BRAKE ACTUATOR INSTALLATION


  1. INSTALL BRAKE ACTUATOR ASSEMBLY


    1. A01CDLE

      Using a hexagon wrench (5 mm), install the No. 2 brake actuator bracket to the brake actuator assembly with the 3 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

      Note


      • Do not remove the hole plugs of a new brake actuator before connecting the 6 brake lines because the brake actuator assembly is filled with brake fluid.

      • Do not hold the actuator by the connector.

    2. A01CBK4

      Install the brake actuator bracket assembly to the brake actuator assembly with No. 2 brake actuator bracket with the 3 nuts.

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

  2. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET


    1. A01CEFK

      Install the brake actuator assembly with bracket to the body with 3 nuts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      Note

      Do not damage the brake lines or wire harness.

    2. A01CFS8E02

      Install the brake line clamp to the brake actuator bracket assembly.

    3. A01CFD9E01

      Temporarily tighten each brake line to the correct positions of the brake actuator assembly with bracket as shown in the illustration.

      Tech Tips


      • *1: To front wheel cylinder RH

      • *2: To front wheel cylinder LH

      • *3: To rear wheel cylinder RH

      • *4: To rear wheel cylinder LH

      • *5: From 2nd of master cylinder

      • *6: From 1st of master cylinder

    4. A01CAW7E01

      Using a union nut wrench (10 mm) and a union nut wrench (12 mm), fully tighten each brake line.

      Torque:
      Flare nut (M10) without a union nut wrench (10 mm)
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      Flare nut (M10) with a union nut wrench (10 mm)
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
      Flare nut (M12) without a union nut wrench (12mm)
      20 N*m  { 199 kgf*cm, 15 ft.*lbf }
      Flare nut (M12) with a union nut wrench (12mm)
      17 N*m  { 177 kgf*cm, 13 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

    5. A01CE4EE01

      Connect the brake actuator connector and install the clamp.

      Note

      Make sure that the connector is locked securely.

  3. INSTALL ENGINE UNDER COVER NO.2 (for 2AZ-FE)

  4. INSTALL AIR CLEANER CASE (for 2AZ-FE)


    1. Install the air cleaner case with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Install the engine wire clamp to the air cleaner case.

    3. Install the air cleaner filter element.

  5. INSTALL AIR CLEANER CASE (for 2GR-FE)


    1. A01CFWV

      Install the air cleaner case with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the wire clamp.

    3. Install the air cleaner filter element.

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


    1. A01CDPJ

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

    2. A01CEYSE01
      Text in Illustration
      *1 No. 1 air cleaner hose clamp
      *2 Groove
      *3 Tab
      *4 95°

      Connect the No. 1 air cleaner hose to the throttle body and release the lock of the No. 1 air cleaner hose clamp.

      Note


      • Align the groove of the air cleaner hose with the tab of the throttle body and install the hose.

      • Make sure that the tab of the No. 1 air cleaner hose clamp stays within the range shown by *4

    3. A01CD15

      Connect the 2 wire harness clamps and the mass air flow meter connector.

    4. A01CFO3

      Connect the ventilation hose.

    5. A01CCLR

      Connect the purge line hose to the No. 1 vacuum switching valve assembly and air cleaner hose.

    6. A01CEOK

      Connect the fuel vapor feed hose to the No. 1 vacuum switching valve assembly.

    7. Connect the wire harness clamp and No. 1 vacuum switching valve connector.

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


    1. A01CB66

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

    2. A01CAN5

      Connect the air cleaner hose to the throttle body with the hose clamp.

    3. Connect the ventilation hose.

    4. A01CBVZE01

      Connect the purge line hose.

    5. Connect the 2 wire harness clamps and mass air flow meter connector.

  8. INSTALL OUTER COWL TOP PANEL


    1. A01CCFB

      Install the outer cowl top panel with the 8 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

    2. Connect the 2 clamps to the outer cowl top panel.

    3. Remove the protective tape.

  9. INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. A01CBAK

      Install the brake master cylinder reservoir with bracket to the outer cowl top panel with the 2 nuts.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  10. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A01CFL4

      Install the windshield wiper motor and link assembly with the 3 bolts as shown in the illustration.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    2. A01CAUN

      Connect the connector.

  11. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. A01CEWQ

      Engage the 15 claws and 2 guides to install the cowl top ventilator louver sub-assembly as shown in the illustration.

    2. A01CFAO

      Install the 2 clips.

  12. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. When reusing the front wiper arm and blade assembly LH:


      1. A01CC1NE01

        Clean the wiper arm serrations.

    2. When reusing the windshield wiper link assembly:


      1. A01CEI7E01

        Clean the wiper pivot serrations with a wire brush.

    3. A01CAPLE01

      Install the front wiper arm and blade assembly LH with the nut to the position shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    4. Operate the front wipers while spraying washer fluid onto the windshield. Make sure that the front wipers function properly and the wipers do not come into contact with the vehicle body.

  13. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. Operate the wiper and stop the windshield wiper motor at the automatic stop position.

    2. When reusing the front wiper arm and blade assembly RH:


      1. A01CC1NE01

        Clean the wiper arm serrations.

    3. When reusing the windshield wiper link assembly:


      1. A01CEI7E01

        Clean the wiper pivot serrations with a wire brush.

    4. A01CG9BE01

      Install the front wiper arm and blade assembly RH with the nut to the position shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  14. INSTALL WINDSHIELD WIPER ARM COVER


    1. A01CEUC

      Engage the 2 claws to install the 2 windshield wiper arm covers.

  15. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A01CCP4

      Fit the 3 retainers and install the V-bank cover sub-assembly.

  16. FILL RESERVOIR WITH BRAKE FLUID


    1. Fill the reservoir with brake fluid.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

      Note

      Before replacing the brake fluid or bleeding the brake system, confirm that the reservoir located above the master cylinder assembly is filled with brake fluid.

  17. BLEED BRAKE MASTER CYLINDER

    Tech Tips

    If the master cylinder is reinstalled or runs out of brake fluid, bleed the master cylinder.

    Note


    • If the master cylinder is reinstalled or runs out of brake fluid, bleed the master cylinder.

    • To prevent brake fluid from damaging painted surface, cover any surrounding parts with a piece of cloth.


    1. A01CBED

      Using a union nut wrench (12 mm), disconnect the 2 brake tubes from the brake master cylinder assembly.

    2. A01CE36

      Slowly depress the brake pedal and hold it down.

    3. A01CECR

      Cover the 2 tube holes with your fingers and release the brake pedal.

    4. Uncover the holes, slowly depress the brake pedal and hold it down. While holding down the brake pedal, cover the tube holes again. Repeat this step 3 or 4 times.

    5. A01CDFTE01

      Using a union nut wrench (12 mm), connect the 2 brake tubes to the brake master cylinder assembly.

      Torque:
      without a union nut wrench
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
      with a union nut wrench
      18 N*m  { 183 kgf*cm, 13 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

  18. BLEED BRAKE LINE

    Note


    • Bleed the brake line of the wheel farthest from the master cylinder first.

    • To prevent air from entering the brake lines, bleed the brake lines while keeping the reservoir filled to the MAX line with brake fluid.


    1. A01CFEO

      Connect a vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times, and while holding down the brake pedal, loosen the bleeder plug*1.

    3. When fluid stops coming out, tighten the bleeder plug and release the brake pedal*2.

    4. Repeat steps *1 and *2 until all the air in the fluid is completely bled out.

      Torque:
      Front disc brake bleeder plug
      8.3 N*m  { 85 kgf*cm, 74 in.*lbf }
      Rear disc brake bleeder plug
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    5. Repeat the above steps to bleed the brake lines for each wheel.

  19. INSPECT BRAKE FLUID LEVEL


    1. A01CFCL

      Check the fluid level.

      Tech Tips

      If brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  20. INSPECT FOR BRAKE FLUID LEAK

  21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  22. INSPECT BRAKE ACTUATOR ASSEMBLY WITH INTELLIGENT TESTER

    Tech Tips

    Click here.

  23. CHECK AND CLEAR DTC

    Tech Tips

    Click here.