Installation [11/2015 - ]: Procedure

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

1. Install the brake booster with master cylinder assembly with the 4 nuts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

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

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

   NOTE:

   • Do not kink or damage the brake lines.
   • Do not carry the brake booster with master cylinder assembly by the portion shown in bold 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 is filled with brake fluid.
2. Temporarily tighten each brake line to the correct position on the brake booster with master cylinder assembly as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *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

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

   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) 

   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 [11/2015 - 06/2017] and Refer to PRECAUTION [06/2017 - ] ).
   • 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)

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   	Connect the connector
   	Lock the lock lever

   NOTE:

   • Make sure that the connector can be connected smoothly. Do not allow foreign matter to enter.
   • Make sure that the connector lock is locked securely.

1. Temporarily install the tube clamp bracket to the brake booster with master cylinder assembly with the front No. 1 brake tube and 2 bolts.
   Fig 1: Tube Clamp Bracket Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Front No. 1 Brake Tube
   *a	The tube clamp bracket contacts the brake booster with master cylinder assembly.

2. Tighten the 2 bolts in the order shown in the illustration.

   Bolt (1) 

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

   Bolt (2) 

   Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

   NOTE:

   When tightening the bolt (1), be sure that the tube clamp bracket contacts the brake booster with master cylinder assembly.

1. Connect the brake actuator hose to the brake master cylinder reservoir assembly with the clip.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   Front of Vehicle

   NOTE:

   • Make sure that the identification mark on the brake actuator hose is positioned within 30° of the brake master cylinder reservoir assembly rib.
   • Make sure to install the hose to the proper location.
   • Install the clip within the range shown in the illustration.

1. Install the reservoir bracket with the 2 bolts.

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

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   Up

   NOTE:

   • Make sure that the identification mark on the No. 1 reservoir hose is positioned within 30° of the brake booster with master cylinder assembly rib.
   • When connecting the reservoir hose, face the identification mark up.
   • Make sure to install the hose to the proper location.
   • Install the clip within the range shown in the illustration.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   Up

   NOTE:

   • Make sure that the identification mark on the No. 2 reservoir hose is positioned within 30° of the brake booster with master cylinder assembly rib.
   • When connecting the reservoir hose, face the identification mark up.
   • Make sure to install the hose to the proper location.
   • Install the clip within the range shown in the illustration.

1. Install the brake master cylinder reservoir assembly with the 2 nuts.

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

See step  2

See step  3

(Refer to PROCEDURE - Step 2 and Refer to PROCEDURE - Step 2 )

See step  2

(Refer to ADJUSTMENT [11/2015 - ] )

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 [11/2015 - ] ).

1. Install the outer cowl top panel sub-assembly with the 8 bolts and nut.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Bolt 

   Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

   Nut 

   Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

   NOTE:

   Tighten the 2 bolts (1) and (2) first, and then tighten the rest of the bolts and nut.

2. Engage the clamp to install the wire harness.

1. Engage the clamp to install the front No. 1 ventilator seal to the outer cowl top panel sub-assembly.

1. Engage the clamp to install the front air shutter seal to the outer cowl top panel sub-assembly.

1. Install the inner cowl top to cowl brace to the outer cowl top panel sub-assembly with the 3 bolts.
   Fig 2: Inner Cowl Top To Cowl Brace Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

   NOTE:

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

(Refer to PROCEDURE - Step 2 )