Brake Booster Assembly: Installation

INSTALL BRAKE BOOSTER
1. Install a new gasket and the brake booster with the 4 nuts.
  Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)
2. Install the clevis to the brake pedal with the wave washer, clevis pin and clip.
3. Using needle-nose pliers, install the pedal return spring.
Fig 1: Identifying Brake Booster Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ADJUST LENGTH OF BOOSTER PUSH ROD
1. Set the SST on the master cylinder, and lower the pin until its tip slightly touches the piston.
  SST 09737-00011
  
  Fig 2: Setting SST On Master Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Turn the SST upside down, and set it on the booster.
  SST 09737-00011
3. Measure the clearance between the booster push rod and pin head (SST).
  Clearance: 0 mm (0 in.)
  
  Fig 3: Measuring Clearance Between Booster Push Rod And Pin Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, adjust the booster push rod length until the push rod lightly touches the pin head.
  SST 09737-00020
CONNECT VACUUM HOSE TO BRAKE BOOSTER

Fig 4: Adjusting Booster Push Rod Length Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE LINES
Using SST, install the 2 brake lines to the ABS actuator.

Torque:

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

14 N.m (143 kgf.cm, 10 ft.lbf) for use with SST

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
INSTALL MASTER CYLINDER (See INSTALLATION )
FILL RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See BRAKE FLUID )

Fig 5: Installing Brake Lines To ABS Actuator Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK FOR FLUID LEAKAGE
CHECK AND ADJUST BRAKE PEDAL (See BRAKE PEDAL )
DO OPERATIONAL CHECK (See BRAKE BOOSTER ASSEMBLY )
INSTALL TOOL BOX
INSTALL LUGGAGE COMPARTMENT TRIM BOX COVER