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Home >> Toyota >> 2019 >> Sienna Limited, AWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) (Service Information) >> Brake Booster >> Installation [12/2015 - 08/2016] >> Procedure

Installation [12/2015 - 08/2016]: Procedure

  1. INSTALL CHECK VALVE GROMMET 
    1. Install a new check valve grommet to the brake booster assembly.
  2. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY 
    1. Install the vacuum check valve assembly to the brake booster assembly.
  3. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new brake booster gasket to the brake booster assembly.
  4. INSTALL BRAKE BOOSTER ASSEMBLY 
    1. Install the brake booster assembly with the 4 nuts.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

      NOTE:

      Be careful not to damage the brake lines or clamps. If any parts are damaged, replace them with new ones.

  5. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS 
    1. Install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.
    2. Tighten the lock nut.

      Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

    3. Apply lithium soap base glycol grease to the push rod pin.
    4. Install the push rod clevis onto the brake pedal support assembly with the push rod pin and new clip.
  6. INSTALL KNEE AIRBAG ASSEMBLY 

    (Refer to INSTALLATION [12/2015 - ] )

  7. INSTALL NO. 1 FRONT BRAKE TUBE ASSEMBLY 
    1. Engage the clamp to install the No. 1 front brake tube assembly.
      NOTE:

      Be careful not to damage the brake lines or clamps. If any parts are damaged, replace them with new ones.

  8. INSTALL ENGINE ROOM MAIN WIRE 
    1. Engage the clamp and 2 bolts and install the engine room main wire.

      Torque: 7.3 N*m (74 kgf*cm, 64 in.*lbf) 

    2. Connect the ECM connector and lower the lever.
      GTY306303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When connecting the connectors, make sure that dirt, water or other foreign matter does not become stuck between the connectors and other parts.
      • Make sure that the lever is securely locked.
    3. Engage the 2 clamps.
  9. CONNECT UNION TO CHECK VALVE HOSE 
    1. Connect the union to check valve hose to the vacuum check valve and slide the clip.
  10. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY 

    See step  2

  11. CONNECT NO. 1 RESERVOIR TUBE 

    See step  3

  12. INSTALL AIR CLEANER AND HOSE 

    Refer to PROCEDURE - Step 4

  13. INSTALL AIR CLEANER INLET COVER ASSEMBLY SEAL 

    Refer to PROCEDURE - Step 62

  14. FILL RESERVOIR WITH BRAKE FLUID 

    See step  2

  15. BLEED BRAKE MASTER CYLINDER 

    See step  3

  16. BLEED BRAKE LINE 

    See step  4

  17. BLEED BRAKE ACTUATOR 

    See step  5

  18. INSPECT FOR BRAKE FLUID LEAK 
  19. INSPECT FLUID LEVEL IN RESERVOIR 

    See step  1

  20. INSTALL COWL PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 11

  21. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to PROCEDURE - Step 2

  22. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  23. INSTALL FRONT FENDER TO COWL SIDE SEAL LH 

    Refer to PROCEDURE - Step 4

  24. INSTALL FRONT FENDER TO COWL SIDE SEAL RH 

    Refer to PROCEDURE - Step 5

  25. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH 

    Refer to PROCEDURE - Step 6

  26. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH 

    Refer to PROCEDURE - Step 7

  27. INSTALL FRONT WIPER ARM HEAD CAP 

    Refer to PROCEDURE - Step 8

  28. INSPECT BRAKE PEDAL HEIGHT 

    See step  1

  29. INSPECT BRAKE PEDAL FREE PLAY 

    See step  3

  30. INSPECT BRAKE PEDAL RESERVE DISTANCE 

    See step  4

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