BRAKE BOOSTER(for RHD) 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. A01MFRXC01
      *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 is filled with brake fluid.

    2. A01MGD3C01
      *a Torque Wrench Fulcrum Length

      Install the brake tube to the vehicle body with the grommet.

    3. Using a 10 mm union nut wrench, connect the brake tube to the front flexible hose.

      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 (6.37 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

      Note

      Do not kink or damage the brake tubes.

    4. A01MGWXC01
      *1 Clamp
      *2 Brake Tube

      Set the brake line to the clamp as shown in the illustration.

      Note

      Securely install the brake line so that it contacts the clamp as shown in the illustration.

    5. 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 }

      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 (6.37 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

      Note

      Do not kink or damage the brake tubes.

    6. A01MG8SC01
      *a Stopper
      *b Torque Wrench Fulcrum Length

      Install the wire harness clamp bracket to the brake booster with master cylinder assembly with the bolt.

      Torque:
      Specified tightening torque
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Note

      Securely install the wire harness clamp bracket so that its stopper contacts the brake booster with master cylinder assembly as shown in the illustration.

      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 (6.37 in.)): 11.4 N*m (116 kgf*cm, 8 ft.*lbf)

    7. A01MHDXC01
      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.

    8. Engage the clamp to install the motor compartment main wire.

  3. CONNECT BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. A01MHY1C01
      *1 No. 1 Reservoir Hose
      *2 No. 2 Reservoir Hose
      *3 No. 2 Brake Actuator Hose
      *a 120°
      *b 60°
      *c 30°
      B006JKV Upper of Vehicle

      Connect the No. 2 brake actuator hose, No. 1 reservoir hose and No. 2 reservoir hose to the brake booster with master cylinder assembly and No. 1 brake actuator tube, and slide the 3 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
        No. 2 Brake Actuator Hose Yellow Yellow

      • 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.

  4. BLEED NO. 1 BRAKE ACTUATOR TUBE

    Note

    Make sure to bleed the air from the No. 1 brake actuator tube. If the air remains in the No. 1 brake actuator tube, the air enters into the brake booster pump assembly and it may cause the brake booster pump assembly to be damaged.


    1. Remove the brake master cylinder reservoir filler cap assembly.

    2. Add brake fluid into the reservoir between the MAX and MIN level on the brake fluid reservoir.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT3

    3. Install the brake master cylinder reservoir filler cap assembly.

    4. A01MHGH

      Remove the nut, disengage the clamp and separate the No. 1 brake actuator tube from the vehicle body.

    5. A01MI63

      Lift up the brake master cylinder reservoir with bracket as far as possible.

      Note

      Do not spill the brake fluid.

    6. A01MFS2

      While holding the brake master cylinder reservoir with bracket, twist and hold the No. 1 brake actuator tube 90° toward the vehicle front, and wait at 5 seconds.*1

      Note

      Do not damage the hoses.

      Tech Tips

      Keeping the No. 1 brake actuator tube twisted causes the remaining air inside the No. 1 brake actuator tube to be expelled to the brake master cylinder reservoir assembly.

    7. Return the No. 1 brake actuator tube to its original state.

    8. A01MHLI

      While holding the brake master cylinder reservoir with bracket, twist and hold the No. 1 brake actuator tube 90° toward the vehicle rear, and wait at 5 seconds.

      Note

      Do not damage the hoses.

      Tech Tips

      Keeping the No. 1 brake actuator tube twisted causes the remaining air inside the No. 1 brake actuator tube to be expelled to the brake master cylinder reservoir assembly.

    9. Return the No. 1 brake actuator tube to its original state.*2

    10. Repeat steps *1 to *2, 5 times.

    11. A01MK02

      While holding the brake master cylinder reservoir with bracket, pinch the brake actuator hose 10 times with your fingers.

      Note

      Do not use pliers or similar to pinch the brake actuator hose. Doing so may cause damage to the brake actuator hose. Make sure to use your fingers.

    12. Repeat steps *1 to *2, 5 times again, and check that air is not expelled from the No. 1 brake actuator tube.

    13. Engage the clamp and install the No. 1 brake actuator tube with the nut.

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

  5. INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. Install the brake master cylinder reservoir with bracket to the vehicle body with the 2 nuts.

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

    2. Engage the clamp to install the wire harness to the brake master cylinder reservoir with bracket.

  6. INSTALL PUSH ROD PIN

    Click here

  7. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  8. FILL RESERVOIR WITH BRAKE FLUID

  9. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  10. INSTALL LUGGAGE TRIM SERVICE HOLE COVER

    Click here

  11. BLEED BRAKE SYSTEM

    Click here

  12. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  13. 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

  14. 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 3 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 2 clamps to install the wire harness to the outer cowl top panel sub-assembly.

  15. INSTALL COWL BODY MOUNTING REINFORCEMENT RH


    1. Install the cowl body mounting reinforcement RH with the 4 bolts.

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

  16. INSTALL WATER GUARD PLATE RH


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

  17. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL


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

  18. INSTALL WINDSHIELD WIPER MOTOR AND LINK

    Click here

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

    Click here

  20. CLEAR DTC

    Click here