BRAKE BOOSTER INSTALLATION

PROCEDURE


  1. TEMPORARILY INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. Install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.

      Tech Tips

      Tighten the lock nut after adjusting the brake pedal height.

  2. INSTALL BRAKE BOOSTER GASKET


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

  3. INSTALL BRAKE BOOSTER ASSEMBLY


    1. A002LN6E05
      Text in Illustration
      *A for LHD
      *B for RHD

      Install the brake booster assembly to the body with the 4 nuts. Tighten the 4 nuts uniformly in alphabetical order.

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

      Note

      Do not damage the brake lines or fuel lines.

  4. INSTALL FRONT BRAKE LINE


    1. for LHD:


      1. A002LPK

        Install the brake tube to the brake actuator bracket with a new clamp.

      2. A002O8K

        Using a union nut wrench, connect the 2 brake tubes to the 2-way.

        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.

      3. A002NMW

        Install the brake tube to the body with 2 new clamps.

      4. A002QGU

        Attach the grommet to the body.

      5. A002QK1

        Using a union nut wrench, connect the brake tube to the front flexible hose RH while holding the flexible hose with a wrench.

        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.

      6. A002NBJ

        Using a union nut wrench, connect the brake tube to the front flexible hose LH while holding the flexible hose with a wrench.

        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.

      7. Install the clamp with the bolt.

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

    2. for RHD:


      1. A002LPK

        Install the brake tube to the brake actuator bracket with a new clamp.

      2. A002QED

        Install the brake tube to the body with a new clamp.

      3. A002OLC

        Using a union nut wrench, connect the 2 brake tubes to the 2-way.

        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.

      4. A002MZJ

        Install the brake tube to the body with a new clamp.

      5. A002QGU

        Attach the grommet to the body.

      6. A002QK1

        Using a union nut wrench, connect the brake tube to the front flexible hose RH while holding the flexible hose with a wrench.

        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.

      7. A002NBJ

        Using a union nut wrench, connect the brake tube to the front flexible hose LH while holding the flexible hose with a wrench.

        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.

      8. Install the clamp with the bolt.

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

  5. INSTALL VACUUM SENSOR GROMMET (for 1WW)


    1. Install a new vacuum sensor grommet to the brake booster assembly.

  6. INSTALL VACUUM SENSOR ASSEMBLY (for 1WW)


    1. Install the vacuum sensor assembly to the brake booster assembly.

  7. INSTALL CHECK VALVE GROMMET


    1. Install a new check valve grommet to the brake booster assembly.

  8. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY


    1. Install the vacuum check valve assembly to the brake booster assembly.

  9. CONNECT VACUUM HOSE


    1. A002P2XE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Connect the vacuum hose with the clip.

  10. INSTALL PUSH ROD PIN

    Click here

  11. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  12. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. Install the brake master cylinder sub-assembly Click here.

  13. INSTALL BRAKE ACTUATOR ASSEMBLY


    1. Install the brake actuator assembly Click here.

  14. INSTALL ENGINE ASSEMBLY


    1. for 1ZR-FAE:

      Install the engine assembly Click here.

    2. for 2ZR-FAE:

      Install the engine assembly Click here.

    3. for 1WW:

      Install the engine assembly Click here.

  15. REMOVE CENTER COWL TOP VENTILATOR LOUVER

    Click here

  16. BLEED BRAKE SYSTEM

    Click here

  17. BLEED AIR FROM CLUTCH LINE (for 1ZR-FAE with Manual Transaxle)

    Click here

  18. BLEED AIR FROM CLUTCH LINE (for 2ZR-FAE with Manual Transaxle)

    Click here

  19. BLEED CLUTCH LINE (for 1WW)

    Click here

  20. INSTALL CENTER COWL TOP VENTILATOR LOUVER

    Click here

  21. INSTALL FRONT WHEEL

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  22. INSPECT AND ADJUST BRAKE PEDAL HEIGHT

    Click here

  23. INSPECT BRAKE PEDAL FREE PLAY

    Click here

  24. INSPECT BRAKE PEDAL RESERVE DISTANCE

    Click here