Toyota Cressida and Van 1983-1990

Power Brake Booster

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REMOVAL & INSTALLATION



Cressida
1983-88 MODELS


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Fig. Fig. 1 The brake booster is mounted on the firewall with the master cylinder attached on the front-1983-88 Cressida shown

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the master cylinder assembly as previously outlined.
  4.  
  5. Remove the instrument lower finish panel and air duct. Working underneath the instrument panel, remove the brake pedal return spring. Remove the clevis pin retaining clip and remove the clevis pin from the brake pedal.
  6.  
  7. Remove the 4 nuts retaining the brake booster to the firewall and pull out the brake booster assembly. Disconnect the vacuum hose from the brake booster.
  8.  
  9. Installation is the reverse order of the removal procedure. It may be necessary to adjust the booster pushrod length until the pushrod lightly touches the pin head. Tighten the brake booster retaining nuts and tighten them to 9 ft. lbs. (13 Nm). Refill the master cylinder, bleed the brake system. Start the engine and check for leaks.
  10.  

1989-90 MODELS


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Fig. Fig. 2 Exploded view of the brake booster mounting-1989-90 Cressida



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Fig. Fig. 3 When removing the brake booster, unbolt the Idle Speed Control (ISC) valve-1989-90 Cressida



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Fig. Fig. 4 Unbolt the EGR pipe from the engine ...



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Fig. Fig. 5 ... then place a suitable container under the cold start injector and remove the injector-1989-90 Cressida



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Fig. Fig. 6 When removing the brake booster, the air intake chamber must be removed and poitioned forward-1989-90 Cressida



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Fig. Fig. 7 Remove the booster mounting nuts and clevis, then remove the booster and gasket from the firewall

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the master cylinder assembly as previously outlined. Disconnect the vacuum hose from the brake booster.
  4.  
  5. Remove the instrument lower finish panel and air duct. Working underneath the instrument panel, remove the brake pedal return spring. Remove the clevis pin retaining clip and remove the clevis pin from the brake pedal.
  6.  
  7. Remove the windshield wiper motor.
  8.  
  9. Remove the brake booster as follows:
  10.  
    1. Remove the alternator assembly.
    2.  
    3. Remove the PCV pipe with hose.
    4.  
    5. Disconnect the No.3 PCV hose from the cylinder head cover.
    6.  
    7. Remove the 2 bolts retaining the idle speed control valve and remove the valve.
    8.  
    9. Disconnect the No.3 water by-pass hose from the throttle body.
    10.  
    11. Remove the EGR pipe retaining bolt and remove the EGR pipe.
    12.  
    13. Place a suitable container or shop rag under the cold start injector tube. Slowly loosen the 2 union bolts of the cold start injector tube and remove the bolts, 4 gaskets and injector tube.
    14.  
    15. Remove the 2 bolts and the intake manifold stay bracket.
    16.  
    17. Remove the air intake chamber and move it forward.
    18.  
    19. Remove the brake booster retaining bolts, located under the instrument panel.
    20.  
    21. Remove the clevis yoke off of the operating rod.
    22.  
    23. Remove the brake booster and gasket.
    24.  

  11. Adjust the booster pushrod length until the pushrod lightly touches the pin head.
  12.  

To install:

  1. Install the brake booster as follows:
  2.  
    1. Install the brake booster and gasket.
    2.  
    3. Install the clevis yoke onto the operating arm.
    4.  
    5. Install the brake booster retaining nuts and torque them to 9 ft. lbs. (13 Nm).
    6.  
    7. Install the clevis pin into the clevis yoke and brake pedal and install the clevis pin retaining clip.
    8.  
    9. Install the air intake chamber to the intake manifold. Install the intake manifold bracket and chamber to manifold retaining bolts. Tighten the bolts to 13 ft. lbs. (18 Nm).
    10.  
    11. Install and tighten the installation bolts to the EGR pipe.
    12.  
    13. Install a new cold start injector tube gasket and the tube to the cold start injector. Tighten the union bolts to 13 ft. lbs. (18 Nm).
    14.  
    15. Connect the No. 3 water-to-bypass hose to the throttle body.
    16.  
    17. Install the idle speed control valve and retaining bolts.
    18.  
    19. Connect the No. 3 PCV hose to the cylinder head cover.
    20.  
    21. Install the PCV pipe with hose.
    22.  
    23. Install the alternator assembly.
    24.  

  3. Install the windshield wiper motor.
  4.  
  5. Install the brake pedal return spring.
  6.  
  7. Install the master cylinder assembly.
  8.  
  9. Connect the vacuum hose to the brake booster.
  10.  
  11. Refill the master cylinder, bleed the brake system. Start the engine and check for leaks.
  12.  

Van
1984-86 MODELS


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Fig. Fig. 8 Exploded view of the brake booster mounting-1984-86 Van

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the master cylinder as previously outlined.
  4.  
  5. Disconnect the vacuum hose from the brake booster.
  6.  
  7. Remove the clevis pin retaining clip and remove the clevis pin from the brake pedal.
  8.  
  9. Remove the 4 nuts retaining the brake booster to the firewall and pull out the brake booster assembly.
  10.  
  11. Installation is the reverse order of the removal procedure. It may be necessary to adjust the booster pushrod length until the pushrod lightly touches the pin head. Tighten the brake booster retaining nuts and torque them to 9 ft. lbs. (13 Nm). Refill the master cylinder, bleed the brake system. Start the engine and check for leaks.
  12.  

1987-89 MODELS


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Fig. Fig. 9 Exploded view of the brake booster mounting-1987-89 Van

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the master cylinder as previously outlined.
  4.  
  5. Disconnect the vacuum hose from the brake booster.
  6.  
  7. Remove the cluster finish lower panel. Remove the steering column assembly and unplug the 4 connectors.
  8.  
  9. Loosen the clutch pedal installation nut and bolt. Remove the nut and pull out the bolt until the bolt head goes in.
  10.  
  11. Loosen the 2 clutch master cylinder retaining bolts and pull them out until the brake pedal bracket is free from the clutch master cylinder.
  12.  
  13. Pull out the throttle cable from the cable hook.
  14.  
  15. Remove the 3 mounting bolts of the pedal bracket lower side.
  16.  
  17. Remove the 2 mounting bolts of the pedal bracket upper side. Pull out the brake booster with the bracket to the underside.
  18.  
  19. Remove the clevis pin cotter pin and the clevis pin from the brake pedal.
  20.  
  21. Remove the 4 nuts retaining the brake booster to the pedal bracket and pull out the brake booster assembly from the bracket.
  22.  

To install:

  1. Adjust the booster pushrod length until the pushrod lightly touches the pin head.
  2.  
  3. Install the brake booster to the pedal bracket along with the 4 retaining nuts. Tighten the nuts to 9 ft. lbs. (13 Nm).
  4.  
  5. Connect the brake pedal and clevis with the clevis pin and install the cotter pin.
  6.  
  7. Install the booster with the pedal bracket from the underside. Tighten the 2 mounting bolts of the pedal bracket upper side. Tighten the 3 mounting bolts of the pedal bracket lower side.
  8.  
  9. Tighten the clutch master cylinder bolts to 9 ft. lbs. (13 Nm).
  10.  
  11. Install the clutch pedal return spring and tighten the pedal bolt and nut to 24 ft. lbs. (32 Nm).
  12.  
  13. Hook the throttle cable to the cable hook.
  14.  
  15. Attach the 4 steering column assembly connectors. Install the steering column assembly. Install the cluster finish lower panel.
  16.  
  17. Install the master cylinder assembly.
  18.  
  19. Connect the vacuum hose to brake booster.
  20.  
  21. Refill the master cylinder, bleed the brake system. Start the engine and check for leaks.
  22.  

 
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