BRAKE BOOSTER(for LHD) INSTALLATION

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. A004FUOE06
      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:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

      Note


      • Do not kink or damage the brake lines.

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

      • Be careful not to allow 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 assembly is filled with brake fluid.

    2. A004EA6E04
      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.

    3. Using a union nut wrench 10 mm, 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.

    4. A004ERR

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

      Text in Illustration
      A004F2L Connect the connector
      A004F32 Lock the lock lever

      Note


      • Make sure that the connector can be connected smoothly. Do not allow foreign matter to enter.

      • Make sure that the connector lock is locked securely.

  3. INSTALL TUBE CLAMP BRACKET


    1. A004FJPE05
      Text in Illustration
      *1 Front No. 1 Brake Tube Clamp
      *a The tube clamp bracket contacts the brake booster with master cylinder assembly.

      Temporarily install the tube clamp bracket to the brake booster with master cylinder assembly and the front No. 1 brake tube clamp with the 2 bolts.

    2. Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      Bolt (1)
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt (2)
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

      Note

      When tightening the bolt (1), be sure that the tube clamp bracket contacts the brake booster with master cylinder assembly.

  4. CONNECT BRAKE ACTUATOR HOSE


    1. A004FNTE04

      Connect the brake actuator hose to the brake master cylinder reservoir assembly with the clip.

      Text in Illustration
      A004F32 Front of Vehicle

      Note


      • Make sure that the identification mark on the brake actuator hose is positioned within 30° of the brake master cylinder reservoir assembly rib.

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

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

  5. INSTALL RESERVOIR BRACKET


    1. Install the reservoir bracket with the 2 bolts.

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

  6. CONNECT NO. 1 RESERVOIR HOSE


    1. A004FQCE01

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

      Text in Illustration
      A004F32 Up

      Note


      • Make sure that the identification mark on the No. 1 reservoir hose is positioned within 30° of the brake booster with master cylinder assembly rib.

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

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

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

  7. CONNECT NO. 2 RESERVOIR HOSE


    1. A004FCDE01

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

      Text in Illustration
      A004F32 Up

      Note


      • Make sure that the identification mark on the No. 2 reservoir hose is positioned within 30° of the brake booster with master cylinder assembly rib.

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

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

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

  8. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. Install the brake master cylinder reservoir assembly and the No. 2 reservoir bracket with the 2 nuts.

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

  9. INSTALL PUSH ROD PIN

    Click here

  10. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  11. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  12. BLEED BRAKE SYSTEM

    Click here

  13. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  14. 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.

  15. DISCONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  16. INSTALL OUTER COWL TOP PANEL


    1. Install the outer cowl top panel with the 8 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Install the No. 2 reservoir bracket to the outer cowl top panel with the nut.

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

    3. Engage the 2 clamps and install the wire harness.

  17. INSTALL INNER COWL TOP TO COWL BRACE


    1. Install the inner cowl top to cowl brace to the outer cowl top panel with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  18. INSTALL FRONT NO. 1 VENTILATOR SEAL


    1. Engage the clamp to install the front No. 1 ventilator seal to the outer cowl top panel.

  19. INSTALL FRONT AIR SHUTTER SEAL RH

    Tech Tips

    Use the same procedure as for the front No. 1 ventilator seal.

  20. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

    Click here

  21. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (w/ Knee Airbag)

    Click here

  22. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Knee Airbag)

    Click here

  23. INSTALL LOWER NO. 2 INSTRUMENT PANEL FINISH PANEL (w/o Knee Airbag)

    Click here

  24. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

    Click here

  25. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here