BRAKE BOOSTER PUMP INSTALLATION

PROCEDURE


  1. INSTALL BRAKE BOOSTER PUMP ASSEMBLY


    1. Install the 2 brake actuator bracket cushions to the brake actuator bracket assembly.

    2. B002I9QC01
      *1 Nut
      *2 Brake Actuator Case Collar
      *3 Brake Booster Pump Bushing
      *4 Brake Actuator Bracket Assembly
      *5 Brake Booster Pump Assembly
      *6 Brake Actuator Bracket Cushion
      *a Union
      *b Connector
      *c Stud

      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


      • When handling the brake booster pump assembly, do not hold it at the parts marked *a, *b and *c in the illustration.

      • Do not drop the brake booster pump assembly when carrying it. Do not use a brake booster pump assembly that has been dropped.

      • Do not damage the brake tubes and clamps. If they get damaged, replace with new ones.

      • Do not allow brake fluid to contact the inside of 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. B002I7JE01

      Install the brake booster pump assembly with bracket with the 3 nuts.

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

      Note

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

    2. Attach the brake tube clamp to the brake actuator bracket assembly.

    3. Attach the clamp to the brake booster pump bracket assembly.

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

  3. INSTALL NO. 1 BRAKE TUBE CLAMP BRACKET


    1. Install the No. 1 brake tube clamp bracket to the brake booster pump assembly with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  4. INSTALL FRONT NO. 1 BRAKE TUBE


    1. Install the front No. 1 brake tube to the brake booster pump assembly with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. B002J7HC01
      *a Torque Wrench Fulcrum Length

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

      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)

  5. CONNECT NO. 1 BRAKE ACTUATOR HOSE


    1. B002KNAC02
      B002I10 Front of Vehicle

      Connect the No. 1 brake actuator hose to the brake booster pump assembly with bracket and secure the hose with the clip.

      Note


      • Connect the No. 1 brake actuator hose with the identification paint mark within 30° of the rib on the brake booster pump assembly with bracket.

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

  6. INSTALL HEATER ACCESSORY ASSEMBLY


    1. B002L1ZC02
      *a Temporary Bolt

      Temporarily install the heater water pump assembly (heater water pump) with the 3 bolts and nut.

    2. Install the 3 bolts and nut in the order as shown in the illustration.

      Torque:
      for Bolt A, Nut A
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      for Bolt B
      7.7 N*m  { 79 kgf*cm, 68 in.*lbf }

    3. Attach the clamp.

    4. Connect the connector.

  7. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY (for LHD)

    Click here

  8. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  9. FILL RESERVOIR WITH BRAKE FLUID

  10. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  11. INSTALL DECK FLOOR BOX LH (w/ Spare Tire)

    Click here

  12. INSTALL REAR DECK FLOOR BOX (w/ Spare Tire)

    Click here

  13. INSTALL NO. 3 DECK BOARD SUB-ASSEMBLY (w/ Spare Tire)

    Click here

  14. BLEED BRAKE SYSTEM

    Click here