FRONT BRAKE FLEXIBLE HOSE > INSTALLATION

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HINT:
  1. Use the same procedures for the LH side and RH side.
  2. The procedures listed below are for the LH side.



1. INSTALL FRONT FLEXIBLE HOSE (2WD)


C111389E02

  1. Connect the flexible hose to the brake cylinder with the union bolt labeled A and a new gasket.

    Torque:
    29 N*m{ 296 kgf*cm , 21 ft.*lbf }

    NOTICE:
    Install the flexible hose lock securely in the lock hole in the brake cylinder.

  1. Install the flexible hose with the bolt labeled B and clip labeled C.

  1. Using SST, connect the brake tube to the flexible hose while holding flexible hose with a wrench.

    SST
    09023-00101  

    Torque:
    15.2 N*m{ 155 kgf*cm , 10 ft.*lbf } without SST
    14 N*m{ 143 kgf*cm , 10 ft.*lbf } with SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.82 in.).

    NOTICE:
    1. Do not bend or damage the brake tube.
    2. Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting points.



2. INSTALL FRONT NO. 1 WHEEL CYLINDER TUBE LH (4WD)


C111391

  1. Using SST, install the wheel cylinder tube to the brake cylinder.

    SST
    09023-00101  

    Torque:
    15.2 N*m{ 155 kgf*cm , 10 ft.*lbf } without SST
    14 N*m{ 143 kgf*cm , 10 ft.*lbf } with SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.82 in.).

    NOTICE:
    1. Do not bend or damage the wheel cylinder tube.
    2. Do not allow any foreign matter such as dirt and dust to enter the wheel cylinder tube from the connecting points.



3. INSTALL FRONT FLEXIBLE HOSE (4WD)


C111390

  1. Attach the 2 clips to the flexible hose.

  1. Using SST, connect the flexible hose to the brake tube and wheel cylinder tube while holding the flexible hose with a wrench.

    SST
    09023-00101  

    Torque:
    15.2 N*m{ 155 kgf*cm , 10 ft.*lbf } without SST
    14 N*m{ 143 kgf*cm , 10 ft.*lbf } with SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.82 in.).

    NOTICE:
    1. Do not bend or damage the brake tube and wheel cylinder tube.
    2. Do not allow any foreign matter such as dirt and dust to enter the brake tube and wheel cylinder tube from the connecting points.



4. FILL RESERVOIR WITH BRAKE FLUID


Fluid:
SAE J1703 or FMVSS No. 116 DOT3



C111283E01



5. BLEED AIR FROM BRAKE MASTER CYLINDER

HINT:
If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.

  1. Using SST, disconnect the 2 brake lines from the master cylinder.

    SST
    09023-00101  



  1. Slowly depress and hold the brake pedal.


    C111284E01

  1. Cover the outer holes with your finger, and release the pedal.

  1. Repeat the 2 previous steps 3 or 4 times.



  1. Using SST, connect the 2 brake lines to the master cylinder.

    SST
    09023-00101  

    Torque:
    15.2 N*m{ 155 kgf*cm , 11 ft.*lbf } without SST
    14 N*m{ 143 kgf*cm , 10 ft.*lbf } with SST


    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

    C111285E01



6. BLEED AIR FROM BRAKE LINE

  1. Remove the bleeder plug cap.

  1. Connect the vinyl tube to the bleeder plugs.

  1. Depress the pedal several times, and then loosen the bleeder plug with the pedal depressed.

  1. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

  1. Repeat the 2 previous steps until all the air in the brake fluid is gone.

  1. Tighten the bleeder plug.

    Torque:
    10.8 N*m{ 110 kgf*cm , 8 ft.*lbf } for front brake
    11 N*m{ 112 kgf*cm , 8 ft.*lbf } for rear brake (2WD)
    10 N*m{ 102 kgf*cm , 7 ft.*lbf } for rear brake (4WD)

  1. Install the cap.



  1. Bleed air from the brake line for each wheel by repeating the above procedures.


    C111286E01



7. BLEED AIR FROM CLUTCH LINE (M/T)


C112661E01

  1. Remove the bleeder plug cap.

  1. Connect the vinyl tube to the bleeder plug.

  1. Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

  1. At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

  1. Repeat the previous 2 steps until all the air in the fluid is completely bled out.

  1. Tighten the bleeder plug.

    Torque:
    11 N*m{ 112 kgf*cm , 8 ft.*lbf }

  1. Install the bleeder plug cap.

  1. Check that all the air has been bled out of the clutch line.



8. CHECK BRAKE FLUID LEVEL IN RESERVOIR


    F052092

  1. Check the fluid level and add fluid if necessary.

    Fluid:
    SAE J1703 or FMVSS No. 116 DOT3

    HINT:
    Add fluid to a level between the reservoir's MIN and MAX lines.



9. CHECK FOR BRAKE FLUID LEAKAGE


10. INSTALL FRONT WHEEL

Torque:
152 N*m{ 1,550 kgf*cm , 112 ft.*lbf } for steel type (2WD)
121 N*m{ 1,234 kgf*cm , 89 ft.*lbf } for aluminum type (2WD)
105 N*m{ 1,071 kgf*cm , 77 ft.*lbf } (4WD)