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. A003Y59E01
      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.

    2. Engage the grommet of the brake line.

    3. A003XEME01
      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. 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. A003VQYE02
      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 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. A003VWHE01
      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. 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 RESERVOIR TUBE ASSEMBLY


    1. A003V98E01
      Text in Illustration
      *1 No. 1 Reservoir Hose
      *2 No. 2 Reservoir Hose
      A003YYF Top of Vehicle

      Connect the No. 1 reservoir hose and No. 2 reservoir hose with the clips.

      Note


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

        Identification Mark Color Connection Color
        No. 1 Reservoir Hose White White (Unpainted)
        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 as shown in the illustration.

  4. SEPARATE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. A003XQ0

      Disengage the 2 clamps.

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

  5. BLEED RESERVOIR TUBE ASSEMBLY


    1. Add brake fluid into the reservoir.

    2. A003Y16

      Lift up the brake master cylinder reservoir assembly as far as possible and rock it back and forth to bleed air from the reservoir tube assembly.

      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.

  6. 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.

  7. INSTALL RESERVOIR TUBE ASSEMBLY


    1. Install the reservoir tube assembly with the 2 bolts and nut.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  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. 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. 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 AUXILIARY BATTERY TERMINAL

    Click here

  12. BLEED BRAKE SYSTEM


    1. Remove the outer cowl top panel sub-assembly.


    2. Bleed the brake system.


      1. A003Y01

        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. A003XHU

        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. A003YQWE01
        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.


  13. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  14. 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.

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


    1. Connect each connector.

    2. Engage the clamp.

    3. Engage the 2 clips.

    4. Install the No. 1 instrument panel under cover sub-assembly with the screw <E>.

  16. INSTALL SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper)


    1. A003VPIE02
      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.

  17. 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.

  18. INSTALL COWL BODY MOUNTING REINFORCEMENT RH


    1. Install the cowl body mounting reinforcement RH with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  19. 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.

  20. 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.

  21. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here