Brake Booster: Installation

INSTALL BRAKE BOOSTER GASKET
1. Install a new brake booster gasket to the brake booster assembly.
INSTALL BRAKE BOOSTER ASSEMBLY
1. Install the brake booster assembly to the body and temporarily tighten the 4 nuts.
  NOTE: Do not damage the brake lines.
  
  HINT:
  
  Fully tighten the 4 nuts after installing the brake master cylinder push rod clevis and push rod clevis lock nut.
  
  Fig 1: Identifying Brake Booster Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the 2 clamps and install the 2 brake lines to the body.
  NOTE: Be careful not to damage the brake lines or clamps. If any parts are damaged, replace them with new ones.
  
  Fig 2: Identifying Brake Lines & Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE WIRE
1. Engage the 9 clamps.
2. Install the engine wire to the body with the bolt.
  Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
  
  Fig 3: Identifying Engine Wire Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE WIRE (w/ Security Horn)
1. Engage the 9 clamps.
2. Connect the alarm horn connector and install the engine wire to the body with the bolt.
  Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
  
  Fig 4: Identifying Alarm Horn Connector & Engine Wire Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHECK VALVE GROMMET
1. Install a new check valve grommet to the brake booster assembly.
INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY
1. Install the vacuum check valve assembly to the brake booster assembly.
CONNECT VACUUM HOSE
1. Connect the vacuum hose to the vacuum check valve and slide the clip.
INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
1. Install the push rod clevis lock nut and brake master cylinder push rod clevis to the brake booster assembly, and temporarily tighten the push rod clevis lock nut.
  NOTE: Do not damage the brake lines.
  
  Fig 5: Identifying Lock Nut & Brake Master Cylinder Push Rod Clevis
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Fully tighten the lock nut after adjusting the brake pedal height.
2. Fully tighten the 4 nuts to install the brake booster assembly to the body.
  Torque: 13 N*m (132 kgf*cm, 10 ft.*lbf)
  
  Fig 6: Identifying Brake Booster Assembly Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS (See INSTALLATION )
INSTALL BRAKE PEDAL RETURN SPRING (See INSTALLATION )
INSPECT AND ADJUST BRAKE PEDAL HEIGHT (See ADJUSTMENT )
INSPECT BRAKE PEDAL FREE PLAY (See ADJUSTMENT )
INSPECT BRAKE PEDAL RESERVE DISTANCE (See ADJUSTMENT )
INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (See INSTALLATION )
CONNECT BRAKE LINE (See INSTALLATION )
CONNECT NO. 1 RESERVOIR TUBE (See INSTALLATION )
INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See INSTALLATION )
INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (See INSTALLATION )
INSTALL WINDSHIELD WIPER MOTOR AND LINK (See INSTALLATION )
INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (See INSTALLATION )
INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See INSTALLATION )
INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See INSTALLATION )
INSTALL V-BANK COVER SUB-ASSEMBLY (See INSTALLATION )
FILL BRAKE FLUID RESERVOIR (See ON-VEHICLE INSPECTION )
BLEED BRAKE MASTER CYLINDER (See ON-VEHICLE INSPECTION )
BLEED BRAKE LINE (See ON-VEHICLE INSPECTION )
BLEED BRAKE ACTUATOR (See ON-VEHICLE INSPECTION )
INSPECT FOR BRAKE FLUID LEAK
INSPECT FLUID LEVEL (See ON-VEHICLE INSPECTION )