracket with the 3 bolts.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
8. INSTALL NO. 1 RESERVOIR HOSE
(a) Install the reservoir connector (labeled A) to the No. 1 reservoir hose (labeled B) with the hose clip (labeled C) as shown in the illustration.
Length "A":
4.0 to 7.0 mm (0.158 to 0.276 in.)
(b) With the paint mark on the hose's tip facing the top of the vehicle, install the No. 1 reservoir hose (labeled B) to the master cylinder with the hose clip (labeled D).
HINT: Install the hose clip so that its claws face the top of the vehicle.
9. INSTALL BRAKE FLUID RESERVOIR
(a) Connect the No. 1 reservoir hose (labeled A) and No. 2 brake actuator hose (labeled B) to the reservoir. The reservoir connector connecting procedure must be followed as described below:
(1) Remove the foreign matter entry prevention plastic bags.
NOTICE: Check that there is no damage or foreign objects on the connected part of the reservoir and reservoir connectors.
(2) Insert the reservoir connector to the reservoir until the reservoir connector makes a "click" sound, so that the reservoir connector tip's groove is aligned with the reservoir's rib.
(3) Securely set the lock of the reservoir connector.
(4) Check that the reservoir connector lock's claw is securely attached.
(b) With the paint mark on the hose's tip facing the top of the vehicle, connect the No. 1 brake actuator hose (labeled C) to the reservoir with the hose clip.
HINT: Install the hose clip so that its claws face the top of the vehicle.
(c) Connect the brake fluid level warning switch connector (labeled D), and then attach the connector clamp (labeled E) to the reservoir bracket.
(d) Install the brake fluid reservoir with the 2 bolts.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
(e) Connect the wire harness clamp (labeled F) to the reservoir.
10. CONNECT ENGINE ROOM NO. 3 RELAY BLOCK
11. INSTALL SKID CONTROL ECU BRACKET
12. INSTALL SKID CONTROL ECU
13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
14. BLEEDING PRECAUTION
CAUTION: Be sure to read the "PRECAUTION" thoroughly before bleeding.
15. DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTORS
16. FILL RESERVOIR WITH BRAKE FLUID
17. DISABLE BRAKE CONTROL
18. BLEED AIR FROM FRONT BRAKE SYSTEM
19. CANCEL DISABLE BRAKE CONTROL
20. CONNECT BRAKE ACCUMULATOR PUMP CONNECTORS
21. BLEED AIR FROM PUMP SUCTION SYSTEM (RR)
22. DISABLE BRAKE CONTROL
23. BLEED AIR FROM REAR BRAKE SYSTEM
24. CANCEL DISABLE BRAKE CONTROL
25. PERFORM ACCUMULATOR ZERO DOWN
26. CHECK AND ADJUST BRAKE FLUID LEVEL IN RESERVOIR
27. INSPECT FOR BRAKE FLUID LEAK
28. CHECK AND ADJUST BRAKE PEDAL HEIGHT
29. ADJUST BRAKE PEDAL STROKE SENSOR
30. CHECK BRAKE PEDAL FREE PLAY
31. CHECK BRAKE PEDAL RESERVE DISTANCE
32. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY
33. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
34. INSTALL NO. 1 INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY
35. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY
36. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY
37. INSTALL STEERING COLUMN COVER
38. INSTALL NO. 1 INSTRUMENT CLUSTER MOULDING
39. INSTALL INSTRUMENT SIDE PANEL LH
40. INSTALL INSTRUMENT PANEL FINISH PANEL END LH
41. INSTALL FRONT WHEEL
Torque: 140 N*m (1428 kgf*cm, 103 ft.*lbf)
42. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY
43. INSTALL COWL TOP VENTILATOR LOUVER PROTECTOR LH
44. INSTALL FRONT FENDER TO COWL SIDE SEAL LH
45. INSTALL FRONT FENDER TO COWL SIDE SEAL RH
46. INSTALL HOOD TO COWL TOP SEAL
47. INSTALL FRONT FENDER PROTECTOR UPPER LH
48. INSTALL FRONT FENDER PROTECTOR UPPER RH
49. INSTALL ENGINE ROOM SIDE COVER RH
50. INSTALL ENGINE ROOM SIDE COVER LH
51. INSTALL FRONT WIPER ARM LH
52. INSTALL FRONT WIPER ARM RH
53. INSTALL COWL TOP VENTILATOR LOUVER RH
54. INSTALL V-BANK COVER SUB-ASSEMBLY
55. PERFORM LINEAR VALVE OFFSET LEARNING
(a) When the brake master cylinder with simulator assembly is replaced, perform the linear valve offset learning.
56. CHECK BRAKE ACTUATOR WITH TESTER
(a) Check the brake actuator and pressure sensor.
57. CHECK BRAKE MASTER CYLINDER WITH TESTER
(a) Check the brake master cylinder and stroke simulator.
58. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light.
59. PERFORM INITIALIZATION
(a) Perform initialization.
NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
60. CLEAR DTC
(a) Clear the DTCs.
61. CHECK MASTER CYLINDER PRESSURE SENSOR SIGNAL
(a) Check the pressure sensor signal.