BRAKE BOOSTER PUMP(for RHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE BOOSTER PUMP ASSEMBLY


    1. B006HMYC01
      *1 Brake Booster Pump Collar
      *2 Brake Booster Pump Bushing
      *a Union
      *b Connector
      *c Wire Harness
      *d Stud

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

      Note


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

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

      • When installing the brake booster pump assembly to the brake actuator bracket assembly, confirm that the 2 brake booster pump bushings and 2 brake booster pump collars are on the brake booster pump assembly.

      • 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.

    2. Install the nut.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    3. B006HISN01

      Engage the claw and 4 clamps to install the brake booster pump assembly wire harness to the brake actuator assembly bracket.

      Note

      Engage the clamps and claw in the order shown in the illustration.

  2. 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 }

  3. INSTALL NO. 1 BRAKE ACTUATOR HOSE


    1. B006J3VC01
      *1 Brake Actuator Hose Clamp
      *a Protector
      *b Identification Mark
      *c Contacts

      Install the No. 1 brake actuator hose to the brake actuator hose clamp.

      Note


      • Make sure to install the No. 1 brake actuator hose so that the protector on the brake booster pump assembly side contacts the brake actuator hose clamp.

      • Make sure to install the No. 1 brake actuator hose so that its identification mark can be seen.

    2. B006I3DC02
      *a Identification Mark
      *b Rib of Brake Booster Pump Assembly Port
      B006IKP 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.

  4. INSTALL BRAKE ACTUATOR WITH BRAKE BOOSTER PUMP ASSEMBLY


    1. B006IR9N01

      Install the brake actuator with brake booster pump assembly to the vehicle body with the 2 bolts and 2 nuts.

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

      Note


      • Tighten the bolts and nuts in the order shown in the illustration.

      • Do not apply excessive force to the brake lines.

      • Do not hold the brake booster pump assembly by the connector, union or wire harness.

      • Do not hold the brake actuator assembly by the connector.

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

      Tech Tips

      Install the brake actuator with brake booster pump assembly while avoiding the brake lines.

    2. Engage the clamp to install the brake tube clamp to the brake actuator bracket assembly.

    3. B006IW6C01
      *a From 1st Chamber of Brake Booster with Master Cylinder Assembly
      *b From 2nd Chamber of Brake Booster with Master Cylinder Assembly
      *c To Front Wheel Cylinder Assembly LH
      *d To Rear Wheel Cylinder Assembly RH
      *e To Rear Wheel Cylinder Assembly LH
      *f To Front Wheel Cylinder Assembly RH

      Temporarily tighten the 6 brake lines to the correct positions on the brake actuator assembly as shown in the illustration.

    4. B006J8MC01
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Using a union nut wrench, fully tighten the 6 brake lines.

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

      Note


      • Do not kink or damage the brake lines.

      • Do not allow the brake lines 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 brake lines 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. B006I21C01
      B006IFV Connect the connector
      B006IV0 Lock the lock lever

      Connect the connector to the brake actuator assembly and lock the lock lever as shown in the illustration.

      Note


      • Make sure that the connector is locked securely.

      • Make sure that the connector can be connected smoothly. Do not allow water, oil or dirt to enter.

    6. Engage the clamp to install the wire harness.

    7. B006HF2C01
      B006IFV Connect the connector
      B006IV0 Lock the lock lever

      Connect the connector to the brake booster pump assembly and lock the lock lever as shown in the illustration.

      Note


      • Make sure that the connector is locked securely.

      • Make sure that the connector can be connected smoothly. Do not allow water, oil or dirt to enter.

  5. INSTALL ACCUMULATOR TO BRAKE MASTER CYLINDER TUBE


    1. Temporarily tighten the accumulator to brake master cylinder tube to the brake booster pump assembly.

    2. Install the accumulator to brake master cylinder tube with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    3. B006H7EC01
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

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

      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)

  6. INSTALL NO. 1 BRAKE ACTUATOR HOSE


    1. B006IDMC01
      *a Identification Mark
      B006IKP Front of the vehicle

      Connect the No. 1 brake actuator hose to the No. 1 brake actuator tube to install it, and slide the clip to secure it.

      Note


      • Make sure to connect the No. 1 brake actuator hose with its identification mark facing the front of the vehicle.

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

  7. BLEED NO. 1 BRAKE ACTUATOR TUBE

    Click here

  8. FILL RESERVOIR WITH BRAKE FLUID

  9. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here

  10. BLEED BRAKE SYSTEM

    Click here