BRAKE BOOSTER (for RHD) INSTALLATION

INSTALL CHECK VALVE GROMMET
1. Install a new check valve grommet to the brake booster assembly.
INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY
1. Install the brake vacuum check valve assembly to the brake booster assembly.

INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS

Temporarily install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.

Text in Illustration
*1	Lock Nut
*2	Brake Master Cylinder Push Rod Clevis
*a	Push Rod Length

Set the push rod length as shown in the illustration.

Push rod length
148.6 to 149.6 mm (5.86 to 5.88 in.)

Tighten the lock nut.

Torque:

26 N*m { 265 kgf*cm, 19 ft.*lbf }

INSTALL BRAKE BOOSTER GASKET
1. Install a new brake booster gasket to the brake booster assembly.
INSTALL BRAKE BOOSTER ASSEMBLY
1. Install the brake booster assembly to the vehicle body with the 4 nuts.
  
  Torque:
  
  13 N*m { 131 kgf*cm, 9 ft.*lbf }
  
  Note
  
  Do not kink or damage the brake lines, air conditioning tube and accessory assembly or suction pipe sub-assembly.
INSTALL PUSH ROD PIN
1. Apply lithium soap base glycol grease to the push rod pin.
  
  Text in Illustration
  
  Lithium Soap Base Glycol Grease
2. Connect the brake master cylinder push rod clevis to the brake pedal support assembly with the push rod pin, and install a new clip as shown in the illustration.
  Note
  - Be sure to insert the pin with its clip end facing the outside of the vehicle.
  - Make sure that the brake master cylinder push rod clevis moves sideway.
CONNECT UNION TO CHECK VALVE HOSE
1. Connect the union to check valve hose to the brake booster assembly, and slide the clip to secure it.
INSTALL VACUUM SWITCHING VALVE ASSEMBLY
1. Install the vacuum switching valve assembly with the bolt.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
2. Connect the 2 vacuum hoses and connector.
3. Connect the union to check valve hose and wire harness clamp.
CONNECT BRAKE LINE
1. Install 2 new clamps to the brake lines.
2. Text in Illustration
  
  *a Torque Wrench Fulcrum Length
  
  Using a union nut wrench, connect the 2 brake lines to the brake actuator assembly.
  
  Torque:
  
  Specified tightening torque
  
  20 N*m { 199 kgf*cm, 14 ft.*lbf }
  Note
  
  Do not kink or damage the brake lines.
  
  Do not allow brake lines to twist and interfere with other parts or vehicle body during flexible hose tightening.
  
  Do not allow any foreign matter such as dirt or dust to enter the brake lines.
  Tech Tips
  
  Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.
  
  When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 250 mm (9.84 in.)):
  
  18 N*m (184 kgf*cm, 13 ft.*lbf)
INSTALL NO. 1 BRAKE TUBE CLAMP
1. Install a new No. 1 brake tube clamp to the vehicle body.
  
  Torque:
  
  7.8 N*m { 80 kgf*cm, 69 in.*lbf }
2. Engage the brake lines to the clamp.
  
  Note
  
  Do not kink or damage the brake lines.
INSTALL SUCTION PIPE SUB-ASSEMBLY
1. Remove the attached vinyl tape from the openings of the disconnected parts.
2. Sufficiently apply compressor oil to a new O-ring, fitting surface of the suction pipe sub-assembly and air conditioning unit.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring on the suction pipe sub-assembly.
  
  Note
  
  Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign matter.
4. Insert the suction pipe sub-assembly to the air conditioning unit.
  Note
  
  Insert the pipe joint into the fitting hole securely.
  
  Do not deform the piping.
  
  Do not damage the plastic clamp.
5. Install the clamp with suction pipe sub-assembly and air conditioning tube and accessory assembly to the No. 1 brake tube clamp.
  Note
  
  Do not deform the air conditioning tube and accessory assembly or suction pipe sub-assembly.
  
  Do not damage the plastic clamp.
6. Install the clamp to the brake actuator bracket assembly.
  Note
  
  Do not deform the suction pipe sub-assembly.
  
  Do not damage the plastic clamp.
INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
1. Remove the attached vinyl tape from the openings of the disconnected parts.
2. Sufficiently apply compressor oil to 2 new O-rings, the fitting surface of the air conditioning tube and accessory assembly, cooler condenser assembly and air conditioning unit.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Install the 2 O-rings on the air conditioning tube and accessory assembly.
  
  Note
  
  Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign matter.
4. Insert the air conditioning tube and accessory assembly to the cooler condenser assembly.
5. Install the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
6. Insert the air conditioning tube and accessory assembly to the air conditioning unit.
  
  Note
  
  Insert the pipe joint into the fitting hole securely.
7. Turn the hook connector and install the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
8. Install the clamp to the vehicle body and connect the pressure sensor connector.
  Note
  
  Do not deform the piping.
  
  Do not damage the plastic clamp.
INSTALL RADIATOR SIDE DEFLECTOR RH

Click here
INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Click here
WARM UP ENGINE

Click here
INSPECT FOR REFRIGERANT LEAK

Click here
INSTALL FRONT BUMPER COVER

Click here
INSPECT AND ADJUST BRAKE PEDAL

Click here