HYDRAULIC BRAKE BOOSTER(for RHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE BOOSTER GASKET


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

  2. INSTALL HYDRAULIC BRAKE BOOSTER ASSEMBLY


    1. Install the hydraulic brake booster assembly with the 4 nuts.

      Torque:
      14 N*m  { 145 kgf*cm, 10 ft.*lbf }
    2. B001FHPE16

      Connect the 4 brake lines to the correct positions of the hydraulic brake booster assembly as shown in the illustration.

      Tech Tips


      • *1: To front wheel cylinder RH

      • *2: To front wheel cylinder LH

      • *3: To rear wheel cylinder RH

      • *4: To rear wheel cylinder LH

    3. Install the clamp with the bolt.

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

    4. Using a union nut wrench, connect the 4 brake lines to the hydraulic brake booster assembly.

      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.

    5. Connect the 2 brake tube clamps to the body.

    6. Install the brake tube to the clamps.

    7. B001HJL

      Connect the 3 connectors to the hydraulic brake booster.

  3. INSTALL PUSH ROD PIN

    Click here

  4. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY


    1. Install the clutch master cylinder assembly Click here.

  5. CONNECT WATER HOSE JOINT


    1. w/ Rear Heater:

      Connect the water hose joint.

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

  6. INSTALL LOWER NO . 1 INSTRUMENT PANEL AIRBAG ASSEMBLY


    1. Install the lower No. 1 instrument panel airbag assembly Click here.

  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here

  8. BLEED BRAKE SYSTEM

    Click here

  9. FILL RESERVOIR WITH BRAKE FLUID

    Click here

  10. BLEED CLUTCH LINE

    Click here

  11. CHECK FLUID LEVEL IN RESERVOIR

    Click here

  12. CHECK FOR BRAKE FLUID LEAK FROM CLUTCH LINE

  13. CHECK AND ADJUST BRAKE PEDAL


    1. Check and adjust brake pedal Click here.

  14. INSPECT BRAKE MASTER CYLINDER OPERATION


    1. Inspect the brake master cylinder operation Click here.

  15. PERFORM YAW RATE AND ACCELERATION SENSOR ZERO POINT CALIBRATION

    Note

    When replacing the hydraulic brake booster assembly, perform yaw rate and acceleration sensor zero point calibration and acquire information about the following specification as necessary Click here,


    • Downhill assist control calibration

    • Crawl control calibration