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Hydraulic Brake Booster: Reassembly

  1. INSTALL BRAKE BOOSTER ACCUMULATOR ASSEMBLY 
    1. Place the brake booster pump in a vise lined with a cloth.
    2. Install the brake booster accumulator pipe, compression spring and a new O-ring.
      NOTE: Ensure that no foreign matter enters the pump.
      Fig 1: Identifying Brake Booster Accumulator Assembly
      G05112451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the brake booster accumulator onto the brake booster pump.

      Torque: 57 N*m (585 kgf*cm, 42 ft.*lbf) 

  2. INSTALL PISTON 
    1. Apply lithium soap base glycol grease to a new piston.
    2. Install the piston into the master cylinder body.
      3. Fig 2: Identifying Piston Into Master Cylinder Body
      G04965636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using 2 screwdrivers, install a new C-ring while pressing the piston.
      NOTE: Do not damage the rubber lips on the piston when reassembling.
  3. INSTALL MASTER CYLINDER BOOT 
  4. INSTALL MASTER CYLINDER PUSH ROD CLEVIS 
    1. Install the master cylinder side lock nut and rod operating adapter.

      Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

      Fig 3: Identifying Brake Master Cylinder Lock Nut
      G05112447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the lock nut and push rod clevis.

      Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

      Fig 4: Identifying Lock Nut
      G05112454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL MASTER CYLINDER SOLENOID 
    1. Place a new gasket onto the master cylinder solenoid.
      Fig 5: Identifying Gasket
      G04965631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the master cylinder solenoid with 6 new bolts.

      Torque: 32 N*m (325 kgf*cm, 24 ft.*lbf) 

      NOTE: Do not let water, dust, or other foreign matter adhere to the surface or fitting surfaces of the master cylinder solenoid, master cylinder body and gasket.
      Fig 6: Locating Master Cylinder Solenoid Bolts
      G05112444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL BRAKE BOOSTER PUMP BRACKET 
    1. Using a 5 mm hexagon wrench, install the brake booster pump bracket with the 2 bolts.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

    2. Install the bush onto the brake booster pump bracket.
      Fig 7: Locating Brake Booster Pump Bracket Bolts
      G05112443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL BRAKE ACTUATOR BRACKET 
    1. Using a 5 mm hexagon wrench, install the brake actuator bracket with the bolt.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      Fig 8: Identifying Brake Actuator Bracket Bolt
      G04965628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY 
    1. Using a 4 mm hexagon wrench, install the 2 pins.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      Fig 9: Identifying Pins
      G05112441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 collars and 2 bushes onto the brake booster with accumulator pump assembly.
    3. Install the brake booster with accumulator pump assembly.
      Fig 10: Identifying Brake Booster With Accumulator Pump Assembly
      G04965625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install a new clip.
      Fig 11: Identifying Clip
      G04965646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the wire harnesses with the 2 screws.

      Torque: 2.9 N*m (30 kgf*cm, 26 in.*lbf) 

      Fig 12: Identifying Wire Harness Screws
      G05112438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install 2 new plugs.
      Fig 13: Identifying Plugs
      G05112437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL BRAKE ACTUATOR NO. 1 TUBE 
    1. Using a union nut wrench, install the brake actuator tube.

      Torque: without union nut wrench 

      15 N*m (155 kgf*cm, 11 ft.*lbf) 

      with union nut wrench 

      14 N*m (144 kgf*cm, 10 ft.*lbf) 

      NOTE:
      • This torque value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.8 in.) and a union nut wrench with a fulcrum length of 22 mm (0.866 in.) (See REPAIR INSTRUCTION ).
        Fig 14: Identifying Fulcrum Length
        G05112464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • This torque value is effective when the union nut wrench is parallel to a torque wrench.
  10. INSTALL BRAKE ACTUATOR HOSE NO.1 
    1. Using needle-nose pliers, install the brake actuator hose with the 2 clips.
      Fig 15: Locating Brake Actuator Hose Clips
      G05112435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY 
    1. Apply lithium soap base glycol grease to 3 new grommets.
    2. Install the 3 grommets onto the master cylinder body.
      NOTE: The grommets are different sizes. Install the grommets in their correct positions.
      Fig 16: Identifying Reservoir Grommets
      G04965651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the master cylinder reservoir with the screw.

      Torque: 1.7 N*m (17 kgf*cm, 15 in.*lbf) 

      Fig 17: Identifying Master Cylinder Reservoir Screw
      G05112433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a pin punch and hammer, install a new pin onto the master cylinder reservoir.
    Fig 18: Identifying Pin Onto Master Cylinder Reservoir
    G05112432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL BRAKE ACTUATOR NO. 1 BRACKET 
    1. Install the fluid level warning switch connector.
    2. Using a 5 mm hexagon wrench, install the brake actuator bracket with the bolt.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

    Fig 19: Identifying Brake Actuator Bracket Bolt
    G04965615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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