BRAKE BOOSTER(for LHD) INSTALLATION

CAUTION / NOTICE / HINT

Note

While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch is turned on. Therefore, when servicing brake system components, do not depress the brake pedal or open/close the doors while the auxiliary battery is connected.

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. A01MJ44C01
      *a Connector Portion
      *b Union
      *c Push Rod Clevis
      *d Boot
      *e 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 assembly is filled with brake fluid.

    2. A01MI1HC01
      *a Torque Wrench Fulcrum Length

      Using a 10 mm union nut wrench, connect the 5 brake tubes to the brake booster with master cylinder assembly.

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

      Note

      Do not kink or damage the brake tubes.

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

    3. Install the No. 1 brake tube clamp bracket to the brake booster with master cylinder assembly with the bolt.

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

    4. Install the brake tube to the No. 1 brake tube clamp bracket with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    5. A01MIZ0C01
      B006JKV Connect the connector
      B006JEG 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.

    6. A01MH2TC01
      *1 No. 1 Reservoir Hose
      *2 No. 2 Reservoir Hose
      *a 120°
      *b 60°
      B006JKV Upper of Vehicle

      Connect the No. 1 reservoir hose and No. 2 reservoir hose to the brake booster with master cylinder assembly, and slide the 2 clips to secure them.

      Note


      • Make sure to match the identification mark on the hose with the brake booster with master cylinder assembly rib.

        Item Hose Identification Mark Color Brake Booster with Master Cylinder Assembly Identification Mark Color
        No. 1 Reservoir Hose White White (Unpainted Color)
        No. 2 Reservoir Hose Green Green

      • When connecting the reservoir hose, face the identification mark to the top of the vehicle.

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

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

    7. Install the reservoir tube and No. 1 brake actuator tube to the vehicle body with the 3 bolts and 2 nuts.

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

  3. INSTALL PUSH ROD PIN

    Click here

  4. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  5. ADD FILL RESERVOIR WITH BRAKE FLUID

  6. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  7. INSTALL LUGGAGE TRIM SERVICE HOLE COVER

    Click here

  8. BLEED BRAKE SYSTEM

    Click here

  9. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  10. OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR

    Tech Tips

    After the brake booster with master cylinder assembly is replaced, obtain the zero point of the yaw rate and acceleration sensor.

    Click here

  11. INSTALL FRONT FENDER APRON REAR EXTENSION LH


    1. Install the front fender apron extension rear LH with the 2 bolts.

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

  12. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. Install the outer cowl top panel sub-assembly with the 9 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Connect the hydrogen detector connector.

    3. for Cold Area Specification Vehicles:


      1. Engage the 4 clamps to install the wire harness to the outer cowl top panel sub-assembly.

      2. Connect the windshield deicer connector.

    4. except Cold Area Specification Vehicles:


      1. Engage the 3 clamps to install the wire harness to the outer cowl top panel sub-assembly.

  13. INSTALL COWL BODY MOUNTING REINFORCEMENT RH


    1. Install the cowl body mounting reinforcement RH to the outer cowl top panel sub-assembly with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  14. INSTALL WATER GUARD PLATE LH


    1. Engage the clamp to install the water guard plate LH to the outer cowl top panel sub-assembly.

  15. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL


    1. Engage the 2 clamps to install the No. 2 heater air duct splash shield seal to the outer cowl top panel sub-assembly.

  16. INSTALL WINDSHIELD WIPER MOTOR AND LINK

    Click here

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

    Click here

  18. CLEAR DTC

    Click here