BRAKE BOOSTER INSTALLATION


  1. INSTALL BRAKE BOOSTER GASKET


    1. Install a new brake booster gasket to the brake booster assembly.

  2. INSTALL BRAKE BOOSTER ASSEMBLY (for LHD)


    1. If installing a new brake booster assembly, cover the threads on the push rod of the brake booster assembly with protective tape.

    2. Install the brake booster assembly to the vehicle body.

      Note

      Do not apply excessive force to the brake lines.

    3. A01CB4O

      Install the brake line to the body with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    4. A01CC00

      Engage the 5 clamps.

      Note

      Be careful not to damage the brake lines or clamps. If any parts are damaged, replace them with new ones.

    5. A01CFQ8E01
      Text in Illustration
      *a Fulcrum Length

      Using a union nut wrench (10 mm), connect the 4 brake lines.

      Torque:
      without union nut wrench
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      with union nut wrench
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

    6. A01CFD9E03
      Text in Illustration
      *1 To front wheel cylinder RH
      *2 To front wheel cylinder LH
      *3 To rear wheel cylinder RH
      *4 To rear wheel cylinder LH
      *5 From 2nd brake line of master cylinder
      *6 From 1st brake line of master cylinder

      Temporarily tighten each brake line to the correct positions of the brake actuator assembly with bracket as shown in the illustration.

    7. A01CDBKE01
      Text in Illustration
      *a Fulcrum Length
      A01CFEA Use Union Nut Wrench 10 mm
      A01CCA7 Use Union Nut Wrench 12 mm

      Using a union nut wrench (10 mm) and a union nut wrench (12 mm), connect the 6 brake lines to the brake actuator.

      Torque:
      Flare nut (M10) without a union nut wrench (10 mm)
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      Flare nut (M10) with a union nut wrench (10 mm)
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
      Flare nut (M12) without a union nut wrench (12mm)
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
      Flare nut (M12) with a union nut wrench (12mm)
      18 N*m  { 183 kgf*cm, 13 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

    8. Connect the vacuum hose to the brake booster assembly and move the clamp back into position.

    9. Remove the protective tape from the threads of the brake booster assembly push rod.

  3. INSTALL BRAKE BOOSTER ASSEMBLY (for RHD)


    1. If installing a new brake booster assembly, cover the threads on the push rod of the brake booster assembly with protective tape.

    2. Install the brake booster assembly to the vehicle body.

      Note

      Do not apply excessive force to the brake lines.

    3. A01CDUI

      Engage the 3 clamps and move the brake lines back into position.

      Note

      Be careful not to damage the brake lines or clamps. If any parts are damaged, replace them with new ones.

    4. Connect the vacuum hose to the brake booster assembly and move the clamp back into position.

    5. Remove the protective tape from the threads of the brake booster assembly push rod.

  4. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. Temporarily install the brake master cylinder push rod clevis with the lock nut.

      Tech Tips

      The lock nut will be fully tightened when the Inspect and Adjust Brake Pedal Height procedure is performed Click here.

  5. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY

    Tech Tips

    Refer to the instructions for installation of the brake pedal support assembly Click here.