BRAKE BOOSTER(for RHD) INSTALLATION

PROCEDURE

1. Click here

   INSTALL BRAKE BOOSTER GASKET

   
   

   1. Install a new brake booster gasket to the brake booster with master cylinder assembly.

2. Click here

   INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

   
   
   1. 

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

      Table 1. Text in Illustration

      *a	Matchmark
      	Cut
      	Excess

      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. 

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

      Table 2. Text in Illustration

      *a	Connector Portion
      *b	Union
      *c	Brake Master Cylinder Push Rod Clevis
      *d	Boot
      *e	Front No. 2 Brake Tube

      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. 

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

      Table 3. Text in Illustration

      *a	to Front Wheel Cylinder LH (Way)
      *b	to Rear Wheel Cylinder RH
      *c	to Brake Booster Pump Assembly
      *d	to Rear Wheel Cylinder LH
      *e	to Front Wheel Cylinder RH

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

      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. 

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

      Table 4. Text in Illustration

      	Connect the connector
      	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. 

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

3. Click here

   INSTALL PUSH ROD PIN

   Click here

4. Click here

   CONNECT NO. 1 RESERVOIR HOSE

   
   
   1. 

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

      Table 5. Text in Illustration

      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. Click here

   CONNECT NO. 2 RESERVOIR HOSE

   
   
   1. 

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

      Table 6. Text in Illustration

      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. Click here

   BLEED RESERVOIR TUBE

   
   

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

   2. 

      Lift up the brake master cylinder reservoir assembly as far as possible and rock it back and forth to bleed air from the reservoir tube.

      Table 7. Text in Illustration

      *1	Reservoir 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 brake actuator tube.

7. Click here

   INSTALL RESERVOIR TUBE

   
   

   1. Install the reservoir tube to the vehicle body with the 2 bolts and nut.

      8.5 N*m

      87 kgf*cm

      75 in.*lbf

8. Click here

   INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

   
   

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

      8.5 N*m

      87 kgf*cm

      75 in.*lbf

9. Click here

   FILL RESERVOIR WITH BRAKE FLUID

10. Click here

    CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    (Click here)

11. Click here

    BLEED BRAKE SYSTEM

    Click here

12. Click here

    INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

13. Click here

    INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

14. Click here

    INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

15. Click here

    INSTALL INLET AIR CLEANER ASSEMBLY

    Click here

16. Click here

    INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

17. Click here

    INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY

    
    

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

       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.

18. Click here

    INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Tip:

    Use the same procedure as for LHD (Click here).

19. Click here

    INSPECT AND ADJUST BRAKE PEDAL

    (Click here)

20. Click here

    OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR

    Tip:

    After the brake booster with master cylinder assembly is replaced, obtain the zero point of the yaw rate and acceleration sensor (Click here).