BRAKE BOOSTER INSTALLATION


  1. INSTALL MASTER CYLINDER PUSH ROD CLEVIS


    1. Temporarily install the push rod clevis with the lock nut.

    2. B007TF7

      Turn the push rod clevis and adjust length "A" shown in the illustration.

      Length "A"
      163.6 to 173.6 mm (6.441 in. to 6.835 in.)

    3. Tighten the push rod lock nut.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  2. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY


    1. Install the grommet and check valve assembly.

  3. INSTALL VACUUM WARNING SWITCH ASSEMBLY (for Diesel)

    Click here

  4. INSTALL BRAKE BOOSTER GASKET


    1. Install a new brake booster gasket to the brake booster assembly.

  5. INSTALL BRAKE BOOSTER ASSEMBLY


    1. B007R8M

      Install the brake booster assembly with the 4 nuts.

      Torque:
      14 N*m  { 145 kgf*cm, 10 ft.*lbf }

    2. Connect the vacuum hose with the clip.

    3. for 2KD-FTV, 5L-E engine type:


      1. Connect the vacuum warning switch connector to the brake booster assembly.

      2. Attach the clamp to the bracket.

  6. INSTALL BRAKE TUBE


    1. for Automatic transmission:

      Connect the 2 tubes to the clamp.

    2. for Manual transmission:


      1. B007QHN

        Connect the 3 tubes to the clamp.

      2. B007SU8

        Using a union nut wrench, connect the clutch tube to the clutch master cylinder.

        Torque:
        25 N*m  { 255 kgf*cm, 18 ft.*lbf }

        Note

        Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  7. INSTALL MASTER CYLINDER PUSH ROD CLEVIS


    1. B007PMME01

      Apply a light coat of lithium soap base glycol grease to the clevis pin.

    2. Install the push rod clevis to the brake pedal support assembly with the clevis pin and a new clip.

  8. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER

    Click here

  9. INSTALL HEADLIGHT ASSEMBLY RH (for RHD with Standard Body)

    Tech Tips

    Install of the headlight assembly RH is the same as the headlight assembly LH.


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

  10. INSTALL HEADLIGHT ASSEMBLY RH (for RHD with Wide Body)

    Tech Tips

    Install of the headlight assembly RH is the same as the headlight assembly LH.


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

  11. INSTALL WINDSHIELD WASHER JAR ASSEMBLY (for LHD with Standard Body)

    Click here

  12. INSTALL RADIATOR GRILLE (for LHD with Standard Body)

    Click here

  13. INSTALL BRAKE MASTER CYLINDER

    Click here

  14. ADD BRAKE FLUID

    Fluid
    SAE J1703 or FMVSS No. 116 DOT3 or equivalent

    Note

    Do not remove the filter from the brake master cylinder reservoir and be sure to fill with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.

  15. BLEED BRAKE MASTER CYLINDER

    Tech Tips

    If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder.


    1. B007TZC

      Using a union nut wrench, disconnect the brake lines from the master cylinder.

    2. Slowly depress the brake pedal and hold it there.

    3. B007OMP

      Block the outer holes with your fingers, and release the brake pedal.

    4. Remove your fingers. Slowly depress the brake pedal and hold it again. Block the outer holes with your fingers and release the brake pedal. Repeat this procedure 3 or 4 times.

    5. B007TNSE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a union nut wrench, connect the brake lines to the master cylinder.

      Torque:
      Specified tightening torque
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Tech Tips


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

      • When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13 N*m (137 kgf*cm, 10 ft.*lbf)

  16. BLEED BRAKE LINE


    1. Connect the vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times and loosen the bleeder plug with the pedal held down.

    3. At the point where the fluid stops coming out, tighten the bleeder plug and release the brake pedal.

    4. Repeat this procedure until the air in the brake fluid is completely bled out.

    5. Tighten the bleeder plug.


      1. Front bleeder plug:

        Torque:
        11 N*m  { 110 kgf*cm, 8 ft.*lbf }

      2. Rear bleeder plug:

        Torque:
        11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    6. Repeat the above procedure to bleed the air out of the brake line for each wheel.

  17. INSPECT BRAKE FLUID LEVEL


    1. Check the fluid level and add fluid if necessary.

      Fluid
      SAE J1703 or FMVSS No.116 DOT3 or equivalent

      Note

      Do not remove the filter from the brake master cylinder reservoir and be sure to fill with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.

  18. CHECK BRAKE FLUID LEAKAGE

  19. VEHICLE PREPARATION FOR HEADLIGHT AIMING ADJUSTMENT


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

  20. PREPARATION FOR HEADLIGHT AIMING (USING A SCREEN)


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

  21. INSPECT HEADLIGHT AIMING


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

  22. ADJUST HEADLIGHT AIMING


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

  23. INSPECT BRAKE PEDAL HEIGHT


    1. B007QNTE01

      Check brake pedal height.

      Pedal height from floor
      151 to 161 mm (5.945 to 6.339 in.) for left hand drive
      154 to 164 mm (6.063 to 6.457 in.) for right hand drive

  24. ADJUST BRAKE PEDAL HEIGHT


    1. Disconnect the stop light switch connector.

    2. Turn the stop light switch assembly counter-clockwise and remove it.

    3. Remove the brake booster Click here.

    4. Loosen the push rod lock nut.

    5. Adjust the pedal height by turning the pedal push rod clevis.

    6. Tighten the push rod lock nut.

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

    7. Install the brake booster Click here.

    8. B007VU2E03

      Insert the stop light switch into the adjuster until it slightly touches the cushion.

      CAUTION:

      Do not depress the brake pedal.

    9. B007VPFE06

      Turn the stop light switch assembly clockwise by approximately 90°.

      CAUTION:

      Do not depress the brake pedal.

    10. Connect the stop light switch connector.

    11. Check the clearance of the shaft.

      Clearance
      0.5 to 2.6 mm (0.020 to 0.102 in.)

  25. INSPECT BRAKE PEDAL FREE PLAY


    1. Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.

    2. B007UEDE03

      Push in the pedal until the beginning of the resistance is felt. Measure the distance as shown in the illustration.

      Pedal free play
      1.0 to 6.0 mm (0.039 to 0.236 in.)

  26. INSPECT BRAKE PEDAL RESERVE DISTANCE


    1. Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.

    2. Release the parking brake handle.

    3. B007OQPE01

      With the engine running, depress the pedal and measure the pedal reserve distance as shown in the illustration.

      Pedal reserve distance from floor
      More than 117 mm (4.61 in.) at 500 N (51 kgf, 112.5 lbf) for left hand drive
      More than 120 mm (4.72 in.) at 500 N (51 kgf, 112.5 lbf) for right hand drive

      Note

      Remove the floor mat before measuring the distance.