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Brake Booster: Installation

  1. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS 
    1. Install the lock nut and brake master cylinder push rod clevis to the brake booster assembly, and temporarily tighten them.
      NOTE: Fully tighten the lock nut after adjusting the pedal height.
  2. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the brake booster assembly.
      Fig 1: Locating Brake Booster Gasket
      G05408111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL BRAKE BOOSTER ASSEMBLY 
    1. Install the brake booster assembly to the body with the 4 nuts.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

      NOTE: Do not damage the brake lines.
      Fig 2: Identifying Nuts On Brake Booster Assembly
      G05001687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL PUSH ROD PIN 
    1. Apply lithium soap base glycol grease to the push rod pin.
    2. Connect the brake master cylinder push rod clevis to the brake pedal sub-assembly and install the push rod pin and a new clip as shown in the illustration.
      Fig 3: Applying Lithium Soap Base Glycol Grease To Push Rod Pin
      G04978369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL BRAKE PEDAL RETURN SPRING 
    1. Install the brake pedal return spring.
  6. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY  (See REASSEMBLY  )
    Fig 4: Locating Brake Pedal Return Spring
    G05001685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT VACUUM HOSE 
    1. Connect the vacuum hose to the brake booster assembly, and slide the clip to secure the vacuum hose.
  8. FILL RESERVOIR WITH BRAKE FLUID  (See BLEEDING  )
  9. BLEED BRAKE MASTER CYLINDER  (See BLEEDING  )
  10. BLEED BRAKE LINE  (See BLEEDING  )
    Fig 5: Locating Vacuum Hose
    G05408107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. BLEED BRAKE ACTUATOR (w/VSC)  (See BLEEDING  )
  12. INSPECT FOR BRAKE FLUID LEAK 
  13. INSPECT FLUID LEVEL IN RESERVOIR  (See BLEEDING  )
  14. INSPECT AND ADJUST BRAKE PEDAL HEIGHT  (See ADJUSTMENT  )
  15. INSPECT BRAKE PEDAL FREE PLAY  (See ADJUSTMENT  )
  16. INSPECT BRAKE PEDAL RESERVE DISTANCE  (See ADJUSTMENT  )
  17. INSTALL AIR CLEANER CASE  (See INSTALLATION )
  18. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE  (See INSTALLATION )
  19. INSTALL COWL TOP PANEL OUTER 
    1. Install the cowl top panel outer with the 4 bolts and 2 nuts.

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

  20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
  21. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 
  22. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  23. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
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