BRAKE BOOSTER(for RHD) INSTALLATION

PROCEDURE


  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. A005EXFE01
      Text in Illustration
      *1 Connector Portion
      *2 Union
      *3 Push Rod Clevis
      *4 Boot
      *5 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. A005BFYE01
      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. A005ESPE05
      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. A005A67E02
      Text in Illustration
      *a Stopper

      Install the wire harness clamp bracket to the brake booster with master cylinder assembly with the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 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. A0059OX

      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 NO. 1 RESERVOIR HOSE


    1. A005C85E03
      Text in Illustration
      *1 No. 1 Reservoir Hose
      *2 No. 2 Reservoir Hose
      *3 No. 2 Brake Actuator Hose
      A005CQU Up

      Connect the No. 1 reservoir hose, No. 2 reservoir hose and No. 2 brake actuator hose to the brake booster with master cylinder assembly and No. 1 brake actuator tube with the 3 clips.

      Note


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

        Hose Identification Mark Color Connection Color
        No. 1 Reservoir Hose White White (Unpainted)
        No. 2 Reservoir Hose Green Green
        No. 2 Brake Actuator Hose Yellow Yellow

      • When connecting the reservoir hose, face the identification mark up.

      • Make sure to install the hose to the proper location.

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

  4. CONNECT NO. 2 RESERVOIR HOSE

  5. CONNECT NO. 2 BRAKE ACTUATOR HOSE

  6. BLEED NO. 1 BRAKE ACTUATOR TUBE

    Note

    Make sure to bleed the air from the No. 1 brake actuator tube. If the air remains in the No. 1 brake actuator tube, the air enters into the brake booster pump assembly and it may cause the brake booster pump assembly to be damaged.


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

    2. Add brake fluid into the reservoir between the MAX and MIN level on the brake fluid reservoir.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT3

    3. Install the brake master cylinder reservoir filler cap assembly.

    4. A005E4A

      Remove the nut, disengage the clamp and separate the No. 1 brake actuator tube from the vehicle body.

    5. A005A3E

      Lift up the brake master cylinder reservoir with bracket as far as possible.

      Note

      Do not spill the brake fluid.

    6. A005BKR

      While holding the brake master cylinder reservoir with bracket, twist and hold the No. 1 brake actuator tube 90° toward the vehicle front, and wait at 5 seconds.*1

      Note

      Do not damage the hoses.

      Tech Tips

      Keeping the No. 1 brake actuator tube twisted causes the remaining air inside the No. 1 brake actuator tube to be expelled to the brake master cylinder reservoir assembly.

    7. Return the No. 1 brake actuator tube to its original state.

    8. A0059QN

      While holding the brake master cylinder reservoir with bracket, twist and hold the No. 1 brake actuator tube 90° toward the vehicle rear, and wait at 5 seconds.

      Note

      Do not damage the hoses.

      Tech Tips

      Keeping the No. 1 brake actuator tube twisted causes the remaining air inside the No. 1 brake actuator tube to be expelled to the brake master cylinder reservoir assembly.

    9. Return the No. 1 brake actuator tube to its original state.*2

    10. Repeat steps *1 to *2, 5 times.

    11. A005AWR

      While holding the brake master cylinder reservoir with bracket, pinch the brake actuator hose 10 times with your fingers.

      Note

      Do not use pliers or similar to pinch the brake actuator hose. Doing so may cause damage to the brake actuator hose. Make sure to use your fingers.

    12. Repeat steps *1 to *2, 5 times again, and check that air is not expelled from the No. 1 brake actuator tube.

    13. A005E4A

      Engage the clamp and install the No. 1 brake actuator tube with the nut.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

  7. 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 clamp.

  8. INSTALL PUSH ROD PIN

    Click here

  9. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  10. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  11. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  12. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  13. FILL RESERVOIR WITH BRAKE FLUID

  14. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  15. BLEED BRAKE SYSTEM

    Click here

  16. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  17. 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.

  18. 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. A005C3Q

      Bend the water guard plate RH and engage the claw.

    3. A005CGM

      Bend the No. 1 heater air duct splash shield seal and engage the claw.

    4. Engage the 2 clamps to install the wire harness to the outer cowl top panel sub-assembly.

    5. Engage the clamp to install the wire harness to the outer cowl top panel sub-assembly.

  19. INSTALL COWL BODY MOUNTING REINFORCEMENT RH


    1. Install the cowl body mounting reinforcement RH with the 3 bolts.

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

  20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

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

    Click here