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Installation (From 12/2010): Installation

WARNING: This page is about a different car, the 2011 Toyota Avalon. However, it is still accessible from the selected car via links, so may be relevant.
  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: Identifying Brake Booster Gasket
      GTY137057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL BRAKE BOOSTER ASSEMBLY 
    1. Install the brake booster assembly to the body with the 4 nuts.
      Fig 2: Identifying Nuts On Brake Booster Assembly
      GTY201594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

      Do not damage the brake lines.

  4. INSTALL PUSH ROD PIN 
    1. Apply lithium soap base glycol grease to the push rod pin.
      Fig 3: Applying Lithium Soap Base Glycol Grease To Push Rod Pin
      GTY112200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  5. INSTALL BRAKE PEDAL RETURN SPRING 
    1. Install the brake pedal return spring.
      Fig 4: Locating Brake Pedal Return Spring
      GTY172398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY  See step  1
  7. CONNECT VACUUM HOSE 
    1. Connect the vacuum hose to the brake booster assembly, and slide the clip to secure the vacuum hose.
      Fig 5: Locating Vacuum Hose
      GTY182116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. FILL RESERVOIR WITH BRAKE FLUID  See step  1
  9. BLEED BRAKE MASTER CYLINDER  See step  2
  10. BLEED BRAKE LINE  See step  3
  11. BLEED BRAKE ACTUATOR  See step  4
  12. INSPECT FOR BRAKE FLUID LEAK 
  13. INSPECT FLUID LEVEL IN RESERVOIR  See step  6
  14. INSPECT AND ADJUST BRAKE PEDAL HEIGHT  See step  1
  15. INSPECT BRAKE PEDAL FREE PLAY  See step  2
  16. INSPECT BRAKE PEDAL RESERVE DISTANCE  See step  3
  17. INSTALL AIR CLEANER CASE  . Refer to INSTALLATION - Step 70
  18. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE  . Refer to INSTALLATION - Step 4
  19. INSTALL COWL TOP PANEL OUTER 
    1. Install the cowl top panel outer with the 4 bolts and 2 nuts.

      Nut 

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

  20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  . Refer to INSTALLATION - Step 2
  21. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 
  22. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH  . Refer to INSTALLATION - Step 3
  23. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH  . Refer to INSTALLATION - Step 4
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