Installation

BRAKE SYSTEM (OTHER): BRAKE BOOSTER: INSTALLATION

INSTALLATION

1. TEMPORARILY TIGHTEN BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.
HINT: Fully tighten the lock nut after adjusting the brake pedal height.

2. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster assembly.
3. INSTALL BRAKE BOOSTER ASSEMBLY





(a) Install the brake booster assembly to the body with the 4 nuts.
Torque: 13 Nm (132 kgf-cm, 10 ft-lbf)
NOTE: Do not damage the brake lines or fuel lines.





(b) Engage the 2 clamps to install the brake lines to the body.
4. INSTALL NO. 5 FRONT BRAKE TUBE





(a) Install the No. 5 front brake tube to the body and engage the grommet.





(b) Using a union nut wrench (10 mm), connect the No. 5 front brake tube to the front brake flexible hose LH.
without a union nut wrench - Torque: 15 Nm (155 kgf-cm, 11 ft-lbf)
with a union nut wrench - Torque: 14 Nm (143 kgf-cm, 10 ft-lbf)

NOTICE:
- Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
- This torque value is effective when the union nut wrench is parallel to the torque wrench.

5. INSTALL CHECK VALVE GROMMET
(a) Install a new check valve grommet to the brake booster assembly.
6. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY
(a) Install the vacuum check valve assembly to the brake booster assembly.
7. CONNECT VACUUM HOSE





(a) Connect the vacuum hose and slide the clip.
8. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS Installation
9. INSTALL BRAKE PEDAL RETURN SPRING Installation
10. INSTALL FRONT WHEEL LH
Torque: 103 Nm (1050 kgf-cm, 76 ft-lbf)
11. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY Installation
12. CONNECT CLUTCH TUBE (for Manual Transaxle) Installation
13. FILL RESERVOIR WITH BRAKE FLUID Service and Repair
14. BLEED CLUTCH LINE
15. BLEED BRAKE MASTER CYLINDER Service and Repair
16. BLEED BRAKE LINE Service and Repair
17. BLEED BRAKE ACTUATOR (w/ VSC) Service and Repair
18. INSPECT FOR BRAKE FLUID LEAK
19. INSPECT FLUID LEVEL Testing and Inspection
20. INSPECT AND ADJUST BRAKE PEDAL HEIGHT Adjustments
21. INSPECT BRAKE PEDAL FREE PLAY Adjustments
22. INSPECT BRAKE PEDAL RESERVE DISTANCE Adjustments
23. INSTALL SUSPENSION TOWER DAMPER ASSEMBLY (w/ Front Strut Bar) Installation
24. INSTALL OUTER COWL TOP PANEL (for TMC Made) Installation
25. INSTALL OUTER COWL TOP PANEL (except TMC Made) Installation
26. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
27. INSTALL COWL TOP VENTILATOR LOUVER LH Installation
28. INSTALL CENTER NO. 1 COWL TOP VENTILATOR LOUVER Installation
29. INSTALL HOOD TO COWL TOP SEAL Installation
30. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
31. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
32. INSTALL FRONT WIPER ARM HEAD CAP Installation
33. INSTALL AIR CLEANER CASE (for 2ZR-FE) Installation
34. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FE) Installation
35. INSTALL NO. 2 CYLINDER HEAD COVER (for 2ZR-FE) Installation
36. INSTALL AIR CLEANER CASE (for 2AZ-FE) Installation
37. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (for 2AZ-FE) Installation
38. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for 2AZ-FE) Installation