BRAKE BOOSTER PUMP INSTALLATION


  1. INSTALL BRAKE BOOSTER PUMP ASSEMBLY


    1. A0041V1E02
      Text in Illustration
      *1 Nut
      *2 Brake Actuator Case Collar
      *3 Brake Booster Pump Bushing
      *4 Brake Actuator Bracket Assembly
      *5 Brake Booster Pump Assembly
      *6 Brake Actuator Bracket Cushion
      *7 Brake Booster Pump Collar

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

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

      Note


      • Do not drop the brake booster pump assembly when carrying it.

      • Do not carry the brake booster pump assembly by the connector.

      • Confirm that the 2 brake actuator bracket cushions are on the brake actuator bracket assembly, and each brake booster pump bushing and brake booster pump collar are on the brake booster pump assembly when installing the brake booster pump assembly to the brake actuator bracket assembly.

      • Do not remove the hole plugs before installing a new brake booster pump assembly because the brake booster pump assembly is filled with brake fluid.

  2. INSTALL BRAKE BOOSTER PUMP ASSEMBLY WITH BRACKET


    1. A004283E01

      Using SST, install the brake booster pump assembly with bracket with the 3 nuts.

      Torque:
      without SST
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
      with SST
      12 N*m  { 121 kgf*cm, 9 ft.*lbf }

      Note


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

      • Tighten the 3 nuts in the order shown in the illustration.

      • Do not damage the fuel line, the brake lines and wire harness.

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

    2. A00414WE03
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Wire Harness Clamp
      *2 Fuel Line
      *3 Front No. 4 Brake Tube

      Install the wire harness clamp, 2 fuel lines and front No. 4 brake tube to the brake actuator bracket assembly.

      Note

      Do not damage the fuel line, brake lines and wire harness.

    3. A0043JCE01
      Text in Illustration
      *1 Brake Actuator Hose
      *2 No. 1 Brake Tube Clamp Bracket
      *3 No. 7 Brake Tube Clamp
      *4 Front No. 1 Brake Tube

      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 }

    4. Using a union nut wrench, connect the front No. 1 brake tube to the brake booster pump assembly.

      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.

    5. Install the No. 7 brake tube clamp to the No. 1 brake tube clamp bracket with the bolt.

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

    6. Connect the brake actuator hose to the brake booster pump assembly with the clip (for RHD).

    7. A0043W1

      Install the wire harness clamp.

    8. Connect the 2 connectors.

  3. INSTALL NO. 5 BRAKE ACTUATOR BRACKET (for RHD)


    1. A0041H6E01

      Install the No. 5 brake actuator bracket with the 2 nuts.

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

      Note

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

    2. Install the wire harness clamp.

  4. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  5. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY (for LHD)

    Click here

  6. SEPARATE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET (for RHD)


    1. A0041QX

      Disengage the clamp.

    2. Remove the 2 nuts and separate the brake master cylinder reservoir with bracket.

  7. BLEED NO. 1 BRAKE ACTUATOR TUBE (for RHD)

    Note

    Make sure to bleed the air from the No. 1 brake actuator tube. If the air remains in the No. 1 brake actuator tube, the air enters into the brake booster pump assembly and it may cause the brake booster pump assembly to be damaged.


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

    2. Add brake fluid into the reservoir between the MAX and MIN level on the brake fluid reservoir.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT3

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

    4. A0043E9

      Remove the nut, disengage the clamp and separate the No. 1 brake actuator tube from the vehicle body.

    5. A0042X2

      Lift up the brake master cylinder reservoir with bracket as far as possible.

      Note

      Do not spill the brake fluid.

    6. A0040P7

      While holding the brake master cylinder reservoir with bracket, twist and hold the No. 1 brake actuator tube 90° toward the vehicle front, and wait at 5 seconds.*1

      Note

      Do not damage the hoses.

      Tech Tips

      Keeping the No. 1 brake actuator tube twisted causes the remaining air inside the No. 1 brake actuator tube to be expelled to the brake master cylinder reservoir assembly.

    7. Return the No. 1 brake actuator tube to its original state.

    8. A004146

      While holding the brake master cylinder reservoir with bracket, twist and hold the No. 1 brake actuator tube 90° toward the vehicle rear, and wait at 5 seconds.

      Note

      Do not damage the hoses.

      Tech Tips

      Keeping the No. 1 brake actuator tube twisted causes the remaining air inside the No. 1 brake actuator tube to be expelled to the brake master cylinder reservoir assembly.

    9. Return the No. 1 brake actuator tube to its original state.*2

    10. Repeat steps *1 to *2, 5 times.

    11. A0041TU

      While holding the brake master cylinder reservoir with bracket, pinch the brake actuator hose 10 times with your fingers.

      Note

      Do not use pliers or similar to pinch the brake actuator hose. Doing so may cause damage to the brake actuator hose. Make sure to use your fingers.

    12. Repeat steps *1 to *2, 5 times again, and check that air is not expelled from the No. 1 brake actuator tube.

    13. A0043E9

      Engage the clamp and install the No. 1 brake actuator tube with the nut.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

  8. INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET (for RHD)


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

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    2. Engage the clamp.

  9. FILL RESERVOIR WITH BRAKE FLUID (for RHD)

  10. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL (for RHD)

    Click here

  11. BLEED BRAKE SYSTEM (for RHD)


    1. Remove the outer cowl top panel sub-assembly.


    2. Bleed the brake system.


      1. A00449B

        Wait at least 2 minutes with the power switch off, and disconnect the reservoir level switch connector.

        Note

        Do not depress the brake pedal or open/close the doors until the reservoir level switch connector is disconnected.

        Tech Tips

        This procedure is not required if the reservoir level switch connector has been disconnected.

      2. A0043HU

        Remove the brake master cylinder reservoir filler cap assembly.

      3. Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.

        Brake fluid
        SAE J1703 or FMVSS No. 116 DOT3

      4. Connect the GTS to the DLC3 and turn the power switch on (IG).

      5. Turn the GTS on and enter the following menus: Chassis / ABS/VSC/TRC / Air Bleeding.

      6. Select "ABS actuator has been replaced" on the GTS display, and bleed air from the brake fluid following the instructions on the GTS.

        Note

        Before following the instructions on the GTS to perform linear valve offset calibration, release the parking brake. When calibration is complete, immediately apply the parking brake.

      7. A0041R2E01
        Text in Illustration
        *1 Stroke Simulator Bleeder Plug

        After air bleeding, tighten each bleeder plug.

        Torque:
        front bleeder plug
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }
        rear bleeder plug
        11 N*m  { 112 kgf*cm, 8 ft.*lbf }
        stroke simulator bleeder plug
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

        Tech Tips

        The stroke simulator bleeder plug is positioned as shown in the illustration.

      8. Clear the DTCs Click here.

      9. Turn the GTS off and turn the power switch off.

    3. Install the brake master cylinder reservoir filler cap.

    4. Inspect for brake fluid leaks.

    5. Install the outer cowl top panel sub-assembly.


  12. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    1. A0041EP

      Install the outer cowl top panel sub-assembly with the 9 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A00423N

      Bend the water guard plate RH and engage the claw.

    3. A0042ZP

      Bend the No. 1 heater air duct splash shield seal and engage the claw.

    4. A00422BE01

      Engage the clamp*2 of the wire harness.

    5. Engage the clamp*1 and connect the connector (w/ Windshield Deicer).

    6. Engage the clamp of the wire harness.

  13. INSTALL COWL BODY MOUNTING REINFORCEMENT RH (for RHD)


    1. A0042J0

      Install the cowl body mounting reinforcement RH with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  14. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for RHD)

    Click here