INSTALLATION (To 8/2009): Installation

INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD See step 1
INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
1. Install a new O-ring to the brake master cylinder sub-assembly.
2. Install the brake master cylinder sub-assembly to the brake booster assembly with the 2 nuts.
  
  Fig 1: Install the brake master cylinder sub-assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf)
  NOTE:
  - The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from 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 out.
  - Do not allow any foreign matter to contaminate the master cylinder piston. If foreign matter gets on the piston, remove it by using a piece of cloth and then apply an even layer of lithium soap based glycol grease around the circumference (sliding part) of the piston.
  - Do not use any other type of grease or fluid.
CONNECT BRAKE LINE
1. Using a union nut wrench, connect the 2 brake lines to the brake master cylinder sub-assembly.
  
  Fig 2: Connect The 2 Brake Lines
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf)
  
  NOTE:
  Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench. Refer to PRECAUTION .
CONNECT NO. 1 RESERVOIR TUBE
1. Connect the No. 1 reservoir tube to the brake master cylinder reservoir sub-assembly.
  
  Fig 3: Connect the No. 1 reservoir tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CLEANER ASSEMBLY . Refer to INSTALLATION - Step 2
INSTALL BATTERY . Refer to INSTALLATION - Step 71
INSTALL NO. 1 AIR CLEANER INLET . Refer to INSTALLATION - Step 72
INSTALL NO. 2 AIR CLEANER INLET . Refer to INSTALLATION - Step 73
INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 113
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .
FILL RESERVOIR WITH BRAKE FLUID See step 1
BLEED BRAKE MASTER CYLINDER See step 2
BLEED BRAKE LINE See step 2
BLEED BRAKE ACTUATOR See step 4
INSPECT FOR BRAKE FLUID LEAK
INSPECT FLUID LEVEL See step 1
INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY
1. Install the outer cowl top panel sub-assembly with the 4 bolts, 4 nuts*1 and 2 nuts*2.
  
  Fig 4: Install the outer cowl top panel sub-assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Nut*1
  
  Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf)
  
  Nut*2
  
  Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
  
  Bolt
  
  Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
2. Engage the grommet and clamp to install the wire harness.
  
  Fig 5: Engage the grommet and clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the connector (w/ Windshield Deicer).
INSTALL FRONT SHOCK ABSORBER CAP LH (w/ Air Suspension) . Refer to INSTALLATION - Step 10
INSTALL FRONT SHOCK ABSORBER CAP RH (w/ Air Suspension)
HINT:

Use the same procedure for the RH side and LH side.
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
HINT:

Refer to the instructions for Installation of the windshield wiper motor and link assembly. Refer to INSTALLATION .