Brake Booster Assembly: Installation

INSTALL BRAKE BOOSTER
1. Install the booster and a new gasket.
2. Install and torque the booster installation nuts.
  Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)
3. Install the clevis, and torque the lock nut.
  Torque: 26 N.m (260 kgf.cm, 19 ft.lbf)
4. Insert the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin.
5. Install the return spring.
When replacing the brake master cylinder only:
ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD
1. Apply chalk to the tip of an accessory tool.
2. Place the accessory tool to the brake booster.
3. Measure the clearance between the brake booster push rod and accessory tool.
  Clearance: 0 mm (0 in.)
  NOTE:
  Adjust the clearance in following cases:
  - If there is a clearance between the accessory tool and the shell of the booster (floating accessory tool), the clearance is small.
  - If the chalk does not stick on the tip of the push rod, the clearance is large.
  Fig 1: Measuring Clearance Between Brake Booster Push Rod And Using Accessory Tool
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. If the clearance is outside of the specified range, fix the push rod using SST and adjust the length of the protruding adjusting bolt.
  SST 09737-00020
NOTE: Make an adjustment with the booster having no vacuum. (Depress the brake pedal several times with the engine stopped.)
CONNECT VACUUM HOSE TO BRAKE BOOSTER
INSTALL ABS ACTUATOR (See REMOVAL )

Fig 2: Installing SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CLEANER ASSEMBLY
INSTALL MASTER CYLINDER (See INSTALLATION )
FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See BRAKE FLUID )
CHECK FOR LEAKS
CHECK AND ADJUST BRAKE PEDAL
(See BRAKE PEDAL )
DO OPERATIONAL CHECK (See BRAKE BOOSTER ASSEMBLY )