BRAKE BOOSTER PUMP > INSTALLATION

for Preparation Click here

1. Install the brake booster pump assembly, 2 brake traction actuator bracket bushings and 2 brake actuator case collars to the brake actuator bracket assembly with the 2 nuts.
   

   Torque:

   5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

   Text in Illustration 

   *1	Nut
   *2	Brake Actuator Case Collar
   *3	Brake Traction Actuator Bracket Bushing
   *4	Brake Actuator Bracket Assembly
   *5	Brake Booster Pump Assembly
   *6	Brake Actuator Bracket Cushion
   *7	Brake Booster Pump Collar
   *8	Brake Booster Pump Bushing

   NOTICE:

   1. Do not drop the brake booster pump assembly when carrying it.
      
   2. Do not carry the brake booster pump assembly by the connector.
      
   3. Confirm that the 2 brake actuator bracket cushions are on the brake actuator bracket assembly, and each brake booster pump bushing and brake booster pump collar are on the brake booster pump assembly when installing the brake booster pump assembly to the brake actuator bracket assembly.
      
   4. Do not remove the hole plugs before installing a new brake booster pump assembly because the brake booster pump assembly is filled with brake fluid.
      

1. Using SST, install the brake booster pump assembly with bracket with the 3 nuts.
   

   SST

   09961-00950  
   

   Torque:

   without SST:

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

   with SST:

   12 N*m{ 121 kgf*cm , 9 ft.*lbf }

   NOTICE:

   1. Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
      
   2. Tighten the 3 nuts in the order shown in the illustration.
      
   3. Do not damage the fuel line, the brake lines or wire harness.
      
   4. Use the formula to calculate special torque values for situations where SST is combined with a torque wrench (Click here).
      

2. Install the wire harness clamp and 2 fuel lines to the brake actuator bracket assembly.
   

   Text in Illustration 

   *A	for RHD
   *1	Wire Harness Clamp
   *2	Fuel Line
   *3	Front No. 4 Brake Tube

   NOTICE:

   Do not kink or damage the fuel lines.

3. for RHD:
   Engage the clamp to install the front No. 4 brake tube to the brake actuator bracket assembly.
   

   NOTICE:

   Do not kink or damage the brake line.

4. Install the No. 1 brake tube clamp bracket to the brake booster pump assembly with the bolt.
   

   Torque:

   7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

5. Using a union nut wrench, connect the front No. 1 brake tube to the brake booster pump assembly.
   

   Torque:

   15 N*m{ 155 kgf*cm , 11 ft.*lbf }

   NOTICE:

   Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench (Click here).

6. Install the No. 1 brake tube clamp to the No. 1 brake tube clamp bracket with the bolt.
   

   Torque:

   7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

7. Install the wire harness clamp.
   

8. Connect the 2 connectors.
   

1. Install the No. 5 brake actuator bracket with the 2 nuts.
   

   Torque:

   8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

   NOTICE:

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

2. Install the wire harness clamp.
   

1. Connect the brake actuator hose to the brake booster pump assembly with the clip.
   

   Text in Illustration 

   Front of Vehicle

   NOTICE:

   1. When connecting the brake actuator hose, face the identification mark to the top of the vehicle.
      
   2. Install the clip within the range shown in the illustration.
      

1. Add brake fluid into the reservoir.
   

2. Lift up the brake master cylinder reservoir assembly as far as possible and rock it back and forth to bleed air from the reservoir tube assembly.
   

   NOTICE:

   1. Do not damage the hose.
      
   2. Do not spill the brake fluid.
      
   3. Continue this procedure until only a minor amount of air remains in the brake actuator tube.
      

1. Install the brake master cylinder reservoir with bracket with the 2 nuts.
   

   Torque:

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

2. Engage the 2 clamps.
   

3. Install the reservoir tube assembly with the 2 bolts and nut.
   

   Torque:

   8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

1. Engage the clamp to install the front No. 4 brake tube to the brake actuator bracket assembly.
   

2. Install the bolt.
   

   Torque:

   8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

3. Using a union nut wrench, connect the front No. 4 brake tube to the front flexible hose.
   

   Torque:

   15 N*m{ 155 kgf*cm , 11 ft.*lbf }

   NOTICE:

   1. Do not kink or damage the brake line.
      
   2. Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench (Click here).
      

1. Remove the outer cowl top panel sub-assembly.
   

   1. for LHD: Click here
      
   2. for RHD: Click here
      

2. Bleed the brake system.
   
   

   
   
   

   1. Wait at least 2 minutes with the power switch off, and disconnect the reservoir level switch connector.
      

      NOTICE:

      Do not depress the brake pedal or open/close the doors until the reservoir level switch connector is disconnected.

      HINT:

      This procedure is not required if the reservoir level switch connector has been disconnected.

   
   
   

   2. Remove the brake master cylinder reservoir filler cap assembly.
      

   3. Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.
      

      Brake fluid:

      SAE J1703 or FMVSS No. 116 DOT3
      

   4. Connect the intelligent tester to the DLC3 and turn the power switch on (IG).
      

   5. Turn the intelligent tester on and enter the following menus: Chassis / ABS/VSC/TRC / Air Bleeding.
      

   6. Select "ABS actuator has been replaced" on the intelligent tester display, and bleed air from the brake fluid following the instructions on the intelligent tester.
      

      NOTICE:

      Before following the instructions on the intelligent tester to perform linear valve offset calibration, release the parking brake. When calibration is complete, immediately apply the parking brake.

   
   
   

   7. After air bleeding, tighten each bleeder plug.
      

      Torque:

      front bleeder plug:

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

      rear bleeder plug:

      11 N*m{ 112 kgf*cm , 8 ft.*lbf }

      stroke simulator bleeder plug:

      8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

      HINT:

      The stroke simulator bleeder plug is positioned as shown in the illustration.

      Text in Illustration 

      *1	Stroke Simulator Bleeder Plug

   8. Clear the DTCs (Click here).
      

   9. Turn the intelligent tester off and turn the power switch off.
      

3. Install the brake master cylinder reservoir filler cap.
   

4. Inspect for brake fluid leaks.
   

5. Install the outer cowl top panel sub-assembly.
   

   1. for LHD: Click here
      
   2. for RHD: Click here
      

1. Install the suspension tower damper with the 2 nuts.
   

   Text in Illustration 

   *1	Label
   *a	LH Side
   *b	RH Side

   Torque:

   35 N*m{ 357 kgf*cm , 26 ft.*lbf }

   HINT:

   Make sure to install the suspension tower damper with the label facing upright.

1. Install the outer cowl top panel sub-assembly with the 9 bolts.
   

   Torque:

   12 N*m{ 122 kgf*cm , 9 ft.*lbf }

2. w/ Wiper Deicer:
   Engage the 3 clamps to install the wire harness.
   

3. Engage the clamp to install the wire harness.
   

1. Install the cowl body mounting reinforcement RH with the 2 bolts.
   

   Torque:

   12 N*m{ 122 kgf*cm , 9 ft.*lbf }

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

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