BRAKE BOOSTER (for LHD) > INSTALLATION

for Preparation Click here



1. INSTALL CHECK VALVE GROMMET
  1. Install the grommet to the booster.



2. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY
  1. Install the check valve to the grommet.



3. INSTALL BRAKE BOOSTER GASKET
  1. Install a new gasket to the booster.



4. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
  1. Install the push rod clevis to the booster.



5. INSTALL BRAKE BOOSTER ASSEMBLY


    C126454
  1. Install the booster with the 4 nuts.

    Torque:
    12.7 N*m{ 130 kgf*cm , 9 ft.*lbf }


6. INSTALL PUSH ROD PIN



C130666E06

  1. Apply lithium soap base glycol grease to the push rod pin.

  1. Install the push rod pin to the push rod clevis.

    NOTICE:
    The push rod pin must be installed as shown in the illustration.
  1. Install the clip to the push rod pin.

    NOTICE:
    The clip must be installed as shown in the illustration.


7. CHECK AND ADJUST BRAKE BOOSTER PUSH ROD

HINT:
Adjust the booster push rod when the master cylinder is replaced with a new one. Adjustment is not necessary when the master cylinder is reinstalled and the booster is replaced with a new one.


    G028332E02
  1. Set SST on the master cylinder and lower the rod of SST until it just touches the piston.

    SST
    09737-00013  

    HINT:
    SST 09737-00012 can also be used.
  1. Apply chalk to the flat tip of the SST rod. Turn SST upside down and measure the clearance between the brake booster push rod and SST.

    Standard clearance:
    -0.21 to 0 mm (-0.0083 to 0 in.)
    If there is clearance between the SST main body and the shell of the brake booster, the push rod is protruding too far. If the chalk does not stick to the tip of the brake booster push rod, the push rod protrusion is insufficient.


    C128539E01
  1. If the clearance is not within the standard, adjust the length by holding the rod using SST and turning the tip of the rod using a 7 mm socket driver.

    SST
    09737-00020  

    NOTICE:
    Check the push rod clearance again after adjusting.


8. CONNECT VACUUM HOSE
  1. Connect the vacuum hose to the check valve.



9. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

NOTICE:
  1. The master cylinder and piston are designed so that the piston can easily fall out. Prevent this by making sure to tip of the master cylinder points downward when handling the master cylinder.
  2. Make sure foreign matter does not attach to the master cylinder's piston. If foreign matter attaches, clean it off with a cloth. Then apply lithium soap base glycol grease to the entire outer circumference contact surface area of the piston.
  1. Install a new O-ring to the master cylinder.



    C127052
  1. Install the master cylinder to the booster with the 2 nuts.

    Torque:
    12.5 N*m{ 127 kgf*cm , 9 ft.*lbf }


    C127051E01
  1. Using a union nut wrench, connect the 2 brake lines labeled C to the master cylinder.

    Torque:
    without union nut wrench:
    15.2 N*m{ 155 kgf*cm , 11 ft.*lbf }
    with union nut wrench:
    14 N*m{ 144 kgf*cm , 10 ft.*lbf }

    HINT:
    1. Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
    2. This torque value is effective when the union nut wrench is parallel to the torque wrench.
  1. Connect the brake fluid level warning switch connector labeled B to the master cylinder.

  1. for Manual Transaxle:
    Connect the clutch reservoir tube labeled A to the master cylinder.



10. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET (w/o VSC)

NOTICE:
Do not remove the hole plug before connecting the brake tube. New actuators are filled with brake fluid.


    C129069E01
  1. Install the actuator with bracket with the 3 nuts.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }

    HINT:
    The nuts should be tightened in order from 1 to 3 as shown in the illustration.

    NOTICE:
    Be careful not to damage the brake tubes.


    C128743
  1. Connect the brake tube clamp to the bracket.

  1. Connect the actuator connector.



11. INSTALL ABS AND TRACTION ACTUATOR ASSEMBLY WITH BRACKET (w/ VSC)

NOTICE:
When installing a new brake actuator, do not remove the hole plug before connecting the brake tube. New actuators are filled with brake fluid.


    C191857E01
  1. Install the actuator with bracket with the 3 nuts.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }

    NOTICE:
    1. Tighten the 3 nuts uniformly in alphabetical order.
    2. Be careful not to damage the brake tubes.
    3. Do not drop the actuator. If dropped, replace it.


    C191856
  1. Connect the brake tube clamp to the bracket.



12. CONNECT BRAKE LINE (w/o VSC)


    C129067E01
  1. Using a union nut wrench, connect the 6 brake lines to the correct locations on the actuator, as shown in the illustration.

    Torque:
    without union nut wrench:
    15 N*m{ 155 kgf*cm , 11 ft.*lbf }
    with union nut wrench:
    14 N*m{ 145 kgf*cm , 10 ft.*lbf }

    HINT:
    1. Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
    2. This torque value is effective when the union nut wrench is parallel to the torque wrench.


13. CONNECT BRAKE LINE (w/ VSC)


    C191854E01
  1. Set each brake line in the correct position on the brake actuator as shown in the illustration.



    C193416E02
  1. Using a union nut wrench, connect the 6 brake lines to the correct locations on the actuator, as shown in the illustration.

    Torque:
    without union nut wrench:
    15 N*m{ 155 kgf*cm , 11 ft.*lbf }
    with union nut wrench:
    14 N*m{ 145 kgf*cm , 10 ft.*lbf }

    HINT:
    1. Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
    2. This torque value is effective when the union nut wrench is parallel to the torque wrench.


14. INSTALL AIR CLEANER BRACKET
  1. for 2AD-FTV:
    Install the air cleaner bracket (Click here).

  1. for 2AD-FHV:
    Install the air cleaner bracket (Click here).



15. INSTALL COWL BODY MOUNTING REINFORCEMENT LH


    C212147
  1. Install the cowl body mounting reinforcement LH with the 2 nuts.

    Torque:
    50 N*m{ 510 kgf*cm , 37 ft.*lbf }


16. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY


    C212146
  1. Install the cowl top panel outer sub-assembly with the 14 bolts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }
  1. Connect the connector.



17. INSTALL COWL VENTILATOR HOUSING SUB-ASSEMBLY


    C212145
  1. Engage the 4 clips to install the cowl ventilator housing sub-assembly.



18. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
  1. Install the windshield wiper motor and link assembly (Click here).



19. FILL RESERVOIR WITH BRAKE FLUID

Fluid:
SAE J1703 or FMVSS No. 116 DOT3

NOTICE:
  1. Make sure there is sufficient brake fluid in the can.
  2. After adding braking fluid, make sure the reservoir is sufficiently full.


20. BLEED AIR FROM BRAKE MASTER CYLINDER


C126433

HINT:
If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.
  1. Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.

  1. Slowly depress and hold the brake pedal.



    C126434
  1. Block the outer holes with your fingers, and release the pedal.

  1. Repeat the 2 previous steps 3 or 4 times.

  1. Using a union nut wrench, connect the 2 brake lines to the master cylinder.

    Torque:
    without union nut wrench:
    15.2 N*m{ 155 kgf*cm , 11 ft.*lbf }
    with union nut wrench:
    14 N*m{ 144 kgf*cm , 10 ft.*lbf }

    HINT:
    1. Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
    2. This torque value is effective when the union nut wrench is parallel to the torque wrench.


21. BLEED AIR FROM BRAKE LINE



C126435E01

  1. Remove the bleeder plug cap.

  1. Connect the vinyl tube to the bleeder plugs.

  1. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.

  1. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

  1. Repeat the 2 previous steps until all the air in the brake fluid is gone.

  1. Tighten the bleeder plug.

    Torque:
    8.3 N*m{ 85 kgf*cm , 73 in.*lbf }
  1. Install the cap.

  1. Bleed air from the brake line for each wheel by repeating the above procedures.



22. BLEED AIR FROM ABS AND TRACTION ACTUATOR ASSEMBLY (w/ VSC)

NOTICE:
After bleeding the air from the brake system, if the height or feel of the brake pedal cannot be obtained, perform air bleeding of the brake actuator with an intelligent tester by following the procedure below.
  1. Depress the brake pedal more than 20 times with the engine off.

  1. Connect the intelligent tester to the DLC3, and turn the ignition switch on (IG).

    NOTICE:
    Do not start the engine.
  1. Select AIR BLEEDING on the intelligent tester.

    HINT:
    Refer to the intelligent tester operator's manual for further details.
  1. Bleed the air out of the suction line.

    NOTICE:
    1. Perform the bleeding at the right front wheel and right rear wheel.
    2. Bleed the air by following the steps displayed on the intelligent tester.

    1. Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel.

    2. Loosen the bleeder plug.

    3. Operate the brake actuator to bleed the air using the intelligent tester.

      NOTICE:
      Release the brake pedal at this time.

      HINT:
      This operation stops automatically after 4 seconds.
    4. Check if the operation has stopped by referring to the intelligent tester display.

    5. Temporarily tighten the bleeder plug.

    6. Repeat the 4 previous steps until all air in the fluid is completely bled out.

    7. Tighten the bleeder plug.

      Torque:
      8.3 N*m{ 85 kgf*cm , 73 in.*lbf }
    8. Repeat all of the above procedures for the right rear wheel to bleed the air out of the suction line.

  1. Bleed the air out of the pressure reduction line.

    NOTICE:
    1. Perform the bleeding at the 4 wheels.
    2. Bleed the air by following the steps displayed on the intelligent tester.

    1. Connect a vinyl tube to either one of the bleeder plugs.

    2. Loosen the bleeder plug.

    3. Using the intelligent tester, operate the brake actuator assembly, completely depress the brake pedal and hold it there.

      NOTICE:
      1. During this procedure, the pedal will feel heavy, but completely depress it so that the brake fluid comes out of the bleeder plug.
      2. Hold the brake pedal depressed. Do not depress and release the pedal repeatedly.

      HINT:
      The operation stops automatically after 4 seconds. When performing this procedure continuously, set an interval of at least 20 seconds.
    4. Tighten the bleeder plug, then release the brake pedal.

    5. Repeat the 3 previous steps until all air in the fluid is completely bled out.

    6. Tighten the bleeder plug.

      Torque:
      8.3 N*m{ 85 kgf*cm , 73 in.*lbf }
    7. Repeat all of the above procedures for the other wheels to bleed the air out of the pressure reduction line.



23. BLEED AIR FROM CLUTCH LINE (for Manual Transaxle)
  1. Fill the brake reservoir with brake fluid and bleed the clutch system (Click here).

    Torque:
    8.3 N*m{ 85 kgf*cm , 73 in.*lbf }


24. CHECK AND ADJUST BRAKE PEDAL HEIGHT


    C200684E02
    C200685E01
  1. Check the pedal height.

    Standard pedal height from dash panel:
    Item
    Specified Condition
    for LHD
    184.2 to 194.2 mm (7.252 to 7.646 in.)
    for RHD
    168.6 to 178.6 mm (6.638 to 7.031 in.)


  1. Adjust the pedal height.

    1. Disconnect the connector from the stop light switch.

    2. Remove the switch.

    3. Loosen the push rod clevis lock nut.

    4. Adjust the pedal height by turning the push rod.

    5. Tighten the lock nut.

      Torque:
      26 N*m{ 265 kgf*cm , 19 ft.*lbf }


    6. C111301E03
    7. Insert the switch into the adjuster until the switch body touches the pedal.

      NOTICE:
      Do not depress the pedal.


    8. C111302E02
    9. Turn the switch a quarter turn clockwise.

      Torque:
      1.5 N*m{ 15 kgf*cm , 13 in.*lbf } or less

      NOTICE:
      Do not depress the pedal.
    10. Connect the connector to the switch.

    11. Check the switch clearance.

      Standard stop light switch clearance:
      0.5 to 2.6 mm (0.020 to 0.102 in.)


25. CHECK BRAKE PEDAL FREE PLAY


C111306E01
  1. Stop the engine. Depress the pedal several times until there is no vacuum in the booster. Then release the pedal.

  1. Depress the pedal until resistance is felt.

  1. Check the pedal free play by measuring the distance between the position in the previous step and the pedal released position.

    Standard pedal free play:
    1.0 to 6.0 mm (0.039 to 0.236 in.)
    If the free play is not as specified, check the switch clearance in the next step.
    If the free play is as specified, proceed to the "CHECK BRAKE PEDAL RESERVE DISTANCE" procedure.
  1. Check the switch clearance.

    Standard stop light switch clearance:
    0.5 to 2.6 mm (0.020 to 0.102 in.)
    If the clearance is not as specified, reinstall the switch and recheck the pedal's free play.
    If the clearance is as specified, troubleshoot the brake system and proceed to the "CHECK BRAKE PEDAL RESERVE DISTANCE" procedure.


26. CHECK BRAKE PEDAL RESERVE DISTANCE
  1. Release the parking brake lever. Start the engine.

  1. Depress the pedal and check the pedal reserve distance.

    1. Depress the pedal with a force of 490 N (50 kgf, 110 lbf).

    2. Measure the distance between the pedal and dash panel.

      Standard pedal reserve distance:
      Item
      Specified Condition
      for 2AD-FTV
      for LHD without VSC
      More than 75 mm (2.95 in.)
      for LHD with VSC
      More than 110 mm (4.33 in.)
      for RHD without VSC
      More than 70 mm (2.75 in.)
      for RHD with VSC
      More than 100 mm (3.93 in.)
      for 2AD-FHV
      for LHD without VSC
      More than 75 mm (2.95 in.)
      for LHD with VSC
      More than 110 mm (4.33 in.)
      for RHD without VSC
      More than 70 mm (2.75 in.)
      for RHD with VSC
      More than 100 mm (3.93 in.)
      If the distance is not as specified, troubleshoot the brake system.


27. CHECK BRAKE FLUID LEVEL IN RESERVOIR


C126431
  1. Check the fluid level and add fluid if necessary.

    Fluid:
    SAE J1703 or FMVSS No. 116 DOT 3

    HINT:
    Add fluid to a level between the reservoir's MIN and MAX lines.


28. CHECK FOR BRAKE FLUID LEAKAGE