Installation
BRAKE SYSTEM (OTHER): BRAKE MASTER CYLINDER: INSTALLATION
1. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake master with simulator cylinder assembly.
2. INSTALL BRAKE MASTER WITH SIMULATOR CYLINDER ASSEMBLY
(a) Install the brake master with simulator cylinder assembly with the 4 nuts.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
(b) Using a union nut wrench, connect the No. 6 front brake tube and No. 7 front brake tube to the brake master with simulator cylinder assembly.
Text in Illustration
Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
NOTICE:
Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench Service Precautions.
(c) Engage the clamp and connect the connector.
3. CONNECT MASTER CYLINDER PUSH ROD CLEVIS Installation
4. INSTALL BRAKE PEDAL RETURN SPRING Installation
5. CONNECT NO. 2 RESERVOIR HOSE
(a) Connect the No. 2 reservoir hose to the brake master cylinder sub-assembly with the clips.
6. CONNECT NO. 1 RESERVOIR HOSE
(a) Connect the No. 1 reservoir hose to the brake master cylinder sub-assembly with the clips.
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
8. CONNECT BRAKE BOOSTER PUMP CONNECTOR
(a) Add brake fluid into the reservoir between MAX and MIN line on the brake fluid reservoir.
Brake fluid:
SAE J1703 or FMVSS No. 116 DOT3
(b) With the power switch off, connect the 2 brake booster pump connectors.
(c) Turn the power switch on (IG) and check that the brake booster pump motor operates and stops.
(d) Turn the power switch off.
9. BLEED BRAKE MASTER CYLINDER Service and Repair
10. INSPECT AND ADJUST BRAKE PEDAL
HINT
Adjustments
11. CHECK BRAKE MASTER CYLINDER WITH TECHSTREAM
(a) Check the brake master cylinder and stroke simulator On-Vehicle Inspection.
12. INSPECT MASTER CYLINDER PRESSURE SENSOR SIGNAL
(a) Inspect the master cylinder pressure sensor signal Test Mode Procedure.
13. CHECK FOR DTC
(a) Check for DTCs. If any DTC is output, perform troubleshooting for that DTC Reading and Clearing Diagnostic Trouble Codes.
14. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation
15. INSTALL AIR CLEANER ASSEMBLY WITH HOSE Installation
16. INSTALL INLET NO. 1 AIR CLEANER Installation
17. INSTALL INLET NO. 2 AIR CLEANER Installation
18. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY Installation
19. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY
(a) Install the outer cowl top panel sub-assembly with the 4 bolts, 4 nuts*1 and 2 nuts*2.
Nut*1 - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)
Nut*2 - Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
Bolt - Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
(b) Engage the grommet and clamp.
(c) Connect the connector (w/ Windshield Deicer).
20. INSTALL FRONT SHOCK ABSORBER CAP LH (w/ Air Suspension) Installation
21. INSTALL FRONT SHOCK ABSORBER CAP RH (w/ Air Suspension)
HINT
Use the same procedure for the LH side and RH side.
22. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
HINT
Refer to the instructions for Installation of the windshield wiper motor and link assembly Installation.
23. INSTALL REAR DECK FLOOR BOX Installation