Installation [11/2015 - ]: Procedure

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

1. Install the brake booster with master cylinder assembly with the 4 nuts.
   Fig 1: Brake Booster With Master Cylinder Assembly With Nuts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Skid Control ECU
   *b	No. 1 Reservoir Hose
   *c	Brake Master Cylinder Push Rod Clevis
   *d	Boot
   *e	Master Cylinder Reservoir Assembly
   *f	Brake Actuator Bracket

   Torque: 12.7 N.m (130 kgf.cm, 9 ft./lbf) 

   NOTE:

   • Tighten the nuts in the order shown in the illustration.
   • Do not kink or damage the brake lines.
   • Do not carry the brake booster with master cylinder assembly by the parts shown 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.

See step  3

See step  4

1. Engage the clamp to install the 3 brake lines.
   NOTE:

   • Do not damage the clamp.
   • Do not kink or damage the brake lines.
2. Using a union nut wrench, connect the 3 brake lines to the brake booster with master cylinder assembly.

   Specified tightening torque 

   Torque: 15.2 N.m (155 kgf.cm, 11 ft./lbf) 

   NOTE:

   • Do not kink or damage the brake lines.
   • Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.
   • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

   HINT: 

   • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

     Refer to PRECAUTION [11/2015 - 11/2017] , or refer to PRECAUTION [11/2017 - 12/2018] , or refer to PRECAUTION [12/2018 - 08/2019] , or refer to PRECAUTION [08/2019 - ]

   • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

     13.38 N.m (136 kgf.cm, 10 ft./lbf)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Torque Wrench Fulcrum Length
   *b	Union Nut Wrench

1. Connect the No. 2 brake actuator hose to the brake booster with master cylinder assembly, and slide the clip to secure it.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Identification Mark
   	Front of the vehicle

   NOTE:

   • Make sure to connect the No. 2 brake actuator hose with its identification mark facing the front of the vehicle.
   • Install the clip within the range shown in the illustration.

1. Connect the connector to the brake booster with master cylinder assembly.
2. Connect the connector to the brake booster with master cylinder assembly and lock the lock lever as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Connect the connector
   	Lock the lock lever

   NOTE:

   • Make sure that the connector is locked securely.
   • Make sure that the connector can be connected smoothly. Do not allow water, oil or dirt to enter the connector.
3. Engage the clamp to install the engine room main wire.

Refer to PROCEDURE - Step 17 , or refer to PROCEDURE - Step 32

Refer to PROCEDURE - Step 72 , or refer to PROCEDURE - Step 72 , or refer to PROCEDURE - Step 72 , or refer to PROCEDURE - Step 72

1. Remove the brake master cylinder reservoir filler cap assembly.
2. Add brake fluid to the reservoir until the fluid level is between the MAX and MIN lines on the brake fluid reservoir.

   Brake Fluid

   SAE J1703 or FMVSS No. 116 DOT3

   SAE J1704 or FMVSS No. 116 DOT4

3. Remove the nut to separate the No. 1 brake actuator tube.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   If the No. 1 brake actuator tube has already been separated, it is not necessary to perform this step.

4. Set SST to the brake master cylinder reservoir assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • SST: 09992-0024209992-00350 
5. Using SST, increase and then maintain the pressure in the brake master cylinder reservoir assembly for 60 seconds.(*1)

   Standard Pressure

   50 to 80 kPa (0.6 to 0.8 kgf/cm² , 7.3 to 11.6 psi)

6. Release the pressure in the brake master cylinder reservoir assembly and wait for 30 seconds.(*2)
7. Repeat steps *1 to *2, 3 times.
8. Remove SST.
9. Pull up the No. 1 brake actuator tube as shown in the illustration as high as possible for 10 seconds without damaging the bracket of the No. 1 brake actuator tube.(*3)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Pull up

   NOTE:

   Do not damage the hoses.

   HINT: 

   Elevating the No. 2 brake actuator hose causes any air in the horizontal portion of the hose to flow to the brake master cylinder reservoir assembly side.

10. Repeat step *3, 5 times.
11. Elevate the No. 1 brake actuator tube for 10 seconds by lifting the No. 1 brake actuator tube as shown in the illustration.(*4)
    NOTE:

    Do not damage the hoses.

    HINT: 

    Elevating the No. 1 brake actuator tube causes any air in the horizontal portion of the tube to flow to the brake master cylinder reservoir assembly side.

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Pull up

12. Lower the No. 1 brake actuator tube for 10 seconds as shown in the illustration.(*5)
    NOTE:

    Do not damage the hoses.

    HINT: 

    Lowering the No. 1 brake actuator tube causes any air in the No. 1 brake actuator tube to flow to the brake master cylinder reservoir assembly side.

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Press down

13. Repeat steps *4 to *5, 5 times.
14. Install the No. 1 brake actuator tube with the nut.

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

HINT: 

Perform this operation only when the accumulator pressure zero down could not be performed using the Techstream.

1. Connect the connector to the brake booster pump assembly and lock the lock lever as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Connect the connector
   	Lock the lock lever

   NOTE:

   • Make sure that the connector is locked securely.
   • Make sure that the connector can be connected smoothly. Do not allow water, oil or dirt to enter the connector.

Refer to PROCEDURE - Step 2 [11/2015 - 12/2018] , or refer to PROCEDURE - Step 2 [12/2018 - ]

See step  3

Refer to ADJUSTMENT [11/2015 - 12/2018] , or refer to ADJUSTMENT [12/2018 - ] 

Refer to CALIBRATION [11/2015 - 12/2018] , or refer to CALIBRATION [12/2018 - 07/2020] , or refer to CALIBRATION [07/2020 - ]

Refer to PROCEDURE - Step 22 [11/2015 - 11/2017] , or refer to PROCEDURE - Step 24 [11/2017 - 08/2019] , or refer to PROCEDURE - Step 23 [08/2019 -]

Refer to PROCEDURE - Step 50 [11/2015 - 12/2018] , or refer to PROCEDURE - Step 46 [12/2018 - 07/2020] , or refer to PROCEDURE - Step 46 [07/2020 -]

Refer to PROCEDURE - Step 51 [11/2015 - 12/2018] , or refer to PROCEDURE - Step 47 [12/2018 - 07/2020] , or refer to PROCEDURE - Step 47 [07/2020 -]

Refer to PROCEDURE - Step 14 [11/2015 - 12/2018] , or refer to PROCEDURE - Step 16 [12/2018 - ]

Refer to PROCEDURE - Step 15 [11/2015 - 12/2018] , or refer to PROCEDURE - Step 17 [12/2018 - ]

Refer to PROCEDURE - Step 16 [11/2015 - 12/2018] , or refer to PROCEDURE - Step 18 [12/2018 - ]

Refer to PROCEDURE - Step 17 [11/2015 - 12/2018] , or refer to PROCEDURE - Step 19 [12/2018 - ]

Refer to PROCEDURE - Step 2