BRAKE BOOSTER(for RHD) INSTALLATION

PROCEDURE

  1. INSTALL BRAKE BOOSTER GASKET

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

  2. INSTALL BRAKE BOOSTER ASSEMBLY

    1. Temporarily install the brake booster assembly to the vehicle body.

      Note:

      Do not apply excessive force to the brake lines or refrigerant lines.

    2. Temporarily install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.

      Note:

      Fully tighten the lock nut when adjusting the brake pedal height.

    3. C302716N01

      Install the 4 nuts to secure the brake booster assembly.

      16 N*m

      163 kgf*cm

      12 ft.*lbf

      Note:

      Tighten the 4 nuts in the order shown in the illustration.

  3. INSTALL PUSH ROD PIN

    Click here

  4. INSTALL ENGINE ROOM MAIN WIRE

    1. C302795N01

      Engage the 3 clamps to install the engine room main wire to the vehicle body.

    2. Install the 2 ground wires with the 2 bolts.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    3. w/ Stop and Start System:

      1. Connect the connector (A) to the vacuum sensor assembly.

  5. INSTALL BRAKE LINE

    1. Engage the 2 clamps to install the 2 brake lines to the No. 2 brake tube clamp and No. 3 brake tube clamp.

      C302791C01

      *1

      No. 2 Brake Tube Clamp

      *2

      No. 3 Brake Tube Clamp
    2. C398672C01

      *a

      Torque Wrench Fulcrum Length

      *b

      Union Nut Wrench

      Temporarily tighten the 2 brake lines to the correct positions on the brake actuator assembly as shown in the illustration.

    3. Using a union nut wrench, fully tighten 2 brake lines.

      19.5 N*m

      199 kgf*cm

      14 ft.*lbf

      Note:

      • Do not kink or damage the brake lines.

      • Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

      Tip:

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        17.4 N*m (177 kgf*cm, 13 ft.*lbf)

  6. INSTALL RELAY BLOCK BRACKET

    Click here

  7. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    Click here

  8. INSTALL BATTERY

    Click here

  9. INSTALL VACUUM HOSE ASSEMBLY

    1. Align the vacuum hose assembly connector with the intake manifold pipe, and push the vacuum hose assembly connector until it makes a "click" sound.

      C396026C01

      *a

      Vacuum Hose Assembly Connector

      *b

      Intake Manifold Pipe

      *c

      Identification Mark

      *d

      Clamp
      V100136

      Push

      		 V100137

      Pull

    2. After connecting the vacuum hose assembly, check that the intake manifold pipe and vacuum hose assembly connector are securely connected by pulling on them.

    3. Engage the 3 clamps to install the vacuum hose assembly.

      Note:

      Install the vacuum hose assembly so that the identification mark of the vacuum hose assembly is positioned as shown in the illustration.

    4. Connect the vacuum hose assembly to the brake booster assembly.

  10. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

    Click here

  12. INSPECT AND ADJUST BRAKE PEDAL

    Click here