BRAKE BOOSTER(for LHD) INSTALLATION

Info Added 2017-08-02

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. A000473E01
      Text in Illustration
      *a Matchmark
      A0005GR Cut
      A00090E Disposal Portion

      Align the matchmarks on the wire harness and a new wire harness clamp, and install it to the wire harness.

      Note

      Make sure to install the wire harness clamp in the correct direction.

    2. Tighten the bands of the clamp and cut off the excess.

    3. A0005C4E06
      Text in Illustration
      *1 Connector Portion
      *2 Union
      *3 Push Rod Clevis
      *4 Boot
      *5 Front No. 2 Brake Tube

      Install the brake booster with master cylinder assembly with the 4 nuts.

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }

      Note


      • Do not kink or damage the brake lines.

      • Do not carry the brake booster with master cylinder assembly by the parts shown in bold in the illustration.

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

      • 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.

    4. A0008OOE06
      Text in Illustration
      *a to Front Wheel Cylinder LH
      *b to Rear Wheel Cylinder RH
      *c to Brake Booster Pump Assembly
      *d to Rear Wheel Cylinder LH
      *e to Front Wheel Cylinder RH

      Temporarily tighten each brake line to the correct position on the brake booster with master cylinder assembly as shown in the illustration.

    5. Using a union nut wrench, fully tighten each brake line.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note


      • Do not kink or damage the brake lines.

      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench Click here.

    6. A0006MM

      Connect the connector to the brake booster with master cylinder assembly.

      Text in Illustration
      A0005GR Connect the connector
      A0009JS Lock the lock lever

      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.

    7. A0005JT

      Push in the wire harness clamp to install it to the brake booster with master cylinder assembly.

  3. INSTALL RESERVOIR BRACKET


    1. A0003X9E04
      Text in Illustration
      *a Claw

      Engage the claw to set the reservoir bracket to the vehicle body.

    2. Install the 3 bolts to secure the reservoir bracket to the vehicle body.

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

    3. Engage the 2 clamps to install the wire harness to the reservoir bracket.

  4. CONNECT NO. 1 RESERVOIR HOSE


    1. A0005USE03

      Connect the No. 1 reservoir hose to the brake booster with master cylinder assembly with the clip.

      Text in Illustration
      A0009JS Up

      Note


      • When connecting the No. 1 reservoir hose, face the identification mark up.

      • Match the identification mark of the No. 1 reservoir hose and the rib of the brake booster with master cylinder assembly.

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

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

  5. CONNECT NO. 2 RESERVOIR HOSE


    1. A0006UEE03

      Connect the No. 2 reservoir hose to the brake booster with master cylinder assembly with the clip.

      Text in Illustration
      A0009JS Up

      Note


      • When connecting the No. 2 reservoir hose, face the identification mark up.

      • Match the identification mark of the No. 2 reservoir hose and the identification mark of the brake booster with master cylinder assembly.

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

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

  6. BLEED NO. 1 BRAKE ACTUATOR TUBE


    1. Add brake fluid into the brake master cylinder reservoir assembly.

    2. A0006M3E04
      Text in Illustration
      *1 No. 1 Brake Actuator Tube

      Lift up the brake master cylinder reservoir assembly as far as possible and rock it back and forth to bleed air from the No. 1 brake actuator tube.

      Note


      • Do not damage the hoses or tubes.

      • Do not spill the brake fluid.

      • Continue this procedure until only a minor amount of air remains in the No. 1 brake actuator tube.

  7. INSTALL NO. 1 BRAKE ACTUATOR TUBE


    1. Install the No. 1 brake actuator tube to the vehicle body with the nut.

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

    2. Install the nut and engage the clamp.

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

  8. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. Install the brake master cylinder reservoir assembly to the reservoir bracket with the 2 bolts.

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

  9. INSTALL PUSH ROD PIN

    Click here

  10. FILL RESERVOIR WITH BRAKE FLUID

  11. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  12. BLEED BRAKE SYSTEM

    Click here

  13. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  14. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  15. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  16. INSTALL INLET AIR CLEANER ASSEMBLY

    Click here

  17. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

  18. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. Install the front outer cowl top panel sub-assembly with the 10 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.

    3. A0006H6E03

      Connect the connector to install the wire harness to the front outer cowl top panel sub-assembly.

    4. Engage the 2 clamps (B).

    5. w/ Wiper Deicer System:

      Engage the clamp (A).

  19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  20. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  21. 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.