BRAKE MASTER CYLINDER INSTALLATION


  1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY


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

    2. Connect the reservoir hose to the brake master cylinder sub-assembly and move the clamp back into position.

    3. Insert the brake master cylinder sub-assembly into the brake booster assembly.

    4. Install the brake master cylinder sub-assembly with the 2 nuts.

      A01CDNLE01
      Text in Illustration
      *A for LHD *B for RHD
      *1 O-ring *2 Piston
      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

      Note


      • Do not try to pull out the piston. Do not hold the brake master cylinder sub-assembly by the piston because the piston is easy to separate from the brake master cylinder sub-assembly. If the piston is separated from the brake master cylinder sub-assembly, replace the brake master cylinder sub-assembly with a new one because the master cylinder may not function properly.

      • Do not damage the piston of the brake master cylinder sub-assembly by applying force to the piston or by holding the piston in a vise.

      • Do not tilt the piston end of the brake master cylinder sub-assembly downward.

      • Do not allow any foreign matter to adhere to the piston of the brake master cylinder sub-assembly. If any foreign matter adhere to the piston, remove them using a piece of cloth and apply lithium soap base glycol grease to the contact surface of the piston.

      • Do not use any grease other than specified.

    5. A01CDFTE02
      Text in Illustration
      *a Fulcrum Length

      Using a union nut wrench (12 mm), connect the 2 brake lines to the brake master cylinder sub-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.

    6. A01CGI4E01

      Connect the reservoir hose to the bracket.

    7. Install the wire harness to the body.

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


    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.

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


    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.

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


    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.

  5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (for 2AZ-FE LHD)


    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.

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


    1. A01CCP4

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

  7. 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.

  8. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A01CECSE02
      Text in Illustration
      *1 Reservoir Hose
      *2 Nut
      *3 Brake Master Cylinder Reservoir Assembly
      *4 Warning Switch Connector
      *5 Reservoir Bracket
      A01CFEA Bolt

      Install the brake master cylinder reservoir assembly to the reservoir bracket with the bolt and nut.

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

    2. Connect the reservoir hose to the brake master cylinder reservoir assembly and move the clamp back into position.

    3. Connect the warning switch connector to the brake master cylinder reservoir assembly.

  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 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 }

  13. 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.

  14. INSTALL WINDSHIELD WIPER ARM COVER


    1. A01CEUC

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

  15. BLEED BRAKE LINE

    Tech Tips

    Refer to the instructions for bleed brake line Click here.