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BRAKE BOOSTER PUMP > INSTALLATION

for Preparation Click here



1. INSTALL BRAKE BOOSTER PUMP ASSEMBLY


    C208396E01

  1. Install the brake booster pump assembly, brake booster pump bushings and brake actuator case collars to the brake actuator bracket assembly with the 2 nuts.

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

    Text in Illustration 
    *1
    		Nut
    *2
    		Brake Actuator Case Collar
    *3
    		Brake Booster Pump Bushing
    *4
    		Brake Actuator Bracket Assembly
    *5
    		Brake Booster Pump Assembly
    *6
    		Cushion

    NOTICE:
    1. Do not drop the brake booster pump assembly when carrying it.
    2. Do not carry the brake booster pump assembly by the connector.
    3. Confirm that the 2 cushions are on the brake actuator bracket, bushings and collars on the brake booster pump assembly when assembling the brake booster pump assembly.
    4. Do not remove the hole plug before installing a new brake booster pump assembly because the brake booster pump assembly is filled with brake fluid.



2. INSTALL BRAKE BOOSTER PUMP ASSEMBLY WITH BRACKET


    C210144E01

  1. Using SST, install the brake booster pump assembly with bracket with the 3 nuts.

    Torque:
    without SST:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }
    with SST:
    12 N*m{ 121 kgf*cm , 9 ft.*lbf }

    NOTICE:
    1. Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
    2. Tighten the 3 nuts in the order shown in the illustration.
    3. Do not damage the fuel line, the brake lines and wire harness.
    4. Use the formula to calculate special torque values for situations where SST is combined with a torque wrench (Click here).



    C210136E01

  1. Install the wire harness clamp, 2 fuel lines and front No. 4 brake tube to the brake booster pump assembly.

    NOTICE:
    Do not damage the fuel line, brake lines and wire harness.

    Text in Illustration 
    *1
    		Wire Harness Clamp
    *2
    		Fuel Line
    *3
    		Front No. 4 Brake Tube



  1. Connect the front No. 1 brake tube.



      C208389E01

    1. Install the No. 2 brake tube clamp to the brake booster pump assembly with the bolt.
      Text in Illustration 
      *1
      		Brake Actuator Hose
      *2
      		No. 2 Brake Tube Clamp
      *3
      		No. 1 Brake Tube Clamp
      *4
      		Front No. 1 Brake Tube

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

    2. Install the front No. 1 brake tube to the brake booster pump assembly.

      Torque:
      15 N*m{ 155 kgf*cm , 11 ft.*lbf }

      NOTICE:
      1. This torque value is effective when the union nut wrench is parallel to the torque wrench.
      2. Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench (Click here).

    3. Install the No. 1 brake tube clamp to the brake booster pump assembly with the bolt.

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

  1. Install the brake actuator hose and clip.



    C208392

  1. Install the wire harness clamp.

  1. Connect the 2 connectors.



3. INSTALL NO. 5 BRAKE ACTUATOR BRACKET


    C208393E01

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

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

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

  1. Install the wire harness clamp.



4. INSTALL FRONT CROSS MEMBER SUB-ASSEMBLY
(Click here)


5. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY (for LHD)
(Click here)


6. SEPARATE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET (for RHD)


    C205563

  1. Disengage the clamp.

  1. Remove the 2 nuts and separate the brake master cylinder reservoir with bracket.



7. BLEED BRAKE ACTUATOR TUBE (for RHD)

NOTICE:
Make sure to bleed the air from the No. 1 brake actuator tube. If the air remains in the No. 1 brake actuator tube, the air enters into the brake booster pump assembly and it may cause the brake booster pump assembly to be damaged.

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

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

    Brake Fluid:
    SAE J1703 or FMVSS No. 116 DOT3

  1. Install the brake master cylinder reservoir filler cap assembly.



    C295621

  1. Remove the nut, disengage the clamp and separate the No. 1 brake actuator tube from the vehicle body.



    C295618

  1. Lift up the brake master cylinder reservoir with bracket as far as possible.

    NOTICE:
    Do not spill the brake fluid.



    C295619

  1. While holding the brake master cylinder reservoir with bracket, twist and hold the No. 1 brake actuator tube 90° toward the vehicle front, and wait at 5 seconds.*1

    NOTICE:
    Do not damage the hoses.

    HINT:
    Keeping the No. 1 brake actuator tube twisted causes the remaining air inside the No. 1 brake actuator tube to be expelled to the brake master cylinder reservoir assembly.

  1. Return the No. 1 brake actuator tube to its original state.



    C295620

  1. While holding the brake master cylinder reservoir with bracket, twist and hold the No. 1 brake actuator tube 90° toward the vehicle rear, and wait at 5 seconds.

    NOTICE:
    Do not damage the hoses.

    HINT:
    Keeping the No. 1 brake actuator tube twisted causes the remaining air inside the No. 1 brake actuator tube to be expelled to the brake master cylinder reservoir assembly.

  1. Return the No. 1 brake actuator tube to its original state.*2

  1. Repeat steps *1 to *2, 5 times.



    C295617

  1. While holding the brake master cylinder reservoir with bracket, pinch the brake actuator hose 10 times with your fingers.

    NOTICE:
    Do not use pliers or similar to pinch the brake actuator hose. Doing so may cause damage to the brake actuator hose. Make sure to use your fingers.

  1. Repeat steps *1 to *2, 5 times again, and check that air is not expelled from the No. 1 brake actuator tube.



    C295621

  1. Engage the clamp and install the No. 1 brake actuator tube with the nut.

    Torque:
    8.4 N*m{ 85 kgf*cm , 74 in.*lbf }



8. INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET (for RHD)


    C205563

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

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

  1. Engage the clamp.



9. FILL RESERVOIR WITH BRAKE FLUID (for RHD)


10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for RHD)

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



11. BLEED BRAKE SYSTEM (for RHD)

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

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



  1. Bleed the brake system.



      C205666

    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. C205665

    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. C209151E01

    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.

  1. Install the brake master cylinder reservoir filler cap.

  1. Inspect for brake fluid leaks.

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

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



12. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    C205557

  1. Install the outer cowl top panel with the 9 bolts.

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



    C205561

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



    C205559

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



    C205555E01

  1. Engage the clamp*2 of the wire harness.

  1. Engage the clamp*1 and connect the connector (w/ Windshield Deicer).



    C205556

  1. Engage the clamp of the wire harness.



13. INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for RHD)


    C205554

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

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



14. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for RHD)
(Click here)


15. INSTALL REAR NO. 3 FLOOR BOARD (for RHD)


    B227791

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



16. INSTALL REAR DECK FLOOR BOX (for RHD)

  1. Install the rear deck floor box.



17. INSTALL REAR NO. 2 FLOOR BOARD (for RHD)


    B227788E01

  1. Engage the 3 guides <A>.

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



18. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

  1. Adjust front wheel alignment (Click here).