BRAKE MASTER CYLINDER(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE MASTER CYLINDER O-RING


    1. Install a new brake master cylinder O-ring to the brake master cylinder sub-assembly.

  2. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Note

    When installing a new brake master cylinder sub-assembly, remove the protectors from the master cylinder piston and outlet ports.


    1. A01W2DT

      Apply a light layer of a grease enclosed with a new brake master cylinder sub-assembly or lithium soap base glycol grease to the circumference of the brake master cylinder sub-assembly and inner surface of the brake booster assembly as shown in the illustration.

      Text in Illustration
      B001NZR Apply Grease

    2. for 6AR-FSE:


      1. A01VZ63E01
        Text in Illustration
        *1 Master Cylinder Piston

        Install the brake master cylinder sub-assembly, wiring harness clamp bracket and front brake tube way to the brake booster assembly with the 2 nuts.

        Torque:
        13 N*m  { 130 kgf*cm, 9 ft.*lbf }

        Note


        • Do not hold the brake master cylinder sub-assembly by the master cylinder piston. Hold the brake master cylinder sub-assembly by its body or its reservoir when carrying it.

        • Do not pull out the master cylinder piston.

        • Do not strike or pinch the master cylinder piston, or cause any damage to the master cylinder piston by any other means.

        • When installing the brake master cylinder sub-assembly to the brake booster assembly, or when removing the brake master cylinder sub-assembly from the brake booster assembly, make sure that the brake master cylinder sub-assembly is kept horizontal or its tip faces downward (the master cylinder piston faces upward) to prevent the master cylinder piston from falling out.

        • Do not allow any foreign matter to contaminate the master cylinder piston. If any foreign matter gets on the master cylinder piston, remove it by using a piece of cloth and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the master cylinder piston.

        • Do not use any other types of grease.

        • Do not kink or damage the brake lines.

        • Do not allow brake lines to twist or interfere with other parts or the vehicle body during flexible hose tightening.

        • Do not allow any foreign matter such as dirt or dust to enter the brake lines.

    3. for 2AR-FE, 2GR-FE:


      1. A01W4WWE03
        Text in Illustration
        *1 Master Cylinder Piston

        Install the brake master cylinder sub-assembly and front brake tube way to the brake booster assembly with the 2 nuts.

        Torque:
        13 N*m  { 130 kgf*cm, 9 ft.*lbf }

        Note


        • Do not hold the brake master cylinder sub-assembly by the master cylinder piston. Hold the brake master cylinder sub-assembly by its body or its reservoir when carrying it.

        • Do not pull out the master cylinder piston.

        • Do not strike or pinch the master cylinder piston, or cause any damage to the master cylinder piston by any other means.

        • When installing the brake master cylinder sub-assembly to the brake booster assembly, or when removing the brake master cylinder sub-assembly from the brake booster assembly, make sure that the brake master cylinder sub-assembly is kept horizontal or its tip faces downward (the master cylinder piston faces upward) to prevent the master cylinder piston from falling out.

        • Do not allow any foreign matter to contaminate the master cylinder piston. If any foreign matter gets on the master cylinder piston, remove it by using a piece of cloth and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the master cylinder piston.

        • Do not use any other types of grease.

        • Do not kink or damage the brake lines.

        • Do not allow brake lines to twist or interfere with other parts or the vehicle body during flexible hose tightening.

        • Do not allow any foreign matter such as dirt or dust to enter the brake lines.

    4. A01W1VQE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a union nut wrench, connect the 6 brake lines and install the brake master cylinder to way tube to the brake master cylinder sub-assembly.

      Torque:
      Specified tightening torque (a)
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      Specified tightening torque (b)
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note


      • Do not kink or damage the brake lines.

      • Do not allow brake lines to twist and interfere with other parts or vehicle body during flexible hose tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 250 mm (9.84 in.)):

        (a): 14 N*m (142 kgf*cm, 10 ft.*lbf)

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 250 mm (9.84 in.)):

        (b): 18 N*m (184 kgf*cm, 13 ft.*lbf)

    5. for 6AR-FSE:


      1. Connect the connector to the vacuum warning switch assembly.

      2. Connect the connector to the wire harness.

    6. Connect the reservoir level switch connector and engage the clamp.

  3. BLEED BRAKE SYSTEM

    Click here

  4. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 6AR-FSE)

    Click here

  5. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for 6AR-FSE)

    Click here

  6. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (for 6AR-FSE)

    Click here

  7. INSTALL INLET AIR CLEANER ASSEMBLY (for 6AR-FSE)

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  8. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for 6AR-FSE)

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  9. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2AR-FE)

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  10. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for 2AR-FE)

  11. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2AR-FE)

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  12. INSTALL INLET AIR CLEANER ASSEMBLY (for 2AR-FE)

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  13. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2GR-FE)

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  14. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for 2GR-FE)

  15. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2GR-FE)

    Click here

  16. INSTALL INLET NO. 2 AIR CLEANER (for 2GR-FE)

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  17. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

  18. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. Install the front outer cowl top panel sub-assembly with the 10 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.

    3. A01W5PJE03

      Connect the connector to install the wire harness to the front outer cowl top panel sub-assembly.

    4. Engage the 2 clamps (B).

    5. w/ Wiper Deicer System:

      Engage the clamp (A).

  19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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