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. A003U7CE01
      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. A003U6D

      Engage 2 new clamps to install the brake line.

    3. A003UKRE02
      Text in Illustration
      *a to Front Wheel Cylinder LH
      *b to Rear Wheel Cylinder RH
      *c to Brake Booster Pump Assembly
      *d to Rear Wheel Cylinder LH
      *e 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. A003SJZE01
      Text in Illustration
      *1 Stopper

      Install the No. 3 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. 3 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. A003TQF

      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. 7 BRAKE ACTUATOR BRACKET


    1. A003S0SE01

      Install the No. 7 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. Engage the clamp.

  4. CONNECT BRAKE ACTUATOR HOSE


    1. A003S7JE01

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

      Text in Illustration
      A003U6N Front of Vehicle

      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. A003TM9E01
      Text in Illustration
      *1 No. 1 Reservoir Hose
      *2 No. 2 Reservoir Hose
      A003U6N 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 Color)
        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. A003UZ3

      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 sub-assembly.

    2. A003SBG

      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. A003TQK

      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. INSTALL BATTERY BOX COVER


    1. Engage the 3 guides to install the battery box cover.

  13. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  14. INSTALL REAR FLOOR MAT


    1. Install the rear floor mat.

  15. BLEED BRAKE SYSTEM


    1. Remove the outer cowl top panel.


    2. Bleed the brake system.


      1. A003S3N

        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. A003UQ7

        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
        SAE J1704 or FMVSS No. 116 DOT4

      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 "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. A003S9YE01
        Text in Illustration
        *1 Stroke Simulator Bleeder Plug

        After air bleeding, tighten each bleeder plug.

        Torque:
        front bleeder plug (for 15 inch Front Brake)
        12 N*m  { 122 kgf*cm, 9 ft.*lbf }
        front bleeder plug (for 16 inch Front Brake)
        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.


  16. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  17. 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.

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


    1. A003S74E03

      Engage the guide.

    2. Engage the claw.

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

  19. INSTALL OUTER COWL TOP PANEL


    1. A003SJJ

      Install the outer cowl top panel with the 8 bolts and nut.

      Torque:
      Bolt
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }
      Nut
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Engage the clamp.

    3. A003UBYE01
      Text in Illustration
      *1 No. 1 Heater Air Duct Splash Shield Seal
      *2 Water Guard Plate RH

      Bend the No. 1 heater air duct splash shield seal and water guard plate RH, and engage each claw.

  20. INSTALL COWL BODY MOUNTING REINFORCEMENT LH


    1. A003TIT

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

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  21. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here