BRAKE BOOSTER(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL VACUUM SENSOR ASSEMBLY (for 6AR-FSE)


    1. Install a new check valve grommet to the brake booster assembly.

    2. B001O56E02
      Text in Illustration
      *a 30° +/- 10°
      B001OAO Up

      Install the vacuum sensor assembly to the brake booster assembly as shown in the illustration.

  2. INSTALL VACUUM WARNING SWITCH ASSEMBLY (for 6AR-FSE)


    1. Install a new check valve grommet to the brake booster assembly.

    2. B001NS6E02
      Text in Illustration
      *a 20° +/- 10°
      B001OAO Up

      Install the vacuum warning switch assembly to the brake booster assembly as shown in the illustration.

  3. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY


    1. Install a new check valve grommet to the brake booster assembly.

    2. Install the brake vacuum check valve assembly to the brake booster assembly.

  4. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. Temporarily install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.

    2. B001ONSE08
      Text in Illustration
      *1 Lock Nut
      *2 Brake Master Cylinder Push Rod Clevis
      *a Push Rod Length

      Set the push rod length as shown in the illustration.

      Push rod length
      148.6 to 149.6 mm (5.86 to 5.88 in.)

    3. Tighten the lock nut.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  5. INSTALL BRAKE BOOSTER GASKET


    1. Install a new brake booster gasket to the brake booster assembly.

  6. INSTALL BRAKE BOOSTER ASSEMBLY


    1. Install the brake booster assembly to the vehicle body with the 4 nuts.

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }

      Note

      Do not kink or damage the brake line.

    2. for 6AR-FSE:


      1. Connect the connector to the vacuum sensor assembly.

  7. INSTALL PUSH ROD PIN

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  8. INSTALL NO. 1 HOSE TO HOSE TUBE (for 2AR-FE)


    1. Install the No. 1 hose to hose tube to the vehicle body with the 2 nuts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    2. Connect the No. 1 hose to hose tube to the brake booster assembly, and slide the clip to secure it.

  9. CONNECT UNION TO CHECK VALVE HOSE (for 6AR-FSE)


    1. Connect the union to check valve hose to the brake booster assembly, and slide the clip to secure it.

  10. CONNECT UNION TO CHECK VALVE HOSE (for 2GR-FE)


    1. Connect the union to check valve hose to the brake booster assembly, and slide the clip to secure it.

  11. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

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  12. INSPECT AND ADJUST BRAKE PEDAL

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