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Brake Booster: Installation

  1. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS 
    1. Temporarily install the push rod clevis with the lock nut.
    2. Adjust and tighten the push rod clevis with the lock nut (see DISASSEMBLY  ).
  2. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY 
    1. Install the grommet and check valve assembly.
  3. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the brake booster assembly.
  4. INSTALL BRAKE BOOSTER ASSEMBLY 
    1. Install the brake booster assembly with the 4 nuts.

      Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf) 

      NOTE: Do not damage the brake tubes.
      Fig 1: Installing Brake Booster Assembly With Nuts
      G04025352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the vacuum hose with the clip.
      Fig 2: Connecting Vacuum Hose With Clip
      G04025353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS 
    1. Apply lithium soap base glycol grease to the clevis pin.
    2. Install the push rod clevis to the brake pedal support assembly with the clevis pin and a new clip.
      Fig 3: Installing Push Rod Clevis To Brake Pedal Support Assembly With Clevis Pin And Clip
      G04025354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL BRAKE PEDAL RETURN SPRING 
    1. Install the brake pedal return spring.
  7. INSTALL ABS AND TRACTION ACTUATOR ASSEMBLY (See  INSTALLATION  ) 
  8. INSTALL BRAKE MASTER WITH PLATE CYLINDER SUB-ASSEMBLY (See  INSPECTION   ) 
  9. INSTALL ENGINE ROOM RELAY BLOCK NO.3 (See  INSPECTION   ) 
  10. ADD BRAKE FLUID (See  BRAKE FLUID (W/ VSC)   ) 
  11. CONNECT BATTERY NEGATIVE TERMINAL 
  12. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See  INSTALLATION  ) 
  13. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See  INSTALLATION  ) 
  14. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See  INSTALLATION  ) 
  15. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See  INSTALLATION  ) 
  16. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See  INSTALLATION  ) 
  17. INSTALL FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY LH (See  INSTALLATION  ) 
  18. INSTALL FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY RH (See  INSTALLATION  ) 
  19. ADD RESERVOIR WITH BRAKE FLUID (See  BRAKE FLUID (W/ VSC)   ) 
  20. BLEED MASTER CYLINDER (See  BRAKE FLUID (W/ VSC)   ) 
  21. BLEED BRAKE LINE (See  BLEEDING   ) 
  22. BLEED ABS AND TRACTION ACTUATOR ASSEMBLY (See  BLEEDING   ) 
  23. INSPECT FLUID LEVEL IN THE RESERVOIR (See  BRAKE FLUID (W/ ECB)   ) 
  24. INSPECT BRAKE FLUID LEAKAGE 
  25. INSPECT ABS AND TRACTION ACTUATOR ASSEMBLY 

    (see ON-VEHICLE INSPECTION )

  26. INSTALL COOL AIR INTAKE DUCT SEAL (See  INSTALLATION  ) 
  27. INSPECT BRAKE PEDAL HEIGHT (See  DISASSEMBLY   ) 
  28. INSPECT PEDAL FREE PLAY (See  ADJUSTMENT   ) 
  29. INSPECT PEDAL RESERVE DISTANCE (See  REASSEMBLY   ) 
  30. INSTALL INSTRUMENT PANEL AIR BAG ASSEMBLY NO.1 LOWER (See  INSTALLATION  ) 
  31. INSTALL INSTRUMENT PANEL SAFETY PAD NO.1 SUB-ASSEMBLY (See  INSTALLATION  ) 
  32. INSTALL INSTRUMENT PANEL UNDER COVER NO.1 SUB-ASSEMBLY (See  INSTALLATION  ) 
  33. INSTALL INSTRUMENT SIDE PANEL LH (See  INSTALLATION  ) 
  34. INSTALL FRONT DOOR OPENING TRIM COVER LH (See  INSTALLATION  ) 
  35. INSTALL FRONT DOOR SCUFF PLATE LH (See  INSTALLATION  ) 
  36. INSTALL INSTRUMENT PANEL FINISH PANEL END LH (See  INSTALLATION  ) 
  37. INSTALL CONSOLE UPPER PANEL SUB-ASSEMBLY (See  INSTALLATION  ) 
  38. INSTALL CONSOLE UPPER PANEL GARNISH FRONT (See  INSTALLATION  ) 
  39. INSTALL ENGINE ROOM COVER SIDE (See ) 
  40. INSTALL ENGINE ROOM SIDE COVER LH (See  INSTALLATION  ) 
  41. INSPECT VSC SENSOR SIGNAL 

    (See DIAGNOSIS SYSTEM )

  42. INSPECT SRS WARNING LIGHT 

    (See DIAGNOSIS SYSTEM )

  43. PERFORM INITIALIZATION 

    (See INITIALIZATION )

    Some systems need initialization after reconnecting the cable to the negative battery terminal.

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