BRAKE BOOSTER PUMP(for LHD) INSTALLATION

PROCEDURE

1. 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:

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

2. INSTALL NO. 1 BRAKE ACTUATOR HOSE

   
   
   1. 

      *a	Alignment Mark
      *b	Rib of Brake Booster Pump Assembly Port
      	Front of the vehicle

      Install the No. 1 brake actuator hose to the brake booster pump assembly, and slide the clip to secure it.

      Note

      
      

      • When installing the No. 1 brake actuator hose, make sure to align its alignment mark with the rib of the brake booster pump assembly.

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

3. INSTALL BRAKE BOOSTER PUMP ASSEMBLY

   
   

   1. 

      Install the brake actuator case collar and brake booster pump bushing to the brake actuator bracket assembly.

   2. Temporarily install the brake actuator bracket assembly to the vehicle body.

      Note

      Do not apply excessive force to the brake lines.

   3. Temporarily install the brake booster pump assembly as shown in the illustration.

      

      *a	Union	*b	Connector
      *c	Wire Harness	*d	Stud
      	Install in this Direction	-	-

      Note

      
      

      • Do not apply excessive force to the brake lines.

      • Do not drop the brake booster pump assembly when carrying it.

      • Be careful not to allow brake fluid to enter the connector.

      • If installing a new brake booster pump assembly, do not remove the hole plugs before connecting the brake lines because the brake booster pump assembly is filled with brake fluid.

      • Do not carry the brake booster pump assembly by the parts shown in the illustration.

      Tech Tips

      
      

      • Move the brake actuator bracket assembly as necessary to allow the brake booster pump assembly to be temporarily installed.

      • Make sure to only temporarily install the brake booster pump assembly as the brake actuator assembly needs to be installed first.

   4. Install the brake actuator bracket assembly with the bolt.

      Torque:

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

   5. 

      Install the 2 nuts.

      Torque:

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

      Note

      Tighten the nuts in the order shown in the illustration.

   6. Engage the clamp to install the No. 3 front brake tube to the brake actuator bracket assembly.

4. INSTALL ACCUMULATOR TO BRAKE MASTER CYLINDER TUBE

   
   

   1. Engage the 3 clamps to install the accumulator to brake master cylinder tube.

      

      *a

      Clamp Cover

      -

      -

   2. Engage the claw to install the clamp cover.

   3. 

      *a	Torque Wrench Fulcrum Length
      *b	Union Nut Wrench

      Using a union nut wrench, connect the accumulator to brake master cylinder tube 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 accumulator to brake master cylinder tube.

      • Do not allow the accumulator to brake master cylinder tube to twist or interfere with other parts or the vehicle body during tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the accumulator to brake master cylinder tube from the connecting parts.

      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 (6.38 in.)):

        13.38 N*m (136 kgf*cm, 10 ft.*lbf)

5. INSTALL NO. 1 BRAKE ACTUATOR TUBE

   
   

   1. Install the No. 1 brake actuator tube with the 2 nuts.

      Torque:

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

6. INSTALL BRAKE ACTUATOR ASSEMBLY

   Click here