INSTALLATION (To 8/2009): Installation

INSTALL BRAKE BOOSTER GASKET
1. Install a new brake booster gasket to the brake booster assembly.
INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
1. Install the push rod clevis lock nut and brake master cylinder push rod clevis to the brake booster assembly, and temporarily tighten the push rod clevis lock nut.
  HINT:
  
  Fully tighten the lock nut after adjusting the brake pedal height.
INSTALL BRAKE BOOSTER ASSEMBLY
1. Install the brake booster assembly with the 4 nuts.
  
  Fig 1: Identifying 4 nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
  
  NOTE:
  Be careful not to damage the brake lines or clamps. If any parts are damaged, replace them with new ones.
CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS See step 2
INSTALL BRAKE PEDAL RETURN SPRING See step 3
INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 39
INSTALL NO. 1 FRONT BRAKE TUBE ASSEMBLY
1. Engage the 3 clamps to install the No. 1 front brake tube assembly.
  
  Fig 2: Identifying 3 clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be careful not to damage the brake lines or clamps. If any parts are damaged, replace them with new ones.
INSTALL NO. 5 FRONT BRAKE TUBE
1. Engage the clamp to install the No. 5 front brake tube.
  
  Fig 3: Engage the clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a union nut wrench, connect the No. 5 front brake tube.
  Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf)
  
  NOTE:
  Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench. Refer to PRECAUTION .
3. Engage the grommet of the No. 5 front brake tube.
  
  Fig 4: Engage the clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a union nut wrench, connect the No. 5 front brake tube to the front brake flexible hose LH.
  
  Fig 5: connect the No. 5 front brake tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf)
  
  NOTE:
  Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench. Refer to PRECAUTION .
INSTALL ENGINE ROOM MAIN WIRE
1. Engage the 6 clamps to install the engine room main wire.
  
  Fig 6: Engage the 6 clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the ECM connector and lower the lever.
  
  Fig 7: Identifying ECM connector and lower the leve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - When connecting the connectors, make sure that dirt, water or other foreign matter does not become stuck between the connectors and other part.
  - Make sure that the lever is securely locked.
3. Engage the 2 clamps.
  
  Fig 8: Identifying 2 clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL VAPOR FEED HOSE
1. Connect the fuel vapor feed hose and slide the clip.
  
  Fig 9: Connect the fuel vapor feed hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHECK VALVE GROMMET
1. Install a new check valve grommet to the brake booster assembly.
INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY
1. Install the vacuum check valve assembly to the brake booster assembly.
CONNECT VACUUM HOSE
1. Connect the vacuum hose to the vacuum check valve and slide the clip.
  
  Fig 10: Connect the vacuum hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
HINT:

Refer to the instructions for Installation of the brake master cylinder sub-assembly. Refer to INSTALLATION .
INSPECT AND ADJUST BRAKE PEDAL HEIGHT See step 1
INSPECT BRAKE PEDAL FREE PLAY See step 2
INSPECT BRAKE PEDAL RESERVE DISTANCE See step 3