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Brake Booster: Installation

WARNING: This page is about a different car, the 2006 Scion tC. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL BRAKE BOOSTER GASKET 
    1. Install a new gasket to the brake booster.
  2. INSTALL BRAKE BOOSTER ASSEMBLY 
    1. Install the grommet and check valve to the brake booster.
    2. Install the brake booster with the 4 nuts.
      Fig 1: Installing Brake Booster Assembly
      G04223254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 12.7 N.m (130 kgf.cm, 9 ft.lbf) 

    3. Connect the vacuum hose to the brake booster with the clamp.
    4. Install the push rod clevis and lock nut to the brake booster.

    HINT:

    After adjusting the brake pedal height, torque the clevis lock nut.

  3. INSTALL BRAKE TUBE 
    1. Install the 3 brake tubes to the clamps as shown in the illustration.
    2. Install the clamp to the brake tubes.
    Fig 2: Installing Brake Tube
    G04223255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CONNECT NO. 5 FRONT BRAKE TUBE 
    1. Using SST, connect the No. 5 front brake tube.

      SST 09023-00101 

      Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) without SST 

      14 N.m (143 kgf.cm, 10 ft.lbf) with SST 

      Fig 3: Connecting No. 5 Front Brake Tube
      G04223256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

      NOTE: Make sure that the grommet is installed correctly.
  5. INSTALL FRONT WHEEL LH 

    Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf) 

  6. INSTALL BRAKE MASTER CYLINDER SUBASSEMBLY (See  REASSEMBLY   ) 
  7. INSTALL AIR CLEANER CAP SUB-ASSEMBLY 
  8. INSTALL LOWER COWL BODY MOUNTING BRACKET LH (See  REASSEMBLY   ) 
  9. INSTALL NO. 1 COWL WATER EXTRACT HOSE (See  REASSEMBLY   ) 
  10. INSTALL OUTER COWL TOP PANEL SUBASSEMBLY (See  REASSEMBLY   ) 
  11. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS (See  INSTALLATION   ) 
  12. FILL RESERVOIR WITH BRAKE FLUID (See  BLEEDING   ) 
  13. BLEED AIR FROM BRAKE MASTER CYLINDER (See  BLEEDING   ) 
  14. BLEED AIR FROM BRAKE LINE (See  BLEEDING   ) 
  15. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See  ADJUSTMENT   ) 
  16. CHECK BRAKE PEDAL FREE PLAY (See  ADJUSTMENT   ) 
  17. CHECK BRAKE PEDAL RESERVE DISTANCE (See  ADJUSTMENT   ) 
  18. CHECK BRAKE FLUID LEVEL IN RESERVOIR (See  BLEEDING   ) 
  19. CHECK FOR BRAKE FLUID LEAKAGE 
  20. INSTALL WINDSHIELD WIPER MOTOR AND LINK (See  INSTALLATION  ) 
  21. INSTALL COWL TOP VENTILATOR LOUVER LH 
  22. INSTALL HOOD TO COWL TOP SEAL 
  23. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See  INSTALLATION  ) 
  24. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See  INSTALLATION  ) 
  25. INSTALL FRONT WIPER ARM HEAD CAP 
  26. CHECK BRAKE BOOSTER ASSEMBLY (See  ON-VEHICLE INSPECTION   ) 
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