Installation
BRAKE: BRAKE MASTER CYLINDER: 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 Nm (130 kgf-cm, 9 ft-lbf)
(b) Connect the brake stroke simulator connector.
3. INSTALL PUSH ROD PIN Installation
4. INSTALL BRAKE PEDAL RETURN SPRING Installation
5. INSTALL BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY Installation
6. CONNECT BRAKE TUBE Installation
7. INSTALL RESERVOIR BRACKET
(a) Install the reservoir bracket with the 3 bolts.
Torque : 8.5 Nm (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 Nm (87 kgf-cm, 75 in-lbf)
(e) Connect the wire harness clamp (labeled F) to the reservoir.
10. CONNECT NO. 3 RELAY BLOCK Installation
11. INSTALL SKID CONTROL ECU BRACKET Installation
12. INSTALL SKID CONTROL ECU Installation
13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE:
* Make sure that the 2 accumulator pump connectors are disconnected.
* When disconnecting the cable, some systems need to be initialized after the cable is reconnected Testing and Inspection.
14. BLEEDING PRECAUTION
CAUTION:
Be sure to read the "PRECAUTION" thoroughly before bleeding Service Precautions.
15. PERFORM ACCUMULATOR ZERO DOWN Procedures
16. FILL RESERVOIR WITH BRAKE FLUID Service and Repair
17. BLEED BRAKE SYSTEM Procedures
18. PERFORM ACCUMULATOR ZERO DOWN Procedures
19. INSPECT AND ADJUST BRAKE FLUID LEVEL IN RESERVOIR Service and Repair
20. INSPECT FOR BRAKE FLUID LEAK
(a) Inspect for brake fluid leak On-Vehicle Inspection.
21. CHECK AND ADJUST BRAKE PEDAL HEIGHT Adjustments
22. ADJUST BRAKE PEDAL STROKE SENSOR Adjustments
23. CHECK BRAKE PEDAL FREE PLAY Adjustments
24. CHECK BRAKE PEDAL RESERVE DISTANCE Adjustments
25. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY Installation
26. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation
27. INSTALL NO. 1 INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY Installation
28. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY Installation
29. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY Installation
30. INSTALL STEERING COLUMN COVER Installation
31. INSTALL NO. 1 INSTRUMENT CLUSTER MOULDING Installation
32. INSTALL INSTRUMENT SIDE PANEL LH Installation
33. INSTALL INSTRUMENT PANEL FINISH PANEL END LH Installation
34. INSTALL FRONT WHEEL Installation
35. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation
36. INSTALL COWL TOP VENTILATOR LOUVER PROTECTOR LH Installation
37. INSTALL FRONT FENDER TO COWL SIDE SEAL LH Installation
38. INSTALL FRONT FENDER TO COWL SIDE SEAL RH Installation
39. INSTALL HOOD TO COWL TOP SEAL Installation
40. INSTALL FRONT FENDER PROTECTOR UPPER LH Installation
41. INSTALL FRONT FENDER PROTECTOR UPPER RH Installation
42. INSTALL ENGINE ROOM SIDE COVER RH Installation
43. INSTALL ENGINE ROOM SIDE COVER LH Installation
44. INSTALL FRONT WIPER ARM LH Installation
45. INSTALL FRONT WIPER ARM RH Installation
46. INSTALL COWL TOP VENTILATOR LOUVER RH Installation
47. INSTALL V-BANK COVER SUB-ASSEMBLY Installation
48. CLEAR DTC
(a) Clear the DTCs Reading and Clearing Diagnostic Trouble Codes.
49. PERFORM LINEAR VALVE OFFSET LEARNING
(a) When the brake master cylinder with simulator assembly is replaced, perform the linear valve offset learning Initialization.
50. CHECK BRAKE ACTUATOR WITH TESTER
(a) Check the brake actuator and pressure sensor On-Vehicle Inspection.
51. CHECK BRAKE MASTER CYLINDER WITH TESTER
(a) Check the brake master cylinder and stroke simulator On-Vehicle Inspection.
52. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light Diagnosis System.
53. CHECK MASTER CYLINDER PRESSURE SENSOR SIGNAL
(a) Check the pressure sensor signal Test Mode Procedure.
54. CHECK FOR DTC
(a) If any DTC is set, perform the troubleshooting for that DTC Reading and Clearing Diagnostic Trouble Codes.
55. READ VALUE OF ACCUMULATOR PRESSURE SENSOR OUTPUT VOLTAGE Installation