BRAKE BOOSTER (for LHD) > INSTALLATION

for Preparation Click here

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

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

   Text in Illustration 

   *1	Connector Portion
   *2	Union
   *3	Push Rod Clevis and Boot
   *4	Front No. 2 Brake Tube

   Torque:

   13 N*m{ 130 kgf*cm , 9 ft.*lbf }

   NOTICE:

   1. Do not kink or damage the brake lines.
      
   2. Do not carry the brake booster with master cylinder assembly by the portion shown in the illustration.
      
   3. Be careful not to allow brake fluid to enter the connector of ECU.
      
   4. 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 the 2 clamps to install the brake line.
   

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

   Text in Illustration 

   *1	to Front Wheel Cylinder LH
   *2	to Rear Wheel Cylinder RH
   *3	to Brake Booster Pump Assembly
   *4	to Rear Wheel Cylinder LH
   *5	to Front Wheel Cylinder RH

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

   Text in Illustration 

   *1

   Stopper

   Torque:

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

   NOTICE:

   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 }

   NOTICE:

   1. Do not kink or damage the brake lines.
      
   2. Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench (Click here).
      

6. Connect the connector.
   

   NOTICE:

   1. Make sure that the connector can be connected smoothly. Do not allow water, oil or dirt to enter.
      
   2. Make sure that the connector lock is locked securely.
      

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

   Torque:

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

2. Engage the clamp.
   

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

   Text in Illustration 

   *1	Front of Vehicle

   NOTICE:

   1. Make sure to match the identification mark (yellowish green) on the hose with the brake booster pump rib.
      
   2. Make sure to install the hose to the proper location.
      
   3. Install the clip within the range shown in the illustration.
      

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

   Text in Illustration 

   *1	No. 1 Reservoir Hose
   *2	No. 2 Reservoir Hose
   *3	Top of vehicle

   NOTICE:

   1. 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)
      No. 2 Reservoir Hose	Green	Green

   2. When connecting the reservoir hose, face the identification mark to the top of the vehicle.
      
   3. Make sure to install the hose to the proper location.
      
   4. Install the clip within the range shown in the illustration.
      

1. Install the brake master cylinder reservoir with bracket with the 2 nuts.
   

   Torque:

   50 N*m{ 510 kgf*cm , 37 ft.*lbf }

1. Apply lithium soap base glycol grease to the push rod pin and installation hole of the brake pedal support assembly.
   

2. Install the push rod pin and a new clip to connect the push rod clevis to the brake pedal support assembly.
   

1. Install the brake pedal return spring to the brake pedal support assembly and push rod pin.
   

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

1. Remove the outer cowl top panel sub-assembly.
   

   HINT:

   1. for LHD: Click here
      
   2. for RHD: Click here
      

2. Bleed the brake system.
   
   

   
   
   

   1. Wait at least 2 minutes with the power switch off, and disconnect the reservoir level switch connector.
      

      NOTICE:

      Do not depress the brake pedal or open/close the doors until the reservoir level switch connector is disconnected.

      HINT:

      This procedure is not required if the reservoir level switch connector has been disconnected.

   
   
   

   2. Remove the brake master cylinder reservoir filler cap assembly.
      

   3. Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.
      

      Brake fluid:

      SAE J1703 or FMVSS No. 116 DOT3
      

   4. Connect the intelligent tester to the DLC3 and turn the power switch on (IG).
      

   5. Turn the intelligent tester on and enter the following menus: Chassis / ABS/VSC/TRC / Air Bleeding.
      

   6. Select the "ABS actuator has been replaced" on the intelligent tester display, and bleed air from the brake fluid following the instructions on the intelligent tester.
      

      NOTICE:

      Before following the instructions on the intelligent tester to perform linear valve offset calibration, release the parking brake. When calibration is complete, immediately apply the parking brake.

   
   
   

   7. After air bleeding, tighten each bleeder plug.
      

      Torque:

      front bleeder plug:

      8.3 N*m{ 85 kgf*cm , 73 in.*lbf }

      rear bleeder plug:

      11 N*m{ 112 kgf*cm , 8 ft.*lbf }

      stroke simulator bleeder plug:

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

      HINT:

      The stroke simulator bleeder plug is positioned as shown in the illustration.

      Text in Illustration 

      *1	Stroke Simulator Bleeder Plug

   8. Clear the DTCs (Click here).
      

   9. Turn the intelligent tester off and turn the power switch off.
      

3. Install the brake master cylinder reservoir filler cap.
   

4. Inspect for brake fluid leaks.
   

5. Install the outer cowl top panel sub-assembly.
   

   HINT:

   1. for LHD: Click here
      
   2. for RHD: Click here
      

HINT:

After the brake booster with master cylinder assembly is replaced, perform emergency brake signal leaning (Click here).

HINT:

After the brake booster with master cylinder assembly is replaced, obtain the zero point of the yaw rate and acceleration sensor (Click here).

1. Install the outer cowl top panel sub-assembly with the 9 bolts.
   

   Torque:

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

2. Bend the water guard plate RH and engage the claw.
   

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

4. Engage the clamp to install the wire harness.
   

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

   Torque:

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

1. Connect each connector.
   

2. Engage the guide and claw.
   

3. Install the No. 1 instrument panel under cover sub-assembly with the 2 screws <D>.
   

1. Engage the 2 guides to install the rear No. 3 floor board.
   

1. Install the rear deck floor box.
   

1. Engage the 3 guides <A>.
   

2. Engage the 2 guides <B> and install the rear No. 2 floor board as shown in the illustration.