OEM 2002 Toyota Avalon Brake Booster

2002 Toyota Avalon Parts Questions & Experts Answers

• Q: How to service and repair the vacuum brake booster on 2002 Toyota Avalon?

  A: Service and repair of the vacuum brake booster starts by taking out the air cleaner cover with the air cleaner hose then the master cylinder. Service and repair of the vacuum brake booster requires precharge pump assembly removal together with the vacuum hose separation from the brake booster when VSC is present. The service sequence starts with removal of lower No. 1 instrument panel and lower LH instrument panel insert together with the No. 2 heater to register duct before the brake booster assembly can be taken out after removing the pedal return spring and clip and clevis pin and four nuts and clevis. Install the new booster by placing it with its gasket then connecting the operating rod clevis before tightening the booster installation nuts to 13 Nm (130 kgf-cm, 9 ft. lbs.). Position the clevis pin through clevis and brake pedal then connect it with the clip while returning the pedal return spring to its original place. Set Special Service Tool: 09737-00011 on the master cylinder master cylinder to measure the booster push rod length by lowering its pin until it touches the piston then flipping the tool and using it to check the pin head clearance with the booster push rod which should be 0 mm (0 inch). Correct the length of the booster push rod via Special Service Tool: 09737-00020 until it produces gentle contact with the pin head. When a vehicle has VSC functionality the precharge pump assembly must be installed first after reinstalling the master cylinder through connection of the brake booster vacuum hose. You should perform a brake fluid addition to the reservoir before conducting the brake system bleeding procedure while inspecting for any fluid leakage and adjusting the brake pedal to proper position. The operation check requires reinstallation of the No. 2 heater to register duct followed by insertion of lower LH instrument panel and lower No. 1 instrument panel.