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BRAKE BOOSTER (for RHD) INSTALLATION

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  1. Click here

    INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. Install the brake master cylinder push rod clevis and push rod clevis lock nut to the brake booster assembly, and temporarily tighten the push rod clevis lock nut.

      Tip:

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

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    INSTALL BRAKE BOOSTER GASKET


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

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    INSTALL BRAKE BOOSTER ASSEMBLY


    1. A017ENQ

      Install the brake booster assembly to the body with the 4 nuts.

      13 N*m 132 kgf*cm 10 ft.*lbf
      Note:

      Do not damage the brake lines.

    2. A017EAZ

      Engage the 4 clamps and install the 2 brake lines to the body.

      Note:

      Be careful not to damage the brake lines or clamps. If any parts are damaged, replace them with new ones.

    3. A017EONE01

      Using a union nut wrench (12 mm), connect the 2 brake lines to the brake actuator.

      without union nut wrench
      20 N*m 204 kgf*cm 15 ft.*lbf
      with union nut wrench
      18 N*m 184 kgf*cm 13 ft.*lbf
      Note:

      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

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    INSTALL NO. 1 COOLER REFRIGERANT SUCTION PIPE (w/o Rear Air Conditioning System)


    1. Remove the attached vinyl tape from the pipe.

    2. Sufficiently apply compressor oil to the O-rings of the tube ends.

      Compressor oil
      ND-OIL 8 or equivalent
    3. A017FOM

      Connect the No. 1 cooler refrigerant suction pipe to the air conditioning unit and move the hook connector as shown in the illustration.

    4. Install the bolt to secure the hook connector.

      9.8 N*m 100 kgf*cm 87 in.*lbf
    5. A017FVGE01

      Connect the suction hose sub-assembly to the No. 1 cooler refrigerant suction pipe with the nut (C).

      9.8 N*m 100 kgf*cm 87 in.*lbf

    6. Install the suction hose bracket to the body with the bolt (B).

      9.8 N*m 100 kgf*cm 87 in.*lbf

    7. Install the discharge tube bracket to the suction hose bracket with the nut (A).

      9.8 N*m 100 kgf*cm 87 in.*lbf
    8. A017CI5

      Engage the 2 clamps to install the No. 1 cooler refrigerant suction pipe.

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    INSTALL NO. 1 COOLER REFRIGERANT SUCTION PIPE (w/ Rear Air Conditioning System)


    1. Remove the attached vinyl tape from the pipe.

    2. Sufficiently apply compressor oil to the O-rings of the tube ends.

      Compressor oil
      ND-OIL 8 or equivalent
    3. A017G5M

      Connect the No. 1 cooler refrigerant suction pipe to the cooler refrigerant suction pipe A.

    4. Install the nut and screw, and engage the clamp.

      Nut
      9.8 N*m 100 kgf*cm 87 in.*lbf
    5. A017DMTE02

      Engage the piping clamp to the No. 1 cooler refrigerant suction pipe and the cooler refrigerant suction pipe A.

      Note:

      After connection, check the fitting of the piping clamp as shown in the illustration.

    6. A017E0D

      Connect the No. 1 cooler refrigerant suction pipe to the air conditioning unit and move the hook connector as shown in the illustration.

    7. Engage the clamp and install the bolt to secure the hook connector.

      9.8 N*m 100 kgf*cm 87 in.*lbf
    8. A017FVGE01

      Connect the suction hose sub-assembly to the No. 1 cooler refrigerant suction pipe with the nut (C).

      9.8 N*m 100 kgf*cm 87 in.*lbf

    9. Install the suction hose bracket to the body with the bolt (B).

      9.8 N*m 100 kgf*cm 87 in.*lbf

    10. Install the discharge tube bracket to the suction hose bracket with the nut (A).

      9.8 N*m 100 kgf*cm 87 in.*lbf
    11. A017CI5

      Engage the 2 clamps to install the No. 1 cooler refrigerant suction pipe.

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    INSTALL CHECK VALVE GROMMET


    1. Install a new check valve grommet to the brake booster assembly.

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    INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY


    1. Install the vacuum check valve assembly to the brake booster assembly.

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    CONNECT VACUUM HOSE


    1. Connect the vacuum hose to the vacuum check valve and slide the clip.

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    CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. A017CCTE01

      Apply lithium soap base glycol grease to the push rod pin.

    2. Connect the brake master cylinder push rod clevis to the brake pedal with the push rod pin, and install a new clip as shown in the illustration.

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    INSTALL BRAKE PEDAL RETURN SPRING


    1. A017F4S

      Install the brake pedal return spring between the instrument panel reinforcement and brake master cylinder push rod clevis.

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    INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. Install a new O-ring to the brake master cylinder sub-assembly.

    2. A017FYQ

      Install the brake master cylinder sub-assembly to the brake booster assembly with the 2 nuts.

      13 N*m 132 kgf*cm 10 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.

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

      • 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 shop rag or 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.

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    CONNECT BRAKE LINE


    1. A017ESME01

      Using a union nut wrench (12 mm), connect the 2 brake lines to the brake master cylinder sub-assembly.

      without union nut wrench
      20 N*m 204 kgf*cm 15 ft.*lbf
      with union nut wrench
      18 N*m 184 kgf*cm 13 ft.*lbf
      Note:

      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

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    CONNECT NO. 1 RESERVOIR TUBE


    1. Connect the No. 1 reservoir tube to the brake master cylinder reservoir assembly.

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    INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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    BLEED BRAKE SYSTEM

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    INSPECT AND ADJUST BRAKE PEDAL

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