BRAKE BOOSTER(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL VACUUM SENSOR GROMMET (w/ Stop And Start System)

    Click here

  2. INSTALL VACUUM SENSOR ASSEMBLY (w/ Stop And Start System)

    Click here

  3. INSTALL CHECK VALVE GROMMET


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

  4. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY


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

  5. INSTALL BRAKE BOOSTER GASKET


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

  6. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. Install the push rod clevis to the brake booster assembly.

  7. INSTALL BRAKE BOOSTER ASSEMBLY


    1. Install the brake booster assembly with the 4 nuts.

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

  8. INSTALL PUSH ROD PIN

    Click here

  9. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  10. CHECK AND ADJUST BRAKE BOOSTER PUSH ROD

    Click here

  11. CONNECT VACUUM HOSE


    1. Connect the vacuum hose to the brake vacuum check valve assembly, and slide the clip to secure it.

  12. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  13. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET

    Click here

  14. CONNECT BRAKE LINE


    1. A01V8ILC01
      *a Torque Wrench Fulcrum Length

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

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

      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 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.378 in.)) : 13.4 N*m (137kgf*cm, 10 ft.*lbf)

    2. A01VAK3

      Install a new No. 4 brake tube clamp and the brake tube to the body.

  15. INSTALL COWL BODY MOUNTING REINFORCEMENT LH


    1. Install the cowl body mounting reinforcement LH with the 2 nuts.

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

  16. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY


    1. Install the cowl top panel outer sub-assembly with the 13 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  17. INSTALL COWL VENTILATOR HOUSING SUB-ASSEMBLY


    1. Engage the 3 clips to install the cowl ventilator housing sub-assembly.

  18. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  19. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. for 2AR-FE:

      Click here

    2. for 3ZR-FE:

      Click here

    3. for 3ZR-FAE:

      Click here

    4. for 2AD-FHV:

      Click here

    5. for 2AD-FTV:

      Click here

    6. for 2WW:

      Click here

  20. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (w/ Driver Side Knee Airbag)

    Click here

  21. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Driver Side Knee Airbag)

    Click here

  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  23. BLEED BRAKE SYSTEM

    Click here

  24. BLEED CLUTCH LINE (for Manual Transaxle)


    1. for 2AD-FTV:

      Click here

    2. for 2AR-FE:

      Click here

    3. for 3ZR-FE:

      Click here

    4. for 3ZR-FAE:

      Click here

    5. for 2WW:

      Click here

  25. INSPECT AND ADJUST BRAKE PEDAL

    Click here