OEM 2003 Toyota Sienna Brake Booster

2003 Toyota Sienna Parts Questions & Experts Answers

• Q: How to service and repair the Vacuum Brake Booster on 2003 Toyota Sienna?

  A: Service and repair of the Vacuum Brake Booster starts with removing 2 cowl top ventilator louvers, master cylinder and outer front cowl top panel. Before proceeding to detach the 2 brake lines use Special Service Tool: 09751-36011 when servicing a vehicle that lacks VSC. The service begins by separating the vacuum hose from the brake booster and following it with lower finish panel removal while taking out the No.1 safety pad insert. The procedure continues with pedal return spring removal together with clip and clevis pin. Professional tool 09751-36011 must be used to detach the brake lines from the ABS & VSC actuator master cylinder and clamp with 19.6 N.m (200 kgf.cm, 14.5 ft.lb) torque force. Begin by removing the brake booster by detaching its four nuts along with the clevis followed by pulling out the brake assembly and its accompanying gasket. The first step of installation requires placing a new gasket between the brake booster and fastening the operating rod clevis and tightening booster installation nuts to 13 N.m (130 kgf.cm, 9 ft.lb). You should implement the clevis pin into the clevis alongside the brake pedal while locking it with the clip prior to installing the pedal return spring. Adjust the booster push rod height by placing the gasket on the master cylinder then positioning Special Service Tool: 09737-00012 on the gasket while lowering the pin until it softly reaches the piston. Special Service Tool: O9737-00010 with the base facing down should be placed on the booster for measurement of the pin head to push rod clearance until it shows 0 mm of distance. Adjust the push rod until it just touches the pin head. The master cylinder installation should proceed followed by line connection for vehicles without VSC using Special Service Tool: 09751-36011 and tightening both nuts to 15.2 N.m (155 kgf.cm, 11 ft.lbf). Vehicles equipped with VSC require Special Service Tool: 09751-36011 to connect brake lines where the master cylinder push rod diameter is torqued to 15.2 N.m (155 kgf.cm, 11 ft.lbf) on the 10 mm nut and 19.6 N.m (200 kgf.cm, 14.5 ft.lbf) on the 12 mm nut. The brake booster should receive the vacuum hose connection while the process includes reinstalling the outer front cowl top panel along with the 2 cowl top ventilator louvers. Next fill the brake reservoir with fluid before performing brake system bleeding. Begin by checking for leaks before you adjust and check the brake pedal position while securing the clevis lock nut using 25 N.m (260 kgf.cm, 19 ft.lbf) of torque and concluding with brake pedal operational tests.