BRAKE BOOSTER(for RHD) INSTALLATION

PROCEDURE


  1. INSTALL CHECK VALVE GROMMET


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

  2. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY


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

  3. 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 }

  4. INSTALL BRAKE BOOSTER GASKET


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

  5. 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 lines, air conditioner tube and accessory assembly or suction pipe sub-assembly.

  6. INSTALL PUSH ROD PIN

    Click here

  7. CONNECT UNION TO CHECK VALVE HOSE (for 2AR-FE)


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

  8. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for 2AR-FE)


    1. Install the vacuum switching valve assembly with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Connect the 2 vacuum hoses and connector.

    3. Connect the union to check valve hose and wire harness clamp.

  9. CONNECT BRAKE LINE


    1. B001O4I

      Install 2 new clamps to the brake lines.

    2. B001NUDE02
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a union nut wrench, connect the 2 brake lines to the brake actuator assembly.

      Torque:
      Specified tightening torque
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note


      • Do not kink or damage the brake lines.

      • Do not allow brake lines to twist and interfere with other parts or vehicle body during flexible hose tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 250 mm (9.84 in.)):

        18 N*m (184 kgf*cm, 13 ft.*lbf)

  10. INSTALL NO. 1 BRAKE TUBE CLAMP


    1. B001O2H

      Install a new No. 1 brake tube clamp to the vehicle body with the bolt.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

    2. Engage the brake lines to the clamp.

      Note

      Do not kink or damage the brake lines.

  11. INSTALL SUCTION PIPE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the openings of the disconnected parts.

    2. Sufficiently apply compressor oil to a new O-ring, the fitting surface of the suction pipe sub-assembly and air conditioning unit.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction pipe sub-assembly.

      Note

      Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign matter.

    4. B001OK8

      Insert the suction pipe sub-assembly to the air conditioning unit.

      Note


      • Insert the pipe joint into the fitting hole securely.

      • Do not deform the piping.

      • Do not damage the clamp.

    5. B001O11

      Install the clamp with suction pipe sub-assembly and air conditioner tube and accessory assembly to the No. 1 brake tube clamp.

      Note


      • Do not deform the air conditioner tube and accessory assembly or suction pipe sub-assembly.

      • Do not damage the clamp.

    6. B001O6T

      Install the clamp to the brake actuator bracket assembly.

      Note


      • Do not deform the suction pipe sub-assembly.

      • Do not damage the clamp.

  12. INSTALL AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. Remove the attached vinyl tape from the openings of the disconnected parts.

    2. Sufficiently apply compressor oil to 2 new O-rings, the fitting surface of the air conditioner tube and accessory assembly, cooler condenser assembly and air conditioning unit.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the 2 O-rings to the air conditioner tube and accessory assembly.

      Note

      Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign matter.

    4. Insert the air conditioner tube and accessory assembly to the cooler condenser assembly.

    5. Install the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    6. B001OB1

      Insert the air conditioner tube and accessory assembly to the air conditioning unit.

      Note

      Insert the pipe joint into the fitting hole securely.

    7. Turn the hook connector and install the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    8. B001OJFE02
      Text in Illustration
      *A for 2AR-FE
      *B for 2GR-FE

      Install the clamp to the vehicle body and connect the pressure sensor connector.

      Note


      • Do not deform the piping.

      • Do not damage the clamp.

  13. INSTALL RADIATOR SIDE DEFLECTOR RH

    Click here

  14. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (for 2GR-FE)

    Click here

  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for 2AR-FE)

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  17. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for 2AR-FE)

    Click here

  18. WARM UP ENGINE (for 2AR-FE)

    Click here

  19. INSPECT FOR REFRIGERANT LEAK (for 2AR-FE)

    Click here

  20. INSTALL FRONT BUMPER COVER

    Click here

  21. INSPECT AND ADJUST BRAKE PEDAL

    Click here