BRAKE BOOSTER INSTALLATION


  1. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS


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

      Tech Tips

      Fully tighten the lock nut after adjusting the brake pedal height Click here.

  2. INSTALL CHECK VALVE GROMMET


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

  3. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY


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

  4. INSTALL BRAKE BOOSTER GASKET


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

  5. INSTALL BRAKE BOOSTER ASSEMBLY (for LHD)


    1. A0162RA

      Install the brake booster assembly with the 4 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Note

      Do not kink or damage the brake lines.

    2. A01612IE02
      Text in Illustration
      *1 Fulcrum Length
      *a Hold
      *b Turn

      Install the front No. 3 brake line and engage the grommet.

    3. Using a union nut wrench, connect the front No. 3 brake line to the front brake flexible hose LH.

      Torque:
      without a union nut wrench
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
      with a union nut wrench
      14 N*m  { 143 kgf*cm, 10 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.

      • Don not kink or damage the brake lines.

      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the clip or bracket.

  6. INSTALL BRAKE BOOSTER ASSEMBLY (for RHD)


    1. A0161Y4

      Install the brake booster assembly with the 4 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Note

      Do not kink or damage the brake lines.

  7. INSTALL BRAKE LINE (for RHD)


    1. A015ZAK

      Engage the clamp to install the front No. 1 brake line and rear No. 1 brake line.

      Note

      Do not damage the brake lines or clamp. If any parts are damaged, replace them with new ones.

  8. CONNECT VACUUM HOSE (for RHD)


    1. A015ZR7

      Connect the vacuum hose to the brake vacuum check valve assembly and slide the clip.

    2. Engage the clamp and inspect the condition of the vacuum tube.

  9. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. A016032E05

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

    2. Connect the brake master cylinder push rod clevis to the brake pedal support assembly with the push rod pin and a new clip.

  10. INSTALL BRAKE PEDAL RETURN SPRING


    1. A01603J

      Install the brake pedal return spring.

  11. INSTALL BRAKE ACTUATOR WITH BRACKET (for LHD)


    1. A0162O3E01

      Install the brake actuator with bracket to the body with the 2 bolts and nut.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      Note


      • Do not damage the brake lines or wire harness.

      • Tighten the 2 bolts and nut in the order shown in the illustration.

    2. A015ZOVE02
      Text in Illustration
      *1 Front No. 1 Brake Line
      *2 Rear No. 1 Brake Line

      Install the front No. 1 brake line and rear No. 1 brake line to the clamp.

    3. A01619C

      Connect the vacuum hose to the check valve with the clip.

    4. A0160OQE03
      Text in Illustration
      *1 Clamp
      *2 Vacuum Hose
      *3 Mark

      Engage the clamps and inspect the condition of the vacuum hose.

      Note

      Align the vacuum hose matchmarks and the clamp as shown in the illustration.

    5. A0163E7E05
      Text in Illustration
      *1 to Front Wheel Cylinder RH
      *2 to Front Wheel Cylinder LH
      *3 to Rear Wheel Cylinder RH
      *4 to Rear Wheel Cylinder LH
      *5 from 1st Master Cylinder Chamber
      *6 from 2nd Master Cylinder Chamber

      Temporarily tighten each brake line to the correct positions of the brake actuator assembly with bracket as shown in the illustration.

    6. A01615R

      Using a union nut wrench, fully tighten each brake line.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

      Note


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

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

    7. A01611NE04
      Text in Illustration
      *1 Lock Lever

      Connect the brake actuator connector.

      Note


      • Make sure that the actuator connector can be connected smoothly. Do not allow water, oil or dirt to enter.

      • Make sure that the connector is locked securely.

  12. INSTALL BRAKE ACTUATOR WITH BRACKET (for RHD)


    1. A0162BLE01

      Temporarily install the brake actuator assembly with bracket.

    2. A015YRVE01

      Install the brake actuator with bracket to the body with the 2 bolts and nut.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      Note


      • Do not damage the brake lines or wire harness.

      • Tighten the 2 bolts and nut in the order shown in the illustration.

    3. A0163GHE04
      Text in Illustration
      *1 Grommet
      *2 Front No. 2 Brake Line

      Install the front No. 2 brake line and grommet.

      Note

      Make sure that the grommet is installed correctly.

    4. A015ZQSE03
      Text in Illustration
      *1 Turn
      *2 Hold
      *3 Fulcrum Length

      Using a union nut wrench (10 mm), connect the brake line to the front flexible hose while holding the flexible hose with a wrench.

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

      Note


      • Do not kink or damage the brake lines.

      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the clip or bracket.

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

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

    5. A0160LFE02
      Text in Illustration
      *1 to Front Wheel Cylinder RH
      *2 to Front Wheel Cylinder LH
      *3 to Rear Wheel Cylinder RH
      *4 to Rear Wheel Cylinder LH
      *5 from 1st Master Cylinder Chamber
      *6 from 2nd Master Cylinder Chamber

      Temporarily tighten each brake tube to the correct position of the brake actuator assembly with bracket as shown in the illustration.

    6. A0160LFE03

      Using a union nut wrench, fully tighten each brake line.

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

      Note


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

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

    7. A0161HR

      Connect the brake actuator connector.

      Note


      • Make sure that the actuator connector can be connected smoothly. Do not allow water, oil or dirt to enter.

      • Make sure that the connector is locked securely.

  13. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (for LHD)


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

    2. A0163D6

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

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    3. A015ZCPE01
      Text in Illustration
      *a Fulcrum Length

      Using a union nut wrench (10 mm), connect the 2 brake lines to the brake master cylinder sub-assembly.

      Torque:
      without a union nut wrench
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
      with a union nut wrench
      14 N*m  { 143 kgf*cm, 10 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.

    4. A015ZEG

      Engage the clamp and connect the connector.

  14. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (for RHD)


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

    2. A015ZUX

      Install the brake master cylinder sub-assembly and wire harness clamp bracket to the booster assembly with the 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    3. A0163KLE02
      Text in Illustration
      *a Fulcrum Length

      Using a union nut wrench (10 mm), connect the 2 brake lines to the brake master cylinder sub-assembly.

      Torque:
      without a union nut wrench
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
      with a union nut wrench
      14 N*m  { 143 kgf*cm, 10 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.

    4. A015YUC

      Engage the clamp and connect the connector.

  15. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK (for LHD)


    1. A0163BG

      Install the No. 3 engine room relay block with the bolt and nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  16. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK (for RHD)


    1. A01613O

      Install the No. 3 engine room relay block with the bolt and nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  17. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY

    Tech Tips

    Refer to the procedure from Install Driver Side Knee Airbag Assembly Click here.

  18. BLEED BRAKE SYSTEM

    Tech Tips

    Click here

  19. INSPECT AND ADJUST BRAKE PEDAL

    Tech Tips

    Click here

  20. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Tech Tips

    Refer to the procedure from Install Cowl Top Ventilator Louver Sub-assembly Click here.