BRAKE BOOSTER(for LHD) INSTALLATION

Info Added 2017-10-06

PROCEDURE


  1. INSTALL BRAKE BOOSTER GASKET


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

  2. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. A005O5FC02
      *1 Skid Control ECU
      *2 No. 1 Reservoir Hose
      *3 Brake Master Cylinder Push Rod Clevis
      *4 Boot
      *5 Master Cylinder Reservoir Assembly
      *6 Brake Actuator Bracket

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

      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.

  3. INSTALL PUSH ROD PIN

    Click here

  4. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  5. CONNECT BRAKE LINE


    1. Engage the 6 clamps to install a new No. 1 brake tube clamp to the brake lines.

      Note

      Do not kink or damage the brake lines.

    2. A005NZGC01
      *a Torque Wrench Fulcrum Length

      Using a union nut wrench, connect the 3 brake lines to the brake booster with master cylinder assembly.

      Torque:
      Specified tightening 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.

      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 (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

  6. CONNECT NO. 2 BRAKE ACTUATOR HOSE


    1. A005O0GC01
      *a Identification Mark
      B0048S8 Front of the vehicle

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

      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.

  7. CONNECT ENGINE ROOM MAIN WIRE


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

    2. A005MM2C01
      B0048R7 Connect the connector
      B0048O3 Lock the lock lever

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

      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.

  8. BLEED NO. 1 BRAKE ACTUATOR TUBE

    Note

    Make sure to bleed the air from the No. 1 brake actuator tube. If the air remains in the No. 1 brake actuator tube, the air will enter the brake booster pump assembly and may damage the brake booster pump assembly.


    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. A005NV9

      Remove the nut and separate the No. 1 brake actuator tube.

      Tech Tips

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

    4. A005NEUN01

      Set SST to the brake master cylinder reservoir assembly.

      SST
      09992-00242

    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. A005NDMC01
      B0048R7 Pull up

      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)

      Note

      Do not damage the hoses.

      Tech Tips

      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. A005ND0C01
      B0048R7 Pull up

      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.

      Tech Tips

      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.

    12. A005N22C01
      B0048R7 Press down

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

      Note

      Do not damage the hoses.

      Tech Tips

      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.

    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 }

  9. CONNECT BRAKE BOOSTER PUMP CONNECTOR

    Tech Tips

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


    1. A005NCNC01
      B0048R7 Connect the connector
      B0048O3 Lock the lock lever

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

      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.

  10. FILL RESERVOIR WITH BRAKE FLUID

    Click here

  11. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  12. BLEED BRAKE SYSTEM

    Click here

  13. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  14. PERFORM INITIALIZATION


    • Perform linear solenoid valve offset learning, ABS holding solenoid valve learning, brake pedal stroke sensor assembly zero point calibration and system information memorization.

      Click here

  15. OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR

    Click here

  16. INSTALL NO. 1 AIR DUCT

    Click here

  17. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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  18. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

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  19. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

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  20. INSTALL WATER GUARD PLATE LH

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  21. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

    Click here

  22. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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