BRAKE BOOSTER INSTALLATION

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.


  1. INSTALL CHECK VALVE GROMMET


    1. Install a new check valve grommet to the brake booster assembly.

  2. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY


    1. Install the brake vacuum check valve assembly to the brake booster assembly.

  3. INSTALL BRAKE BOOSTER GASKET


    1. Install a new brake booster gasket to the brake booster assembly.

  4. INSTALL BRAKE BOOSTER ASSEMBLY


    1. Install the brake booster assembly with the 4 nuts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

      Note

      Do not damage the brake tubes.

    2. Connect the vacuum hose with the clip.

    3. Install the push rod clevis to the booster.

    4. Partially tighten the push rod clevis lock nut.

      Tech Tips

      The push rod clevis lock nut will be tightened to the specified torque in the Check and Adjust Brake Pedal Height procedures.

  5. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. A01FH7EE01
      Text in Illustration
      *1 Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the push rod pin.

    2. Install the push rod clevis to the brake pedal support assembly with the push rod pin and a new clip.

  6. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  7. INSTALL BRAKE ACTUATOR WITH BRACKET

    Click here

  8. INSTALL BRAKE PEDAL RETURN SPRING


    1. Install the brake pedal return spring to the brake pedal support assembly.

  9. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY

    Click here

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  11. BLEED BRAKE SYSTEM

    CAUTION:

    If air is bled without using the GTS, damage or accidents may result. Therefore, always use the GTS when bleeding air.


    1. Remove the brake master cylinder reservoir filler cap assembly.

    2. Add brake fluid until the fluid level is between the MIN and MAX lines of the reservoir.

    3. A01FI0L

      Using a union nut wrench, disconnect the 2 brake tubes from the master cylinder.

    4. A01FG9C

      Slowly depress and hold the brake pedal.

    5. A01FFTQ

      Block the tube holes with your fingers, and then release the brake pedal.

    6. Remove your fingers, slowly depress and hold the brake pedal, block the tube holes with your fingers again, and then release the brake pedal. Repeat this step 3 or 4 times.

    7. A01FI0L

      Using a union nut wrench, connect the 2 brake tubes to the brake master cylinder assembly.

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

      Note

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

    8. Loosen the bleeder plug of the front brake cylinder RH.

    9. Repeatedly depress the brake pedal and bleed the air from the bleeder plug of the front brake cylinder RH.

      Note

      Add fluid as necessary so that the fluid in the reservoir does not decrease below the MIN level.

    10. After air is completely bled out, tighten the bleeder plug while depressing the brake pedal.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    11. Bleed the air from the bleeder plug of the front disc brake cylinder LH using the same procedure as for the RH side.

    12. Loosen the bleeder plug of the rear brake cylinder RH.

    13. Repeatedly depress the brake pedal and bleed the air from the bleeder plug of the rear brake cylinder RH.

      Note

      Add fluid as necessary so that the fluid in the reservoir does not decrease below the MIN level.

    14. After the air is completely bled out, tighten the bleeder plug while depressing the brake pedal.

      Torque:
      8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

    15. Bleed the air from the bleeder plug of the rear disc brake cylinder LH using the same procedure as for the RH side.

    16. Depress the brake pedal more than 20 times with the engine switch off.

    17. Connect the GTS to the DLC3.

    18. Turn the engine switch on (IG) and turn the tester on.

      Note

      Do not start the engine.

    19. Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Air Bleeding.

    20. Select and run "Inhalation" from the Air Bleeding screen on the GTS.

      Note

      Follow the prompts on the tester screen to bleed the air for both wheels (front and rear) on the right side.

    21. Loosen the bleeder plug of the right front wheel.*1

    22. Using the GTS, operate the actuator.

      Tech Tips


      • To protect the actuator, the operation stops automatically.

      • Make sure the brake pedal is released.

    23. Check the GTS screen to confirm that the operation stopped.

    24. Tighten the bleeder plug.*2

    25. Repeat the procedures above from *1 to *2 until the air is completely bled out.

    26. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    27. Bleed the air for the right rear wheel using the same procedure as for the right front wheel.

    28. Select and run "Decrease" from the Air Bleeding screen on the GTS.

      Note

      Follow the prompts on the tester screen to bleed the air for all 4 wheels.

    29. Loosen the bleeder plug of the right front wheel.*3

    30. Using the GTS, operate the actuator and at the same time fully depress and hold the brake pedal.

      Tech Tips

      To protect the solenoids, the actuator operation stops automatically in 4 seconds. When operating the actuator repeatedly, follow the prompts on the tester screen and wait for 20 seconds or more between each operation.

      Note


      • At this time, the brake pedal becomes difficult to depress. However, be sure to hold the brake pedal in the fully depressed position until brake fluid comes out of the bleeder plug.

      • Do not repeatedly depress the brake pedal; hold the brake pedal in the fully depressed position.

    31. Tighten the bleeder plug and release the brake pedal.*4

    32. Repeat the procedures above from *3 to *4 until the air is completely bled out.

    33. Tighten the bleeder plug.

      Torque:
      for Front Brake
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }
      for Rear Brake
      8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

    34. Bleed the air for the other 3 wheels using the same procedure as for the right front wheel.

    35. Repeat the procedure in which air is bled from the brake line by repeatedly depressing the brake pedal.

      Note

      Repeat this step for each wheel until air is completely bled out.

    36. Check for brake fluid leaks.

    37. Check the fluid level in the reservoir Click here.

  12. CHECK AND ADJUST BRAKE PEDAL

    Click here

  13. INSTALL ENGINE ROOM SIDE COVER LH


    1. Attach the 2 clips to install the engine room side cover LH.