BRAKE BOOSTER(for RHD) INSTALLATION

PROCEDURE

1. INSTALL VACUUM SENSOR GROMMET (w/ Stop And Start System)

   1. Install a new vacuum sensor grommet to the brake booster assembly.

2. INSTALL VACUUM SENSOR ASSEMBLY (w/ Stop And Start System)

   1. Install the vacuum sensor assembly to the vacuum sensor grommet.

3. INSTALL CHECK VALVE GROMMET

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

4. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY

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

5. INSTALL BRAKE BOOSTER GASKET

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

6. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS

   1. Install the brake master cylinder push rod clevis to the brake booster assembly.

7. INSTALL BRAKE BOOSTER ASSEMBLY

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

      12.7 N*m

      130 kgf*cm

      9 ft.*lbf

      Note:

      Do not damage the brake tubes.

8. INSTALL PUSH ROD PIN

   Click here

9. INSTALL BRAKE PEDAL RETURN SPRING

   Click here

10. CHECK AND ADJUST BRAKE BOOSTER PUSH ROD

    Click here

11. CONNECT NO. 4 BRAKE TUBE CLAMP

    1. 

       Connect a new No. 4 brake tube clamp and the brake tube to the body.

12. CONNECT VACUUM HOSE

    1. Connect the vacuum hose to the brake vacuum check valve assembly, and slide the clip to secure it.

13. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

14. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (w/ Driver Side Knee Airbag)

    Click here

15. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Driver Side Knee Airbag)

    Click here

16. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

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

       50 N*m

       510 kgf*cm

       37 ft.*lbf

17. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY

    1. Install the cowl top panel outer sub-assembly with the 13 bolts.

       5.5 N*m

       56 kgf*cm

       49 in.*lbf

18. INSTALL COWL VENTILATOR HOUSING SUB-ASSEMBLY

    1. Engage the 3 clips to install the cowl ventilator housing sub-assembly.

19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

21. BLEED BRAKE SYSTEM

    Click here

22. BLEED CLUTCH LINE (for Manual Transaxle)

    1. for 2AD-FTV:

       Click here

    2. 2AR-FE:

       Click here

    3. for 3ZR-FE:

       Click here

    4. for 3ZR-FAE:

       Click here

    5. for 2WW:

       Click here

23. INSPECT AND ADJUST BRAKE PEDAL

    Click here