BRAKE BOOSTER (w/ VSC) INSTALLATION


  1. INSTALL BRAKE BOOSTER ASSEMBLY


    1. Install a new gasket to the brake booster.

    2. A01DVHU

      Install the booster with the 4 nuts.

      Torque:
      14 N*m  { 145 kgf*cm, 10 ft.*lbf }

    3. Install the push rod clevis.

    4. Apply a light coat of lithium soap base glycol grease to the clevis pin.

    5. A01DXHTE01

      Install the clevis pin and a new clip.

      Note

      The clip must be installed as shown in the illustration.

    6. Install the return spring.

    7. Install the check valve and grommet to the booster.

    8. Connect the vacuum hose with the clip.

    9. Install the vacuum warning switch and grommet to the booster and connect the vacuum warning switch connector.

  2. CHECK AND ADJUST BRAKE BOOSTER PUSH ROD

    Tech Tips

    Adjust the booster push rod when the master cylinder is replaced with a new one. Adjustment is not necessary when the master cylinder is reinstalled and the booster is replaced with a new one.


    1. A01DUXNE05

      Set SST on the master cylinder and lower the rod of SST until it just touches the piston.

      SST
      09737-00013

      Tech Tips

      SST 09797-00012 can also be used.

    2. Apply chalk to the flat tip of the rod of SST. Turn SST upside down and measure the clearance between the brake booster push rod and SST.

      Standard clearance
      0 mm (0 in.)

      If there is clearance between the main body of SST and the shell of the brake booster, the push rod is protruding too far. If the chalk does not stick to the tip of the brake booster push rod, the push rod protrusion is insufficient.

    3. A01DVX6E01

      If the clearance is not as specified, adjust the length by holding the rod using SST and turning the tip of the rod using a 7 mm socket driver.

      SST
      09737-00020

      Note

      Check the push rod clearance again after adjustment.

  3. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. Install the brake master cylinder Click here.

  4. FILL RESERVOIR WITH BRAKE FLUID

    Fluid
    Item Specified Condition
    except TSAM Made SAE J1703 or FMVSS No. 116 DOT 3
    for TSAM Made SAE J1704 or FMVSS No. 116 DOT 4

  5. BLEED AIR FROM BRAKE MASTER CYLINDER

    Tech Tips

    If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.


    1. A01DYWH

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

    2. Slowly depress and hold the brake pedal.

    3. A01DXKZ

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

    4. Remove the 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.

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

      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.

  6. BLEED AIR FROM BRAKE LINE


    1. Remove the bleeder plug cap.

    2. Connect a vinyl tube to the bleeder plugs.

    3. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.

    4. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

    5. Repeat the 2 previous steps until all the air in the brake fluid is gone.

    6. Tighten the bleeder plug.

      Torque:
      for front brake
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }
      for rear brake
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    7. Install the cap.

    8. A01E31B

      Bleed air from the brake line for each wheel by repeating the above procedures.

  7. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)

    A01DZWL

    1. Remove the bleeder plug cap.

    2. Connect the vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

    4. At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled out.

    6. Tighten the bleeder plug.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled out of the clutch line.

  8. CHECK AND ADJUST BRAKE PEDAL HEIGHT

    A01E0GXE01

    1. Check the pedal height.

      Pedal height from dash panel
      Item Specified Condition
      LHD (M/T) 152.9 to 162.9 mm (6.020 to 6.413 in.)
      LHD (A/T) 154.1 to 164.1 mm (6.067 to 6.461 in.)
      RHD (M/T) 156.9 to 166.9 mm (6.177 to 6.571 in.)
      RHD (A/T) 158.1 to 168.1 mm (6.224 to 6.618 in.)

    2. Adjust the pedal height.


      1. Disconnect the connector from the stop light switch.

      2. Remove the switch.

      3. Loosen the push rod clevis lock nut.

      4. Adjust the pedal height by turning the push rod.

      5. Tighten the lock nut.

        Torque:
        26 N*m  { 265 kgf*cm, 19 ft.*lbf }
      6. A01DYMCE04

        Insert the switch into the adjuster until it slightly touches the pedal.

        Note

        Do not depress the pedal.

      7. A01E1P4E03

        Turn the switch a quarter turn clockwise.

        Torque:
        1.5 N*m  { 15 kgf*cm, 13 in.*lbf, or less }

        Note

        Do not depress the pedal.

      8. Connect the connector to the switch.

      9. Check the switch clearance.

        Stop light switch clearance
        1.5 to 2.5 mm (0.0591 to 0.0984 in.)

  9. CHECK BRAKE PEDAL FREE PLAY

    A01E31ZE02

    1. Stop the engine. Depress the pedal several times until there is no vacuum in the booster. Then release the pedal.

    2. Depress the pedal until resistance is felt.

    3. Check the pedal free play by measuring the distance between the position in the previous step and the pedal's released position.

      Pedal free play
      1.0 to 6.0 mm (0.0394 to 0.236 in.)

      If the free play is not as specified, check the switch clearance in the next step.

      If the free play is as specified, proceed to the "check brake pedal reserve distance" procedure.

    4. Check the switch clearance.

      Stop light switch clearance
      1.5 to 2.5 mm (0.0591 to 0.0984 in.)

      If the clearance is not as specified, adjust the clearance and recheck the pedal free play.

      If the clearance is as specified, troubleshoot the brake system and proceed to the "check brake pedal reserve distance" procedure.

  10. CHECK BRAKE PEDAL RESERVE DISTANCE

    A01DVJIE08

    1. Release the parking brake lever. Start the engine.

    2. Depress the pedal and check the pedal reserve distance.


      1. Depress the pedal with a force of 490 N (50 kgf, 110 lbf).

      2. Measure the distance between the pedal and dash panel shown in the illustration.

        Pedal reserve distance
        Model Specified Condition
        for LHD 85.0 mm (3.347 in.)
        for RHD 89.0 mm (3.504 in.)

        If the distance is not as specified, troubleshoot the brake system.

  11. CHECK BRAKE FLUID LEVEL IN RESERVOIR


    1. A01E2XS

      Check the fluid level.

      If the brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Fluid
      Item Specified Condition
      except TSAM Made SAE J1703 or FMVSS No. 116 DOT 3
      for TSAM Made SAE J1704 or FMVSS No. 116 DOT 4

  12. CHECK FOR BRAKE FLUID LEAKAGE

  13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  14. CHECK SRS WARNING LIGHT


    1. w/ Airbag System:

      Check the SRS warning light Click here.