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. A003SWGE01
      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. A003SD1

      Engage the grommet of the brake line.

    3. A003UGUE01
      Text in Illustration
      *1 Clamp
      *2 Brake Line

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

      Note

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

    4. A003S90

      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. A003TJNE02
      Text in Illustration
      *1 Clamp
      *2 Brake Line
      *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

      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 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. A003RFBE01
      Text in Illustration
      *1 Stopper

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

      Torque:
      18 N*m  { 184 kgf*cm, 13 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. A003USH

      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. A003SQNE01
      Text in Illustration
      *1 No. 1 Reservoir Hose
      *2 No. 2 Reservoir Hose
      *3 No. 2 Brake Actuator Hose
      A003U6N 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


    1. Add brake fluid into the reservoir.

    2. A003UNRE01
      Text in Illustration
      *1 No. 1 Brake Actuator Hose
      *2 No. 2 Brake Actuator Hose
      *3 Brake Actuator Tube

      Lift up the brake master cylinder reservoir assembly as far as possible and rock it back and forth as well as alternatively pinch the No. 1 brake actuator hose and No. 2 brake actuator hose to bleed air from the brake actuator tube.

      Note


      • Do not damage the hose.

      • Do not spill the brake fluid.

      • Continue this procedure until only a minor amount of air remains in the brake actuator tube.

  7. INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. A003SP0

      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. A003TLD

      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. A003UK4

      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 OUTER COWL TOP PANEL


    1. A003UWL

      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 of the wire harness.

    3. A003SKXE01
      Text in Illustration
      *1 Water Guard Plate RH
      *2 No. 1 Heater Air Duct Splash Shield Seal

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

  19. INSTALL COWL BODY MOUNTING REINFORCEMENT LH


    1. A003TW0

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

      Torque:
      8.8 N*m  { 90 kgf*cm, 73 in.*lbf }

  20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  21. 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>.