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. 

      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. 

      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. for 1KR-FE with Stop and Start System, 1PP:

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

5. INSTALL AIR CONDITIONER HOSE AND ACCESSORY (for 1PP with Air Conditioning System)

   1. Install the air conditioner hose and accessory to the vehicle body with the bolt.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

      Note:

      Do not deform the refrigerant lines.

6. INSTALL RADIATOR RESERVE TANK ASSEMBLY (for 1PP with Air Conditioning System)

   1. 

      *a

      Grommet

      Install the radiator reserve tank assembly and engage the guide and grommet as shown in the illustration.

   2. Install the bolt to secure the radiator reserve tank assembly.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

7. 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.

      

      *1

      No. 2 Brake Tube Clamp

      *2

      No. 3 Brake Tube Clamp

   2. 

      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.

      w/o VSC

      15.2 N*m

      155 kgf*cm

      11 ft.*lbf

      w/ VSC

      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.

      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

        Click hereClick here

8. INSTALL CLUTCH RELEASE CABLE CLAMP (for 1PP)

   Click here

9. INSTALL RELAY BLOCK BRACKET

   Click here

10. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    for 1KR-FE:Click hereClick here

    for 1PP:Click here

11. INSTALL BATTERY

    for 1KR-FE:Click hereClick here

    for 1PP:Click here

12. 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.

       

       *A	for 1KR-FE	*B	for 1PP
       *a	Vacuum Hose Assembly Connector	*b	Intake Manifold Pipe
       	Push		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. for 1KR-FE:

       1. Engage the 2 clamps to install the vacuum hose assembly.

    4. for 1PP:

       1. Engage the clamp to install the vacuum hose assembly.

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

13. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

    Click hereClick here

15. INSPECT AND ADJUST BRAKE PEDAL

    Click here