BRAKE BOOSTER PUMP(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY


    1. Engage the clamp to install the frame wire to the brake actuator bracket assembly.

    2. A004FGJE03

      Install the brake actuator bracket assembly with the 3 bolts in the order shown in the illustration.

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

      Note

      Do not kink or damage the brake lines.

    3. Engage the 2 clamps to install the frame wire to the brake actuator bracket assembly.

  2. INSTALL ENGINE UNDER COVER LH

  3. INSTALL FRONT WHEEL LH

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  4. INSTALL BRAKE BOOSTER PUMP ASSEMBLY


    1. A004F8WE03
      Text in Illustration
      *1 Union
      *2 Connector
      *3 Stud
      *4 Brake Booster Pump Collar
      *5 Brake Booster Pump Bushing
      *6 Brake Actuator Bracket Cushion

      Install the brake booster pump assembly to the brake actuator bracket assembly with the 2 brake booster pump bushings, 2 brake actuator case collars and the 2 nuts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      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. If the brake booster pump assembly has been dropped, replace it with a new one.

      • Do not kink or damage the brake lines. If they are damaged, replace them with new ones.

      • 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 brake booster pump collar*4 and the brake booster pump bushing*5 are installed on the brake booster pump assembly, and the 2 brake actuator bracket cushions*6 are installed on the brake actuator bracket assembly.

      • If installing a new brake booster pump assembly, do not remove the hole plug before connecting the brake lines because the brake booster pump assembly is filled with brake fluid.

    2. Connect the 2 connectors to the brake booster pump assembly.

  5. INSTALL NO. 1 BRAKE TUBE CLAMP BRACKET


    1. Install the No. 1 brake tube clamp bracket to the brake booster pump assembly with the bolt.

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

  6. INSTALL FRONT NO. 1 BRAKE TUBE


    1. Temporarily tighten the union nut of the front No. 1 brake tube to the brake booster pump assembly.

    2. Install the bolt to secure the front No. 1 brake tube to the No. 1 brake tube clamp bracket.

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

    3. Using a union nut wrench 10 mm, fully tighten the front No. 1 brake tube.

      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.

  7. INSTALL BRAKE ACTUATOR HOSE


    1. A004EO8E02
      Text in Illustration
      *a Identification Mark (Red)
      *b Identification Mark (Yellowish Green)
      *c Rib (Unpainted)

      Connect the brake actuator hose to the brake booster pump assembly.

      Note


      • Make sure that the identification mark (yellowish green) on the brake actuator hose is positioned within 30° of the brake booster pump rib.

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

    2. A004GHME01

      Move the clip to secure the brake actuator hose.

      Text in Illustration
      A004F32 Front of Vehicle

      Note

      Install the clip within the range shown in the illustration.

  8. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

    Click here