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. B002ISUC01
      *a Connector Portion
      *b Union
      *c Push Rod Clevis
      *d Boot
      *e 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 tubes.

      • 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. B002JLQC01
      *a Torque Wrench Fulcrum Length

      Using the union nut wrench, connect each brake tube to the brake booster with master cylinder assembly.

      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 union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm(6.3779 in.)): 13.4 N*m (137 kgf*cm,10 ft.*lbf)

      Note

      Do not kink or damage the brake tube.

    3. B002HHNC01
      B002HVY Connect the connector
      B002I10 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 PUSH ROD PIN

    Click here

  4. INSTALL RESERVOIR BRACKET


    1. Install the reservoir bracket with the 2 bolts.

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

  5. CONNECT NO. 2 BRAKE ACTUATOR HOSE


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

      Note


      • When connecting the No. 2 brake actuator hose, connect it with the identification paint mark facing the front of the vehicle.

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

  6. CONNECT NO. 1 RESERVOIR HOSE


    1. B002K3JC01
      B002I10 Up

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

      Note


      • Connect the No. 1 eservoir hose with the identification paint mark within 30° of the rib of the 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.

  7. CONNECT NO. 2 RESERVOIR HOSE


    1. B002K3DC01
      B002I10 Up

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

      Note


      • Connect the No. 2 reservoir hose with the identification paint mark within 30° of the rib of the 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.

  8. BLEED NO. 1 BRAKE ACTUATOR TUBE


    1. Add brake fluid into the brake master cylinder reservoir assembly.

    2. B002J6KC01
      *1 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.

  9. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. Install the brake master cylinder reservoir assembly to the reservoir bracket with the 2 bolts.

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

    2. Connect the reservoir level switch connector to the reservoir bracket.

  10. INSTALL COWL BODY MOUNTING REINFORCEMENT RH


    1. B002KHVN01

      Install the cowl body mounting reinforcement RH with the 3 nuts.

      Torque:
      Nut (A)
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }
      Nut (B)
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  11. INSTALL OUTER COWL TOP PANEL

    Click here

  12. INSTALL SUSPENSION TOWER DAMPER (w/ Performance Rod)

    Click here

  13. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  14. FILL RESERVOIR WITH BRAKE FLUID

  15. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  16. BLEED BRAKE SYSTEM

    Click here

  17. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  18. OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR

    Click here

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

    Click here