Installation [10/2014 - ]: Procedure

1. Install a new brake booster gasket to the brake booster with master cylinder assembly.

1. Align the matchmarks on the wire harness and a new wire harness clamp, and install it to the wire harness.

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   *a	Matchmark
   	Cut
   	Excess

   NOTE:

   Make sure to install the wire harness clamp in the correct direction.

2. Tighten the bands of the clamp and cut off the excess.
3. Install the brake booster with master cylinder assembly with the 4 nuts.

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   *1	Connector Portion
   *2	Union
   *3	Push Rod Clevis
   *4	Boot
   *5	Front No. 2 Brake Tube

   Torque: 13 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 bold in the illustration.
   • Be careful not to allow any 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 is filled with brake fluid.
4. Temporarily tighten each brake line to the correct position on the brake booster with master cylinder assembly as shown in the illustration.

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   *a	To Front Wheel Cylinder LH
   *b	To Rear Wheel Cylinder RH
   *c	To Brake Booster Pump Assembly
   *d	To Rear Wheel Cylinder LH
   *e	To Front Wheel Cylinder RH

5. Using a union nut wrench, fully tighten each brake line.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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   *a	Torque Wrench Fulcrum Length

   Specified tightening torque 

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

   NOTE:

   Do not kink or damage the brake lines.

   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)

6. Connect the connector to the brake booster with master cylinder assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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   	Connect
   	Lock

   NOTE:

   • Make sure that the connector can be connected smoothly. Do not allow water, oil or dirt to enter.
   • Make sure that the connector lock is locked securely.
7. Push in the wire harness clamp to install it to the brake booster with master cylinder assembly.

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1. Engage the claw to temporarily install the reservoir bracket to the vehicle body.

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   *a

   Claw

2. Install the reservoir bracket with the 3 bolts.

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

3. Engage the 2 clamps to connect the wire harness to the reservoir bracket.

1. Connect the No. 1 reservoir hose to the brake booster with master cylinder assembly with the hose clamp.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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   Up

   NOTE:

   • When connecting the No. 1 reservoir hose, face the identification mark up.
   • Match the identification mark of the No. 1 reservoir hose and the rib of the brake booster with master cylinder assembly.
   • Make sure to install the hose to the proper location.
   • Install the hose clamp within the range shown in the illustration.

1. Connect the No. 2 reservoir hose to the brake booster with master cylinder assembly with the hose clamp.

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   Up

   NOTE:

   • When connecting the No. 2 reservoir hose, face the identification mark up.
   • Match the identification mark of the No. 2 reservoir hose and the identification mark of the brake booster with master cylinder assembly.
   • Make sure to install the hose to the proper location.
   • Install the hose clamp within the range shown in the illustration.

1. Add brake fluid to the brake master cylinder reservoir assembly.
2. Lift up the brake master cylinder reservoir assembly as far as possible and rock it back and forth to bleed air from the No. 1 brake actuator tube.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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   *1	No. 1 Brake Actuator Tube

   NOTE:

   • Do not damage the hoses or tubes.
   • Do not spill the brake fluid.
   • Continue this procedure until only a minor amount of air remains in the No. 1 brake actuator tube.

1. Install the No. 1 brake actuator tube to the vehicle body with the nut.

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

2. Install the nut and engage the clamp.

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

1. Install the brake master cylinder reservoir assembly to the reservoir bracket with the 2 bolts.

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

See step  3

(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

1. Install the front outer cowl top panel sub-assembly with the 10 bolts.

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.

(Refer to PROCEDURE - Step 2 )

(Refer to ADJUSTMENT [10/2014 - ] )

HINT: 

After the brake booster with master cylinder assembly is replaced, obtain the zero point of the yaw rate and acceleration sensor (Refer to CALIBRATION [10/2014 - ] ).