BRAKE BOOSTER (for LHD) INSTALLATION


  1. INSTALL BRAKE BOOSTER GASKET


    1. Install a new brake booster gasket to the brake booster with master cylinder assembly.

  2. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. A01JAFFE01
      Text in Illustration
      *1 Connector Portion
      *2 Union
      *3 Push Rod Clevis and Boot
      *4 Front No. 2 Brake Tube

      Install the brake booster with master cylinder assembly with the 4 nuts.

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

      Note


      • Do not kink or damage the brake lines.

      • Do not carry the brake booster with master cylinder assembly by the portion shown in the illustration.

      • Be careful not to allow brake fluid to enter the connector of ECU.

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

    2. A01J9R4

      Engage the 2 clamps to install the brake line.

    3. A01JA9EE01
      Text in Illustration
      *1 to Front Wheel Cylinder LH
      *2 to Rear Wheel Cylinder RH
      *3 to Brake Booster Pump Assembly
      *4 to Rear Wheel Cylinder LH
      *5 to Front Wheel Cylinder RH

      Temporarily tighten each brake line to the correct position on the brake booster with master cylinder assembly as shown in the illustration.

    4. A01JDC7E01
      Text in Illustration
      *1 Stopper

      Install the No. 2 brake tube clamp bracket to the brake booster with master cylinder assembly with the 2 bolts.

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

      Note

      Securely install the No. 2 brake tube clamp bracket so that its stopper contacts the brake booster with master cylinder assembly as shown in the illustration.

    5. Using a union nut wrench, fully tighten each brake line.

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

      Note


      • Do not kink or damage the brake lines.

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

    6. A01J9X8

      Connect the connector.

      Note


      • Make sure that the connector can be connected smoothly. Do not allow water, oil or dirt to enter.

      • Make sure that the connector lock is locked securely.

  3. INSTALL NO. 5 BRAKE ACTUATOR BRACKET


    1. A01JBXI

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

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

    2. Engage the clamp.

  4. CONNECT BRAKE ACTUATOR HOSE


    1. A01J8GZE01
      Text in Illustration
      *1 Front of Vehicle

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

      Note


      • Make sure to match the identification mark (yellowish green) on the hose with the brake booster pump rib.

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

      • Install the clip within the range shown in the illustration.

  5. CONNECT NO. 1 RESERVOIR HOSE


    1. A01JB66E01
      Text in Illustration
      *1 No. 1 Reservoir Hose
      *2 No. 2 Reservoir Hose
      *3 Top of vehicle

      Connect the No. 1 reservoir hose and No. 2 reservoir hose to the brake booster with master cylinder assembly with the 2 clips.

      Note


      • Make sure to match the identification marks on the hoses and brake booster with master cylinder assembly.

        Hose Identification Mark Color Brake Booster with Master Cylinder Assembly Identification Mark Color
        No. 1 Reservoir Hose White White (Unpainted)
        No. 2 Reservoir Hose Green Green

      • When connecting the reservoir hose, face the identification mark to the top of the vehicle.

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

      • Install the clip within the range shown in the illustration.

  6. CONNECT NO. 2 RESERVOIR HOSE

  7. INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. A01JBYA

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

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

  8. INSTALL PUSH ROD PIN


    1. Apply lithium soap base glycol grease to the push rod pin and installation hole of the brake pedal sub-assembly.

    2. A01J9SJ

      Install the push rod pin and a new clip to connect the push rod clevis to the brake pedal sub-assembly.

  9. INSTALL BRAKE PEDAL RETURN SPRING


    1. A01JCI1

      Install the brake pedal return spring to the brake pedal support sub-assembly and push rod pin.

  10. FILL RESERVOIR WITH BRAKE FLUID

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  12. BLEED BRAKE SYSTEM


    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


  13. INSPECT AND ADJUST BRAKE PEDAL

    Tech Tips

    Click here

  14. PERFORM EMERGENCY BRAKE SIGNAL LEARNING (w/ Emergency Brake Signal)

    Tech Tips

    After the brake booster with master cylinder assembly is replaced, perform emergency brake signal leaning Click here.

  15. OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR

    Tech Tips

    After the brake booster with master cylinder assembly is replaced, obtain the zero point of the yaw rate and acceleration sensor Click here.

  16. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A01J9P5

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

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A01JBKT

      Bend the water guard plate RH and engage the claw.

    3. A01JC2W

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

    4. A01JCF9

      Engage the clamp to install the wire harness.

  17. INSTALL COWL BODY MOUNTING REINFORCEMENT LH


    1. A01JAL3

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

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

  18. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Tech Tips

    Refer to the procedure from Install Windshield Wiper Motor And Link Assembly Click here.

  19. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY


    1. Connect each connector.

    2. A01JB1P

      Engage the guide and claw.

    3. Install the No. 1 instrument panel under cover sub-assembly with the 2 screws <D>.

  20. INSTALL REAR NO. 3 FLOOR BOARD


    1. A01JC33

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

  21. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  22. INSTALL REAR NO. 2 FLOOR BOARD


    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.