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Home >> Lexus >> 2024 >> ES 350 Base >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) - Service Information (2 Of 2) >> BRAKE BOOSTER (for HV Model) >> Installation [08/2021 - ] >> Procedure

Installation [08/2021 - ]: Procedure

  1. INSTALL BRAKE MASTER CYLINDER GASKET 
    1. Install a new brake master cylinder gasket to the brake booster with master cylinder assembly.
  2. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY 
    1. Install the brake booster with master cylinder assembly with the 4 nuts.
      GTY745056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Skid Control ECU
      *b No. 1 Reservoir Hose
      *c Brake Master Cylinder Push Rod Clevis
      *d Boot
      *e Master Cylinder Reservoir Assembly

      Torque: 12.8 N.m (131 kgf/cm, 9 ft.lbf) 

      NOTE:
      • Do not kink or damage the brake lines.
      • Do not carry the brake booster with master cylinder assembly by the parts shown in the illustration.
      • Be careful not to allow brake fluid to enter the connector.
      • If installing a new brake booster with master cylinder assembly, do not remove the hole plugs before connecting the brake lines because the brake booster with master cylinder assembly is filled with brake fluid.
  3. INSTALL BRAKE PEDAL LINK PIN 
    1. Apply lithium soap base glycol grease to the brake pedal link pin.
      GTY759014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lithium Soap Base Glycol Grease
    2. Connect the brake master cylinder push rod clevis to the brake pedal support assembly with the brake pedal link pin, and install a new clip as shown in the illustration.
      GTY745586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The brake pedal link pin can be installed in either direction.

  4. CONNECT BRAKE LINE 
    1. Using a union nut wrench, connect the 3 brake lines to the brake booster with master cylinder assembly.

      Specified tightening torque 

      Torque: 15.2 N.m (155 kgf/cm, 11 ft.lbf) 

      NOTE:
      • Do not kink or damage the brake lines.
      • Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [06/2018 - ]

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        13.4 N.m (137 kgf/cm, 10 ft.lbf)

      GTY742779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
  5. CONNECT NO. 1 BRAKE ACTUATOR HOSE 
    1. Connect the No. 1 brake actuator hose to the brake booster with master cylinder assembly and slide the clip to secure it.
      GTY762101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Identification Mark
      Front of the vehicle
      NOTE:
      • Make sure to connect the No. 1 brake actuator hose with its identification mark facing the front of the vehicle.
      • Install the clip within the range shown in the illustration.
  6. CONNECT ENGINE ROOM MAIN WIRE 
    1. Connect the connector to the brake booster with master cylinder assembly and lock the lock lever as shown in the illustration.
      GTY751024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Connect the connector
      Lock the lock lever
      NOTE:
      • Make sure that the connector is locked securely.
      • Make sure that the connector can be connected smoothly.
      • Do not allow water, oil or dirt to enter the connector.
    2. Connect the connector to the brake booster with master cylinder assembly.
      GTY745589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. BLEED NO. 1 BRAKE ACTUATOR TUBE 
    NOTE:

    Make sure to bleed the air from the No. 1 brake actuator tube. If the air remains in the No. 1 brake actuator tube, the air will enter the brake booster pump assembly and may damage the brake booster pump assembly.

    1. Remove the brake master cylinder reservoir filler cap assembly.
    2. Add brake fluid to the reservoir until the fluid level is between the MAX and MIN lines on the brake fluid reservoir.

      Brake Fluid

      SAE J1703 or FMVSS No. 116 DOT3

      SAE J1704 or FMVSS No. 116 DOT4

    3. Remove the 2 nuts to separate the No. 1 brake actuator tube.
      GTY745581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Set SST to the brake master cylinder reservoir assembly.
      GTY748563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09992-0024209992-00350 
    5. Using SST, increase and then maintain the pressure in the brake master cylinder reservoir assembly for 60 seconds.(*1)

      Standard Pressure

      50 to 80 kPa (0.6 to 0.8 kgf/cm2 , 7.3 to 11.6 psi)

    6. Release the pressure in the brake master cylinder reservoir assembly and wait for 30 seconds.(*2)
    7. Repeat steps *1 to *2, 3 times.
    8. Remove SST.
    9. Elevate the No. 1 brake actuator tube for 10 seconds by lifting the No. 1 brake actuator tube as shown in the illustration.(*3)
      GTY749599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Pull up
      NOTE:

      Do not damage the hoses by applying excessive force.

    10. Repeat step *3, 5 times.
    11. Elevate the No. 1 brake actuator tube for 10 seconds by lifting the No. 1 brake actuator tube as shown in the illustration.(*4)
      NOTE:

      Do not damage the hoses by applying excessive force.

      GTY757224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Pull up
    12. Lower the No. 1 brake actuator tube for 10 seconds as shown in the illustration.(*5)
      NOTE:

      Do not damage the hoses by applying excessive force.

      GTY754691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Press down
    13. Repeat steps *4 to *5, 5 times.
    14. Install the No. 1 brake actuator tube with the 2 nuts.

      Torque: 8.5 N.m (87 kgf/cm, 75 in.lbf) 

  8. CONNECT BRAKE BOOSTER PUMP CONNECTOR 

    HINT: 

    Perform this operation only when the accumulator pressure zero down operation could not be performed using the Techstream.

    1. Connect the connector to the brake booster pump assembly and lock the lock lever as shown in the illustration.
      GTY769881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Connect the connector
      Lock the lock lever
      NOTE:
      • Make sure that the connector is locked securely.
      • Make sure that the connector can be connected smoothly.
      • Do not allow water, oil or dirt to enter the connector.
  9. FILL RESERVOIR WITH BRAKE FLUID 
  10. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2

  11. BLEED BRAKE SYSTEM 

    Refer to PROCEDURE - Step 3

  12. INSPECT AND ADJUST BRAKE PEDAL 

    Refer to ADJUSTMENT [08/2021 - ]

  13. OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR 

    Refer to CALIBRATION [06/2018 - ]

  14. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 44

  15. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY 
    1. Temporarily install the front center upper suspension brace sub-assembly with the 6 bolts and 4 nuts.
      GTY750634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Fully tighten the 2 nuts (A).

      Torque: 50 N.m (510 kgf/cm, 37 ft.lbf) 

    3. Fully tighten the 6 bolts and 2 nuts (B) to install the front center upper suspension brace sub-assembly.

      Bolt 

      Torque: 8.9 N.m (91 kgf/cm, 79 in.lbf) 

      Nut (B) 

      Torque: 39 N.m (398 kgf/cm, 29 ft.lbf) 

    4. Engage the 2 clamps to install the wire harness.
    5. Connect the connector.
    6. w/ Windshield Deicer System:
      1. Engage the 3 clamps to install the wire harness.
      2. Connect the connector.
  16. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to INSTALLATION [06/2018 - ]

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