Installation [10/2014 - ]: Procedure

1. Insert the stud of the brake booster pump assembly to the hole of the brake actuator bracket assembly, and insert the 2 pins of the brake actuator bracket assembly into the 2 brake booster pump bushings*5.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	Union
   *2	Stud
   *3	Connector Box and Wire Harness
   *4	Pin
   *5	Brake Booster Pump Bushing
   *6	Brake Booster Pump Collar
   *7	Brake Actuator Case Collar
   *8	Brake Booster Pump Bushing

   NOTE:

   • Do not carry the brake booster pump assembly by the parts shown in bold (*1, *2 and *3) in the illustration.
   • Do not drop the brake booster pump assembly when carrying it.
   • Be careful not to allow any brake fluid to enter the connector.
   • When installing the brake booster pump assembly to the brake actuator bracket assembly, confirm that the 2 brake booster pump collars*6 and 2 brake booster pump bushings*5 are installed on the brake booster pump assembly.
   • Do not remove the hole plugs before installing a new brake booster pump assembly because the brake booster pump assembly is filled with brake fluid.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Install the brake actuator case collar*7, brake booster pump bushing*8 and brake booster pump assembly to the brake actuator bracket assembly with the nut.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

3. Engage the wire harness clamp to the brake actuator bracket assembly.

1. Install the No. 2 brake actuator hose to the brake booster pump assembly with the hose clamp.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   Up

   NOTE:

   • Match the identification mark of the No. 2 brake actuator hose and the rib of the brake booster pump assembly.
   • Install the hose clamp within the range shown in the illustration.

1. Engage the claw to temporarily install the brake booster pump assembly with bracket to the vehicle body.
   Fig 1: Brake Booster Pump Assembly With Bracket Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *a

   Claw

   NOTE:

   Do not kink or damage the brake line, suction hose sub-assembly or air conditioner tube and accessory assembly.

2. Install the brake booster pump assembly with bracket with the 3 bolts.

   Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

   NOTE:

   Tighten the 3 bolts in the order shown in the illustration.

3. Engage the claw to temporarily install the connector box to the brake actuator bracket assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1	Connector Box
   *a	Claw

4. Install the connector box with the bolt.

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

5. Connect the 2 connectors to the brake booster pump assembly.

1. Using a union nut wrench, connect the front No. 1 brake tube to the brake booster pump assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *a	Torque Wrench Fulcrum Length

   Specified tightening torque 

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

   HINT: 

   • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (Refer to PRECAUTION [10/2014 - ] ).
   • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 250 mm (9.84 in.)):

     14 N*m (142 kgf*cm, 10 ft.*lbf)

1. Connect the No. 2 brake actuator hose to the No. 1 brake actuator tube with the hose clamp.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   Up

   NOTE:

   • Match the identification mark of the No. 2 brake actuator hose and the identification mark of the No. 1 brake actuator tube.
   • Install the hose clamp within the range shown in the illustration.

See step  6

See step  7

See step  8

1. Remove the vinyl tape from the openings of the disconnected parts.
2. Sufficiently apply compressor oil to a new O-ring, the fitting surface of the suction hose sub-assembly and air conditioning unit.

   Compressor Oil

   ND-OIL 11 or equivalent

   NOTE:

   Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

3. Install the O-ring to the suction hose sub-assembly.
   NOTE:

   Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign matter.

4. Insert the suction hose sub-assembly into the air conditioning unit.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   • Insert the pipe joint into the fitting hole securely.
   • Do not deform the piping.
   • Do not damage the clamp.

1. Remove the vinyl tape from the openings of the disconnected parts.
2. Sufficiently apply compressor oil to a new O-ring, the fitting surface of the air conditioner tube and accessory assembly and air conditioning unit.

   Compressor Oil

   ND-OIL 11 or equivalent

   NOTE:

   Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

3. Install the O-ring to the air conditioner tube and accessory assembly.
   NOTE:

   Keep the O-ring and O-ring fitting surface free from dirt or any foreign matter.

4. Insert the air conditioner tube and accessory assembly into the air conditioning unit.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Insert the pipe joint into the fitting hole securely.

5. Turn the hook connector and install the bolt.

   Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

(Refer to PROCEDURE - Step 2 )

See step  2

Refer to PROCEDURE - Step 62

Refer to PROCEDURE - Step 63

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 65

Refer to PROCEDURE - Step 3 and PROCEDURE - Step 3

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 4

See step  18

(Refer to PROCEDURE - Step 2 )