Brake Master Cylinder: Installation

INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (See INSPECTION )
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 and brake tube way to the brake booster assembly with the 2 nuts.
  Torque: 13 N*m (132 kgf*cm, 10 ft.*lbf)
  NOTE:
  - 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.
    
    Fig 1: Locating Brake Tube Nuts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a union nut wrench (10 mm), connect the 4 brake lines to the brake master cylinder sub-assembly.
  Torque: without a union nut wrench
  
  15 N*m (155 kgf*cm, 11 ft.*lbf)
  
  with a union nut wrench
  
  14 N*m (143 kgf*cm, 10 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.
    
    Fig 2: Connecting Brake Lines To Brake Master Cylinder Sub-Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Engage the clamp and connect the connector.
  
  Fig 3: Locating Brake Master Cylinder Clamp And Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT CLUTCH TUBE (for Manual Transaxle)
1. Connect the clutch tube to the brake master cylinder reservoir assembly with the clip.
FILL RESERVOIR WITH BRAKE FLUID (See ON-VEHICLE INSPECTION )
BLEED CLUTCH LINE (for C59) (See BLEEDING )
BLEED CLUTCH LINE (for E351) (See BLEEDING )
BLEED BRAKE MASTER CYLINDER (See BLEEDING )
BLEED BRAKE LINE (See REPLACEMENT )

Fig 4: Locating Clutch Tube Clip
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
BLEED BRAKE ACTUATOR (w/ VSC) (See BLEEDING )
INSPECT FOR BRAKE FLUID LEAK
INSPECT FLUID LEVEL (See ON-VEHICLE INSPECTION )
INSTALL AIR CLEANER CASE (for 2ZR-FE) (See INSTALLATION )
INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (for 2ZR-FE) (See INSTALLATION )
INSTALL NO. 2 CYLINDER HEAD COVER (for 2ZR-FE) (See INSTALLATION )
INSTALL AIR CLEANER CASE (for 2AZ-FE) (See INSTALLATION )
INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (for 2AZ-FE) (See INSTALLATION )
INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for 2AZ-FE) (See INSTALLATION )
INSTALL SUSPENSION TOWER DAMPER ASSEMBLY (w/ Front Strut Bar) (See INSTALLATION )
INSTALL OUTER COWL TOP PANEL
1. Install the outer cowl top panel with the 12 bolts.
  Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf)
2. Engage the clamp.
  
  Fig 5: Locating Outer Cowl Top Panel Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Bend the water guard plate RH as shown in the illustration and engage the clamp.
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See INSTALLATION )
INSTALL COWL TOP VENTILATOR LOUVER LH (See INSTALLATION )
INSTALL COWL TOP VENTILATOR LOUVER RH (See INSTALLATION )
INSTALL HOOD TO COWL TOP SEAL (See INSTALLATION )

Fig 6: Bending Water Guard Plate RH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See INSTALLATION )
INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See INSTALLATION )
INSTALL FRONT WIPER ARM HEAD CAP (See INSTALLATION )