BRAKE BOOSTER INSTALLATION


  1. TEMPORARILY INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. Install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.

      Tech Tips

      Tighten the lock nut after adjusting the brake pedal height.

  2. INSTALL BRAKE BOOSTER GASKET


    1. Install a new brake booster gasket to the brake booster assembly.

  3. INSTALL BRAKE BOOSTER ASSEMBLY


    1. A00OM1ME01

      Install the brake booster assembly to the body with the 4 nuts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

      Note

      Do not damage the brake lines or fuel lines.

  4. INSTALL FRONT BRAKE LINE


    1. for LHD:


      1. A00OIS7

        Install a new clamp and the brake tube to the brake actuator bracket.

      2. A00OLGRE01

        Using a union nut wrench, connect the 2 brake tubes to the 2-way.

        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.

      3. A00OM9J

        Install 2 new clamps and the brake tube to the body.

      4. A00OHQS

        Attach the grommet to install the brake tube to the body.

      5. A00OM9B

        Using a union nut wrench, connect the brake tube to the front brake flexible hose RH.

        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. A00OJ59

        Using a union nut wrench, connect the brake tube to the front brake flexible hose LH.

        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.

      7. Install the clamp with the bolt.

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

    2. for RHD:


      1. A00OIS7

        Attach a new clamp and the brake tube to the brake actuator bracket.

      2. A00OJ4RE01

        Install a new clamp and the brake tube to the body.

      3. A00OM5P

        Using a union nut wrench, connect the 2 brake tubes to the 2-way.

        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.

      4. A00OKEJ

        Install a new clamp and the brake tube to the body.

      5. A00OHQS

        Attach the grommet to install the brake tube to the body.

      6. A00OM9B

        Using a union nut wrench, connect the brake tube to the front flexible hose RH.

        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.

      7. A00OJ59

        Using a union nut wrench, connect the brake tube to the front flexible hose LH.

        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.

      8. Install the clamp with the bolt.

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

  5. INSTALL CHECK VALVE GROMMET


    1. Install a new check valve grommet to the brake booster assembly.

  6. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY


    1. Install the vacuum check valve assembly to the brake booster assembly.

  7. CONNECT VACUUM HOSE


    1. A00OHW0E01

      Connect the vacuum hose with the clip.

  8. CONNECT PUSH ROD PIN


    1. A00ONDRE01
      Text in Illustration
      *1 Lithium soap base glycol grease

      Apply lithium soap base glycol grease to the push rod pin.

    2. Connect the brake master cylinder push rod clevis to the brake pedal with the push rod clevis pin and install a new clip as shown in the illustration.

  9. INSTALL BRAKE PEDAL RETURN SPRING


    1. A00OK1LE01

      Install the brake pedal return spring between the brake pedal support sub-assembly and brake master cylinder push rod clevis.

  10. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. Install the brake master cylinder sub-assembly Click here.

  11. INSTALL BRAKE ACTUATOR ASSEMBLY


    1. Install the brake actuator assembly Click here.

  12. INSTALL ENGINE ASSEMBLY


    1. for 1ZR-FAE:

      Install the engine assembly Click here.

    2. for 2ZR-FAE:

      Install the engine assembly Click here.

    3. for 3ZR-FE:

      Install the engine assembly Click here.

    4. for 3ZR-FAE:

      Install the engine assembly Click here.

  13. FILL RESERVOIR WITH BRAKE FLUID


    1. Fill the reservoir with brake fluid.

      Brake Fluid
      SAE 1704 or FMVSS No. 116 DOT 4

      Note

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

  14. BLEED BRAKE MASTER CYLINDER

    Note


    • If the master cylinder is reinstalled or if the reservoir becomes empty, bleed the master cylinder.

    • To prevent brake fluid from damaging painted surfaces, cover any surrounding parts with a piece of cloth.


    1. A00OIF4E01

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

    2. A00OJ9E

      Slowly depress the brake pedal and hold it.*1

    3. A00ON52

      Cover the 2 outer holes with fingers and release the brake pedal.*2

    4. Repeat *1 and *2 3 or 4 times.

    5. A00OIF4E01

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

      Torque:
      20 N*m  { 199 kgf*cm, 14 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.

  15. BLEED BRAKE LINE

    Note


    • Bleed the brake line of the wheel farthest from the master cylinder first.

    • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


    1. Connect a vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1

    3. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2

    4. Repeat *1 and *2 until all the air in the fluid is completely bled out.

    5. Tighten the bleeder plug completely.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    6. Repeat the above procedure for each wheel to bleed the brake line.

  16. BLEED CLUTCH LINE (for EB60)

    A005SXJE01
    Text in Illustration
    *1 Bleeder Plug Cap
    *2 Bleeder Plug

    1. Remove the bleeder plug cap.

    2. Connect a vinyl tube to the bleeder plug.

    3. Depress the clutch pedal 5 times, and then loosen the bleeder plug while the pedal is depressed.

    4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat both of the previous 2 steps 6 times.

    6. Tighten the bleeder plug.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    7. Depress the clutch pedal 10 times or more and confirm its operation.

      Note

      This must be performed before the engine is started.

    8. Install the bleeder plug cap.

    9. Check that all the air has been bled from the clutch line.

  17. BLEED CLUTCH LINE (for EC60)

    A005RU3E01
    Text in Illustration
    *1 Bleeder Plug Cap
    *2 Bleeder Plug

    1. Remove the bleeder plug cap.

    2. Connect a vinyl tube to the bleeder plug.

    3. Depress the clutch pedal 5 times, and then loosen the bleeder plug while the pedal is depressed.

    4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat both of the previous 2 steps 6 times.

    6. Tighten the bleeder plug.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    7. Depress the clutch pedal 10 times or more and confirm its operation.

      Note

      This must be performed before the engine is started.

    8. Install the bleeder plug cap.

    9. Check that all the air has been bled from the clutch line.

  18. INSPECT FOR BRAKE FLUID LEAK

  19. INSPECT FLUID LEVEL


    1. A010LQYE01

      Check the fluid level.

      If the brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Brake Fluid
      SAE J1704 or FMVSS No. 116 DOT 4

  20. INSTALL FRONT WHEEL

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

  21. INSPECT AND ADJUST BRAKE PEDAL HEIGHT


    1. Check the brake pedal height.


      1. A00OMDEE01
        Text in Illustration
        *1 Stop Light Switch
        *2 Clevis Lock Nut
        *3 Floor Panel

        for LHD:

        Pedal Height from Floor Panel
        Item Specified Condition
        for AT and CVT 144.3 to 154.3 mm (5.68 to 6.07 in.)
        for MT

      2. for RHD:

        Pedal Height from Floor Panel
        Item Specified Condition
        for AT and CVT 131.5 to 141.5 mm (5.18 to 5.57 in.)
        for MT 132.2 to 142.2 mm (5.20 to 5.60 in.)

    2. Adjust the brake pedal height.


      1. Disconnect the stop light switch connector.

      2. Remove the stop light switch assembly.

      3. Loosen the push rod clevis lock nut.

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

      5. Tighten the push rod clevis lock nut.

        Torque:
        22 N*m  { 224 kgf*cm, 16 ft.*lbf }

      6. Insert the stop light switch into the adjuster mounting until the switch body touches the brake pedal.

        Note

        Do not depress the brake pedal.

      7. Turn the switch a quarter turn clockwise.

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

        Note

        Do not depress the pedal.

      8. Connect the connector to the switch.

      9. Check the switch clearance.

        Stop light switch clearance
        1.5 to 2.5 mm (0.0591 to 0.0984 in.)

  22. INSPECT BRAKE PEDAL FREE PLAY


    1. Stop the engine. Depress the brake pedal several times until no vacuum is left in the brake booster. Release the brake pedal.

    2. A00OL5EE01

      Depress the pedal until a slight resistance is felt. Measure the distance as shown in the illustration.

      Pedal free play
      1.0 to 6.0 mm (0.0394 to 0.236 in.)

      If the pedal free play is not as specified, check the stop light switch clearance. If the pedal free play is as specified, proceed to the Inspect Brake Pedal Reserve Distance procedure.

  23. INSPECT BRAKE PEDAL RESERVE DISTANCE

    Tech Tips

    Measure the distance at the same point used for the brake pedal height inspection.


    1. Release the parking brake.

    2. With the engine running, depress the brake pedal and measure the pedal reserve distance.

      Pedal Reserve Distance from the Floor Panel at 294 N (30 kgf, 66 lbf)
      87 mm (3.43 in.)

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