BRAKE BOOSTER PUMP(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE BOOSTER PUMP ASSEMBLY


    1. A01KSE2C01
      *1 Brake Actuator Case Collar
      *2 Brake Booster Pump Bushing
      *3 Brake Actuator Bracket Assembly
      *4 Brake Booster Pump Assembly
      *5 Brake Actuator Bracket Cushion
      *6 Brake Booster Pump Collar
      *a Nut

      Install the brake booster pump assembly, 2 brake booster pump bushings and 2 brake actuator case collars to the brake actuator bracket assembly with the 2 nuts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Note


      • Do not drop the brake booster pump assembly when carrying it.

      • Do not carry the brake booster pump assembly by the connector.

      • When installing the brake booster pump assembly to the brake actuator bracket assembly, confirm that the 2 brake actuator bracket cushions are on the brake actuator bracket assembly, and brake booster pump bushing and brake booster pump collar are on the brake booster pump assembly.

      • Do not remove the hole plug before installing a new brake booster pump assembly because the brake booster pump assembly is filled with brake fluid.

  2. INSTALL BRAKE BOOSTER PUMP ASSEMBLY WITH BRACKET


    1. A01KRJRC01
      *a Length of SST 150 mm (5.91 in.)
      *b Length of Torque Wrench 250 mm (9.84 in.)
      A01KR22 Turn

      Using SST, install the brake booster pump assembly with bracket with the 3 nuts.

      SST
      09961-00950
      Torque:
      without SST [Torque wrench (N*m (kgf*cm, ft.*lbf))]
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
      with SST [Reading of Torque wrench (N*m (kgf*cm, ft.*lbf))]
      11.9 N*m  { 121 kgf*cm, 9 ft.*lbf }

      Note


      • This torque value is effective when SST is parallel to the torque wrench.

      • The "with SST" torque value is effective when using SST with a fulcrum length of 150 mm (5.91 in.).

      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 250 mm (9.84 in.).

      • If using a torque wrench with a different length, or connecting the torque wrench and SST at an angle, refer to the alternate values.

        Click here

      • Tighten the 3 nuts in the order shown in the illustration.

      • Do not damage the fuel lines, brake lines and wire harness.

    2. A01KRCP

      Engage the wire harness clamp and 2 fuel line clamps to the brake booster pump bracket assembly.

      Note

      Do not kink or damage the fuel lines.

    3. A01KU3N

      Engage the clamp to install the wire harness to the brake booster pump bracket assembly.

    4. Connect the 2 connectors to the brake booster pump assembly.

  3. INSTALL FRONT NO. 1 BRAKE TUBE


    1. A01KTBYC02
      *1 No. 2 Brake Tube Clamp Bracket
      *2 No. 4 Brake Tube Clamp
      *3 Front No. 1 Brake Tube

      Install the No. 2 brake tube clamp bracket to the brake booster pump assembly with the bolt (A).

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

    2. Using a union nut wrench, connect the front No. 1 brake tube to the brake booster pump assembly to install it.

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

      Note

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

      Click here

    3. Install the No. 4 brake tube clamp to the No. 2 brake tube clamp bracket with the bolt (B).

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

  4. INSTALL FRONT NO. 4 BRAKE TUBE


    1. A01KR1E

      Engage the clamp to install the front No. 4 brake tube clamp to the brake booster pump bracket assembly.

      Note

      Do not kink or damage the front No. 4 brake tube.

    2. A01KSR8

      Install the bolt.

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

    3. Using a union nut wrench, connect the front No. 4 brake tube to the front flexible hose.

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

      Note


      • Do not kink or damage the brake line.

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

        Click here

  5. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  6. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

    Click here