Installation

BRAKE: BRAKE MASTER CYLINDER: INSTALLATION

1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

NOTICE:
Make the adjustment with no vacuum in the brake booster. (Depress the brake pedal several times with the engine stopped.)

HINT
* Adjustment of the brake booster push rod is required when the brake master cylinder sub-assembly is replaced with a new one.
* Adjustment is not necessary when the removed brake master cylinder sub-assembly is reused and the brake booster assembly is replaced with a new one.

(a) Apply chalk to the tip of the accessory tool.

HINT
An accessory tool is enclosed with a new brake master cylinder sub-assembly.

(b) Place the accessory tool on the brake booster assembly.





Text in Illustration





(c) Measure the clearance between the brake booster push rod and accessory tool.

Standard clearance:

0 mm (0 in.)

HINT
Adjust the clearance in the following cases:

* If there is a clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the push rod is protruding too far.
* If the chalk does not stick on the tip of the brake booster push rod, the push rod protrusion is insufficient.

(d) If the clearance is not as specified, adjust the push rod length by holding the rod using SST and turning the tip of the rod using a socket driver 7 mm (0.28 in.).





SST : 09737-00020

HINT
Check the push rod clearance again after adjustment.

2. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

(a) Install a new O-ring onto the brake master cylinder sub-assembly.

(b) Install the brake master cylinder sub-assembly and wire harness clamp bracket with the 2 nuts.

Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)

(c) Using a union nut wrench 12 mm, install the 2 brake tubes onto the brake master cylinder sub-assembly.

Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)

NOTICE:
Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Service Precautions.

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

3. CONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle)

(a) Connect the clutch reservoir tube with the clip.

4. INSTALL BATTERY CARRIER Installation

5. INSTALL BATTERY TRAY

6. INSTALL BATTERY Installation

7. FILL RESERVOIR WITH BRAKE FLUID Service and Repair

8. BLEED MASTER CYLINDER Service and Repair

9. BLEED BRAKE LINE Service and Repair

10. BLEED BRAKE ACTUATOR Service and Repair

11. CHECK FLUID LEVEL IN RESERVOIR Service and Repair

12. INSPECT FOR BRAKE FLUID LEAK

13. INSTALL CENTER COWL TOP VENTILATOR LOUVER Service and Repair