BRAKE BOOSTER (for RHD) 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. A01JBSZE01
      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. A01JC97

      Engage the grommet of the brake line.

    3. A01JBURE01
      Text in Illustration
      *1 Clamp
      *2 Brake Line

      Set the brake line to the clamp as shown in the illustration.

      Note

      Securely install the brake line so that it contacts the clamp as shown in the illustration.

    4. A01J9ZT

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

      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.

    5. A01JBYNE01
      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
      *6 Clamp
      *7 Brake Line

      Using a union nut wrench, connect each brake line to the brake booster with master cylinder assembly as shown in the illustration.

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

      Note


      • Do not kink or damage the brake lines.

      • Securely install the brake line so that it contacts the clamp as shown in the illustration.

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

    6. A01JBMPE01
      Text in Illustration
      *1 Stopper

      Install the wire harness clamp bracket to the brake booster with master cylinder assembly with the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Note

      Securely install the wire harness clamp bracket so that its stopper contacts the brake booster with master cylinder assembly as shown in the illustration.

    7. A01JC05

      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.

    8. Engage the clamp.

  3. CONNECT NO. 1 RESERVOIR HOSE


    1. A01J8JHE01
      Text in Illustration
      *1 No. 1 Reservoir Hose
      *2 No. 2 Reservoir Hose
      *3 No. 2 Brake Actuator Hose
      *4 Top of Vehicle

      Connect the No. 1 reservoir hose, No. 2 reservoir hose and No. 2 brake actuator hose with the clips.

      Note


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

        Identification Mark Color Connection Color
        No. 1 Reservoir Hose White White (Unpainted)
        No. 2 Reservoir Hose Green Green
        No. 2 Brake Actuator Hose Yellow Yellow

      • 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 as shown in the illustration.

  4. CONNECT NO. 2 RESERVOIR HOSE

  5. CONNECT NO. 2 BRAKE ACTUATOR HOSE

  6. BLEED BRAKE ACTUATOR TUBE

    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 }

  7. INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    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.

  8. INSTALL PUSH ROD PIN


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

    2. A01JBOO

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

  9. INSTALL BRAKE PEDAL RETURN SPRING


    1. A01JD2O

      Install the brake pedal return spring to the brake pedal support 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

    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. 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.

  17. INSTALL COWL BODY MOUNTING REINFORCEMENT LH


    1. A01JDA9

      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

    Click here

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


    1. Connect each connector.

    2. Engage the guide and 2 claws.

    3. Install the No. 1 instrument panel under cover sub-assembly with the screw <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.