542 BRAKE SYSTEM INSTALLATION ON VEHICLE NOTE: (a) Ensure that the TMC flange surface is free from dirt, dent and burr before mounting it. (b) It is essential that reservoir cap must be removed and cleaned while assembling the reservoir cap on the reservoir. 1. Install TMC assembly on firewall and tighten mounting nuts to specified torque. TIGHTENING TORQUE FOR MOUNTING NUTS OF TMC ASSEMBLY = 2.3 Kg-m 2. Connect all hydraulic lines of TMC assembly to their respective ports and tightened to specified torque. TIGHTENING TORQUE OF BRAKE LINE ATTACHED TO TMC ASSEMBLY = 1.4 - 1.6 Kg-m 3. Connect shackle pin. 4. Fill reservoir with fresh brake fluid, check brake pedal play (refer pedal play inspection) and perform bleeding operation (Refer bleeding of hydraulic system) 5. Perform brake test. 9. Fit the fluid reservoir grommets (08) after liberally lubricating the inlet ports with fresh brake fluid 10. Fit the fluid reservoir after liberally lubricating the inlet ports with fresh brake fluid 11. Fit the spring pin by tapping, ensure spring pin protrudes equally on both side. NOTE: If major kit is to be used to repair TMC assembly, then follow assembly procedure from step (4) onwards with the installation of new parts supplied in the kit.
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