BRAKE PEDAL INSTALLATION


  1. TEMPORARILY TIGHTEN BRAKE PEDAL SUPPORT ASSEMBLY


    1. A003FN4

      Using the 5 bolts and nut, temporarily install the brake pedal support assembly to the dash panel.

  2. INSTALL ACCELERATOR PEDAL ROD ASSEMBLY


    1. A003HHU

      Install the accelerator pedal rod assembly with the 2 nuts.

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

  3. CONNECT WIRE HARNESS


    1. A003DLA

      Connect the 2 connectors.

  4. INSTALL BRAKE BOOSTER GASKET

  5. INSTALL BRAKE BOOSTER ASSEMBLY


    1. A003BDM

      Install the brake booster assembly with the 4 nuts.

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

    2. Connect the vacuum hose with the clip.

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


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

      2. Attach the clamp to the bracket.

  6. FULLY TIGHTEN BRAKE PEDAL SUPPORT ASSEMBLY


    1. A003FN4

      Fully tighten the 5 bolts and nut.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    2. A003F1B

      Fully tighten the nut.

      Torque:
      23 N*m  { 239 kgf*cm, 17 ft.*lbf }

  7. INSTALL BRAKE TUBE


    1. for Automatic transmission:

      Connect the 2 tubes to the clamp.

    2. for Manual transmission:


      1. A003FHO

        Connect the 3 tubes to the clamp.

      2. A003FI0

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

        Torque:
        25 N*m  { 255 kgf*cm, 18 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 MASTER CYLINDER PUSH ROD CLEVIS


    1. A003HHHE01

      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.

  9. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER

    Click here

  10. INSTALL WINDSHIELD WASHER JAR ASSEMBLY (for LHD with Standard Body)

    Click here

  11. INSTALL HEADLIGHT ASSEMBLY RH (for RHD with Standard Body)

    Tech Tips

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


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

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

    Tech Tips

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


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

  13. INSTALL RADIATOR GRILLE (for LHD with Standard Body)

    Click here

  14. INSTALL BRAKE MASTER CYLINDER


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

    2. for 1KD-FTV, 2KD-FTV and 5L-E:


      1. Install the brake master cylinder and bracket to the booster with the 2 nuts.

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

        Note

        Check that the stopper of the harness clamp bracket is securely holding on the brake master cylinder assembly.

    3. for 1TR-FE, 2TR-FE:


      1. Install the brake master cylinder to the brake booster with the 2 nuts.

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

    4. for Manual Transmission:


      1. Connect the clutch tube to the brake master cylinder reservoir sub-assembly with the clip.

    5. w/o VSC:


      1. A003COCE05
        Text in Illustration
        *a Torque Wrench Fulcrum Length

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

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

        Tech Tips


        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

        • When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13 N*m (137 kgf*cm, 10 ft.*lbf)

    6. w/ VSC:


      1. A003COCE05
        Text in Illustration
        *a Torque Wrench Fulcrum Length

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

        Torque:
        Specified tightening torque
        25 N*m  { 255 kgf*cm, 18 ft.*lbf }

        Tech Tips


        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

        • When using a union nut wrench (fulcrum length of 20 mm (0.7874 in.)) + torque wrench (fulcrum length of 180 mm (7.0866 in.)): 23 N*m (229 kgf*cm, 17 ft.*lbf)

    7. Connect the level warning light switch connector.

    8. Attach the brake fluid level warning switch connector clamp.

  15. ADD BRAKE FLUID

    Fluid
    SAE J1703 or FMVSS No. 116 DOT3 or equivalent

    Note

    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 problems.

  16. 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. A003B4W

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

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

    3. A003AVB

      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. A003COCE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

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

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

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13 N*m (137 kgf*cm, 10 ft.*lbf)

  17. 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:
        11 N*m  { 110 kgf*cm, 8 ft.*lbf }

      2. Rear bleeder plug:

        Torque:
        11 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.

  18. INSPECT BRAKE FLUID LEVEL


    1. Check the fluid level and add fluid if necessary.

      Fluid
      SAE J1703 or FMVSS No.116 DOT3 or equivalent

      Note

      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 problems.

  19. CHECK BRAKE FLUID LEAKAGE

  20. VEHICLE PREPARATION FOR HEADLIGHT AIMING ADJUSTMENT


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

  21. PREPARATION FOR HEADLIGHT AIMING (USING A SCREEN)


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

  22. INSPECT HEADLIGHT AIMING


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

  23. ADJUST HEADLIGHT AIMING


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

  24. INSPECT BRAKE PEDAL HEIGHT


    1. A003BRLE01

      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

  25. 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. A003G97E03

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

      CAUTION:

      Do not depress the brake pedal.

    9. A003BDWE06

      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.)

  26. 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. A003GF0E03

      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.)

  27. 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. A003H76E01

      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.