Brake Booster: Installation

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL CHECK VALVE GROMMET
1. Install the grommet to the booster.
INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY
1. Install the check valve to the grommet.
INSTALL BRAKE BOOSTER GASKET
1. Install a new gasket to the booster.
INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
1. Install the push rod clevis to the booster.
2. Temporarily tighten the push rod clevis lock nut.
  HINT:
  
  The push rod clevis lock nut will be tightened to a torque specification in the "CHECK AND ADJUST BRAKE PEDAL HEIGHT" procedures. (See 20).
INSTALL BRAKE BOOSTER ASSEMBLY
1. Install the booster with the 4 nuts.
  Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf)
  
  Fig 1: Identifying Brake Booster Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PUSH ROD PIN

Fig 2: Installing Push Rod Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Apply lithium soap base glycol grease to the push rod pin.
2. Install the push rod pin to the push rod clevis.
  NOTE: The push rod pin must be installed as shown in Fig 2.
3. Install the clip to the push rod pin.
  NOTE: The clip must be installed as shown in Fig 2.
CHECK AND ADJUST BRAKE BOOSTER PUSH ROD (See INSPECTION )
CONNECT VACUUM HOSE
1. Connect the vacuum hose to the check valve.
INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (See REASSEMBLY )
INSTALL ABS AND TRACTION ACTUATOR ASSEMBLY WITH BRACKET (See appropriate step(s) under INSTALLATION )
CONNECT BRAKE LINES (See appropriate step(s) under INSTALLATION )
INSTALL COWL BODY MOUNTING REINFORCEMENT LH

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Install the cowl body mounting reinforcement LH with the 2 nuts.
Torque:

50 N.m {510 kgf-cm, 37 ft-lbf}
INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Install the cowl top panel outer sub-assembly with the 14 bolts.
Torque:

7.5 N.m {76 kgf-cm, 66 in-lbf}
INSTALL COWL VENTILATOR HOUSING SUB-ASSEMBLY

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Engage the 4 clips to install the cowl ventilator housing sub-assembly.
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
- Install the windshield wiper motor and link assembly. INSTALLATION .
FILL RESERVOIR WITH BRAKE FLUID (See BRAKE FLUID )
BLEED AIR FROM BRAKE MASTER CYLINDER (See BLEEDING )
BLEED AIR FROM BRAKE LINE (See BLEEDING )
BLEED AIR FROM ABS AND TRACTION ACTUATOR ASSEMBLY (See BLEEDING )
CHECK AND ADJUST BRAKE PEDAL HEIGHT (See ADJUSTMENT )
CHECK BRAKE PEDAL FREE PLAY (See ADJUSTMENT )
CHECK BRAKE PEDAL RESERVE DISTANCE (See ADJUSTMENT )
CHECK BRAKE FLUID LEVEL IN RESERVOIR (See BRAKE FLUID )
CHECK FOR BRAKE FLUID LEAKAGE
INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2AZ-FE)
1. Install the air cleaner case (see appropriate step(s) under INSTALLATION ).
  HINT:
  
  Refer to the procedures from the installation of the air cleaner case up until the installation of the purge VSV.
INSTALL AIR CLEANER CASE (for 2GR-FE)
1. Install the air cleaner case (see appropriate step(s) under INSTALLATION ).
  HINT:
  
  Refer to the procedures from the installation of the air cleaner case up until the installation of the air cleaner cap sub-assembly.