HYDRAULIC BRAKE BOOSTER(for LHD) REASSEMBLY

PROCEDURE


  1. INSTALL BRAKE BOOSTER PISTON SUB-ASSEMBLY


    1. A01WW2L

      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 on the piston.

      Tech Tips

      Tape the screwdriver tip before use.

  2. INSTALL MASTER CYLINDER BOOT

  3. INSTALL MASTER CYLINDER PUSH ROD CLEVIS


    1. A01WSCX

      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. A01WSTT

      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. A01WVWW

      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. A01WPNF

      Install the master cylinder solenoid with 6 new bolts.

      Torque:
      32 N*m  { 325 kgf*cm, 24 ft.*lbf }

  5. INSTALL BRAKE BOOSTER ACCUMULATOR PIPE


    1. A01WTOF

      Install the brake booster accumulator pipe and compression spring.

      Note

      Ensure 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. 1 BRAKE BOOSTER PUMP BRACKET


    1. A01WTI2

      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 }

  7. INSTALL BRAKE BOOSTER WITH ACCUMULATOR PUMP ASSEMBLY


    1. A01WU5Y

      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. A01WU2B

      Install 2 new brake booster pump collars and the 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. A01WRHP

      Install a new clip.

    5. A01WRCIE05
      *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. A01WPBV

      Install 2 new plugs.

  8. INSTALL NO. 1 BRAKE ACTUATOR TUBE


    1. A01WSUAE04
      *1 Union Nut Wrench
      *2 Fulcrum Length

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

      Torque:
      without union nut wrench
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      with union nut wrench
      14 N*m  { 145 kgf*cm, 10 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).

      • The torque value for use with a union nut wrench is effective when the union nut wrench is parallel to the torque wrench.

  9. INSTALL NO. 1 BRAKE ACTUATOR HOSE


    1. A01WR0I

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

  10. INSTALL MASTER CYLINDER RESERVOIR GROMMET


    1. A01WV72

      Apply 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.

  11. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY


    1. A01WT2H

      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. A01WU3GE06
      *1 Pin Punch

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

  12. INSTALL NO. 1 BRAKE ACTUATOR BRACKET


    1. A01WP90

      Connect 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 }