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Brake Master Cylinder Sub-Assembly






BRAKE MASTER CYLINDER SUB-ASSY
REPLACEMENT
1. REMOVE FR WIPER ARM LH
2. REMOVE FR WIPER ARM RH
3. REMOVE HOOD TO COWL TOP SEAL
4. REMOVE COWL TOP VENTILATOR LOUVER LH
5. REMOVE COWL TOP VENTILATOR LOUVER RH
6. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY
7. BRAKE CONTROL (ECB) OFF

NOTICE: Prohibit the brake control (ECB) certainly before bleeding the brake fluid.





a) With the power switch off to prohibit brake control, remove the motor relays No.1 and No.2.

NOTICE: If the pump motor operates while there is air remaining inside the brake actuator hose, the air will enter the actuator, resulting in difficulty in air bleeding.

HINT: Brake control (ECB) can be prohibited by selecting "ECB IN VALID" on the hand-held tester.

8. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT





a) Remove the 2 bolts and separate the engine room R/B No.2.





b) Remove the 3 clamps from the cowl top panel sub-assy outer front.





c) Remove the 7 bolts and separate the cowl top panel sub-assy outer front.
9. REMOVE W/CONVERTER INVERTER ASSY

HINT: Refer to the procedures from the removal of the engine undercover LH up until the removal of the inverter assy with converter.

10. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.

11. REMOVE INSTRUMENT PANEL REGISTER ASSY NO.1
12. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER
13. REMOVE BRAKE MASTER CYLINDER SUB-ASSY





a) Remove the brake return spring.
b) Remove the clip and brake master cylinder push rod pin, and separate the push rod clevis from the brake pedal.





c) Remove the 4 clips and 2 reservoir tube hoses.





d) Remove the bolt from the actuator bracket.
e) Using SST, remove the front brake tube No.1.
SST 09023-00100





f) Using SST, separate the front brake tube No.2 from the clamp and brake master cylinder sub-assy.
SST 09023-00100





g) Remove the 2 nuts, and remove the brake master cylinder gasket and brake master cylinder sub-assy from the bracket.





h) Using SST, remove the brake tube and 2 way from the brake master cylinder sub-assy.
SST 09023-00100





i) Remove the screw, and remove the brake master cylinder union No.1 and 2 grommets from the brake master cylinder sub-assy.





j) Loosen the clevis lock nut and remove the brake master cylinder push rod clevis.
14. INSTALL BRAKE MASTER CYLINDER SUB-ASSY





a) Install the brake master cylinder push rod clevis to the brake master cylinder sub-assy, and fix by the lock nut.

HINT: After adjusting the brake pedal height, torque the lock nut.

b) Apply lithium soap base glycol grease to the 2 new grommets.
c) Install the brake master cylinder union No.1 and 2 grommets to the brake master cylinder sub-assy with a screw.
Torque: 1.8 Nm (18 kgf-cm, 16 inch lbs.)





d) Using SST, install the brake tube and 2 way to the brake master cylinder sub-assy.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





e) Placing the gasket in between, install the brake master cylinder sub-assy to the bracket with 2 nuts.
Torque: 13 Nm (127 kgf-cm, 9 ft. lbs.)





f) Using SST, connect the front brake tube No.2 to the clamp and brake master cylinder sub-assy.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





g) Using SST, connect the front brake tube No. 1.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
h) Install the bolt to the actuator bracket.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)





i) Connect the 2 reservoir tube hoses and hold them there with clips.





j) Install the push rod clevis with the brake master cylinder push rod pin to the brake pedal.
k) Install the clip and brake pedal return spring.
15. INSTALL W/CONVERTER INVERTER ASSY

HINT: Refer to the procedures from the installation of the inverter assy with converter up until the installation of the engine under cover LH.

16. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT





a) Install the cowl top panel sub-assy outer front with the 7 bolts.
Torque: 6.4 Nm (65 kgf-cm, 57 inch lbs.)





b) Install the 3 clamps to the cowl top panel sub-assy outer front.





c) Install the engine room R/B No.2 with the 2 bolts.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
17. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY
18. INSTALL FR WIPER ARM LH
19. INSTALL FR WIPER ARM RH
20. FILL RESERVOIR WITH BRAKE FLUID
21. BLEED MASTER CYLINDER
SST 09023-00100
22. BLEED MASTER CYLINDER /STROKE SIMULATOR
23. CHECK BRAKE FLUID LEAKAGE
24. CHECK FLUID LEVEL IN RESERVOIR
25. CHECK AND ADJUST BRAKE PEDAL HEIGHT
26. CHECK PEDAL FREE PLAY
27. CHECK PEDAL RESERVE DISTANCE
28. INSTALL INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER
29. INSTALL INSTRUMENT PANEL REGISTER ASSY NO.1
30. CHECK AND CLEAR DTC

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