OEM 2002 Toyota Sienna Brake Booster

2002 Toyota Sienna Parts Questions & Experts Answers

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

  A: Starting the vacuum brake booster service requires first removing the 2 cowl top ventilator louvers and outer front cowl top panel after which the master cylinder. For vehicles without VSC disconnect the ABS actuator assembly whereas vehicles with VSC require application of Special Service Tool: 09751-36011 for brake line detachment. The first step requires breaking the vacuum connection of the brake booster followed by lowering the finish panel and extracting the No.1 safety pad insert. Proceed to remove the pedal return spring along with its clip and clevis pin and then detach the brake booster through 4 nuts and clevis removal before pulling out the brake booster and gasket. To install the system, begin by placing new gasket onto the brake booster followed by installing the booster along with the clevis to the operating rod before torque application on the booster installation nuts to 13 Nm (130 kgf-cm, 9 ft. lbs.). Install the clevis pin into the clevis and brake pedal before attaching it with the clip followed by returning the pedal return spring. The adjustment of booster push rod length occurs by positioning the gasket on the master cylinder followed by installing Special Service Tool: 09737-00012 on that gasket and finally reducing the pin until receiving a slight touch from the piston. The gasket along with the ABS actuator bracket needs placement onto the booster before tightening its two nuts only to a slight point of firmness. Special Service Tool: 09737-00010 needs to be inverted on top of the booster to measure push rod clearance to the pinhead at 0.35 mm (0.014 inch) for non-VSC vehicles or 0 mm (0 inch) for VSC vehicles by adjusting the push rod until it touches the pinhead. The ABS actuator assembly should be installed first before the master cylinder if relevant. When working on vehicles equipped with VSC, users must employ Special Service Tool: 09751-36011 for connecting brake lines before applying torque to 19.6 Nm (200 kgf-cm, 14.5 ft. lbs.). First connect the vacuum hose to the brake booster before installing the outer front cowl top panel and the 2 cowl top ventilator louvers and then fill the brake reservoir with brake fluid followed by bleaching the brake system. First inspect for any leaks in the system before checking the brake pedal adjustment while tightening the clevis lock nut to 25 Nm (260 kgf-cm, 19 ft. lbs.) before conducting the operational check.