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Brake Booster: Installation: Installation

WARNING: This page is about a different car, the 2009 Lexus IS 350 and 2009 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.
  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 step  1.
  2. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY 
    1. Install the grommet and check valve assembly.
  3. INSTALL BRAKE BOOSTER ASSEMBLY 
    1. Install a new brake booster gasket to the brake booster assembly.
    2. Install the brake booster assembly with the 4 nuts.
      Fig 1: Identifying Brake Booster Assembly & Nuts
      GTY113844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

      Do not damage the brake lines.

    3. Install the No. 3 front brake tube and engage the grommet.
      Fig 2: Installing No. 3 Front Brake Tube & Engaging Grommet
      GTY141275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a union nut wrench (10 mm), connect the No. 3 front brake tube to the front flexible hose LH.

      without a union nut wrench 

      Torque: 15 N*m ( 155 kgf*cm, 11 ft.*lbf) 

      with a union nut wrench 

      Torque: 14 N*m ( 143 kgf*cm, 10 ft.*lbf) 

      NOTE:
      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
      • Do not kink or damage the brake line.
      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the clip or bracket.
  4. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET  . Refer to INSTALLATION - Step 3
  5. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS 
    1. Apply lithium soap base glycol grease to the push rod pin.
      Fig 3: Identifying Brake Master Cylinder Push Rod Clevis
      GTY114180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the push rod clevis to the brake pedal support assembly with the push rod pin and a new clip.
  6. INSTALL BRAKE PEDAL RETURN SPRING 
    1. Install the brake pedal return spring.
  7. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY  See step  1
  8. CONNECT CLUTCH RESERVOIR HOSE (for Manual Transmission)  See step  2
  9. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK  See step  3
  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  11. FILL RESERVOIR WITH BRAKE FLUID  See step  1
  12. BLEED MASTER CYLINDER  See step  2
  13. BLEED BRAKE LINE  See step  3
  14. BLEED BRAKE ACTUATOR ASSEMBLY  See step  4
  15. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)  . Refer to BLEEDING - Step 1
  16. INSPECT FLUID LEVEL IN RESERVOIR  See step  5
  17. INSPECT FOR BRAKE FLUID LEAK 
  18. INSPECT BRAKE PEDAL HEIGHT  See step  1
  19. INSPECT BRAKE PEDAL FREE PLAY  See step  2
  20. INSPECT BRAKE PEDAL RESERVE DISTANCE  See step  3
  21. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  22. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY  . Refer to INSTALLATION - Step 1
  23. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY  . Refer to INSTALLATION - Step 24
  24. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY  . Refer to INSTALLATION - Step 25
  25. INSTALL INSTRUMENT SIDE PANEL LH  . Refer to INSTALLATION - Step 26
  26. INSTALL FRONT DOOR OPENING TRIM COVER LH  . Refer to INSTALLATION - Step 18
  27. INSTALL FRONT DOOR SCUFF PLATE LH (w/o Illumination)  . Refer to INSTALLATION - Step 88
  28. INSTALL FRONT DOOR SCUFF PLATE LH (w/ Illumination)  . Refer to INSTALLATION - Step 90
  29. INSPECT BRAKE ACTUATOR ASSEMBLY 

    HINT: 

    Refer to ON-VEHICLE INSPECTION

  30. INSTALL FRONT WHEEL 
  31. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  . Refer to INSTALLATION - Step 3
  32. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH  . Refer to INSTALLATION - Step 5
  33. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH  . Refer to INSTALLATION - Step 4
  34. INSTALL FRONT WIPER ARM HEAD CAP  . Refer to INSTALLATION - Step 6
  35. INSTALL ROOF DRIP SIDE FINISH MOULDING RH 
  36. INSTALL ROOF DRIP SIDE FINISH MOULDING LH 
  37. INSTALL FRONT UPPER FENDER PROTECTOR RH  . Refer to INSTALLATION - Step 10
  38. INSTALL FRONT UPPER FENDER PROTECTOR LH  . Refer to INSTALLATION - Step 9
  39. INSTALL ENGINE ROOM SIDE COVER RH  . Refer to INSTALLATION - Step 88
  40. INSTALL ENGINE ROOM SIDE COVER LH  . Refer to INSTALLATION - Step 87
  41. INSTALL COOL AIR INTAKE DUCT SEAL  . Refer to INSTALLATION - Step 89
  42. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  43. INSPECT VSC SENSOR SIGNAL 
    1. Inspect the VSC sensor signal. Refer to TEST MODE PROCEDURE .
  44. INSPECT SRS WARNING LIGHT 

    HINT: 

    Refer to DIAGNOSIS SYSTEM

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