Installation

BRAKE SYSTEM (OTHER): BRAKE BOOSTER: INSTALLATION

1. INSTALL BRAKE BOOSTER GASKET

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

2. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

(a) Install the brake booster with master cylinder assembly with the 4 nuts.





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Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

NOTICE:
* Do not kink or damage the brake lines.
* Do not carry the brake booster with master cylinder assembly by the portion shown in bold 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.

(b) Engage 2 new clamps to install the brake line.

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





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





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Torque : 7.0 Nm (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.

(e) Using a union nut wrench, fully tighten each brake line.

Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

NOTICE:
* Do not kink or damage the brake lines.
* Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench Service Precautions.

(f) Connect the connector.

NOTICE:
* 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.

3. INSTALL NO. 5 BRAKE ACTUATOR BRACKET

(a) Install the No. 5 brake actuator bracket with the 2 nuts.





Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

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

(b) Engage the clamp.

4. CONNECT BRAKE ACTUATOR HOSE

(a) Connect the brake actuator hose to the brake booster pump assembly with the clip.





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NOTICE:
* When connecting the brake actuator hose, face the identification mark (yellowish green) to the inside of the vehicle.
* Make sure to install the hose to the proper location.
* Install the clip within the range shown in the illustration.

5. CONNECT RESERVOIR HOSE

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





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NOTICE:
* Make sure to match the identification marks on the hoses and brake booster with master cylinder assembly.






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

6. INSTALL BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET

(a) Install the brake master cylinder reservoir with bracket with the 2 nuts.

Torque : 50 Nm (510 kgf-cm, 37 ft-lbf)

(b) Engage the 2 clamps.

7. INSTALL PUSH ROD PIN Installation

8. INSTALL BRAKE PEDAL RETURN SPRING Installation

9. FILL RESERVOIR WITH BRAKE FLUID

10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Battery: Installation

11. BLEED BRAKE SYSTEM Service and Repair

12. INSPECT AND ADJUST BRAKE PEDAL

Adjustments

13. OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR

HINT
After the brake booster with master cylinder assembly is replaced, obtain the zero point of the yaw rate and acceleration sensor Calibration.

14. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation

15. INSTALL SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper) Installation

16. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

(a) Install the outer cowl top panel sub-assembly with the 9 bolts.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

(b) Engage the 3 clamps to install the wire harness (w/ Wiper Deicer).

(c) Engage the clamp to install the wire harness.

17. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

(a) Install the cowl body mounting reinforcement LH with the 2 bolts.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

18. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL

(a) Engage the claw and guide to install the No. 2 heater air duct splash shield seal.

19. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

(a) Engage the 2 claws to install the No. 1 heater air duct splash shield seal.

20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Installation