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. While pushing the suction pipe sub-assembly toward the bottom of the vehicle, temporarily install the brake booster assembly to the vehicle.

      Note


      • Do not apply excessive force to the suction pipe sub-assembly.

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

    2. Return the front No. 1 brake tube, front No. 2 brake tube and front No. 3 brake tube to their original positions.

      Note

      Do not apply excessive force to the brake tubes.

    3. 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.

    4. A005PSFN01

      Install the 4 nuts to secure the brake booster assembly.

      Torque:
      12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }

      Note

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

    5. Remove the protective tape.

    6. w/ Stop and Start System:

      Connect the vacuum sensor assembly connector to the vacuum sensor assembly.

    7. w/ Vacuum Warning Switch:


      1. Connect the vacuum warning switch connector to the vacuum warning switch assembly.

  3. SEPARATE SUCTION PIPE SUB-ASSEMBLY (for TMMT Made)


    1. Install the suction pipe sub-assembly to the engine mounting sub-assembly and vehicle body with the 2 nuts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  4. INSTALL SUCTION PIPE SUB-ASSEMBLY (for TMC Made)


    1. Engage the 2 clamps to install the suction pipe sub-assembly to the piping clamp.

  5. INSTALL BRAKE TUBE


    1. Engage the 3 clamps to install a new No. 1 brake tube clamp to the front No. 1 brake tube, front No. 2 brake tube and front No. 3 brake tube.

    2. Engage the 2 clamps to install 2 new No. 2 brake tube clamps to the vehicle body.

    3. Engage the 6 clamps to install the 2 No. 2 brake tube clmaps to the front No. 1 brake tube, front No. 2 brake tube and front No. 3 brake tube.

    4. for Manual Transaxle:


      1. Engage the 2 clamps to install the clutch tube to the 2 brake tube clamps.

    5. A005PEPC01
      *a Torque Wrench Fulcrum Length

      Engage the 11 clamps to install the 2 new No. 1 brake tube clmaps to the front No. 1 brake tube, front No. 2 brake tube, front No. 3 brake tube and front No. 5 brake tube.

    6. Temporarily install front No. 1 brake tube, front No. 2 brake tube and front No. 3 brake tube to the correct position on the brake actuator assembly.

    7. Using a 10 mm and 12 mm union nut wrench, tighten the front No. 1 brake tube, front No. 2 brake tube and front No. 3 brake tube.

      Torque:
      Specified tightening torque (A)
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }
      Specified tightening torque (B)
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note


      • Do not kink or damage the brake tubes.

      • Do not allow the brake tubes 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 tubes from the connecting parts.

      Tech Tips


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

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)) (A): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)) (B): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

    8. Temporarily install front No. 3 brake tube to the front flexible hose.

    9. A005Q15C01
      *a Torque Wrench Fulcrum Length

      Using a 10 mm union nut wrench, tighten the front No. 3 brake tube.

      Torque:
      Specified tightening torque
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note


      • Do not kink or damage the brake tubes.

      • Do not allow the brake tubes 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 tubes from the connecting parts.

      Tech Tips


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

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

  6. CONNECT CHECK VALVE TO CONNECTOR TUBE HOSE


    1. Connect the check valve to connector tube hose to the brake booster assembly and slide the clip to secure it.

  7. INSTALL VACUUM HOSE ASSEMBLY


    1. Install the vacuum hose assembly to the vehicle body with the 2 nuts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  8. INSTALL DASH PANEL HEAT INSULATOR


    1. A005OESN01

      Temporarily install dash panel heat insulator to the vehicle body with the 2 nuts (A).

    2. A005PF0N01

      Install the nut (B).

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Tighten the 2 nuts (A).

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  9. INSTALL NO. 1 ENGINE UNDER COVER

    Click here

  10. INSTALL PUSH ROD PIN

    Click here

  11. INSTALL BRAKE PEDAL RETURN SPRING

    Click here

  12. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY (for Manual Transaxle)

    Click here

  13. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  14. INSTALL NO. 2 CYLINDER HEAD COVER

    Click here

  15. INSPECT AND ADJUST BRAKE PEDAL

    Click here