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Brake Booster: Installation

  1. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY 
    1. Install the grommet and the check valve assembly to the brake booster assembly.
  2. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the brake booster assembly.
  3. INSTALL BRAKE BOOSTER ASSEMBLY 
    1. Install the brake booster assembly with the 4 nuts.
      Fig 1: Installing Brake Booster Assembly
      G04090707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

      NOTE: Be careful not to damage the brake tubes and the wire harness.
    2. Connect the vacuum hose to the brake booster assembly and slide the clip.
    Fig 2: Connecting Vacuum Hose To Brake Booster Assembly
    G04090708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL BRAKE TUBE 
    1. Install the 2 clamps of the brake tube to the body.
    NOTE: Be careful not to damage the brake tubes.
    Fig 3: Installing Brake Tube
    G04090709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL WIRE HARNESS 
    1. Install the clip of the wire harness to the body.
    2. Install the grommet of the wire harness to the body.
    3. Install the bolt.
    Fig 4: Installing Wire Harness
    G04090710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS 
    1. Install the push rod clevis and the push rod lock nut.

      Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

      HINT:

      After adjusting the brake pedal height, torque the lock nut.

    2. Apply lithium soap base glycol grease to the clevis pin.
    3. Install the push rod pin and the clip.
  7. INSTALL BRAKE PEDAL RETURN SPRING 
    1. Install the brake pedal return spring.
  8. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER 
  9. INSTALL FRONT SHOCK ABSORBER CAP RH 
  10. INSTALL FRONT SHOCK ABSORBER CAP LH (See  INSTALLATION  ) 
  11. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSEMBLY 
    12. Fig 5: Installing Brake Master Cylinder Push Rod Clevis
    G04090711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY 
  13. INSTALL FRONT FENDER TO COWL SIDE SEAL LH 
  14. INSTALL FRONT FENDER TO COWL SIDE SEAL RH 
  15. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH 
  16. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH 
  17. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD 

    SST 09737-00020 

  18. INSTALL BRAKE MASTER CYLINDER SUBASSEMBLY 

    SST 09023-00101 

  19. INSTALL AIR CLEANER HOSE NO.1 
  20. INSTALL AIR CLEANER ASSEMBLY 
  21. INSTALL V-BANK COVER SUB-ASSEMBLY (See  INSTALLATION  ) 
  22. FILL RESERVOIR WITH BRAKE FLUID 
  23. BLEED MASTER CYLINDER 

    HINT:

    See REMOVAL  .

    SST 09023-00101 

  24. BLEED BRAKE LINE 

    HINT:

    See REMOVAL  .

  25. CHECK FLUID LEVEL IN RESERVOIR 

    HINT:

    See REMOVAL  .

  26. CHECK BRAKE FLUID LEAKAGE 
  27. CHECK AND ADJUST BRAKE PEDAL HEIGHT 

    HINT:

    See REMOVAL  .

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