BRAKE BOOSTER(for RHD) 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 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:
      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 CYLINDER HEAD COVER SUB-ASSEMBLY (for 2GR-FKS)

    Click here

  6. INSTALL IGNITION COIL ASSEMBLY (for 2GR-FKS)


    1. Install the 3 ignition coil assemblies with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

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


    1. Install the engine wire with the 3 bolts.

      B007YUJC01
      B007WXX Connector B00803L Bolt
      Torque:
      8.35 N*m  { 85 kgf*cm, 74 in.*lbf }

    2. Engage the 4 clamps and connect the 8 connectors.

  8. INSTALL INJECTOR VIBRATION INSULATOR (for 2GR-FKS)

    Click here

  9. INSTALL NO. 1 DELIVERY PIPE SPACER (for 2GR-FKS)

    Click here

  10. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (for 2GR-FKS)

    Click here

  11. CONNECT FUEL TUBE SUB-ASSEMBLY (for 2GR-FKS)

    Click here

  12. CONNECT NO. 2 VENTILATION HOSE (for 2GR-FKS)


    1. Connect the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.

  13. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/o Sub-cool Accelerator)


    1. for 2GR-FKS with Rear Air Conditioning System:


      1. Remove the vinyl tape from the air conditioner tube and accessory assembly.

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

        Compressor Oil
        ND-OIL 8 or equivalent

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

      4. B007XST

        Connect the air conditioner tube and accessory assembly to the air conditioning hose and accessory.

        Note

        Do not deform the refrigerant lines.

      5. B007X0I

        Install the piping clamp to the air conditioner tube and accessory assembly.

        Click here

  14. CONNECT SUCTION PIPE SUB-ASSEMBLY (w/o Sub-cool Accelerator)


    1. for 2GR-FKS with Rear Air Conditioning System:


      1. Remove the vinyl tape from the suction pipe sub-assembly.

      2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the suction pipe sub-assembly.

        Compressor Oil
        ND-OIL 8 or equivalent

      3. Install the 2 O-rings to the suction pipe sub-assembly.

      4. B007X2L

        Connect the suction pipe sub-assembly to the air conditioning hose and accessory.

        Note

        Do not deform the refrigerant lines.

      5. B007YR0

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

        Click here

  15. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/o Sub-cool Accelerator)


    1. Remove the vinyl tape from the air conditioner tube and accessory assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioner tube and accessory assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

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

    4. B007ZMR

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

    5. for 2GR-FKS:


      1. B007ZYX

        Engage the clamp to install the air conditioner tube and accessory assembly.

        Note


        • Do not deform the refrigerant lines.

        • Do not damage the clamp.

      2. B007Y32

        Install the air conditioner tube and accessory assembly with the bolt.

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

        Note

        Do not deform the refrigerant lines.

      3. B007YEA

        Engage the clamp.

      4. Connect the connector to the air conditioner tube and accessory assembly.

    6. for 8AR-FTS:


      1. B00804O

        Install the air conditioner tube and accessory assembly with the bolt.

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

        Note

        Do not deform the refrigerant lines.

      2. B007X76

        Engage the clamp to install the air conditioner tube and accessory assembly.

        Note


        • Do not deform the refrigerant lines.

        • Do not damage the clamp.

  16. INSTALL SUCTION PIPE SUB-ASSEMBLY (w/o Sub-cool Accelerator)


    1. Remove the vinyl tape from the suction pipe sub-assembly.

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

      Compressor Oil
      ND-OIL 8 or equivalent

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

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

    5. B007YDS

      Rotate the hook connector as shown in the illustration.

    6. Insert the tube joint into the fitting hole securely and install the bolt.

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

    7. for 8AR-FTS:


      1. B007YZ8

        Engage the clamp to install the suction pipe sub-assembly.

        Note


        • Do not deform the refrigerant lines.

        • Do not damage the clamp.

      2. B007XTY

        Engage the clamp to the suction pipe sub-assembly.

    8. for 2GR-FKS:


      1. B007ZYU

        Engage the clamp to install the suction pipe sub-assembly.

        Note


        • Do not deform the refrigerant lines.

        • Do not damage the clamp.

      2. B007ZXF

        Engage the clamp to the suction pipe sub-assembly.

  17. INSTALL NO. 2 AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/ Sub-cool Accelerator)


    1. Remove the vinyl tape from the No. 2 air conditioner tube and accessory assembly.

    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the No. 2 air conditioner tube and accessory assembly.

      Compressor Oil
      ND-OIL 12 or equivalent

    3. Install the 2 O-rings to the No. 2 air conditioner tube and accessory assembly.

    4. Insert the No. 2 air conditioner tube and accessory assembly to the air conditioning unit assembly.

    5. B007XBO

      Rotate the hook connector as shown in the illustration.

    6. Insert the tube joint into the fitting hole securely and install the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    7. B007XMF

      Install the No. 2 air conditioner tube and accessory assembly with the bolt.

      Note

      Do not deform the refrigerant lines.

  18. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/ Sub-cool Accelerator)


    1. Remove the vinyl tape from the air conditioner tube and accessory assembly.

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

      Compressor Oil
      ND-OIL 12 or equivalent

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

    4. B007YLU

      Connect the air conditioner tube and accessory assembly to the No. 2 air conditioner tube and accessory assembly.

      Note

      Do not deform the refrigerant lines.

    5. B00804O

      Install the air conditioner tube and accessory assembly with the bolt.

      Note

      Do not deform the refrigerant lines.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    6. B007Z85

      Install the piping clamp to the air conditioner tube and accessory assembly.

      Click here

  19. CONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Sub-cool Accelerator)


    1. Remove the vinyl tape from the suction hose sub-assembly.

    2. B007ZNUC04
      *1 Suction Hose Sub-assembly
      *2 Piping Clamp
      *a Groove

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

      Note


      • Securely engage the inside step of the piping clamp into the groove of the suction hose sub-assembly.

      • Do not widen the opening of the piping clamp more than the diameter of the suction hose sub-assembly when installing it.

      • Do not install the piping clamp with the large diameter section in the wrong direction.

    3. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the suction hose sub-assembly.

      Compressor Oil
      ND-OIL 12 or equivalent

    4. Install the 2 O-rings to the suction hose sub-assembly

    5. B007YV0

      Connect the suction hose sub-assembly to the No. 2 air conditioner tube and accessory assembly.

      Click here

      Note

      Do not deform the refrigerant lines.

  20. INSTALL BRAKE LINE


    1. Install the front No. 6 brake tube and front No. 7 brake tube, and engage the 2 clamps to secure the 2 brake lines.

      Note


      • Do not damage the 2 clamps.

      • Do not kink or damage the brake lines.

    2. B007YN4C02
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Using a union nut wrench, connect the No. 6 brake tube and front No. 7 brake tube to the brake actuator assembly.

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

      Note


      • Do not kink or damage the brake lines.

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

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

      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 162 mm (6.38 in.)):

        17.36 N*m (177 kgf*cm, 13 ft.*lbf)

  21. INSTALL ENGINE ROOM MAIN WIRE


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

    2. for 8AR-FTS:


      1. Connect the connector to the vacuum sensor assembly.

    3. for 2GR-FKS:


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

  22. CONNECT CHECK VALVE TO BRAKE BOOSTER HOSE (for 8AR-FTS)


    1. B008007

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

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


    1. w/o Rear Air Conditioning System:


      1. B00802V

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

    2. w/ Rear Air Conditioning System:


      1. B007YSU

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

  24. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for 8AR-FTS)

    Click here

  25. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY WITH WAY

    Click here

  26. INSTALL FUEL PUMP ASSEMBLY (for 2GR-FKS)

    Click here

  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  28. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    for HFC-134a (R134a): Click here

    for HFO-1234yf (R1234yf): Click here

  29. WARM UP ENGINE

    for HFC-134a (R134a): Click here

    for HFO-1234yf (R1234yf): Click here

  30. INSPECT FOR REFRIGERANT LEAK

    for HFC-134a (R134a): Click here

    for HFO-1234yf (R1234yf): Click here

  31. INSPECT AND ADJUST BRAKE PEDAL

    Click here

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

    Click here

  33. INSTALL COWL SIDE TRIM BOARD RH

    Tech Tips

    Use the same procedure as for the LH side.

    Click here

  34. INSTALL FRONT DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure as for the LH side.

    w/o Rear No. 2 Seat: Click here

    w/ Rear No. 2 Seat: Click here