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Hydraulic Brake Booster Reassembly LC200

This document provides instructions for reassembling a hydraulic brake booster. It describes 12 steps: 1) installing the brake booster piston sub-assembly; 2) installing the master cylinder boot; 3) installing the master cylinder push rod clevis; 4) installing the master cylinder solenoid; 5) installing the brake booster accumulator pipe; 6) installing the No. 1 brake booster pump bracket; 7) installing the brake booster with accumulator pump assembly; 8) installing the No. 1 brake actuator tube; 9) installing the No. 1 brake actuator hose; 10) installing the master cylinder reservoir grommet; 11) installing the brake master cylinder reservoir sub-assembly; and 12) installing the

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Yannick de Walque
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558 views11 pages

Hydraulic Brake Booster Reassembly LC200

This document provides instructions for reassembling a hydraulic brake booster. It describes 12 steps: 1) installing the brake booster piston sub-assembly; 2) installing the master cylinder boot; 3) installing the master cylinder push rod clevis; 4) installing the master cylinder solenoid; 5) installing the brake booster accumulator pipe; 6) installing the No. 1 brake booster pump bracket; 7) installing the brake booster with accumulator pump assembly; 8) installing the No. 1 brake actuator tube; 9) installing the No. 1 brake actuator hose; 10) installing the master cylinder reservoir grommet; 11) installing the brake master cylinder reservoir sub-assembly; and 12) installing the

Uploaded by

Yannick de Walque
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd

HYDRAULIC BRAKE BOOSTER (for

LHD) > REASSEMBLY


for Preparation Click here

1. INSTALL BRAKE BOOSTER PISTON SUB-ASSEMBLY

1. Apply lithium soap base glycol grease to a new piston.

2. Install the piston.

NOTICE:
When installing, be careful not to damage the seals, etc.

3. Install the plug.

4. Using 2 screwdrivers, install a new C-ring while pressing on the piston.

HINT:
Tape the screwdriver tip before use.

2. INSTALL MASTER CYLINDER BOOT

3. INSTALL MASTER CYLINDER PUSH ROD CLEVIS


1. Install the brake master cylinder side lock nut and rod operating adapter to the brake
master cylinder.

Torque:
26 N*m{ 260 kgf*cm , 19 ft.*lbf }

2. Install the lock nut and master cylinder push rod clevis to the rod operating adapter.

Torque:
26 N*m{ 260 kgf*cm , 19 ft.*lbf }

4. INSTALL MASTER CYLINDER SOLENOID


1. Install a new gasket.

NOTICE:
Keep all surfaces of the master cylinder solenoid, master cylinder and gasket,
especially contact surfaces, away from water and dust.

2. Install the master cylinder solenoid with 6 new bolts.

Torque:
32 N*m{ 325 kgf*cm , 24 ft.*lbf }

5. INSTALL BRAKE BOOSTER ACCUMULATOR PIPE


1. Install the brake booster accumulator pipe and compression spring.

NOTICE:
Ensure that no foreign matter enters the pump.

2. Install a new O-ring to the brake booster accumulator assembly.

3. Install the brake booster accumulator assembly.

Torque:
57 N*m{ 585 kgf*cm , 42 ft.*lbf }

6. INSTALL NO. 1 BRAKE BOOSTER PUMP BRACKET

1. Install the brake booster pump bush to the No. 1 brake booster pump bracket.

2. Using a 5 mm hexagon wrench, install the No. 1 brake booster pump bracket with the
2 bolts.

Torque:
7.8 N*m{ 80 kgf*cm , 69 in.*lbf }

7. INSTALL BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY

1. Using a 4 mm hexagon wrench, install the 2 pins to the brake master cylinder.

Torque:
7.8 N*m{ 80 kgf*cm , 69 in.*lbf }

2. Install 2 new brake booster pump collars and 2 brake booster pump bushes to the
brake booster with accumulator pump assembly.

3. Install the brake booster with accumulator pump assembly to the brake master
cylinder.
4. Install a new clip.

5. Connect the wire harnesses with the 2 screws.

Torque:
2.9 N*m{ 30 kgf*cm , 26 in.*lbf }
6. Install 2 new plugs.

8. INSTALL NO. 1 BRAKE ACTUATOR TUBE

1. Using a union nut wrench, install the No. 1 brake actuator tube.

Torque:
without union nut wrench:
15 N*m{ 155 kgf*cm , 11 ft.*lbf }
with union nut wrench:
14 N*m{ 145 kgf*cm , 10 ft.*lbf }
HINT:

 Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).


 The torque value for use with a union nut wrench is effective when the union
nut wrench is parallel to the torque wrench.

9. INSTALL NO. 1 BRAKE ACTUATOR HOSE


1. Using needle nose pliers, install the brake actuator hose with the 2 clips.

10. INSTALL MASTER CYLINDER RESERVOIR GROMMET

1. Apply lithium soap base glycol grease to 3 new reservoir grommets.

2. Install the 3 reservoir grommets to the brake master cylinder.

NOTICE:
Be careful of the size of each grommet.

11. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY


1. Install the brake master cylinder reservoir sub-assembly with the screw.

Torque:
1.7 N*m{ 17 kgf*cm , 15 in.*lbf }

2. Install the master cylinder reservoir filler cap.

3. Using a pin punch and hammer, install a new pin to the brake master cylinder
reservoir.

12. INSTALL NO. 1 BRAKE ACTUATOR BRACKET


1. Install the brake fluid level warning switch connector to the No. 1 brake actuator
bracket.

2. Using a 5 mm hexagon wrench, install the No. 1 brake actuator bracket with the bolt.

Torque:
7.8 N*m{ 80 kgf*cm , 69 in.*lbf }

HYDRAULIC BRAKE BOOSTER (for LHD) > REASSEMBLY for Preparation Click here (http://manualespurdy.cisdigital.com/Toyota/Land
1. Install the brake master cylinder side lock nut and rod operating adapter to the brake master cylinder. Torque:
1. Install a new gasket. NOTICE: Keep all surfaces of the master cylinder solenoid, master cylinder and gasket, especial
1. Install the brake booster accumulator pipe and compression spring. NOTICE: Ensure that no foreign matter enters the pu
7.8 N*m{ 80 kgf*cm , 69 in.*lbf } 7. INSTALL BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY 1. Using a 4 mm he
4. Install a new clip. 5. Connect the wire harnesses with the 2 screws. Torque: 2.9 N*m{ 30 kgf*cm , 26 in.*lbf
6. Install 2 new plugs. 8. INSTALL NO. 1 BRAKE ACTUATOR TUBE 1. Using a union nut wrench, install the No. 1 b
1. Using needle nose pliers, install the brake actuator hose with the 2 clips. 10. INSTALL MASTER CYLINDER RESERVOIR
1. Install the brake master cylinder reservoir sub-assembly with the screw. Torque: 1.7 N*m{ 17 kgf*cm , 15 in.*lbf }
1. Install the brake fluid level warning switch connector to the No. 1 brake actuator bracket. 2. Using a 5 mm hexagon wr

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