BRAKE BOOSTER(for LHD) 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. B005ZEZE01
      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 2 clamps to install the brake line.

    3. B005XIKE05
      Text in Illustration
      *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

      Temporarily tighten each brake line to the correct position on the brake booster with master cylinder assembly as shown in the illustration.

    4. B005ZU4E03
      Text in Illustration
      *1 Stopper

      Install the No. 2 brake tube clamp bracket to the brake booster with master cylinder assembly with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

      Note

      Securely install the No. 2 brake tube clamp bracket so that its stopper contacts the brake booster with master cylinder assembly as shown in the illustration.

    5. Using a union nut wrench, fully tighten each brake line.

      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.

    6. B005XGA

      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.

  3. INSTALL NO. 5 BRAKE ACTUATOR BRACKET


    1. B005YX0E04

      Install the No. 5 brake actuator bracket with the 2 nuts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      Note

      Tighten the 2 nuts in the order shown in the illustration.

    2. Engage the clamp.

  4. CONNECT BRAKE ACTUATOR HOSE


    1. B005YOME03

      Connect the brake actuator hose to the brake booster pump assembly with the clip.

      Text in Illustration
      B005Y3Y Front of Vehicle

      Note


      • Make sure to match the identification mark (yellowish green) on the hose with the brake booster pump rib.

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

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

  5. CONNECT NO. 1 RESERVOIR HOSE


    1. B005ZB3E03
      Text in Illustration
      *1 No. 1 Reservoir Hose
      *2 No. 2 Reservoir Hose
      B005Y3Y Up

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

      Note


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

        Hose Identification Mark Color Brake Booster with Master Cylinder Assembly Identification Mark Color
        No. 1 Reservoir Hose White White (Unpainted Color)
        No. 2 Reservoir Hose Green Green

      • 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 shown in the illustration.

  6. CONNECT NO. 2 RESERVOIR HOSE

  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 }

  8. INSTALL PUSH ROD PIN

    Click here

  9. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  10. FILL RESERVOIR WITH BRAKE FLUID

  11. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  12. BLEED BRAKE SYSTEM

    Click here

  13. INSPECT AND ADJUST BRAKE PEDAL

    Click here

  14. 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.

  15. 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. B005Y6O

      Bend the water guard plate RH and engage the claw.

    3. B005YDQ

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

    4. Engage the clamp to install the wire harness.

  16. INSTALL COWL BODY MOUNTING REINFORCEMENT LH


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

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

  17. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

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

    Click here