BRAKE BOOSTER INSTALLATION


  1. INSTALL BRAKE BOOSTER ASSEMBLY


    1. Install a new gasket to the brake booster.

    2. A01J3D3

      Install the booster with the 4 nuts.

      Torque:
      14 N*m  { 145 kgf*cm, 10 ft.*lbf }

    3. Install the push rod clevis.

    4. Apply a light coat of lithium soap base glycol grease to the clevis pin.

    5. A01J4R0E01

      Install the clevis pin and a new clip.

      Note

      The clip must be installed as shown in the illustration.

    6. Install the return spring.

    7. Install a new grommet and check valve to the booster.

    8. Connect the vacuum hose.

  2. CHECK AND ADJUST BRAKE BOOSTER PUSH ROD

    Note

    The brake booster interior must not be a vacuum when adjusting the booster. Stop the engine and depress the brake pedal several times until there is no vacuum in the booster.

    Tech Tips

    Adjust the booster push rod when the master cylinder is replaced with a new one. Adjustment is not necessary when the master cylinder is reinstalled and the booster is replaced with a new one.


    1. A01J5OEE05

      Set SST on the master cylinder and lower the rod of SST until it just touches the piston.

      SST
      09737-00013

      Tech Tips

      SST 09737-00012 can also be used.

    2. Apply chalk to the flat tip of the rod of SST. Turn SST upside down and measure the clearance between the brake booster push rod and SST.

      Standard clearance
      0 mm (0 in.)

      If there is clearance between the main body of SST and the shell of the brake booster, the push rod is protruding too far. If the chalk does not stick to the tip of the brake booster push rod, the push rod protrusion is insufficient.

    3. A01J690E01

      If the clearance is not as specified, adjust the length by holding the rod using SST and turning the tip of the rod using a 7 mm socket driver.

      SST
      09737-00020

      Note

      Check the push rod clearance again after adjustment.

  3. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. Install the brake master cylinder Click here.

  4. FILL RESERVOIR WITH BRAKE FLUID

    Fluid
    SAE J1703 or FMVSS No. 116 DOT3

  5. BLEED AIR FROM BRAKE MASTER CYLINDER

    Tech Tips

    If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.


    1. Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.

    2. A01J701

      Slowly depress and hold the brake pedal.

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      Cover the outer holes with your fingers, and release the pedal.

    4. Repeat the 2 previous steps 3 or 4 times.

    5. Using a union nut wrench, connect the 2 brake lines to the master cylinder.

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

      Note

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

  6. BLEED AIR FROM BRAKE LINE

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    1. Remove the bleeder plug cap.

    2. Connect the vinyl tube to the bleeder plugs.

    3. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.

    4. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

    5. Repeat the 2 previous steps until all the air in the brake fluid is gone.

    6. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf, for front brake }
      10 N*m  { 102 kgf*cm, 7 ft.*lbf, for rear brake }

    7. Install the cap.

    8. Bleed air from the brake line for each wheel by repeating the above procedures.

  7. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)


    1. Remove the brake master cylinder reservoir filler cap assembly.

    2. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the clutch line.

      Fluid
      SAE J1703 or FMVSS No. 116 DOT3

    3. Remove the bleeder plug cap.

    4. A01J7CPE07

      Connect a vinyl tube to the bleeder plug.

    5. Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

    6. At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

    7. Repeat the previous 2 steps until all the air in the fluid is completely bled out.

    8. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    9. Install the bleeder plug cap.

    10. Check that all the air has been bled out of the clutch line.

    11. Check for brake fluid leaks.

    12. Check the brake fluid level in the reservoir Click here.

    13. Install the brake master cylinder reservoir filler cap assembly.

  8. CHECK AND ADJUST BRAKE PEDAL HEIGHT

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    1. Check the pedal height.

      Standard pedal height from dash panel
      Model Specified Condition
      for Manual Transmission 152.9 to 162.9 mm (6.020 to 6.413 in.)
      for Automatic Transmission 154.1 to 164.1 mm (6.067 to 6.461 in.)

    2. Adjust the pedal height.


      1. Disconnect the connector from the stop light switch.

      2. Remove the switch.

      3. Loosen the push rod clevis lock nut.

      4. Adjust the pedal height by turning the push rod.

      5. Tighten the lock nut.

        Torque:
        26 N*m  { 265 kgf*cm, 19 ft.*lbf }
      6. A01J63IE01

        Insert the switch into the adjuster until it slightly touches the pedal.

        Note

        Do not depress the pedal.

      7. A01J39UE01

        Turn the switch a quarter turn clockwise.

        Torque:
        1.5 N*m  { 15 kgf*cm, 13 in.*lbf }

        Note

        Do not depress the pedal.

      8. Connect the connector to the switch.

      9. Check the switch clearance.

        Standard stop light switch clearance
        1.5 to 2.5 mm (0.059 to 0.098 in.)

  9. CHECK BRAKE PEDAL FREE PLAY

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    1. Stop the engine. Depress the pedal several times until there is no vacuum in the booster. Then release the pedal.

    2. Depress the pedal until resistance is felt.

    3. Check the pedal's free play by measuring the distance between the position in the previous step and the pedal's released position.

      Standard pedal free play
      1.0 to 6.0 mm (0.039 to 0.236 in.)

      If the free play is not as specified, check the switch clearance in the next step.

      If the free play is as specified, proceed to the "CHECK BRAKE PEDAL RESERVE DISTANCE" procedure.

    4. Check the switch clearance.

      Standard stop light switch clearance
      1.5 to 2.5 mm (0.059 to 0.098 in.)

      If the clearance is not as specified, adjust the clearance and recheck the pedal's free play.

      If the clearance is as specified, troubleshoot the brake system and proceed to the "CHECK BRAKE PEDAL RESERVE DISTANCE" procedure.

  10. CHECK BRAKE PEDAL RESERVE DISTANCE

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    1. Release the parking brake lever. Start the engine.

    2. Depress the pedal and check the pedal reserve distance.


      1. Depress the pedal with a force of 490 N (50 kgf, 110 lbf).

      2. Measure the distance between the pedal and dash panel shown in the illustration.

        Standard pedal reserve distance
        85.0 mm (3.347 in.)

        If the distance is not as specified, troubleshoot the brake system.

  11. CHECK BRAKE FLUID LEVEL IN RESERVOIR

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    1. Check the fluid level and add fluid if necessary.

      Fluid
      SAE J1703 or FMVSS No. 116 DOT3

      Tech Tips

      Add fluid to a level between the reservoir's MIN and MAX lines.

  12. CHECK FOR BRAKE FLUID LEAKAGE