BRAKE BOOSTER(for RHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE BOOSTER GASKET


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

  2. INSTALL BRAKE BOOSTER ASSEMBLY


    1. Temporarily install the brake booster assembly to the vehicle body.

      Note

      Do not apply excessive force to the brake lines or refrigerant lines.

    2. Temporarily install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.

      Note

      Fully tighten the lock nut when adjusting the brake pedal height.

    3. Install the 4 nuts to secure the brake booster assembly.

      Torque:
      12.8 N*m  { 131 kgf*cm, 9 ft.*lbf }

  3. INSTALL PUSH ROD PIN

    Click here

  4. INSTALL BRAKE LINE


    1. Engage the 3 clamps to install a new No. 2 brake tube clamp to the brake lines.

      Note

      Do not kink or damage the brake lines.

    2. B00703C

      Engage the clamp and install the No. 2 brake tube clamp to the vehicle body.

      Note

      Do not kink or damage the brake lines.

    3. B006WTQ

      Install the front brake tube way to the vehicle body with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  5. CONNECT UNION TO CHECK VALVE HOSE


    1. Connect the union to check valve hose to the brake booster assembly and slide the clip to secure it.

  6. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. Remove the vinyl tape from the air conditioner tube and accessory assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioner tube and accessory assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the air conditioner tube and accessory assembly.

      Note

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. B006YIV

      Insert the air conditioner tube and accessory assembly to the air conditioning unit assembly.

    5. B006ZBJ

      Engage the clamp to install the air conditioner tube and accessory assembly.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    6. B006XT3

      Connect the connector to the air conditioner tube and accessory assembly.

  7. CONNECT SUCTION PIPE SUB-ASSEMBLY


    1. Remove the vinyl tape from the suction pipe sub-assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe sub-assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction pipe sub-assembly.

      Note

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. Insert the suction pipe sub-assembly to the air conditioning unit assembly.

    5. B006ZLZ

      Rotate the hook connector as shown in the illustration.

    6. Insert the tube joint into the fitting hole securely and install the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    7. B006WYG

      Engage the clamp to install the suction pipe sub-assembly to the engine mounting insulator sub-assembly RH.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    8. B006YLW

      Engage the clamp to install the suction pipe sub-assembly to the brake tube clamp bracket.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

  8. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

    Click here

  9. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

    Click here

  10. INSTALL FRONT DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure as for the LH side.

    Click here

  11. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  12. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  13. WARM UP ENGINE

    Click here

  14. INSPECT FOR REFRIGERANT LEAK

    Click here

  15. INSPECT AND ADJUST BRAKE PEDAL

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