BRAKE BOOSTER INSTALLATION


  1. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. Temporarily install the lock nut and brake master cylinder push rod clevis onto the brake booster assembly.

      Tech Tips

      Tighten the lock nut when adjusting the brake pedal height.

  2. INSTALL BRAKE BOOSTER ASSEMBLY


    1. Install the brake booster assembly onto the pedal bracket assembly with the 4 nuts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

    2. Install a new O-ring onto the brake master less reservoir tank cylinder sub-assembly.

    3. Install the wire harness clamp bracket and the brake master less reservoir tank cylinder sub-assembly onto the brake booster assembly with the 2 nuts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

      Note


      • The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.

      • Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.

      • Release the vacuum from the booster by depressing the brake pedal several times. Then remove the brake master cylinder from the brake booster.

      • When installing the brake master cylinder sub-assembly onto the brake booster, or when removing the brake master cylinder sub-assembly from the brake booster, make sure that the brake master cylinder sub-assembly is kept horizontal or its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling off.

      • Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a piece of cloth and then apply an even layer of lithium soap based glycol grease around the circumference (sliding part) of the piston.

      • Do not use any other type of grease or fluid.

    4. Connect the 2 master cylinder reservoir tubes onto the brake master less reservoir tank cylinder sub-assembly with the 2 clips.

    5. Install a new clamp and the 2 brake tubes.

    6. Using a 12 mm union nut wrench, install the 2 brake tubes onto the brake master less reservoir tank cylinder sub-assembly.

      Torque:
      24 N*m  { 245 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. Using a 12 mm union nut wrench, install the 2 brake tubes onto the brake tube way.

      Torque:
      24 N*m  { 245 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.

    8. Connect the vacuum hose onto the brake booster assembly with the clip.

  3. INSTALL PEDAL BRACKET ASSEMBLY

    Click here