BRAKE BOOSTER INSTALLATION


  1. INSTALL MASTER CYLINDER PUSH ROD CLEVIS


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

    2. A01BDPL

      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


    1. Clean the vacuum warning switch assembly.

    2. Apply seal packing black to 2 or 3 threads of the bolts.

      Seal packing
      Seal packing black or equivalent

    3. Install the warning switch assembly to the brake booster.

      Torque:
      13.7 N*m  { 140 kgf*cm, 10 ft.*lbf }

  4. INSTALL BRAKE BOOSTER GASKET


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

  5. INSTALL BRAKE BOOSTER ASSEMBLY


    1. A01BA98

      Install the brake booster assembly with the 4 nuts.

      Torque:
      14 N*m  { 145 kgf*cm, 10 ft.*lbf }
    2. A01BGZHE02

      Connect the vacuum hose with the clip.

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

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

  6. INSTALL BRAKE TUBE


    1. for Automatic transmission:

      Connect the 2 tubes to the clamp.

    2. for Manual transmission:


      1. A01BHT4

        Connect the 3 tubes to the clamp.

      2. A01BGEN

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

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

        Note

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

  7. INSTALL MASTER CYLINDER PUSH ROD CLEVIS


    1. A01BD94E10

      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)

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

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

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

  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. A01BFQO

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

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

    3. A01BA5G

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

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

      Note

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

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

      2. Rear bleeder plug:

        Torque:
        11.0 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

  18. CHECK BRAKE FLUID LEAKAGE

  19. VEHICLE PREPARATION FOR HEADLIGHT AIM ADJUSTMENT


    1. Prepare the vehicle:


      • Ensure that there is no damage or deformation to the body around the headlights.

      • Fill the fuel tank.

      • Make sure that the oil is filled to the specified level.

      • Make sure that the coolant is filled to the specified level.

      • Inflate the tires to the appropriate pressure.

      • Unload the trunk and vehicle, ensuring that the spare tire, tools and jack are in their original positions.

      • Have a person of average weight (75 kg, 165 lb) sit in the driver seat.

  20. PREPARATION FOR HEADLIGHT AIMING (USING A SCREEN)


    1. A01BGCUE02
      Text in Illustration
      *a 25 or 3 m

      Prepare the vehicle (except China and Indonesia):


      • Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the headlights can be observed and above which it cannot.

      • Place the vehicle at a 90° angle to the wall.

      • Create a 25 m (82 ft.) distance between the vehicle (headlight bulb center) and the wall.

      • Make sure that the vehicle is on a level surface.

      • Bounce the vehicle up and down to settle the suspension.

      Note

      A distance of 25 m (82 ft.) between the vehicle (headlight bulb center) and the wall is necessary for proper aim adjustment. If unavailable, secure a distance of exactly 3 m (9.84 ft.) for check and adjustment. (The target zone will change with the distance so follow the instructions in the illustration.)

    2. A01BGCUE02
      Text in Illustration
      *a 10 or 3 m

      Prepare the vehicle (for China and Indonesia):


      • Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the headlights can be observed and above which it cannot.

      • Place the vehicle at a 90° angle to the wall.

      • Create a 10 m (32.8 ft.) distance between the vehicle (headlight bulb center) and the wall.

      • Make sure that the vehicle is on a level surface.

      • Bounce the vehicle up and down to settle the suspension.

      Note

      A distance of 10 m (32.8 ft.) between the vehicle (headlight bulb center) and the wall is necessary for proper aim adjustment. If unavailable, secure a distance of exactly 3 m (9.84 ft.) for check and adjustment. (The target zone will change with the distance so follow the instructions in the illustration.)

    3. Prepare a piece of thick white paper approximately 2 m (6.56 ft.) (height) x 4 m (13.1 ft.) (width) to use as a screen.

    4. Draw a vertical line down the center of the screen (V line).

    5. except China and Indonesia:

      Set the screen as shown in the illustration.

      Tech Tips


      • Stand the screen perpendicular to the ground.

      • Align the V line on the screen with the center of the vehicle.

      A01BDDNE02

    6. for China and Indonesia:

      Set the screen as shown in the illustration.

      Tech Tips


      • Stand the screen perpendicular to the ground.

      • Align the V line on the screen with the center of the vehicle.

      A01BDDNE03
    7. A01BF4TE01
      Text in Illustration
      *a V LH Line
      *b V Line
      *c V RH Line
      *d H Line
      *e Ground

      Draw base lines (H, V LH, and V RH lines) on the screen as shown in the illustration.

      Tech Tips


      • The base lines differ for "low beam inspection" and "high beam inspection".

      • Mark the headlight bulb center marks on the screen. If the center mark cannot be observed on the headlight, use the center of the headlight bulb or the name of the manufacturer marked on the headlight as the center mark.


      1. H Line (Headlight height):

        Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the headlight bulb center marks of the low beam headlights.

      2. V LH Line, V RH Line (Center mark position of the left-hand (LH) and right-hand (RH) headlights):

        Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the low beam headlight bulbs).

  21. HEADLIGHT AIMING INSPECTION


    1. Cover or disconnect the connector of the headlight on the opposite side to prevent light from the headlight not being inspected from affecting headlight aiming inspection.

      Note

      Do not keep the headlight covered for more than 3 minutes. The headlight lens is made of synthetic resin, which may melt or be damaged due to excessive heat.

    2. Start the engine.

    3. With headlight leveling switch:

      Set the headlight leveling switch to 0 (zero).

    4. except China and Indonesia:

      Turn on the headlights and check if the cutoff line for each low beam matches the preferred cutoff line in the illustration.

      A01BAC7E09

      Tech Tips


      • Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure.

      • If the alignment distance is 25 m (82 ft.):

        The low beam cutoff line should be within 48 mm (1.89 in.) and 698 mm (2.29 ft.) below the H line as well as 248 mm (9.76 in.) left or right of the V LH or V RH line.

      • If the alignment distance is 3 m (9.84 ft.):

        The low beam cutoff line should be within 6 mm (0.24 in.) and 84 mm (3.30 in.) below the H line as well as 30 mm (1.18 in.) left or right of the V LH or V RH line.

      • If the alignment distance is 25 m (82 ft.):

        The horizontal line of the preferred low beam cutoff line is 248 mm (9.76 in.) below the H line and point A of the preferred low beam cutoff line is on the V LH or V RH line.

      • If the alignment distance is 3 m (9.84 ft.):

        The horizontal line of the preferred low beam cutoff line is 30 mm (1.18 in.) below the H line and point A of the preferred low beam cutoff line is on the V LH or V RH line.

    5. for China:

      Turn on the headlights and check if the cutoff line for each low beam matches the preferred cutoff line in the illustration.

      A01BAC7E07

      Tech Tips


      • Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure.

      • If the alignment distance is 10 m (32.8 ft.):

        The low beam cutoff line should be within 94 mm (3.70 in.) and 285 mm (11.2 in.) below the H line as well as 99 mm (3.89 in.) left or right of the V LH or V RH line.

      • If the alignment distance is 3 m (9.84 ft.):

        The low beam cutoff line should be within 28 mm (1.10 in.) and 85 mm (3.34 in.) below the H line as well as 29 mm (1.14 in.) left or right of the V LH or V RH line.

      • If the alignment distance is 10 m (32.8 ft.):

        The horizontal line of the preferred low beam cutoff line is 188 mm (7.40 in.) below the H line and point A of the preferred low beam cutoff line is on the V LH or V RH line.

      • If the alignment distance is 3 m (9.84 ft.):

        The horizontal line of the preferred low beam cutoff line is 56 mm (2.20 in.) below the H line and point A of the preferred low beam cutoff line is on the V LH or V RH line.

    6. for Indonesia:

      Turn on the headlights and check if the cutoff line for each low beam matches the preferred cutoff line in the illustration.

      A01BFWOE01

      Tech Tips


      • Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure.

      • If the alignment distance is 10 m (32.8 ft.):

        The low beam cutoff line should be within 19 mm (0.74 in.) and 150 mm (5.90 in.) below the H line as well as 66 mm (2.59 in.) left or right of the V LH or V RH line.

      • If the alignment distance is 3 m (9.84 ft.):

        The low beam cutoff line should be within 6 mm (0.23 in.) and 45 mm (1.77 in.) below the H line as well as 19 mm (0.74 in.) left or right of the V LH or V RH line.

      • If the alignment distance is 10 m (32.8 ft.):

        The horizontal line of the preferred low beam cutoff line is 99 mm (3.89 in.) below the H line and point A of the preferred low beam cutoff line is on the V LH or V RH line.

      • If the alignment distance is 3 m (9.84 ft.):

        The horizontal line of the preferred low beam cutoff line is 29 mm (1.14 in.) below the H line and point A of the preferred low beam cutoff line is on the V LH or V RH line.

    7. except China and Indonesia:

      Turn on the high beams and check if the center of intensity for each high beam matches the center of intensity in the illustration.

      A01BGQME11

      Tech Tips


      • Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure.

      • If the alignment distance is 25 m (82 ft.):

        The high beam center of intensity should be within 174 mm (6.85 in.) above and 248 mm (9.76 in.) below the H line as well as 497 mm (1.63 ft.) left or right of the V LH or V RH line.

      • If the alignment distance is 3 m (9.84 ft.):

        The high beam center of intensity should be within 20 mm (0.78 in.) above and 29 mm (1.14 in.) below the H line as well as 59 mm (2.32 in.) left or right of the V LH or V RH line.

    8. for China:

      Turn on the high beams and check if the center of intensity for each high beam matches the center of intensity in the illustration.

      A01BAMQE02

      Tech Tips


      • Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure.

      • If the alignment distance is 10 m (32.8 ft.):

        The high beam center of intensity should be within 47 mm (1.85 in.) below the H line.

      • If the alignment distance is 3 m (9.84 ft.):

        The high beam center of intensity should be within 14 mm (0.55 in.) below the H line.

      • If the alignment distance is 10 m (32.8 ft.):

        The high beam center of intensity for the headlight assembly LH should be within 169 mm (6.65 in.) left and 349 mm (1.14 ft.) right of the V LH line.

      • If the alignment distance is 3 m (9.84 ft.):

        The high beam center of intensity for the headlight assembly LH should be within 50 mm (1.96 in.) left and 104 mm (4.09 in.) right of the V LH line.

      • If the alignment distance is 10 m (32.8 ft.):

        The high beam center of intensity for the headlight assembly RH should be within 349 mm (1.14 ft.) left or right of the V RH line.

      • If the alignment distance is 3 m (9.84 ft.):

        The high beam center of intensity for the headlight assembly RH should be within 104 mm (4.09 in.) left or right of the V RH line.

    9. for Indonesia:

      Turn on the high beams and check if the center of intensity for each high beam matches the center of intensity in the illustration.

      A01BGQME13

      Tech Tips


      • Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure.

      • If the alignment distance is 10 m (32.8 ft.):

        The high beam center of intensity should be within 69 mm (2.71 in.) above and 99 mm (3.89 in.) below the H line as well as 198 mm (7.79 in.) left or right of the V LH or V RH line.

      • If the alignment distance is 3 m (9.84 ft.):

        The high beam center of intensity should be within 20 mm (0.78 in.) above and 29 mm (1.14 in.) below the H line as well as 59 mm (2.32 in.) left or right of the V LH or V RH line.

  22. ADJUST HEADLIGHT AIMING

    A01BHV6E02
    Text in Illustration
    *A w/ Leveling Motor
    *B w/o Leveling Motor
    *1 Aiming Screw A
    *2 Aiming Screw B
    *3 Screwdriver

    1. Adjust the aim vertically:

      Adjust the aim of each headlight to the specified range by turning each aiming screw A with a screwdriver.

      Note

      The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.

      Tech Tips


      • Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure.

      • If it is not possible to correctly adjust headlight aim, check the bulb, headlight unit and headlight unit reflector installation.

      • The headlight aim moves down when turning the aiming screw clockwise, and moves up when turning the aiming screw counterclockwise.

      • Confirm the direction of rotation of the aiming screw by observing it while it is being adjusted. Due to the position of the screwdriver, the direction of rotation of the adjusting screw can be different than the direction of rotation of the screwdriver being used to adjust it.

    2. Adjust the aim horizontally:

      Adjust the aim of each headlight to the specified range by turning each aiming screw B with a screwdriver.

      Note

      The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.

      Tech Tips


      • Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure.

      • If it is not possible to correctly adjust headlight aim, check the bulb, headlight unit and headlight unit reflector installation.

      • Confirm the direction of rotation of the aiming screw by observing it while it is being adjusted. Due to the position of the screwdriver, the direction of rotation of the adjusting screw can be different than the direction of rotation of the screwdriver being used to adjust it.

  23. INSPECT BRAKE PEDAL HEIGHT


    1. A01BBDYE01

      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. A01BDASE03

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

      CAUTION:

      Do not depress the brake pedal.

    9. A01BDW4E06

      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. A01BF1UE03

      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. A01BERVE01

      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.