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Hydraulic Brake Booster: Installation

  1. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the hydraulic brake booster assembly.
  2. INSTALL HYDRAULIC BRAKE BOOSTER ASSEMBLY 
    1. Install the hydraulic brake booster assembly with the 4 nuts.

      Torque: 14 N*m (145 kgf*cm, 10 ft.*lbf) 

      Fig 1: Locating Brake Pedal Support Assembly Nuts
      G05638921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 4 brake lines to the correct positions of the hydraulic brake booster assembly as shown in the illustration.
      Fig 2: Connecting Brake Lines To Correct Positions Of Hydraulic Brake Booster Assembly
      G05638946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a union nut wrench, tighten the 4 brake lines.

      Torque: without union nut wrench 

      15 N*m (155 kgf*cm, 11 ft.*lbf) 

      With union nut wrench 

      14 N*m (145 kgf*cm, 10 ft.*lbf) 

      Fig 3: Identifying Fulcrum Length
      G05638989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
      • The torque value for use with a union nut wrench is effective when the union nut wrench is parallel to the torque wrench.
    4. Connect the 3 connectors to the hydraulic brake booster assembly.
  3. INSTALL PUSH ROD PIN  (See INSTALLATION  )
  4. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY  (See REMOVAL )
  5. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL  (See INSTALLATION )
  6. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY  (See INSTALLATION )
  7. INSTALL COWL SIDE TRIM BOARD LH  (See INSTALLATION )
    Fig 4: Locating Hydraulic Brake Booster Assembly Connectors
    G05638990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DOOR SCUFF PLATE LH  (See INSTALLATION )
  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  10. FILL RESERVOIR WITH BRAKE FLUID  (See REPLACEMENT  )
  11. BLEED BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY  (See REPLACEMENT  )
  12. BLEED BRAKE LINE  (See BRAKE PEDAL  )
  13. BLEED MASTER CYLINDER SOLENOID  (See BRAKE PEDAL  )
  14. CHECK BRAKE PEDAL HEIGHT  (See ADJUSTMENT  )
  15. CHECK PEDAL FREE PLAY  (See ADJUSTMENT  )
  16. CHECK PEDAL RESERVE DISTANCE  (See ADJUSTMENT  )
  17. CHECK FLUID LEVEL IN RESERVOIR  (See ON-VEHICLE INSPECTION  )
  18. INSPECT FOR BRAKE FLUID LEAK 
  19. INSPECT BRAKE MASTER CYLINDER OPERATION 
    1. Inspect the brake master cylinder operation (See ON-VEHICLE INSPECTION  ).
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