BRAKE BOOSTER(for RHD) 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. A01G3ZVC02
      *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. Engage the grommet of the brake line.

    3. A01G3V0C01
      *1 No. 1 Brake Tube Clamp
      *a Brake Line

      Set the brake line to the No. 1 brake tube clamp as shown in the illustration.

      Note

      Securely install the brake line so that it contacts the No. 1 brake tube clamp as shown in the illustration.

    4. Using a union nut wrench, connect the brake line to the front flexible hose RH.

      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. A01G2ZZC01
      *1 No. 1 Brake Tube Clamp
      *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
      *f Brake Line

      Using the union nut wrench, connect each brake line to the brake booster with master cylinder assembly as shown in the illustration.

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

      Note


      • Do not kink or damage the brake lines.

      • Securely install the brake line so that it contacts the No. 1 brake tube clamp as shown in the illustration.

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

        Click here

    6. A01G2SZC01
      *a Stopper

      Install the wire harness clamp bracket to the brake booster with master cylinder assembly with the bolt.

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

      Note

      Securely install the wire harness clamp bracket so that its stopper contacts the brake booster with master cylinder assembly as shown in the illustration.

    7. A01G2YAC01
      A01G309 Connect the connector
      A01G33F 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.

    8. Engage the clamp.

  3. CONNECT NO. 2 BRAKE ACTUATOR HOSE


    1. A01G3Q2C01
      A01G33F Up

      Connect the No. 2 brake actuator hose to the No. 1 brake actuator tube, and slide the clip to secure it.

      Note


      • Make sure to match the identification mark (yellow) on the No. 2 brake actuator hose with the No. 1 brake actuator tube.

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

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

  4. CONNECT NO. 1 RESERVOIR HOSE


    1. A01G3B5C01
      A01G33F 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 No. 1 reservoir 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.

  5. CONNECT NO. 2 RESERVOIR HOSE


    1. A01G35MC01
      A01G33F 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.

  6. BLEED NO. 1 BRAKE ACTUATOR TUBE


    1. Add brake fluid into the reservoir.

    2. A01G3ZBC01
      *1 Brake Actuator Hose
      *2 No. 2 Brake Actuator Hose
      *3 No. 1 Brake Actuator Tube

      Lift up the brake master cylinder reservoir assembly as far as possible and rock it back and forth to bleed air from the No. 1 brake actuator tube.

      Note


      • Do not damage the hoses.

      • Do not spill brake fluid.

      • Continue this procedure until only a minor amount of air remains in the brake actuator tube.

  7. INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. A01G3RU

      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 clamp to install the wire harness.

  8. INSTALL PUSH ROD PIN

    Click here

  9. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  10. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. Connect the No. 2 steering intermediate shaft assembly to the steering column assembly.

      Tech Tips

      Use the same procedure as for LHD.

      Click here

  11. FILL RESERVOIR WITH BRAKE FLUID

  12. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

    for Wagon: Click here

    for Hatchback: Click here

  13. BLEED BRAKE SYSTEM

    Click here

  14. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  15. 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

  16. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

    Click here

  17. INSTALL OUTER COWL TOP PANEL


    1. A01G3ZUC01
      A01G309 Bolt
      A01G33F Nut

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

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

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


    1. A01G36X

      Engage the clamp to install the No. 2 heater air duct splash shield seal to the outer cowl top panel.

  19. INSTALL WATER GUARD PLATE LH

    A01G2U7

    1. Engage the clamp to install the water guard plate LH to the outer cowl top panel.

  20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Tech Tips

    Use the same procedure as for LHD.

    Click here