Installation

BRAKE: BRAKE MASTER CYLINDER: INSTALLATION

INSTALLATION

1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD





(a) Set SST on the master cylinder sub-assembly and lower the rod of SST until it just touches the piston.
SST: 09737-00013
HINT: SST: 09737-00012 can also be used.

(b) Apply chalk to the flat tip of the SST rod. Turn SST upside down and measure the clearance between the brake booster push rod and SST.
Standard Clearance:
-0.21 to 0 mm (-0.0083 to 0 in.)
If there is clearance between the SST main body and the shell of the brake booster, the push rod is protruding too far. If the chalk does not stick to the tip of the brake booster push rod, the push rod protrusion is insufficient.





(c) If the clearance is not within the standard, adjust the length by holding the rod using SST and turning the tip of the rod using a 7 mm socket driver.
SST: 09737-00020
NOTE: Check the push rod clearance again after adjusting.

2. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (w/ ABS)
(a) Install a new O-ring onto the brake master cylinder sub-assembly.





(b) Install the brake master cylinder sub-assembly with the 2 nuts.
Torque: 13 Nm (127 kgf-cm, 9 ft-lbf)





(c) Using a union nut wrench, install the brake tubes onto the brake master cylinder sub-assembly.
without union nut wrench - Torque: 15 Nm (155 kgf-cm, 11 ft-lbf)
with union nut wrench - Torque: 14 Nm (144 kgf-cm, 10 ft-lbf)
HINT:
- This torque value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.8 in.) and a union nut wrench with a fulcrum length of 22 mm (0.866 in.) Service Precautions.
- This torque value is effective when the union nut wrench is parallel to the torque wrench.

(d) Connect the brake fluid level warning switch connector.
3. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (w/o ABS)
(a) Install a new O-ring onto the brake master cylinder sub-assembly.





(b) Install the brake master cylinder sub-assembly and brake tube way with the 2 nuts.
Torque: 13 Nm (127 kgf-cm, 9 ft-lbf)





(c) Using a union nut wrench, install the brake tubes onto the brake master cylinder sub-assembly and brake tube way.
without union nut wrench - Torque: 15 Nm (155 kgf-cm, 11 ft-lbf)
with union nut wrench - Torque: 14 Nm (144 kgf-cm, 10 ft-lbf)
HINT:
- This torque value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.8 in.) and a union nut wrench with a fulcrum length of 22 mm (0.866 in.) Service Precautions.
- This torque value is effective when the union nut wrench is parallel to the torque wrench.

(d) Connect the brake fluid level warning switch connector.





4. CONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle)
(a) Connect the reservoir tube with the clip.
5. INSTALL BATTERY CARRIER Installation
6. INSTALL BATTERY TRAY
7. INSTALL BATTERY Installation
8. FILL RESERVOIR WITH BRAKE FLUID Service and Repair
9. BLEED MASTER CYLINDER Service and Repair
10. BLEED BRAKE LINE Service and Repair
11. CHECK FLUID LEVEL IN RESERVOIR Service and Repair
12. CHECK FOR BRAKE FLUID LEAKAGE