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.

Text in Illustration

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 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 the 2 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.

Text in Illustration

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

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.

(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)

(b) Engage the clamp.

4. 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.

5. 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.

6. CONNECT NO. 2 RESERVOIR HOSE

7. 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)

8. INSTALL PUSH ROD PIN Installation

9. INSTALL BRAKE PEDAL RETURN SPRING Installation

10. FILL RESERVOIR WITH BRAKE FLUID

11. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

12. BLEED BRAKE SYSTEM Service and Repair

13. INSPECT AND ADJUST BRAKE PEDAL

HINT
Adjustments

14. 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.

15. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY 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) Bend the water guard plate RH and engage the claw.

(d) Engage the 2 clamps and guide to install the wire harness.

Text in Illustration

17. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

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

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

18. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Installation

19. INSTALL REAR NO. 3 FLOOR BOARD Installation

20. INSTALL REAR DECK FLOOR BOX Installation

21. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type) Installation