Installation

BRAKE SYSTEM (OTHER): BRAKE BOOSTER: INSTALLATION

1. TEMPORARILY TIGHTEN BRAKE MASTER CYLINDER PUSH ROD CLEVIS

(a) Install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.

HINT
Fully tighten the lock nut after adjusting the brake pedal height.

2. INSTALL BRAKE BOOSTER GASKET

(a) Install a new brake booster gasket to the brake booster assembly.

3. INSTALL BRAKE BOOSTER ASSEMBLY

(a) Install the brake booster assembly to the body with the 4 nuts.





Torque : 13 Nm (132 kgf-cm, 10 ft-lbf)

NOTICE:
Do not damage the brake lines or fuel lines.

(b) Engage the 2 clamps to install the brake lines to the body.





4. INSTALL NO. 5 FRONT BRAKE TUBE

(a) Install the No. 5 front brake tube to the body and engage the grommet.





(b) Using a union nut wrench (10 mm), connect the No. 5 front brake tube to the front brake flexible hose LH.





without a union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

with a union nut wrench - Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
* This torque value is effective when the union nut wrench is parallel to the torque wrench.
5. INSTALL CHECK VALVE GROMMET

(a) Install a new check valve grommet to the brake booster assembly.

6. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY

(a) Install the vacuum check valve assembly to the brake booster assembly.

7. CONNECT VACUUM HOSE

(a) Connect the vacuum hose and slide the clip.





8. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS Installation

9. INSTALL BRAKE PEDAL RETURN SPRING Installation

10. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY Installation

11. CONNECT CLUTCH TUBE (for Manual Transaxle) Installation

12. FILL RESERVOIR WITH BRAKE FLUID Service and Repair

13. BLEED CLUTCH LINE (for C59)

14. BLEED CLUTCH LINE (for E351)

15. BLEED BRAKE MASTER CYLINDER Service and Repair

16. BLEED BRAKE LINE Service and Repair

17. BLEED BRAKE ACTUATOR (w/ VSC) Service and Repair

18. INSPECT FOR BRAKE FLUID LEAK

19. INSPECT FLUID LEVEL Testing and Inspection

20. INSPECT AND ADJUST BRAKE PEDAL HEIGHT Adjustments

21. INSPECT BRAKE PEDAL FREE PLAY Adjustments

22. INSPECT BRAKE PEDAL RESERVE DISTANCE Adjustments

23. INSTALL FRONT WHEEL LH

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

24. INSTALL AIR CLEANER CASE (for 2ZR-FE) Installation

25. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (for 2ZR-FE) Installation

26. INSTALL NO. 2 CYLINDER HEAD COVER (for 2ZR-FE) Installation

27. INSTALL AIR CLEANER CASE (for 2AZ-FE) Installation

28. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (for 2AZ-FE) Installation

29. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for 2AZ-FE) Installation

30. INSTALL SUSPENSION TOWER DAMPER ASSEMBLY (w/ Front Strut Bar) Installation

31. INSTALL OUTER COWL TOP PANEL Installation

32. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

33. INSTALL COWL TOP VENTILATOR LOUVER LH Installation

34. INSTALL COWL TOP VENTILATOR LOUVER RH Installation

35. INSTALL HOOD TO COWL TOP SEAL Installation

36. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

37. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

38. INSTALL FRONT WIPER ARM HEAD CAP Installation