Brake Booster (W/ Vsc) Installation

Install a new gasket to the brake booster.

Install the booster with the 4 nuts.

Torque:

14 N*m{145 kgf*cm, 10 ft.*lbf}

Install the push rod clevis.

Apply a light coat of lithium soap base glycol grease to the clevis pin.

Install the clevis pin and a new clip.

NOTICE:

The clip must be installed as shown in the illustration.

Install the return spring.

Install the check valve and grommet to the booster.

Connect the vacuum hose with the clip.

Install the vacuum warning switch to the booster and connect the vacuum warning switch connector.

Set SST on the master cylinder, and then lower the pin until its tip slightly touches the piston.

SST

09737-00013

HINT:

SST 09797-00012 can also be used.

Turn SST upside down, and then set it on the booster.

Measure the clearance between the booster push rod and pin head (SST).

Standard clearance:

0 mm (0 in.)

To adjust the clearance of the rod, first depress the pedal so that the rod protrudes. Then fix the rod in place using SST and rotate the hexagon cap nut to adjust the clearance.

SST

09737-00020

Install the brake master cylinder (Toyota Fortuner RM000001HK601VX.html).

Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.

Slowly depress and hold the brake pedal.

Cover the outer holes with your fingers, and release the pedal.

Repeat the 2 previous steps 3 or 4 times.

Using a union nut wrench, connect the 2 brake lines to the master cylinder.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

Remove the bleeder plug cap.

Connect a vinyl tube to the bleeder plugs.

Depress the pedal several times, and then loosen the bleeder plug with the pedal depressed.

When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

Repeat the 2 previous steps until all the air in the brake fluid is gone.

Tighten the bleeder plug.

Torque:

for front brake:

11 N*m{110 kgf*cm, 8 ft.*lbf}

for rear brake:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install the cap.

Bleed air from the brake line for each wheel by repeating the above procedures.

Remove the bleeder plug cap.

Connect the vinyl tube to the bleeder plug.

Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

Repeat the previous 2 steps until all the air in the fluid is completely bled out.

Tighten the bleeder plug.

Torque:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Install the bleeder plug cap.

Check that all the air has been bled out of the clutch line.

Check the pedal height.

Pedal height from dash panel:

Model	Specified Condition
for Manual Transmission	156.9 to 166.9 mm (6.177 to 6.571 in.)
for Automatic Transmission	158.1 to 168.1 mm (6.224 to 6.618 in.)

Adjust the pedal height.

1. Disconnect the connector from the stop light switch.
   

2. Remove the switch.
   

3. Loosen the push rod clevis lock nut.
   

4. Adjust the pedal height by turning the push rod.
   

5. Tighten the lock nut.
   

   Torque:

   26 N*m{265 kgf*cm, 19 ft.*lbf}





6. Insert the switch into the adjuster until it slightly touches the pedal.
   

   NOTICE:

   Do not depress the pedal.





7. Turn the switch a quarter turn clockwise.
   

   Torque:

   1.5 N*m{15 kgf*cm, 13 in.*lbf}or less

   NOTICE:

   Do not depress the pedal.

8. Connect the connector to the switch.
   

9. Check the switch clearance.
   

   Stop light switch clearance:

   1.5 to 2.5 mm (0.059 to 0.098 in.)
   

Stop the engine. Depress the pedal several times until there is no vacuum in the booster. Then release the pedal.

Depress the pedal until resistance is felt.

Check the pedal free play by measuring the distance between the position in the previous step and the pedal's released position.

Pedal free play:

1.0 to 6.0 mm (0.0394 to 0.236 in.)

Check the switch clearance.

Stop light switch clearance:

1.5 to 2.5 mm (0.0590 to 0.0984 in.)

Release the parking brake lever. Start the engine.

Depress the pedal and check the pedal reserve distance.

1. Depress the pedal with a force of 490 N (50 kgf, 110 lbf).
   

2. Measure the distance between the pedal and dash panel shown in the illustration.
   

   Pedal reserve distance:

   89.0 mm (3.504 in.)
   

   If the distance is not as specified, troubleshoot the brake system.
   

Check the fluid level and add fluid if necessary.

Fluid:

SAE J1703 or FMVSS No. 116 DOT 3

HINT:

Add fluid to a level between the reservoir's MIN and MAX lines.

Check SRS warning light (Toyota Fortuner RM000000XFD06DX.html).