BRAKE BOOSTER PUMP INSTALLATION

PROCEDURE


  1. INSTALL BRAKE BOOSTER PUMP ASSEMBLY


    1. B001N7WE04
      Text in Illustration
      *1 Nut
      *2 Brake Actuator Case Collar
      *3 Brake Traction Actuator Bracket Bushing
      *4 Brake Actuator Bracket Assembly
      *5 Brake Booster Pump Assembly
      *6 Brake Actuator Bracket Cushion
      *7 Brake Booster Pump Collar
      *8 Brake Booster Pump Bushing

      Install the brake booster pump assembly, 2 brake traction actuator bracket bushings and 2 brake actuator case collars to the brake actuator bracket assembly with the 2 nuts.

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

      Note


      • Do not drop the brake booster pump assembly when carrying it.

      • Do not carry the brake booster pump assembly by the connector.

      • Confirm that the 2 brake actuator bracket cushions are on the brake actuator bracket assembly, and each brake booster pump bushing and brake booster pump collar are on the brake booster pump assembly when installing the brake booster pump assembly to the brake actuator bracket assembly.

      • Do not remove the hole plugs before installing a new brake booster pump assembly because the brake booster pump assembly is filled with brake fluid.

  2. INSTALL BRAKE BOOSTER PUMP ASSEMBLY WITH BRACKET


    1. B001KUXE03

      Using SST, install the brake booster pump assembly with bracket with the 3 nuts.

      SST
      09961-00950
      Torque:
      without SST
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
      with SST
      12 N*m  { 121 kgf*cm, 9 ft.*lbf }

      Note


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

      • Tighten the 3 nuts in the order shown in the illustration.

      • Do not damage the fuel line, the brake lines or wire harness.

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

    2. B001KAZE02
      Text in Illustration
      *A for RHD
      *1 Wire Harness Clamp
      *2 Fuel Line
      *3 Front No. 4 Brake Tube

      Install the wire harness clamp and 2 fuel lines to the brake actuator bracket assembly.

      Note

      Do not kink or damage the fuel lines.

    3. for RHD:

      Engage the clamp to install the front No. 4 brake tube to the brake actuator bracket assembly.

      Note

      Do not kink or damage the brake line.

    4. Install the No. 1 brake tube clamp bracket to the brake booster pump assembly with the bolt.

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

    5. Using a union nut wrench, connect the front No. 1 brake tube to the brake booster pump assembly.

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

      Note

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

    6. Install the No. 1 brake tube clamp to the No. 1 brake tube clamp bracket with the bolt.

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

    7. Install the wire harness clamp.

    8. Connect the 2 connectors.

  3. INSTALL NO. 5 BRAKE ACTUATOR BRACKET (for RHD)


    1. B001MGBE02

      Install the No. 5 brake actuator bracket with the 2 nuts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      Note

      Tighten the 2 nuts in the order shown in the illustration.

    2. Install the wire harness clamp.

  4. CONNECT BRAKE ACTUATOR HOSE (for RHD)


    1. B001LPVE02
      Text in Illustration
      *a Identification Mark
      B001NB3 Front of Vehicle

      Connect the brake actuator hose to the brake booster pump assembly with the clip.

      Note


      • When connecting the brake actuator hose, face the identification mark to the inside of the vehicle.

      • Match the identification mark of the brake actuator hose and the rib of the brake booster pump assembly.

      • Install the clip within the range shown in the illustration.

  5. BLEED RESERVOIR TUBE ASSEMBLY (for RHD)

    Click here

  6. INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET (for RHD)


    1. Install the brake master cylinder reservoir with bracket with the 2 nuts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    2. Engage the 2 clamps.

    3. Install the reservoir tube assembly with the 2 bolts and nut.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  7. INSTALL FRONT NO. 4 BRAKE TUBE (for LHD)


    1. Engage the clamp to install the front No. 4 brake tube to the brake actuator bracket assembly.

    2. Install the bolt.

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

    3. Using a union nut wrench, connect the front No. 4 brake tube to the front flexible hose.

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

      Note


      • Do not kink or damage the brake line.

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

  8. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  9. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY (for LHD)

    Click here

  10. FILL RESERVOIR WITH BRAKE FLUID (for RHD)

  11. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL (for RHD)


  12. BLEED BRAKE SYSTEM (for RHD)

    Click here

  13. INSTALL SUSPENSION TOWER DAMPER (for RHD with Suspension Tower Damper)

    Click here

  14. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  15. INSTALL COWL BODY MOUNTING REINFORCEMENT RH (for RHD)

    Click here

  16. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  17. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  18. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for RHD)

    Click here