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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 fully tighten the push rod clevis with the lock nut (See ADJUSTMENT  ).
  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 lines.
      Fig 1: Installing Brake Booster Assembly With Nuts
      G04047788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the vacuum hose with the clip.
    Fig 2: Connecting Vacuum Hose With Clip
    G04047789Courtesy 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
    G04047790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL BRAKE PEDAL RETURN SPRING 
    1. Install the brake pedal return spring.
  7. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (See  INSTALLATION   ) 
  8. CONNECT CLUTCH RESERVOIR HOSE (for Manual Transmission) (See Step 2 in  INSTALLATION   ) 
  9. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET (See Step 3 in  INSTALLATION  ) 
  10. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK (See Step 3 in  INSTALLATION   ) 
  11. CONNECT BATTERY NEGATIVE TERMINAL 
  12. FILL RESERVOIR WITH BRAKE FLUID (See  BLEEDING   ) 
  13. BLEED MASTER CYLINDER (See Step 2 in  BLEEDING   ) 
  14. BLEED BRAKE LINE (See Step 3 in  BLEEDING   ) 
  15. BLEED BRAKE ACTUATOR ASSEMBLY (See Step 4 in  BLEEDING   ) 
  16. BLEED AIR FROM CLUTCH LINE (for Manual Transmission) (See  BLEEDING  ) 
  17. INSPECT FLUID LEVEL IN RESERVOIR (See Step 5 in  BLEEDING   ) 
  18. INSPECT BRAKE FLUID LEAKAGE 
  19. INSPECT BRAKE PEDAL HEIGHT (See  ADJUSTMENT   ) 
  20. INSPECT PEDAL FREE PLAY (See Step 2 in  ADJUSTMENT   ) 
  21. INSPECT PEDAL RESERVE DISTANCE (See Step 3 in  ADJUSTMENT   ) 
  22. DISCONNECT BATTERY NEGATIVE TERMINAL 
    CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working.
  23. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY (See  INSTALLATION  ) 
  24. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See Step 24 in  INSTALLATION  ) 
  25. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See Step 25 in  INSTALLATION  ) 
  26. INSTALL INSTRUMENT SIDE PANEL LH (See Step 26 in  INSTALLATION  ) 
  27. INSTALL FRONT DOOR OPENING TRIM COVER LH (See Step 27 in  INSTALLATION  ) 
  28. INSTALL FRONT DOOR SCUFF PLATE LH (w/o Illumination) (See Step 88 in  INSTALLATION  ) 
  29. INSTALL FRONT DOOR SCUFF PLATE LH (w/ Illumination) (See Step 90 in  INSTALLATION  ) 
  30. INSPECT BRAKE ACTUATOR ASSEMBLY 

    HINT:

    (See ON-VEHICLE INSPECTION )

  31. INSTALL FRONT WHEEL 
  32. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    (See Step 3 in  INSTALLATION  ) 

  33. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See Step 5 in  INSTALLATION  ) 
  34. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See Step 4 in  INSTALLATION  ) 
  35. INSTALL FRONT WIPER ARM HEAD CAP (See Step 6 in  INSTALLATION  ) 
  36. INSTALL ROOF DRIP SIDE FINISH MOLDING RH 
  37. INSTALL ROOF DRIP SIDE FINISH MOLDING LH 
  38. INSTALL FRONT UPPER FENDER PROTECTOR RH (See Step 10 in  INSTALLATION  ) 
  39. INSTALL FRONT UPPER FENDER PROTECTOR LH (See Step 9 in  INSTALLATION  ) 
  40. INSTALL ENGINE ROOM SIDE COVER RH (See Step 117 in  INSTALLATION  ) 
  41. INSTALL ENGINE ROOM SIDE COVER LH (See Step 116 in  INSTALLATION  ) 
  42. INSTALL COOL AIR INTAKE DUCT SEAL (See Step 118 in  INSTALLATION  ) 
  43. CONNECT BATTERY NEGATIVE TERMINAL 
  44. INSPECT VSC SENSOR SIGNAL 
    1. Inspect the VSC sensor signal.
    SYSTEM REFERENCE

    System Proceed to
    w/o VDIM See DIAGNOSIS SYSTEM
  45. INSPECT SRS WARNING LIGHT 

    HINT:

    (See PROBLEM SYMPTOMS TABLE )

  46. PERFORM INITIALIZATION 

    Some systems need initialization after reconnecting the negative battery terminal (See INITIALIZATION ).

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