Installation
BRAKE SYSTEM (OTHER): BRAKE MASTER CYLINDER: INSTALLATION
1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD Testing and Inspection
2. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
(a) Install a new O-ring to the brake master cylinder sub-assembly.
(b) Install the brake master cylinder sub-assembly and brake tube way to the brake booster assembly with the 2 nuts.
Torque : 13 Nm (132 kgf-cm, 10 ft-lbf)
NOTICE:
* The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as being dropped. Do not reuse a master cylinder that has been dropped.
* Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.
* When installing the master cylinder to the brake booster, or when removing the master cylinder from the brake booster, make sure that the master cylinder is kept horizontal or its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling off.
* Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the 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 piston.
* Do not use any other type of grease or fluid.
(c) Using a union nut wrench (10 mm or 12 mm), connect the 2 brake lines (A) to the brake master cylinder sub-assembly.
for 2AZ-FE without a union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
for 2AZ-FE with a union nut wrench - Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
for 2ZR-FE without a union nut wrench - Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)
for 2ZR-FE with a union nut wrench - Torque : 18 Nm (178 kgf-cm, 13 ft-lbf)
NOTICE:
* 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.
(d) Using a union nut wrench (10 mm), connect the 2 brake lines (B) to the brake tube way.
without a union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
with a union nut wrench - Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
NOTICE:
* 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.
(e) Engage the clamp and connect the connector.
3. CONNECT CLUTCH TUBE (for Manual Transaxle)
(a) Connect the clutch tube to the brake master cylinder reservoir assembly with the clip.
4. FILL RESERVOIR WITH BRAKE FLUID Service and Repair
5. BLEED CLUTCH LINE (for C59)
6. BLEED CLUTCH LINE (for E351)
7. BLEED BRAKE MASTER CYLINDER Service and Repair
8. BLEED BRAKE LINE Service and Repair
9. BLEED BRAKE ACTUATOR Service and Repair
10. INSPECT FOR BRAKE FLUID LEAK
11. INSPECT FLUID LEVEL Testing and Inspection
12. INSTALL AIR CLEANER CASE (for 2ZR-FE) Installation
13. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (for 2ZR-FE) Installation
14. INSTALL NO. 2 CYLINDER HEAD COVER (for 2ZR-FE) Installation
15. INSTALL AIR CLEANER CASE (for 2AZ-FE) Installation
16. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (for 2AZ-FE) Installation
17. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for 2AZ-FE) Installation
18. INSTALL SUSPENSION TOWER DAMPER ASSEMBLY (w/ Front Strut Bar) Installation
19. INSTALL OUTER COWL TOP PANEL
(a) Install the outer cowl top panel with the 12 bolts.
Torque : 8.8 Nm (90 kgf-cm, 78 in-lbf)
(b) Engage the clamp.
(c) Bend the water guard plate RH as shown in the illustration and engage the clamp.
20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
21. INSTALL COWL TOP VENTILATOR LOUVER LH Installation
22. INSTALL COWL TOP VENTILATOR LOUVER RH Installation
23. INSTALL HOOD TO COWL TOP SEAL Installation
24. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
25. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
26. INSTALL FRONT WIPER ARM HEAD CAP Installation