Brake Booster ASSY: Replacement

HINT:

COMPONENTS 

1. REMOVE FR WIPER ARM & BLADE ASSY LH (SEE  REPLACEMENT  ) 
2. REMOVE FR WIPER ARM & BLADE ASSY RH (SEE  REPLACEMENT  ) 
3. REMOVE COWL TOP VENTILATOR LOUVER RH (SEE  REPLACEMENT  ) 
4. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (SEE  REPLACEMENT  ) 
5. REMOVE COWL TOP PANEL OUTER 
   1. Remove the 4 bolts, 2 nuts and cowl top panel outer from the body.
6. DRAIN BRAKE FLUID 
   NOTE: Wash brake fluid off immediately if it adheres to any painted surface.
7. REMOVE AIR CLEANER ASSY 
8. REMOVE BRAKE MASTER W/PLATE CYLINDER SUB-ASSY (SEE  REPLACEMENT  ) 

   SST 09023-00101

9. DISCONNECT VACUUM HOSE ASSY 
   1. Slide the clip and disconnect the vacuum hose from the brake booster assy.
      Fig 1: Disconnecting Vacuum Hose Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE FRONT BRAKE TUBE NO.5 
    1. Using SST, remove front brake tube No.5.

       SST 09023-00101

       Fig 2: Removing Front Brake Tube

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE FRONT DOOR SCUFF PLATE LH (SEE  REPLACEMENT  ) 
12. REMOVE COWL SIDE TRIM SUB-ASSY LH (SEE  REPLACEMENT  ) 
13. REMOVE INSTRUMENT SIDE PANEL LH (SEE  REPLACEMENT  ) 
14. REMOVE INSTRUMENT PANEL FINISH LOWER PANEL LH (SEE  REPLACEMENT  ) 
15. REMOVE INSTRUMENT PANEL AIR BAG ASSY LOWER NO.1 (SEE  REPLACEMENT  ) 
16. REMOVE BRAKE PEDAL RETURN SPRING 
    1. Remove the brake pedal return spring.
       Fig 3: Removing Brake Pedal Return Spring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE PUSH ROD PIN 
    1. Remove the clip and push rod pin.
       Fig 4: Removing Push Rod Pin

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. REMOVE BRAKE BOOSTER ASSY 
    1. Remove the 4 nuts.
    2. Pull out the brake booster assy.
       NOTE: Do not damage the brake tubes and the wire harness.
       Fig 5: Removing Brake Booster Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE BRAKE BOOSTER GASKET 
20. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the brake booster.
21. INSTALL BRAKE BOOSTER ASSY 
    1. Install the brake booster with the 4 nuts.

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

       NOTE: Do not damage the brake tubes and the wire harness.
       Fig 6: Installing Brake Booster Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. INSTALL MASTER CYLINDER PUSH ROD CLEVIS 
    1. Install the push rod clevis and the push rod lock nut.

       HINT:

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

23. INSTALL PUSH ROD PIN 
    1. Apply lithium soap base glycol grease to the parts indicated by arrows (see COMPONENTS ).
    2. Install the push rod pin and clip.
24. INSTALL BRAKE PEDAL RETURN SPRING 
25. INSTALL INSTRUMENT PANEL AIR BAG ASSY LOWER NO.1 (SEE  REPLACEMENT  ) 
26. INSTALL INSTRUMENT PANEL FINISH LOWER PANEL LH (SEE  REPLACEMENT  ) 
27. INSTALL INSTRUMENT SIDE PANEL LH (SEE  REPLACEMENT  ) 
28. INSTALL COWL SIDE TRIM SUB-ASSY LH (SEE  REPLACEMENT  ) 
29. INSTALL FRONT DOOR SCUFF PLATE LH (SEE  REPLACEMENT  ) 
30. INSTALL FRONT BRAKE TUBE NO.5 
    1. Using SST, install front brake tube No.5.

       SST 09023-00101

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

       Fig 7: Installing Front Brake Tube

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. CONNECT VACUUM HOSE ASSY 
    1. Connect the vacuum hose to the brake booster assy and install the clip.
       Fig 8: Connecting Vacuum Hose Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (SEE  REPLACEMENT  ) 

    SST 09737-00020

33. INSTALL BRAKE MASTER W/PLATE CYLINDER SUB-ASSY (SEE  REPLACEMENT  ) 

    SST 09023-00101

34. FILL RESERVOIR WITH BRAKE FLUID (SEE  BLEEDING  ) 
35. BLEED MASTER CYLINDER (SEE  BLEEDING  ) 

    SST 09023-00101

36. BLEED BRAKE LINE (SEE  BLEEDING  ) 
37. INSTALL AIR CLEANER ASSY 
38. CHECK FLUID LEVEL IN RESERVOIR (SEE  BLEEDING  ) 
39. CHECK BRAKE FLUID LEAKAGE 
40. INSTALL COWL TOP PANEL OUTER 
    1. Install the cowl top panel outer with the 4 bolts and nut.

       Torque: 80 N.m (816 kgf.cm, 59 ft.lbf) (Nut) 

41. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY (SEE  REPLACEMENT  ) 
42. INSTALL FR WIPER ARM & BLADE ASSY RH (SEE  REPLACEMENT  ) 
43. INSTALL FR WIPER ARM & BLADE ASSY LH (SEE  REPLACEMENT  ) 
44. CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE  ADJUSTMENT  )