BRAKE BOOSTER(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE BOOSTER GASKET


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

  2. INSTALL BRAKE BOOSTER ASSEMBLY


    1. Temporarily install the brake booster assembly to the vehicle body.

      Note

      Do not apply excessive force to the brake lines.

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

      Note

      Fully tighten the lock nut when adjusting the brake pedal height.

    3. Install the 4 nuts to secure the brake booster assembly.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  3. INSTALL PUSH ROD PIN

    Click here

  4. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  5. INSTALL BRAKE LINE


    1. Install the 2 brake lines to the brake tube clamp.

      Note


      • Do not kink or damage the brake lines.

      • Do not damage the clamp.

  6. INSTALL AIR CONDITIONING HOSE AND ACCESSORY (w/ Rear Air Conditioning System)


    1. Install the air conditioning hose and accessory with the nut.

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

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

  7. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY (for 8AR-FTS)


    1. B005NPR

      Connect the fuel vapor feed hose assembly, and slide the clip to secure it.

  8. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY (for 2GR-FKS)


    1. B005P26

      Connect the fuel vapor feed hose assembly, and slide the clip to secure it.

  9. INSTALL ENGINE ROOM MAIN WIRE


    1. for 8AR-FTS:


      1. B005NYL

        Install the engine room relay block assembly with the 2 bolts.

        Torque:
        8.35 N*m  { 85 kgf*cm, 74 in.*lbf }

      2. Engage the clamp.

    2. for 2GR-FKS:


      1. B005QAR

        Install the engine room relay block assembly with the 3 bolts.

        Torque:
        8.35 N*m  { 85 kgf*cm, 74 in.*lbf }

      2. Engage the clamp.

    3. B005QC5

      Engage the clamp and pin to install the wire harness protector.

    4. Install the bolt to secure the wire harness protector.

      Torque:
      8.35 N*m  { 85 kgf*cm, 74 in.*lbf }

    5. w/ Security Horn Assembly:


      1. Connect the connector to the security horn assembly.

    6. for 8AR-FTS:


      1. Connect the connector to the vacuum sensor assembly.

    7. for 2GR-FKS:


      1. Connect the connector to the vacuum warning switch assembly.

    8. Engage the 6 clamps to install the engine room main wire.

    9. for 8AR-FTS:


      1. B005P1X

        Engage the 2 clamps to install the engine wire.

      2. Install the nut.

        Torque:
        8.35 N*m  { 85 kgf*cm, 74 in.*lbf }

  10. INSTALL ECM (for 8AR-FTS)

    Click here

  11. CONNECT UNION TO CHECK VALVE HOSE (for 8AR-FTS)


    1. B005PEY

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

  12. CONNECT UNION TO CHECK VALVE HOSE (for 2GR-FKS)


    1. w/o Rear Air Conditioning System:


      1. B005LRY

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

      2. Install the union to check valve hose to the engine room main wire.

    2. w/ Rear Air Conditioning System:


      1. B005M00

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

      2. Engage the clamp to install the union to check valve hose to the suction pipe sub-assembly.

  13. INSTALL RESERVOIR BRACKET


    1. Install the reservoir bracket with the 2 bolts.

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

  14. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. B005MPEC01
      *1 Brake Master Cylinder Reservoir Assembly
      *2 Reservoir Bracket

      Move the brake master cylinder reservoir assembly as shown in the illustration to engage the 2 claws.

    2. Connect the reservoir level switch connector and install the bolt.

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

  15. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  16. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

  17. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

    Click here

  18. INSTALL COWL SIDE TRIM BOARD LH

    Click here

  19. INSTALL FRONT DOOR SCUFF PLATE LH

    w/o Rear No. 2 Seat: Click here

    w/ Rear No. 2 Seat: Click here

  20. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY WITH WAY

    Click here

  21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  22. INSPECT AND ADJUST BRAKE PEDAL

    Click here