BRAKE BOOSTER INSTALLATION

PROCEDURE


  1. TEMPORARILY INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS


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

      Tech Tips

      Tighten the lock nut after adjusting the brake pedal height.

  2. INSTALL BRAKE BOOSTER GASKET


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

  3. INSTALL BRAKE BOOSTER ASSEMBLY


    1. A004RQ9E04
      Text in Illustration
      *A for LHD
      *B for RHD

      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 or fuel lines.

  4. INSTALL FRONT BRAKE LINE


    1. for LHD:


      1. A004T7G

        Install a new clamp and the brake tube to the brake actuator bracket.

      2. A004RD7

        Using a union nut wrench, connect the 2 brake tubes to the 2-way.

        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 is combined with a torque wrench Click here.

      3. A004S3B

        Install 2 new clamps and the brake tube to the body.

      4. A004QTR

        Attach the grommet to install the brake tube to the body.

      5. A004SYW

        Using a union nut wrench, connect the brake tube to the front brake flexible hose RH.

        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 is combined with a torque wrench Click here.

      6. A004NY6

        Using a union nut wrench, connect the brake tube to the front brake flexible hose LH.

        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 is combined with a torque wrench Click here.

      7. Install the clamp with the bolt.

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

    2. for RHD:


      1. A004T7G

        Attach a new clamp and the brake tube to the brake actuator bracket.

      2. A004MQU

        Install a new clamp and the brake tube to the body.

      3. A004SFG

        Using a union nut wrench, connect the 2 brake tubes to the 2-way.

        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 is combined with a torque wrench Click here.

      4. A004STY

        Install a new clamp and the brake tube to the body.

      5. A004QTR

        Attach the grommet to install the brake tube to the body.

      6. A004SYW

        Using a union nut wrench, connect the brake tube to the front flexible hose RH.

        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 is combined with a torque wrench Click here.

      7. A004NY6

        Using a union nut wrench, connect the brake tube to the front flexible hose LH.

        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 is combined with a torque wrench Click here.

      8. Install the clamp with the bolt.

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

  5. INSTALL CHECK VALVE GROMMET


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

  6. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY


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

  7. CONNECT VACUUM HOSE


    1. A004SYQE04
      Text in Illustration
      *A for LHD
      *B for RHD

      Connect the vacuum hose with the clip.

  8. CONNECT PUSH ROD PIN

    Click here

  9. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  10. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. Install the brake master cylinder sub-assembly Click here.

  11. INSTALL BRAKE ACTUATOR ASSEMBLY (for LHD)


    1. Install the brake actuator assembly Click here.

  12. INSTALL ENGINE ASSEMBLY


    1. for 1WW:

      Click here

    2. for 2WW:

      Click here

  13. FILL RESERVOIR WITH BRAKE FLUID

    Click here

  14. BLEED BRAKE MASTER CYLINDER

    Click here

  15. BLEED BRAKE LINE

    Click here

  16. BLEED CLUTCH LINE (for 1WW, 2WW)

    Click here

  17. INSPECT FOR BRAKE FLUID LEAK

  18. INSPECT FLUID LEVEL

    Click here

  19. INSTALL FRONT WHEEL

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  20. INSPECT AND ADJUST BRAKE PEDAL HEIGHT

    Click here

  21. INSPECT BRAKE PEDAL FREE PLAY

    Click here

  22. INSPECT BRAKE PEDAL RESERVE DISTANCE

    Click here