BRAKE BOOSTER PUMP(for LHD)

INSTALL BRAKE BOOSTER PUMP ASSEMBLY

Insert the stud of the brake booster pump assembly to the hole of the brake actuator bracket assembly, and insert the 2 pins of the brake actuator bracket assembly to the 2 brake booster pump bushings (*5).

Text in Illustration
*1	Union
*2	Stud
*3	Connector Box and Wire Harness
*4	Pin
*5	Brake Booster Pump Bushing
*6	Brake Booster Pump Collar
*7	Brake Actuator Case Collar
*8	Brake Booster Pump Bushing

Note

Do not carry the brake booster pump assembly by the parts shown in bold (*1, *2 and *3) in the illustration.
Do not drop the brake booster pump assembly when carrying it.
Be careful not to allow any 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 collars (*6) and 2 brake booster pump bushings (*5) are installed on the brake booster pump assembly.
Do not remove the hole plugs before installing a new brake booster pump assembly because the brake booster pump assembly is filled with brake fluid.

Install the brake actuator case collar (*7), brake booster pump bushing (*8) and brake booster pump assembly to the brake actuator bracket assembly with the nut.

Torque:

5.4 N*m { 55 kgf*cm, 48 in.*lbf }
Engage the wire harness clamp to the brake actuator bracket assembly.

INSTALL NO. 2 BRAKE ACTUATOR HOSE

Install the No. 2 brake actuator hose to the brake booster pump assembly with the clip.

Text in Illustration

Up
Note
- Match the identification mark of the No. 2 brake actuator hose and the rib of the brake booster pump assembly.
- Install the clip within the range shown in the illustration.

Text in Illustration
	Up

INSTALL BRAKE BOOSTER PUMP ASSEMBLY WITH BRACKET

Text in Illustration

*a Claw

Engage the claw to set the brake booster pump assembly with bracket to the vehicle body.

Note

Do not kink or damage the brake line, suction pipe sub-assembly or air conditioning tube and accessory assembly.
Install the 3 bolts to secure the brake booster pump assembly with bracket to the vehicle body.

Torque:

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

Note

Tighten the 3 bolts in the order shown in the illustration.
Text in Illustration

*1 Connector Box

*a Claw

Engage the claw to set the connector box to the brake actuator bracket assembly.
Install the bolt to secure the connector box to the brake actuator bracket assembly.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Connect the 2 connectors to the brake booster pump assembly.

Text in Illustration
*a	Claw

Text in Illustration
*1	Connector Box
*a	Claw

CONNECT FRONT NO. 1 BRAKE TUBE

Using a union nut wrench, connect the front No. 1 brake tube to the brake booster pump assembly.

Torque:

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

Note

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

CONNECT NO. 2 BRAKE ACTUATOR HOSE

Connect the No. 2 brake actuator hose to the No. 1 brake actuator tube with the clip.

Text in Illustration

Up
Note
- Match the identification mark of the No. 2 brake actuator hose and No. 1 brake actuator tube.
- Install the clip within the range shown in the illustration.

Text in Illustration
	Up

BLEED NO. 1 BRAKE ACTUATOR TUBE

Click here

INSTALL NO. 1 BRAKE ACTUATOR TUBE

Click here

INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

Click here

INSTALL SUCTION PIPE SUB-ASSEMBLY

Remove the vinyl tape from the openings of the disconnected parts.
Sufficiently apply compressor oil to a new O-ring, the fitting surface of the suction pipe sub-assembly and air conditioning unit.

Compressor oil

ND-OIL 11 or equivalent

Note

Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.
Install the O-ring to the suction pipe sub-assembly.

Note

Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign matter.
Insert the suction pipe sub-assembly to the air conditioning unit.
Note
- Insert the pipe joint into the fitting hole securely.
- Do not deform the piping.
- Do not damage the plastic clamp.

Compressor oil
ND-OIL 11 or equivalent

INSTALL AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY

Remove the vinyl tape from the openings of the disconnected parts.
Sufficiently apply compressor oil to a new O-ring, the fitting surface of the air conditioning tube and accessory assembly and air conditioning unit.

Compressor oil

ND-OIL 11 or equivalent

Note

Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.
Install the O-ring to the air conditioning tube and accessory assembly.

Note

Keep the O-ring and O-ring fitting surface free from dirt or any foreign matter.
Insert the air conditioning tube and accessory assembly to the air conditioning unit.

Note

Insert the pipe joint into the fitting hole securely.
Turn the hook connector and install the bolt.

Torque:

9.8 N*m { 100 kgf*cm, 87 in.*lbf }