BRAKE MASTER CYLINDER (for LHD) INSTALLATION


  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. A01G570

      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
      A01G6PZ Apply Grease
    2. A01G92UE01
      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.

    3. A01G84GE01

      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:
      a
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      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 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.

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

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

  3. BLEED BRAKE SYSTEM

    Click here

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


    1. A01G579E01
      Text in Illustration
      *a Hole
      *b Projection

      Insert the projection of the air cleaner case sub-assembly into the hole of the No. 2 air cleaner bracket as shown in the illustration.

    2. Install the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Connect the wire harness clamp.

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

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


    1. A01G6AKE01
      Text in Illustration
      *a Hinge
      *b Clamp

      Connect the 2 hinges of the air cleaner cap sub-assembly.

    2. Install the air cleaner cap sub-assembly with the 2 clamps.

    3. Connect the air cleaner cap sub-assembly to the throttle with motor body assembly the hose clamp.

    4. Connect the ventilation hose to the cylinder head cover.

    5. Install the fuel vapor feed hose to the air cleaner hose.

    6. Connect the mass air flow meter connector and 2 wire harness clamps to the air cleaner cap sub-assembly.

    7. Connect the vacuum switching valve assembly to the air cleaner cap sub-assembly.

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


    1. Install the inlet air cleaner assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

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


    1. A01G68JE01
      Text in Illustration
      *1 Air Cleaner Case Sub-assembly
      *2 Inlet No. 1 Air Cleaner
      *a Projection
      *b Hole

      Install the air cleaner case sub-assembly to the inlet No. 1 air cleaner.

    2. Insert the projection of the air cleaner case sub-assembly to the hole of the No. 2 air cleaner bracket as shown in the illustration.

    3. Tighten the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    4. Connect the 3 wire harness clamps, connector, vacuum hose and No. 1 fuel vapor feed hose.

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

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


    1. Connect the air cleaner cap sub-assembly to the throttle with motor body assembly with the hose clamp.

    2. Install the air cleaner cap sub-assembly to the air cleaner case with the 2 clamps.

    3. Connect the 3 hoses.

    4. Connect the ventilation hose.

    5. Connect the mass air flow meter connector and wire harness clamp.

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


    1. Install the inlet No. 2 air cleaner to the air cleaner case sub-assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the 2 wire harness clamps and vacuum hose clamp.

  12. INSTALL COOL AIR INTAKE DUCT SEAL


    1. Install the cool air intake duct seal with the 9 clips.

  13. 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. A01G885E01

      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).

  14. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here