BRAKE BOOSTER PUMP INSTALLATION


  1. INSTALL BRAKE BOOSTER PUMP ASSEMBLY


    1. A01JA1CE01
      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 Cushion

      Install the brake booster pump assembly, brake booster pump bushings and 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 cushions are on the brake actuator bracket, bushings and collars on the brake booster pump assembly when assembling the brake booster pump assembly.

      • Do not remove the hole plug 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. A01JCV7E01

      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. A01JBC0E01
      Text in Illustration
      *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 booster pump assembly.

      Note

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

    3. Connect the front No. 1 brake tube.


      1. A01J9EUE01
        Text in Illustration
        *1 Brake Actuator Hose
        *2 No. 2 Brake Tube Clamp
        *3 No. 1 Brake Tube Clamp
        *4 Front No. 1 Brake Tube

        Install the No. 2 brake tube clamp to the brake booster pump assembly with the bolt.

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

      2. Install the front No. 1 brake tube to the brake booster pump assembly.

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

        Note


        • This torque value is effective when the union nut wrench is parallel to the torque wrench.

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

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

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

    4. Install the brake actuator hose and clip.

    5. A01JBVF

      Install the wire harness clamp.

    6. Connect the 2 connectors.

  3. INSTALL NO. 5 BRAKE ACTUATOR BRACKET


    1. A01JA6ZE01

      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 CROSS MEMBER SUB-ASSEMBLY

    Tech Tips

    Refer to the procedure from Install Front Cross Member Sub-assembly Click here.

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

    Tech Tips

    Refer to the procedure from Install Brake Booster with Master Cylinder assembly Click here.

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


    1. A01J9NV

      Disengage the clamp.

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

  7. BLEED 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. A01JA2F

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

    5. A01JAQ4

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

      Note

      Do not spill the brake fluid.

    6. A01JATA

      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. A01JCAO

      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. A01J92K

      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. A01JA2F

      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. A01J9NV

      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 BATTERY TERMINAL (for RHD)

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  11. BLEED BRAKE SYSTEM (for RHD)


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

      Tech Tips


    2. Bleed the brake system.


      1. A01JAIJ

        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. A01J8Z1

        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 intelligent tester to the DLC3 and turn the power switch on (IG).

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

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

        Note

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

      7. A01JBGRE01
        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 intelligent tester 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.

      Tech Tips


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


    1. A01J9HT

      Install the outer cowl top panel with the 9 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A01J91Q

      Bend the water guard plate RH and engage the claw.

    3. A01JA93

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

    4. A01JB4QE01

      Engage the clamp*2 of the wire harness.

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

    6. A01JAH2

      Engage the clamp of the wire harness.

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


    1. A01JDA9

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

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

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

    Tech Tips

    Refer to the procedure from Install windshield wiper motor and link assembly Click here.

  15. INSTALL REAR NO. 3 FLOOR BOARD (for RHD)


    1. A01JC33

      Engage the 2 guides to install the rear No. 3 floor board.

  16. INSTALL REAR DECK FLOOR BOX (for RHD)


    1. Install the rear deck floor box.

  17. INSTALL REAR NO. 2 FLOOR BOARD (for RHD)


    1. A01JCWRE01

      Engage the 3 guides <A>.

    2. Engage the 2 guides <B> and install the rear No. 2 floor board as shown in the illustration.

  18. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT


    1. Adjust front wheel alignment Click here.