HYDRAULIC BRAKE BOOSTER(for LHD) REASSEMBLY

PROCEDURE


  1. INSTALL BRAKE BOOSTER PISTON SUB-ASSEMBLY


    1. A01XDPS

      Apply lithium soap base glycol grease to a new piston.

    2. Install the piston.

      Note

      When installing, be careful not to damage the seals, etc.

    3. Install the plug.

    4. Using 2 screwdrivers, install a new C-ring while pressing in the piston.

      Tech Tips

      Tape the screwdriver tip before use.

  2. INSTALL MASTER CYLINDER BOOT

  3. INSTALL MASTER CYLINDER PUSH ROD CLEVIS


    1. Install the brake master cylinder side lock nut and rod operating adapter to the brake master cylinder.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

    2. Install the lock nut and master cylinder push rod clevis to the rod operating adapter.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

  4. INSTALL MASTER CYLINDER SOLENOID


    1. Install a new gasket.

      Note

      Keep all surfaces of the master cylinder solenoid, master cylinder and gasket, especially contact surfaces, away from water and dust.

    2. Install the master cylinder solenoid with 6 new bolts.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  5. INSTALL BRAKE BOOSTER ACCUMULATOR PIPE


    1. Install the brake booster accumulator pipe and compression spring.

      Note

      Make sure that no foreign matter enters the pump.

    2. Install a new O-ring to the brake booster accumulator assembly.

    3. Install the brake booster accumulator assembly.

      Torque:
      57 N*m  { 585 kgf*cm, 42 ft.*lbf }

  6. INSTALL NO. 3 BRAKE ACTUATOR BRACKET


    1. Install the No. 3 brake actuator bracket.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

  7. INSTALL NO. 1 BRAKE BOOSTER PUMP BRACKET


    1. Install the brake booster pump bush to the No. 1 brake booster pump bracket.

    2. Using a 5 mm hexagon wrench, install the No. 1 brake booster pump bracket with the 2 bolts.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

  8. INSTALL BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY


    1. Using a 4 mm hexagon wrench, install the 2 pins to the brake master cylinder.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

    2. Install 2 new brake booster pump collars and 2 brake booster pump bushes to the brake booster with accumulator pump assembly.

    3. Install the brake booster with accumulator pump assembly to the brake master cylinder.

    4. A01XD4P

      Install a new clip.

    5. A01XH8JE05
      Text in Illustration
      *1 Red Cable
      *2 Black Cable

      Connect the wire harnesses with the 2 screws.

      Torque:
      2.9 N*m  { 30 kgf*cm, 26 in.*lbf }

    6. Install 2 new plugs.

  9. INSTALL NO. 1 BRAKE ACTUATOR TUBE


    1. Using a union nut wrench, install the No. 1 brake actuator tube.

      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.

  10. INSTALL NO. 1 BRAKE ACTUATOR HOSE


    1. Using needle nose pliers, install the brake actuator hose with the 2 clips.

  11. INSTALL MASTER CYLINDER RESERVOIR GROMMET


    1. A01XDBC

      Apply a light coat of lithium soap base glycol grease to 3 new reservoir grommets.

    2. Install the 3 reservoir grommets to the brake master cylinder.

      Note

      Be careful of the size of each grommet.

  12. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY


    1. Install the brake master cylinder reservoir sub-assembly with the screw.

      Torque:
      1.7 N*m  { 17 kgf*cm, 15 in.*lbf }

    2. Install the master cylinder reservoir filler cap.

    3. Using a pin punch and hammer, install a new pin to the brake master cylinder reservoir.

  13. INSTALL NO. 1 BRAKE ACTUATOR BRACKET


    1. Install the brake fluid level warning switch connector to the No. 1 brake actuator bracket.

    2. Using a 5 mm hexagon wrench, install the No. 1 brake actuator bracket with the bolt.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }