BRAKE BOOSTER(for RHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE BOOSTER GASKET


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

  2. INSTALL BRAKE BOOSTER ASSEMBLY


    1. Temporarily install the brake booster assembly to the vehicle body.

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

      Note

      Fully tighten the lock nut when adjusting the brake pedal height.

    3. Install the 4 nuts to secure the brake booster assembly.

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

  3. INSTALL PUSH ROD PIN

    Click here

  4. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  6. INSTALL OIL PIPE

    Click here

  7. INSTALL NO. 2 TIMING GEAR COVER

    Click here

  8. INSTALL FUEL HOSE PROTECTOR

    Click here

  9. INSTALL IGNITION COIL ASSEMBLY


    1. Install the 3 ignition coil assemblies with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  10. INSTALL ENGINE WIRE


    1. Install the engine wire to the cylinder head cover sub-assembly with the bolt.

    2. B00409RC01
      B003ZIE Bolt
      B003Z8F Connector

      Install the bolt, engage the 4 clamps and connect the 10 connectors.

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

  11. INSTALL HOSE BRACKET


    1. Install the hose bracket with the bolt.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

    2. Engage the clamp to install the engine wire.

  12. CONNECT NO. 2 VENTILATION HOSE


    1. Connect the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.

  13. INSTALL NO. 1 SURGE TANK STAY

    Click here

  14. INSTALL THROTTLE BODY BRACKET

    Click here

  15. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Click here

  16. INSTALL THROTTLE BODY GASKET

    Click here

  17. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  18. INSTALL BRAKE LINE


    1. B003Z9ZC01
      *1 Front No. 6 Brake Tube
      *2 Front No. 7 Brake Tube
      *3 Front No. 8 Brake Tube

      Install the front No. 6 brake tube and front No. 7 brake tube, and engage the 3 clamps to secure the 3 brake lines.

      Note


      • Do not damage the 3 clamps.

      • Do not kink or damage the brake lines.

      Tech Tips

      Install the front No. 6 brake tube and front No. 7 brake tube while avoiding the front No. 8 brake tube.

    2. A002BALN01

      Engage the clamp to secure the 3 brake lines.

      Note


      • Do not damage the clamp.

      • Do not kink or damage the brake lines.

    3. Using a union nut wrench, connect the 3 brake lines to the brake actuator assembly.

      Torque:
      Brake Line (A)
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }
      Brake Line (B)
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note


      • Do not kink or damage the brake lines.

      • Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

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

        Click here

  19. CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape from the suction hose sub-assembly.

    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the suction hose sub-assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the 2 O-rings to the suction hose sub-assembly

    4. A002ARC

      Connect the suction hose sub-assembly to the No. 1 air conditioning accessory assembly.

      Note

      Do not deform the refrigerant lines.

    5. A002BFJ

      Install the piping clamp to the suction hose sub-assembly.

      Click here

  20. INSTALL AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. Remove the vinyl tape from the air conditioner tube and accessory assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioner tube and accessory assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the air conditioner tube and accessory assembly.

    4. Insert the air conditioner tube and accessory assembly to the air conditioning unit assembly.

    5. Install the air conditioner tube and accessory assembly with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note

      Do not deform the refrigerant lines.

    6. Install the air conditioner tube and accessory assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note

      Do not deform the refrigerant lines.

    7. Engage the clamp to install the air conditioner tube and accessory assembly to the brake actuator assembly.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    8. Engage the clamp to install the air conditioner tube and accessory assembly.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

  21. INSTALL SUCTION HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape from the suction hose sub-assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction hose sub-assembly.

    4. Insert the suction hose sub-assembly to the air conditioning unit assembly.

    5. A002A7H

      Rotate the hook connector as shown in the illustration.

    6. Insert the tube joint into the fitting hole securely and install the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    7. A0027JC

      Install the suction hose sub-assembly to the piping clamp.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    8. Engage the claw to lock the piping clamp.

    9. Install the suction hose sub-assembly to the suction hose clamp, and engage the claw to secure it.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    10. Engage the clamp to install the suction hose sub-assembly to the brake actuator assembly.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    11. Engage the clamp to install the suction hose sub-assembly.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

  22. INSTALL ENGINE MOVING CONTROL ROD BRACKET

    Click here

  23. INSTALL NO. 2 ENGINE MOUNTING STAY RH

    Click here

  24. 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.

  25. INSTALL RESERVOIR BRACKET


    1. Install the reservoir bracket with the 2 nuts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Engage the clamp to install the engine room main wire.

  26. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A002CMXC01
      *1 Brake Master Cylinder Reservoir Assembly
      *2 Reservoir Bracket

      Move the brake master cylinder reservoir assembly as shown in the illustration to engage the 2 claws.

    2. Connect the reservoir level switch connector and install the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  27. INSTALL ENGINE ROOM MAIN WIRE


    1. B003ZCLC01
      *a Wire Harness Protector

      Engage the 5 clamps to install the engine room main wire.

    2. Engage the clamp to install the wire harness protector.

    3. Install the bolt to secure the wire harness protector.

  28. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  29. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  30. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  31. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY WITH WAY

    Click here

  32. ADD ENGINE COOLANT

    Click here

  33. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  34. WARM UP ENGINE

    Click here

  35. INSPECT FOR REFRIGERANT LEAK

    Click here

  36. INSPECT FOR COOLANT LEAK

    Click here

  37. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK

    Click here

  38. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  39. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  40. INSTALL FRONT WHEEL RH

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }