BRAKE BOOSTER(for RHD) INSTALLATION

INSTALL BRAKE BOOSTER GASKET

Install a new brake booster gasket to the brake booster with master cylinder assembly.

INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

*a	Connector Portion
*b	Union
*c	Push Rod Clevis
*d	Boot
*e	Front No. 2 Brake Tube

Install the brake booster with master cylinder assembly with the 4 nuts.

12.7 N*m

130 kgf*cm

9 ft.*lbf

Note:

Do not kink or damage the brake tubes.
Do not carry the brake booster with master cylinder assembly by the portion shown 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.

*a	Torque Wrench Fulcrum Length

Using the union nut wrench, connect each brake tube to the brake booster with master cylinder assembly.

Specified tightening torque

15.2 N*m

155 kgf*cm

11 ft.*lbf

Tip:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here Click here Click here Click here
When using union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm(6.3779 in.)): 13.4 N*m (137 kgf*cm,10 ft.*lbf)

Note:

Do not kink or damage the brake tube.

	Connect the connector
	Lock the lock lever

Connect the connector to the brake booster with master cylinder assembly.

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.

INSTALL PUSH ROD PIN

Click here

INSTALL RESERVOIR BRACKET

Install the reservoir bracket with the 2 bolts.

8.5 N*m

87 kgf*cm

75 in.*lbf

CONNECT NO. 2 BRAKE ACTUATOR HOSE

Connect the No. 2 brake actuator hose to the No. 1 brake actuator tube, and slide the clip to secure it.
Note:
- When connecting the No. 2 brake actuator hose, connect it with the identification paint mark facing the front of the vehicle.
- Make sure to install the hose to the proper location.

CONNECT NO. 1 RESERVOIR HOSE

	Up

Connect the No. 1 reservoir hose to the brake booster with master cylinder assembly, and slide the clip to secure it.

Note:

Connect the No. 1 reservoir hose with the identification paint mark within 30° of the rib of the brake booster with master cylinder assembly.
When connecting the No. 1 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.

CONNECT NO. 2 RESERVOIR HOSE

	Up

Connect the No. 2 reservoir hose to the brake booster with master cylinder assembly, and slide the clip to secure it.

Note:

Connect the No. 2 reservoir hose with the identification paint mark within 30° of the rib of the brake booster with master cylinder assembly.
When connecting the No. 2 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.

BLEED NO. 1 BRAKE ACTUATOR TUBE

Add brake fluid into the brake master cylinder reservoir assembly.

*1	No. 1 Brake Actuator Tube

Lift up the brake master cylinder reservoir assembly as far as possible and rock it back and forth to bleed air from the No. 1 brake actuator tube.

Note:

Do not damage the hoses.
Do not spill brake fluid.
Continue this procedure until only a minor amount of air remains in the brake actuator tube.

CONNECT BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

Connect the brake master cylinder reservoir assembly to the reservoir bracket with the 2 bolts.

8.5 N*m

87 kgf*cm

75 in.*lbf
Connect the reservoir level switch connector to the reservoir bracket.

INSTALL COWL BODY MOUNTING REINFORCEMENT RH