BRAKE BOOSTER PUMP INSTALLATION


  1. INSTALL BRAKE BOOSTER PUMP ASSEMBLY


    1. A003XBTE03
      Text in Illustration
      *1 Nut
      *2 Brake Actuator Case Collar
      *3 Brake Traction Actuator Bracket Bushing
      *4 Brake Actuator Bracket Assembly
      *5 Brake Booster Pump Assembly
      *6 Brake Actuator Bracket Cushion
      *7 Brake Booster Pump Collar
      *8 Brake Booster Pump Bushing

      Install the brake booster pump assembly, 2 brake traction actuator bracket 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 brake actuator bracket 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. A003W9ME01

      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. A003X6FE01
      Text in Illustration
      *A for RHD
      *1 Wire Harness Clamp
      *2 Fuel Line
      *3 Front No. 4 Brake Tube

      Install the wire harness clamp and 2 fuel lines to the brake actuator bracket assembly.

      Note

      Do not kink or damage the fuel lines.

    3. for RHD:

      Engage the clamp to install the front No. 4 brake tube to the brake actuator bracket assembly.

      Note

      Do not kink or damage the brake line.

    4. 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 }

    5. 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.

    6. Install the No. 1 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 }

    7. Install the wire harness clamp.

    8. Connect the 2 connectors.

  3. INSTALL NO. 5 BRAKE ACTUATOR BRACKET (for RHD)


    1. A003YL8E01

      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. Install the wire harness clamp.

  4. CONNECT BRAKE ACTUATOR HOSE (for RHD)


    1. A003XNIE01
      Text in Illustration
      *a Identification Mark
      A003YYF Front of Vehicle

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

      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.

      • Install the clip within the range shown in the illustration.

  5. BLEED RESERVOIR TUBE ASSEMBLY (for RHD)


    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 (for RHD)


    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.

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

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

  7. INSTALL FRONT NO. 4 BRAKE TUBE (for LHD)


    1. Engage the clamp to install the front No. 4 brake tube to the brake actuator bracket assembly.

    2. Install the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    3. Using a union nut wrench, connect the front No. 4 brake tube to the front flexible hose.

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

      Note


      • Do not kink or damage the brake line.

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

  8. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

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

    Click here

  10. FILL RESERVOIR WITH BRAKE FLUID (for RHD)

  11. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL (for RHD)

    Click here

  12. BLEED BRAKE SYSTEM (for RHD)


    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. INSTALL SUSPENSION TOWER DAMPER (for RHD with 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.

  14. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    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.

  15. INSTALL COWL BODY MOUNTING REINFORCEMENT RH (for RHD)


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

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

  16. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. Engage the claw and guide to install the No. 2 heater air duct splash shield seal.

  17. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. Engage the 2 claws to install the No. 1 heater air duct splash shield seal.

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

    Click here