BRAKE BOOSTER INSTALLATION


  1. INSTALL CHECK VALVE GROMMET


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

  2. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY


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

  3. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS


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

    2. A01EMDNE04
      Text in Illustration
      *1 Push Rod Length
      *2 Lock Nut
      *3 Brake Master Cylinder Push Rod Clevis

      Set the push rod length as shown in the illustration.

      Standard length*1
      155.1 to 156.1 mm (6.11 to 6.15 in.)

    3. Tighten the lock nut.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  4. INSTALL BRAKE BOOSTER GASKET


    1. A01EJPD

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

  5. INSTALL BRAKE BOOSTER ASSEMBLY


    1. A01ELWW

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

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

      Note

      Do not damage the brake lines.

  6. INSTALL PUSH ROD PIN


    1. A01ELOCE01

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

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

  7. INSTALL NO. 1 VACUUM HOSE CONNECTOR


    1. A01EL87

      Install the No. 1 vacuum hose connector with the 2 nuts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    2. Connect the vacuum hose to the brake booster assembly, and slide the clip to secure the vacuum hose.

  8. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Note

    When install a new brake master cylinder sub-assembly, remove the protectors from the piston and outlet ports.


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

    2. A01EM3TE01

      Apply a light layer of lithium soap base glycol grease to the entire circumference of the brake master cylinder sub-assembly and inner surface of the brake booster assembly as shown in the illustration.

    3. A01ELMX

      Install the brake master cylinder sub-assembly and front brake tube way with the 2 nuts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

      Note


      • Do not kink or damage the brake line.

      • Do not allow brake line to twist and interfere with other parts or body during flexible hose tightening.

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

    4. A01EJEV

      Using a union nut wrench, connect the 2 brake lines and install the No. 1 front brake tube to the brake master cylinder sub-assembly.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note


      • Do not kink or damage the brake line.

      • Do not allow brake line to twist and interfere with other parts or body during flexible hose tightening.

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

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

    5. A01EL8X

      Using a union nut wrench, connect the 2 brake lines to the front brake tube way.

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

      Note


      • Do not kink or damage the brake line.

      • Do not allow brake line to twist and interfere with other parts or body during flexible hose tightening.

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

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

    6. A01EJV4

      Connect the connector and engage the clamp.

  9. FILL RESERVOIR WITH BRAKE FLUID


    1. A01EJ3G

      Remove the brake master cylinder reservoir filler cap.

    2. Fill the reservoir with brake fluid.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

      Note


      • Make sure that there is sufficient brake fluid in the reservoir.

      • Do not remove the filter from the brake master cylinder reservoir and be sure to fill with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problem.

  10. BLEED BRAKE MASTER CYLINDER

    Note


    • To prevent brake fluid from damaging painted surfaces, cover any surrounding parts with a piece of cloth.

    • Be sure to clean your hands before bleeding from master cylinder to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problem.

    Tech Tips

    If the master cylinder is reinstalled or runs out of brake fluid, bleed the master cylinder.


    1. A01EL46

      Using a union nut wrench, disconnect the 2 brake tubes from the brake master cylinder assembly.

    2. A01ELBP

      Slowly depress the brake pedal and hold it down.

    3. A01EM39

      Cover the 2 tube holes with your fingers and release the brake pedal.

    4. Uncover the holes, slowly depress the brake pedal and hold it down. While holding down the brake pedal, cover the tube holes again. Repeat this step 3 or 4 times.

    5. A01EL46

      Using a union nut wrench, connect the 2 brake tubes to the brake master cylinder assembly.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note


      • Do not bend or damage the brake lines.

      • Do not allow brake line to twist and interfere with other parts or body during tightening.

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

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

  11. BLEED BRAKE LINE

    Note

    Bleed the brake line of the wheel farthest from the master cylinder first.


    1. Connect a vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times, and while holding down the brake pedal, loosen the bleeder plug*1.

    3. When fluid stops coming out, tighten the bleeder plug and release the brake pedal*2.

    4. Repeat steps *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid comes out.

    5. Tighten the bleeder plug completely.

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

    6. Repeat the above steps to replace the brake fluid of the brake lines for each wheel.

  12. INSPECT FOR BRAKE FLUID LEAK

  13. INSPECT FLUID LEVEL IN RESERVOIR


    1. A01EKWYE01
      Text in Illustration
      *1 MAX Line
      *2 MIN Line

      Check the fluid level.

      Tech Tips

      If brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  14. INSPECT AND ADJUST BRAKE PEDAL

    Tech Tips

    Click here

  15. INSTALL SECURITY HORN ASSEMBLY (w/ Security Horn)


    1. A01EL4H

      Connect the connector.

    2. A01EJHF

      Install the security horn assembly with the bolt.

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

  16. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A01EK1G

      Install the air cleaner case sub-assembly with the 3 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. connect the wire harness clamp.

  17. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  18. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A01EKRC

      Connect the air-cleaner cap sub-assembly to the throttle body assembly and lock the hose band.

    2. A01EJ98

      Install the air cleaner cap sub-assembly with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    3. A01EKWW

      Connect the ventilation hose to the cylinder head cover.

    4. A01EKFY

      Connect the mass air flow meter connector and install the wire harness clamp to the air cleaner cap.

    5. Install the hose to the hose clamp.

  19. INSTALL OUTER COWL TOP PANEL


    1. A01EL1AE01
      Text in Illustration
      *1 Bolt
      *2 Nut

      Install the outer cowl top panel with the 4 bolts and 4 nuts.

      Torque:
      Nut
      85 N*m  { 866 kgf*cm, 63 ft.*lbf }
      Bolt
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }
    2. A01EIQY

      Engage the 2 wire harness clamps to the outer cowl top panel.

    3. A01EKSW

      Engage the 2 wire harness clamps to the outer cowl top panel and connect the connector (w/ Windshield Deicer).

  20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A01EJ0O

      Install the windshield wiper motor and link assembly with the 3 bolts as shown in the illustration.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    2. A01EIMEE01

      Connect the connector.

  21. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. A01ELR9

      Engage the 13 claws and install the cowl top ventilator louver sub-assembly as shown in the illustration.

    2. A01ELGA

      Install the 2 clips.

  22. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

    Tech Tips

    Use the same procedure for the RH side and LH side.

  23. INSTALL FRONT FENDER TO COWL SIDE SEAL LH


    1. A01EKVY

      Engage the claw and 2 guides to install the front fender to cowl side seal LH.

  24. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. Operate the wiper and stop the windshield wiper motor at the automatic stop position.

    2. When reusing the front wiper arm and blade assembly RH:


      1. A01EJK9E02
        Text in Illustration
        *1 Wiper Arm Serration

        Clean the wiper arm serrations.

    3. When reusing the windshield wiper link assembly:


      1. A01ELCGE02
        Text in Illustration
        *1 Wire Brush
        *2 Wiper Pivot Serration

        Clean the wiper pivot serrations with a wire brush.

    4. A01EMJQE02
      Text in Illustration
      *1 Ceramic Notch

      Install the front wiper arm and blade assembly RH with the nut to the position shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  25. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. When reusing the front wiper arm and blade assembly LH:


      1. A01EJK9E04
        Text in Illustration
        *1 Wiper Arm Serration

        Clean the wiper arm serrations.

    2. When reusing the windshield wiper link assembly:


      1. A01ELCGE03
        Text in Illustration
        *1 Wire Brush
        *2 Wiper Pivot Serration

        Clean the wiper pivot serrations with a wire brush.

    3. A01EKJDE02
      Text in Illustration
      *1 Ceramic Notch

      Install the front wiper arm and blade assembly LH with the nut to the position shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    4. Operate the front wipers while spraying washer fluid onto the windshield. Make sure that the front wipers function properly and the wipers do not come into contact with the vehicle body.

  26. INSTALL FRONT WIPER ARM HEAD CAP


    1. A01EJBP

      Install the 2 front wiper arm head caps.