Brake Booster: Installation

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
1. Temporarily install the brake master cylinder push rod clevis and lock nut
HINT:

Fully tighten the lock nut after adjusting the brake pedal height (See BRAKE PEDAL )
INSTALL CHECK VALVE GROMMET
1. Install the check valve grommet to the brake booster assembly
INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY
1. Install the brake vacuum check valve assembly to the brake booster assembly
INSTALL BRAKE BOOSTER GASKET
1. Install a new brake booster gasket to the brake booster assembly.
INSTALL BRAKE BOOSTER ASSEMBLY
1. Install the brake booster assembly with the 4 nuts.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)

NOTE: Do not damage the brake lines.

Fig 1: Locating Brake Booster Assembly With Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT VACUUM HOSE
1. Connect the vacuum hose to the brake vacuum check valve and slide the clip.
  
  Fig 2: Locating Vacuum Hose Clip And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the clamp and inspect the condition of the vacuum hose
NOTE: Align the vacuum hose matchmarks and the hose clamp as shown in the illustration.

Fig 3: Identifying Vacuum Hose Matchmarks And Hose Clamp
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS
1. Apply lithium soap base glycol grease to the push rod pin.
2. Connect the brake master cylinder push rod clevis to the brake pedal support assembly with the push rod pin and a new clip
Fig 4: Applying Lithium Soap Base Glycol Grease To Push Rod Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE PEDAL RETURN SPRING
1. Install the brake pedal return spring
Fig 5: Identifying Brake Pedal Return Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY (See INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
HINT.

Refer to the instructions for Installation of the brake master cylinder sub-assembly (See INSTALLATION ).
INSPECT AND ADJUST BRAKE PEDAL HEIGHT (See BRAKE PEDAL )
INSPECT BRAKE PEDAL FREE PLAY (See BRAKE PEDAL )
INSPECT BRAKE PEDAL RESERVE DISTANCE (See BRAKE PEDAL )
INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See INSTALLATION )
INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See INSTALLATION )
INSTALL SIDE INSTRUMENT PANEL LH (See INSTALLATION )
INSTALL FRONT DOOR OPENING TRIM COVER LH (See INSTALLATION )
INSTALL FRONT DOOR SCUFF PLATE LH (See INSTALLATION )