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. TEMPORARILY INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

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

Text in Illustration

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

3. INSTALL PUSH ROD PIN

(a) Apply lithium soap base glycol grease to the push rod pin and installation hole of the brake pedal sub-assembly.

(b) To connect the push rod clevis to the brake pedal sub-assembly, install the push rod pin after pushing the brake booster with master cylinder assembly toward the engine compartment. This will secure enough room to install the push rod pin.

NOTICE:
* Do not kink or damage the brake lines.
* Do not push the brake booster with master cylinder assembly too far toward the engine compartment, or it may fall out of position.

(c) Install a new clip to the push rod pin.

4. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

(a) Tighten the 4 nuts to install the brake booster with master cylinder assembly.

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

(b) 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.

5. INSTALL BRAKE PEDAL RETURN SPRING Installation

6. CONNECT BRAKE LINE

(a) Engage the 2 clamps to install the brake line.

(b) 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

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.

(d) 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.

7. INSTALL HEATER ACCESSORY ASSEMBLY

(a) Install the heater accessory assembly with the 2 nuts.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

NOTICE:
Do not damage the water hoses.

(b) Connect the connector.

8. CONNECT BRAKE ACTUATOR HOSE

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

Text in Illustration

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

9. CONNECT NO. 1 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.

Text in Illustration

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.

10. CONNECT NO. 2 RESERVOIR HOSE

11. 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)

12. INSTALL AIR CLEANER CASE Installation

13. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

14. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation

15. FILL RESERVOIR WITH BRAKE FLUID

16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation

17. INSTALL LUGGAGE COMPARTMENT FLOOR MAT Installation

18. BLEED BRAKE SYSTEM Service and Repair

19. INSPECT AND ADJUST BRAKE PEDAL

HINT
Adjustments

20. 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.

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

22. 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 2 clamps to install the wire harness.

23. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

(a) Install the cowl body mounting reinforcement RH with the 3 bolts.

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

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

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

25. INSTALL WATER GUARD PLATE RH

(a) Engage the 2 claws to install the water guard plate RH.

(b) Engage the clamp.

26. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

HINT
Refer to the procedure from Install Windshield Wiper Motor and Link Assembly Installation.