Hydraulic Brake Booster: Reassembly

WARNING: This page is about a different car, the 2007 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL BRAKE BOOSTER ACCUMULATOR ASSEMBLY
1. Install the silencer, spring and a new O-ring.
2. Using SST, install the accumulator.
  SST 09318-12010
  
  Torque: 54 N.m (550 kgf.cm, 36 ft. lb.)
  
  Fig 1: Installing Accumulator Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PISTON
NOTE:
- If the piston is installed at an angle, there is possibility that the cylinder bore could be damaged.
- Be careful not to damage the rubber lips on the pistons.
INSTALL OIL PRESSURE SENSOR
1. Using a 30 mm deep socket, install the oil pressure sensor.
  Torque: 81 N.m (830 kgf.cm, 60 ft. lb.)
  
  NOTE: If replacing the pressure sensor, since the sensor is non-reusable, use a sensor of the supply part No. shown below.
  
  Part No.: 89637-30050
  
  Fig 2: Installing Oil Pressure Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE BOOSTER PUMP ASSEMBLY
1. Install the cushion to the No. 2 pump bracket.
2. Install the No. 2 pump bracket with the 2 bolts.
3. Install the 2 washers, 2 cushions, 2 collars and sleeve.
4. Install the No. 1 pump bracket with the bolt.
5. Install the booster pump with the 2 bolts.
6. Install the accumulator bracket with the 2 bolts.
  1. When installing the accumulator bracket, adjust to secure the clearance as shown.
    A + B: 0.1 mm (0.161 in.) or less
    
    C: 0.3 to 3.8 mm (0.012 to 0.150 in.)
    
    Fig 3: Installing Brake Booster Pump Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    HINT:
    
    Secure more than 0.3 mm (0.012 in.) clearance for A and B each.
7. Install the wire harness to the booster pump with the 4 screws.
8. Install the actuator hose.
INSTALL NO. 1 BRAKE ACTUATOR TUBE
1. Using SST, install the actuator tube.
  SST 09023-00101
  
  Torque: 15 N.m (155 kgf.cm, 11 ft. lb.) without SST
  
  14 N.m (143 kgf.cm, 10 ft. lb.) with SST
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
  
  Fig 4: Installing Actuator Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CYLINDER BOOT
1. Install the cylinder boot.
INSTALL MASTER CYLINDER PUSH ROD CLEVIS
1. Install the clevis and lock nut.
2. Tighten the lock nut.
  Torque: 25 N.m (260 kgf.cm, 19 ft. lb.)
INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
1. Install the 3 grommets.
2. Install the reservoir with the 3 screws.
  Torque: 1.7 N.m (17.5 kgf.cm, 15.2 in..lbf)
3. Install the reservoir cap.
INSTALL FLUID LEVEL WARNING SWITCH CONNECTOR CLAMP
1. Install the clamp with the bolt.
2. Connect the connector.