BRAKE BOOSTER (for LHD) INSTALLATION

INSTALL BRAKE BOOSTER GASKET
1. Install a new brake booster gasket to the brake booster with master cylinder assembly.

INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

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 bold 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.

Engage 2 new clamps to install the brake line.

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.

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.
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.
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.

INSTALL NO. 5 BRAKE ACTUATOR BRACKET
1. Install the No. 5 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.
CONNECT BRAKE ACTUATOR HOSE
1. Connect the brake actuator hose to the brake booster pump assembly with the clip.
  
  Text in Illustration
  
  Front of Vehicle
  Note
  
  When connecting the brake actuator hose, face the identification mark to the inside of the vehicle.
  
  Match the identification mark of the brake actuator hose and the rib of the brake booster pump assembly.
  
  Make sure to install the hose to the proper location.
  
  Install the clip within the range shown in the illustration.

Text in Illustration
*1	Stopper

Text in Illustration
	Front of Vehicle

CONNECT RESERVOIR HOSE

Text in Illustration
*1	No. 1 Reservoir Hose
*2	No. 2 Reservoir Hose
	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.

INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET
1. 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 2 clamps.
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. Install the push rod pin and a new clip to connect the push rod clevis to the brake pedal sub-assembly.
INSTALL BRAKE PEDAL RETURN SPRING
1. Install the brake pedal return spring to the brake pedal support assembly and push rod pin.
FILL RESERVOIR WITH BRAKE FLUID
CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

Click here
BLEED BRAKE SYSTEM
1. Remove the outer cowl top panel sub-assembly.
  - for LHD: Click here
  - for RHD: Click here
2. Bleed the brake system.
  1. 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. 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 "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. 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.
  - for LHD: Click here
  - for RHD: Click here
INSPECT AND ADJUST BRAKE PEDAL

Click here
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.
INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
1. Connect each connector.
2. Engage the clamp.
3. Engage the clip.
4. Install the No. 1 instrument panel under cover sub-assembly with the 2 screws <E>.

Brake fluid
SAE J1703 or FMVSS No. 116 DOT3

Text in Illustration
*1	Stroke Simulator Bleeder Plug

INSTALL SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper)

Text in Illustration
*1	Label
*a	LH Side
*b	RH Side

Install the suspension tower damper with the 2 nuts.

Torque:: 35 N*m { 357 kgf*cm, 26 ft.*lbf }

Tech Tips

Make sure to install the suspension tower damper with the label facing upright.

INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY
1. Install the outer cowl top panel sub-assembly with the 9 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
2. w/ Wiper Deicer:
  
  Engage the 3 clamps to install the wire harness.
3. Engage the clamp to install the wire harness.
INSTALL COWL BODY MOUNTING REINFORCEMENT LH
1. Install the cowl body mounting reinforcement LH with the 2 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL
1. Engage the claw and guide to install the No. 2 heater air duct splash shield seal.
INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL
1. Engage the 2 claws to install the No. 1 heater air duct splash shield seal.
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here