BRAKE MASTER CYLINDER(for LHD) INSTALLATION

PROCEDURE

1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

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2. INSTALL BRAKE MASTER CYLINDER O-RING

   
   

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

3. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY WITH WAY

   Note

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

   
   

   1. Install the brake master cylinder sub-assembly with way to the brake booster assembly with the 2 nuts.

      Torque:

      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

      Note

      
      

      • The brake master cylinder sub-assembly requires careful handling. Do not allow the brake master cylinder sub-assembly to receive any impact, such as from being dropped. Do not reuse a brake master cylinder sub-assembly that has been dropped.

      • 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 with its tip facing downward (the master cylinder piston is facing 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 new and dry cloth. Do not use water or detergent. 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 the brake lines to twist or interfere with other parts or the vehicle body during tightening.

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

   2. Using a union nut wrench, connect the 2 brake lines to the brake master cylinder sub-assembly with way.

      Torque:

      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note

      
      

      • Do not kink or damage the brake lines.

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

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

      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

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4. CONNECT NO. 1 RESERVOIR HOSE

   
   

   1. Connect the No. 1 reservoir hose to the brake master cylinder sub-assembly, and slide the clip to secure it.

5. BLEED BRAKE SYSTEM

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6. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1AR-FE)

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7. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for 1AR-FE)

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8. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (for 1AR-FE)

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9. INSTALL INLET AIR CLEANER ASSEMBLY (for 1AR-FE)

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10. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for 1AR-FE)

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

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

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13. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (for 2GR-FE)

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14. INSTALL INLET AIR CLEANER ASSEMBLY (for 2GR-FE)

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15. INSTALL V-BANK COVER SUB-ASSEMBLY (for 2GR-FE)

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16. INSTALL COOL AIR INTAKE DUCT SEAL

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17. INSTALL RADIATOR SIDE SEAL RH

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18. INSTALL RADIATOR SIDE DEFLECTOR SEAL LH

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