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Brake Booster: Installation

  1. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the brake booster assembly.
  2. 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: Locating Brake Booster Assembly Nuts
      G05417901Courtesy 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: Locating Brake Lines Clamps
      G05417938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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
      G05417936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. 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) 

  5. INSTALL CHECK VALVE GROMMET 
    1. for 1AR-FE:
      1. Install 2 new check valve grommets to the brake booster assembly.
    2. for 2GR-FE:
      1. Install a new check valve grommet to the brake booster assembly.
        Fig 4: Identifying Engine Wire Clamps
        G05417937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY 
    1. for 1AR-FE:
      1. Install the 2 brake vacuum check valve assemblies to the brake booster assembly.
    2. for 2GR-FE:
      1. Install the brake vacuum check valve assembly to the brake booster assembly.
  7. INSTALL VACUUM HOSE ASSEMBLY (for 1AR-FE) 
    1. Install the vacuum hose assembly with the 2 nuts.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 5: Locating Vacuum Hoses Nuts
      G06116779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the vacuum hoses to the vacuum check valve assemblies and slide the 2 clips.
      Fig 6: Connecting Vacuum Hoses To Vacuum Check Valve
      G06116778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT VACUUM HOSE (for 2GR-FE) 
    1. Connect the vacuum hose to the vacuum check valve assembly and slide the clip.
      Fig 7: Locating Vacuum Hose Clip
      G06116780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. 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.

      HINT:

      Fully tighten the lock nut after adjusting the brake pedal height.

      Fig 8: Identifying Push Rod Clevis And Lock Nut
      G05417935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  10. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS  (See INSTALLATION  )
  11. INSTALL BRAKE PEDAL RETURN SPRING  (See INSTALLATION  )
    Fig 9: Locating Brake Booster Assembly Nuts
    G05417901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT AND ADJUST BRAKE PEDAL HEIGHT  (See ADJUSTMENT  )
  13. INSPECT BRAKE PEDAL FREE PLAY  (See ADJUSTMENT  )
  14. INSPECT BRAKE PEDAL RESERVE DISTANCE  (See ADJUSTMENT  )
  15. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY  (See REASSEMBLY  )
  16. CONNECT BRAKE LINE  (See INSTALLATION  )
  17. CONNECT NO. 1 RESERVOIR TUBE  (See INSTALLATION  )
  18. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for 1AR-FE)  (See INSTALLATION )
  19. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1AR-FE)  (See INSTALLATION )
  20. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for 2GR-FE)  (See INSTALLATION )
  21. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2GR-FE)  (See INSTALLATION )
  22. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY  (See INSTALLATION )
  23. INSTALL WINDSHIELD WIPER MOTOR AND LINK  (See INSTALLATION )
  24. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  25. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  26. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  27. INSTALL EJECTOR TUBE (for 1AR-FE)  (See INSTALLATION  )
  28. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for 1AR-FE)  (See INSTALLATION )
  29. INSTALL V-BANK COVER SUB-ASSEMBLY (for 2GR-FE)  (See INSTALLATION )
  30. FILL BRAKE FLUID RESERVOIR  (See REPLACEMENT  )
  31. BLEED BRAKE MASTER CYLINDER  (See REPLACEMENT  )
  32. BLEED BRAKE LINE  (See REPLACEMENT  )
  33. BLEED BRAKE ACTUATOR  (See REPLACEMENT  )
  34. INSPECT FOR BRAKE FLUID LEAK 
  35. INSPECT FLUID LEVEL  (See ON-VEHICLE INSPECTION  )
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