Reassembly
BRAKE: HYDRAULIC BRAKE BOOSTER: REASSEMBLY
NOTICE:
As high pressure will be applied to the No. 1 brake actuator tube, make sure that it does not deform.
1. FIX BRAKE BOOSTER PUMP ASSEMBLY
(a) Mount the pump in a vise with a cloth.
2. INSTALL BRAKE BOOSTER ACCUMULATOR ASSEMBLY
(a) Install the accumulator pipe, compression spring and new O-ring.
NOTICE:
Keep the pump free from foreign matter.
(b) Using SST, install the accumulator.
SST : 09318-12010
Torque : 54 Nm (550 kgf-cm, 36 ft-lbf)
3. INSTALL NO. 2 BRAKE BOOSTER PUMP BRACKET
(a) Install the bush.
(b) Using a 5 mm hexagon wrench, install the bracket with the 2 bolts.
Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)
4. INSTALL NO. 1 BRAKE BOOSTER PUMP BRACKET
(a) Install the shaft, 2 collars, 2 bushes and 2 washers.
(b) Install the bracket with the bolt.
Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)
5. INSTALL BRAKE BOOSTER W/ACCUMULATOR PUMP ASSEMBLY
(a) Install the booster.
6. INSTALL BRAKE BOOSTER PUMP BRACKET
(a) Using a 5 mm hexagon wrench, install the bracket with the bolt.
Torque : 12 Nm (122 kgf-cm, 8.9 ft-lbf)
7. INSTALL NO. 3 BRAKE BOOSTER PUMP BRACKET
(a) Using a 5 mm hexagon wrench, install the bracket with the 2 bolts.
Torque : 12 Nm (122 kgf-cm, 8.9 ft-lbf)
8. INSPECT BRAKE BOOSTER PUMP BRACKET CLEARANCE
(a) When installing the brackets, use a feeler gauge to adjust the clearances A, B, D and E under the following conditions:
(1) The clearance "C" is within the C range.
C range:
0.1 to 0.4 mm (0.00394 to 0.0157 in.)
(2) The clearances "A, B, D, E" are within the specified ranges in the graphs below.
9. INSTALL BRAKE CONTROL WIRE
(a) Install a new wire with the 4 screws.
for brake master cylinder side - Torque : 1.7 Nm (17.5 kgf-cm, 15 in-lbf)
for brake booster pump side - Torque : 2.9 Nm (30 kgf-cm, 26 in-lbf)
(b) Connect the wire harness clamp.
10. INSTALL NO. 1 BRAKE MASTER CYLINDER UNION
(a) Install 2 new gaskets and the union with the union bolt.
Torque : 32 Nm (326 kgf-cm, 23 ft-lbf)
11. INSTALL NO. 2 BRAKE MASTER CYLINDER UNION
(a) Install 2 new gaskets and the union with the union bolt.
Torque : 32 Nm (326 kgf-cm, 23 ft-lbf)
12. INSTALL BRAKE ACTUATOR HOSE NO.1
(a) Install the hose with the 2 clips.
13. INSTALL NO. 1 BRAKE ACTUATOR TUBE
NOTICE:
As high pressure will be applied to the No. 1 brake actuator tube, make sure that it does not deform.
(a) Using a union nut wrench (10 mm), install the tube.
without union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
with union nut wrench - Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
NOTICE:
* Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
* This torque value is effective when the union nut wrench is parallel to the torque wrench.
14. INSTALL NO. 1 BRAKE ACTUATOR BRACKET
(a) Using a 5 mm hexagon wrench, install the bracket with the bolt.
Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)
15. INSTALL NO. 3 BRAKE ACTUATOR BRACKET
(a) Using a 5 mm hexagon wrench, install the bracket with the bolt.
Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)
(b) Connect the level warning switch connector to the bracket.
16. INSTALL BRAKE MASTER CYLINDER KIT
(a) Apply lithium soap base glycol grease to a new piston and plug.
(b) Install the piston and plug.
(c) Pressing the plug, install a new snap ring.
17. INSTALL MASTER CYLINDER RESERVOIR GROMMET
(a) Apply lithium soap base glycol grease to 3 new grommets.
(b) Install the 3 grommets to the reservoir.
18. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
(a) Install the reservoir with the 3 screws.
Torque : 1.7 Nm (17.5 kgf-cm, 15 in-lbf)
19. INSTALL BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSEMBLY
20. INSTALL MASTER CYLINDER BOOT
21. INSTALL MASTER CYLINDER PUSH ROD CLEVIS
(a) Install the lock nut and push rod clevis.
22. INSTALL BRAKE BOOSTER GASKET
(a) Install a new gasket to the master cylinder.