BRAKE BOOSTER(for RHD) 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. A01V1AHE02
      Text in Illustration
      *1 Connector Portion
      *2 Union
      *3 Brake Master Cylinder 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. Install the wire harness clamp to the stud bolt of the brake booster with master cylinder assembly.

    3. A01UZOL

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

      Text in Illustration
      A01V0R7 Connect the connector
      A01UY2W 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. CONNECT BRAKE LINE


    1. Engage the brake tube clamp to the clamp bracket of the brake booster with master cylinder assembly.

    2. A01UXYGE02
      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. INSTALL PUSH ROD PIN

    Click here

  5. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  6. INSTALL RESERVOIR BRACKET


    1. Install the reservoir bracket with the bolt and nut.

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

  7. CONNECT NO. 2 BRAKE ACTUATOR HOSE


    1. A01V1C6E01

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

      Text in Illustration
      A01UY2W Front of Vehicle

      Note


      • When connecting the No. 2 brake actuator hose, face the identification mark to the front of the vehicle.

      • Make sure to install the No. 2 brake actuator hose to the proper location.

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

  8. CONNECT NO. 1 RESERVOIR HOSE


    1. A01V1KEE02

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

      Text in Illustration
      A01UY2W 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.

  9. CONNECT NO. 2 RESERVOIR HOSE


    1. A01UYEZE02

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

      Text in Illustration
      A01UY2W 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.

  10. BLEED NO. 1 BRAKE ACTUATOR TUBE


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

    2. A01V1Y8E02
      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 brake actuator tube.

  11. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


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

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

  12. FILL RESERVOIR WITH BRAKE FLUID

  13. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  14. BLEED BRAKE SYSTEM

    Click here

  15. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  16. 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.

  17. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  18. 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 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.

  19. 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 }

  20. INSTALL FRONT NO. 1 VENTILATOR SEAL


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

  21. INSTALL FRONT AIR SHUTTER SEAL RH

    Tech Tips

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

  22. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

    Click here

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

    Click here

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

    Click here

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

    Click here

  26. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here