BRAKE BOOSTER (for LHD) INSTALLATION


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


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

    2. B000HVJE01
      Text in Illustration
      *a 30° +/- 10°
      B000IB9 Up

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

  2. 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.

  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. B000IUEE05
      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 line.

  6. INSTALL PUSH ROD PIN


    1. B000KFC

      Apply lithium soap base glycol grease to the push rod pin.

      Text in Illustration
      B000I6M Lithium Soap Base Glycol Grease

    2. Connect the brake master cylinder push rod clevis to the brake pedal support assembly with the push rod pin, and install a new clip as shown in the illustration.

      Note


      • Be sure to insert the pin with its clip end facing the outside of the vehicle.

      • Make sure that the brake master cylinder push rod clevis moves sideway.

  7. 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.

  8. 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.

  9. 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.

  10. CONNECT ENGINE WIRE (for 6AR-FSE)


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

  11. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

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  12. INSPECT AND ADJUST BRAKE PEDAL

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