BRAKE BOOSTER PUMP(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE BOOSTER PUMP ASSEMBLY


    1. A005CO7E05
      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. A005AK6E04

      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. A005DDOE04
      Text in Illustration
      *1 Wire Harness Clamp
      *2 Fuel Line
      *3 Front No. 4 Brake Tube

      Install the wire harness clamp, 2 fuel lines and front No. 4 brake tube to the brake actuator bracket assembly.

      Note

      Do not damage the fuel line, the brake lines and wire harness.

    3. A005BM6E06
      Text in Illustration
      *1 No. 1 Brake Tube Clamp Bracket
      *2 No. 7 Brake Tube Clamp
      *3 Front No. 1 Brake Tube

      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 }

    4. 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.

    5. Install the No. 7 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 }

    6. Install the wire harness clamp to the brake actuator bracket assembly.

    7. Connect the 2 connectors to the brake booster pump assembly.

  3. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  4. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

    Click here