BRAKE BOOSTER PUMP(for RHD) INSTALLATION

PROCEDURE

1. INSTALL BRAKE BOOSTER PUMP ASSEMBLY

   
   

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

   2. 

      *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 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 NO.1 BRAKE TUBE CLAMP BRACKET

   
   

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

      Torque:

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

3. INSTALL BRAKE BOOSTER PUMP WITH BRACKET ASSEMBLY

   
   

   1. 

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

      Torque:

      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

   3. Engage the clamp to install the wire harness to the brake booster pump assembly with bracket.

   4. Engage the clamp to install the front No. 4 brake tube to the brake booster pump with bracket assembly.

   5. Connect the 2 brake booster pump assembly connectors.

   6. Engage the clamp to install the wire harness to the brake booster pump with bracket assembly.

4. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

   Click here

5. CONNECT FRONT NO. 1 BRAKE TUBE

   

   *a	Torque Wrench Fulcrum Length

   
   

   1. Using a 10 mm union nut wrench, connect the front No. 1 brake tube to the brake booster pump with bracket 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)

6. INSTALL NO. 6 BRAKE TUBE CLAMP

   
   

   1. Install the No. 6 brake tube clamp with the bolt.

      Torque:

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

7. CONNECT BRAKE ACTUATOR HOSE

   
   
   1. 

      *a	135°
      *b	145°
      	Front of the Vehicle

      Connect the brake actuator hose to the brake booster pump with bracket assembly , and slide the clip to secure it

      Note

      
      

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

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

8. INSTALL WIRING HARNESS CLAMP BRACKET

   
   

   1. Install the wire harness clamp bracket to the brake booster pump with bracket assembly with the bolt and nut.

      Torque:

      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

9. CONNECT BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET

   Click here

10. BLEED NO. 1 BRAKE ACTUATOR TUBE

    Click here

11. INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET

    Click here

12. FILL RESERVOIR WITH BRAKE FLUID

13. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

14. INSTALL LUGGAGE TRIM SERVICE HOLE COVER

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15. BLEED BRAKE SYSTEM

    Click here

16. INSPECT BRAKE FLUID LEAK

17. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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18. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

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

    Click here

20. INSTALL WATER GUARD PLATE RH

    Click here

21. INSTALL WINDSHIELD WIPER MOTOR AND LINK

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22. CLEAR DTC

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