BRAKE BOOSTER PUMP INSTALLATION


  1. INSTALL BRAKE BOOSTER PUMP ASSEMBLY


    1. A003STIE02
      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
      *7 Brake Booster Pump Collar

      Install the brake booster pump assembly, 2 brake booster pump bushings and 2 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 assembly, and each brake booster pump bushing and brake booster pump collar are on the brake booster pump assembly when installing the brake booster pump assembly to the brake actuator bracket assembly.

      • Do not remove the hole plugs 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. A003RK2E01

      Using SST, install the brake booster pump assembly with bracket with the 3 nuts.

      SST
      09961-00950
      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 or wire harness.

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

    2. A003TXXE03
      Text in Illustration
      *A for LHD
      *B for RHD
      *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 actuator bracket assembly.

      Note

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

    3. Connect the front No. 1 brake tube.


      1. A003U1LE01
        Text in Illustration
        *1 Brake Actuator Hose
        *2 No. 1 Brake Tube Clamp Bracket
        *3 No. 13 Brake Tube Clamp
        *4 Front No. 1 Brake Tube

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

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

      2. Using a union nut wrench, connect the front No. 1 brake tube to the brake booster pump assembly.

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

        Note

        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. 13 brake tube clamp to the No. 1 brake tube clamp bracket with the bolt.

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

    4. Connect the brake actuator hose to the brake booster pump assembly with the clip (for RHD).

    5. A003ST3

      Install the wire harness clamp.

    6. Connect the 2 connectors.

  3. INSTALL NO. 7 BRAKE ACTUATOR BRACKET (for RHD)


    1. A003TOCE01

      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. Install the wire harness clamp.

  4. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

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

    Click here

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


    1. A003SP0

      Disengage the clamp.

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

  7. BLEED BRAKE ACTUATOR TUBE (for RHD)


    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.

  8. INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET (for RHD)


    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.

  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. INSTALL BATTERY BOX COVER (for RHD)


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

  12. INSTALL REAR DECK FLOOR BOX (for RHD)


    1. Install the rear deck floor box.

  13. INSTALL REAR FLOOR MAT (for RHD)


    1. Install the rear floor mat.

  14. BLEED BRAKE SYSTEM (for RHD)


    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.


  15. INSTALL OUTER COWL TOP PANEL (for RHD)


    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.

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


    1. A003TW0

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

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

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

    Click here