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 or refrigerant 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:
      12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }

  3. INSTALL PUSH ROD PIN

    Click here

  4. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  5. INSTALL BRAKE LINE


    1. Install the 3 brake lines to the brake tube clamp.

      Note


      • Do not kink or damage the brake lines.

      • Do not damage the clamp.

    2. Install the bolt to secure front No. 1 brake tube way.

      Torque:
      4.9 N*m  { 50 kgf*cm, 43 in.*lbf }

      Note

      Do not kink or damage the brake lines.

  6. INSTALL AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. Install the air conditioner tube and accessory assembly 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. INSTALL SUCTION HOSE SUB-ASSEMBLY


    1. A0027JC

      Install the suction hose sub-assembly to the piping clamp.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    2. Engage the claw to secure the suction hose sub-assembly.

  8. CONNECT NO. 1 VACUUM HOSE CONNECTOR (for 1AR-FE)


    1. Install the No. 1 vacuum hose connector with the 2 nuts.

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

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

  9. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY


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

  10. INSTALL ENGINE ROOM MAIN WIRE


    1. Engage the 2 pins to install the engine room relay block assembly.

    2. Install the 2 bolts.

    3. B003Z0YC01
      *a Clamp
      *b Pin

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

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

    5. Install the earth wire with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    6. for 2GR-FKS:


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

    7. Engage the 5 clamps to install the engine room main wire.

  11. INSTALL ENGINE WIRE (for 1AR-FE)


    1. Engage the 3 clamps to install the engine wire.

  12. INSTALL ENGINE WIRE (for 2GR-FKS)


    1. Engage the 2 clamps to install the engine wire.

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


    1. 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.

  14. INSTALL ECM

    for 1AR-FE: Click here

    for 2GR-FKS: Click here

  15. INSTALL RESERVOIR BRACKET


    1. Install the reservoir bracket with the 2 bolts.

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

  16. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A0027AVC01
      *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 }

  17. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  18. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  19. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY WITH WAY

    Click here

  20. INSPECT AND ADJUST BRAKE PEDAL

    Click here