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Brake Booster: Installation

  1. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the brake booster.
  2. INSTALL BRAKE BOOSTER ASSEMBLY 
    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 1: Installing Brake Booster With Nuts
      G05001687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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.

  4. INSTALL PUSH ROD PIN 
    1. Apply lithium soap base glycol grease to the parts indicated by arrows (See REASSEMBLY ).
    2. Install the push rod pin and clip.
  5. INSTALL BRAKE PEDAL RETURN SPRING 
  6. INSTALL INSTRUMENT PANEL AIR BAG ASSEMBLY LOWER NO. 1 
  7. INSTALL INSTRUMENT PANEL FINISH LOWER PANEL 
  8. INSTALL INSTRUMENT SIDE PANEL 
  9. INSTALL COWL SIDE TRIM SUB-ASSEMBLY 
  10. INSTALL FRONT DOOR SCUFF PLATE 
  11. 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 2: Installing Front Brake Tube No.5
    G05001690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. CONNECT VACUUM HOSE ASSEMBLY 
    1. Connect the vacuum hose to the brake booster assembly and install the clip.
    Fig 3: Connecting Vacuum Hose To Brake Booster Assembly And Install Clip
    G05001683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

    SST 09737-00020 

  14. INSTALL BRAKE MASTER WITH PLATE CYLINDER SUB-ASSEMBLY

    SST 09023-00101 

  15. FILL RESERVOIR WITH BRAKE FLUID  (See BRAKE FLUID )
  16. BLEED MASTER CYLINDER  (See BRAKE FLUID )
  17. BLEED BRAKE LINE  (See BRAKE FLUID )
  18. INSTALL AIR CLEANER ASSEMBLY 
  19. CHECK FLUID LEVEL IN RESERVOIR  (See BLEEDING )
  20. INSPECT FOR FLUID LEAK 
  21. INSTALL COWL TOP PANEL OUTER 
    1. Install the cowl top panel outer with the 4 bolts and nut.

      Torque: Nut 

      80 N*m (816 kgf*cm, 59 ft.*lbf) 

  22. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
  23. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  24. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  25. CHECK AND ADJUST BRAKE PEDAL HEIGHT  (See ADJUSTMENT )
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