BRAKE BOOSTER(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE BOOSTER GASKET


    1. Install a new brake booster gasket to the brake booster with master cylinder assembly.

  2. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. A00YP9EC01
      *1 Connector Portion
      *2 Union
      *3 Push Rod Clevis
      *4 Boot
      *5 Front No. 2 Brake Tube

      Install the brake booster with master cylinder assembly with the 4 nuts.

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

      Note


      • Do not kink or damage the brake lines.

      • Do not carry the brake booster with master cylinder assembly by the portion shown in the illustration.

      • Be careful not to allow brake fluid to enter the connector of ECU.

      • If installing a new brake booster with master cylinder assembly, do not remove the hole plugs before connecting the brake lines because the brake booster with master cylinder is filled with brake fluid.

    2. A00YQ99C01
      *a To Front Wheel Cylinder LH
      *b To Rear Wheel Cylinder RH
      *c To Brake Booster Pump Assembly
      *d To Rear Wheel Cylinder LH
      *e To Front Wheel Cylinder RH

      Temporarily tighten each brake line to the correct position on the brake booster with master cylinder assembly as shown in the illustration.

    3. A00YMSOC01
      *a Stopper

      Install the No. 2 brake tube clamp bracket to the brake booster with master cylinder assembly with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

      Note

      Securely install the No. 2 brake tube clamp bracket so that its stopper contacts the brake booster with master cylinder assembly as shown in the illustration.

    4. Using a union nut wrench, fully tighten each brake line.

      Torque:
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note


      • Do not kink or damage the brake lines.

      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

        Click here

    5. A00YPJMC01
      A00YN9X Connect the connector
      A00YQ1Y Lock the lock lever

      Connect the connector to the brake booster with master cylinder assembly.

      Note


      • Make sure that the connector can be connected smoothly. Do not allow water, oil or dirt to enter.

      • Make sure that the connector lock is locked securely.

  3. INSTALL NO. 5 BRAKE ACTUATOR BRACKET


    1. A00YQ5BN01

      Install the No. 5 brake actuator bracket with the 2 nuts.

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

      Note

      Tighten the 2 nuts in the order shown in the illustration.

    2. Engage the clamp.

  4. CONNECT BRAKE ACTUATOR HOSE


    1. A00YP5MC01
      A00YQ1Y Front of vehicle

      Connect the brake actuator hose to the brake booster pump assembly with the clip.

      Note


      • Make sure to match the identification mark (yellowish green) on the hose with the brake booster pump rib.

      • Make sure to install the hose to the proper location.

      • Install the clip within the range shown in the illustration.

  5. CONNECT NO. 1 RESERVOIR HOSE


    1. A00YNQBC01
      A00YQ1Y Up

      Connect the No. 1 reservoir hose to the brake booster with master cylinder assembly, and slide the clip to secure it.

      Note


      • Make sure to match the identification mark (white (unpainted color)) on the hose and brake booster with master cylinder assembly.

      • When connecting the No. 1 reservoir hose, face the identification mark up.

      • Make sure to install the hose to the proper location.

      • Install the clip within the range shown in the illustration.

  6. CONNECT NO. 2 RESERVOIR HOSE


    1. A00YMY1C01
      A00YQ1Y Up

      Connect the No. 2 reservoir hose to the brake booster with master cylinder assembly, and slide the clip to secure it.

      Note


      • Make sure to match the identification mark (green) on the No. 2 reservoir hose and brake booster with master cylinder assembly.

      • When connecting the No. 2 reservoir hose, face the identification mark up.

      • Make sure to install the hose to the proper location.

      • Install the clip within the range shown in the illustration.

  7. INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. A00YOBD

      Install the brake master cylinder reservoir with bracket with the 2 nuts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    2. Engage the 2 clamps to install the wire harness.

  8. INSTALL PUSH ROD PIN

    Click here

  9. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  10. FILL RESERVOIR WITH BRAKE FLUID

  11. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

    Click here

  12. BLEED BRAKE SYSTEM

    Click here

  13. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  14. OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR

    Tech Tips

    After the brake booster with master cylinder assembly is replaced, obtain the zero point of the yaw rate and acceleration sensor.

    Click here

  15. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (w/ Instrument Panel Under Cover)

    Click here

  16. INSTALL OUTER COWL TOP PANEL


    1. A00YO8LC01
      A00YN9X Bolt
      A00YQ1Y Nut

      Install the outer cowl top panel with the 11 bolts and nut.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  17. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL


    1. A00YNYH

      Engage the clamp to install the No. 2 heater air duct splash shield seal.

  18. INSTALL WATER GUARD PLATE LH


    1. A00YNRJ

      Engage the clamp to install the water guard plate LH.

  19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here