Brake Booster (W/ Vsc) Installation

Temporarily install the push rod clevis with the lock nut.

Adjust and tighten the push rod clevis with the lock nut. (Click here)

Install the grommet and check valve assembly.

Install a new brake booster gasket to the brake booster assembly.

Install the brake booster assembly with the 4 nuts.

Torque:

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

NOTICE:

Do not damage the brake tubes.

Connect the vacuum hose with the clip.

Apply lithium soap base glycol grease to the clevis pin.

Install the push rod clevis to the brake pedal support assembly with the clevis pin and a new clip.

Install the brake pedal return spring.

Install the actuator assembly with bracket to the body with the 2 bolts and nut.

Torque:

19 N*m{195 kgf*cm, 14 ft.*lbf}

NOTICE:

Do not to damage the brake tubes.

Using SST, connect the brake No.3 tube to the flexible hose. (for LHD)

SST

09023-00101

Torque:

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

Using SST, connect the brake No.2 tube to the flexible hose. (for RHD)

SST

09023-00101

Torque:

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

Install the grommet to the body.

NOTICE:

Make sure that the grommet is installed correctly.

Temporarily tighten each brake tube to the connect positions of the actuator assembly with bracket as shown in the illustration.

Using SST, fully tighten each brake tube to the correct positions of the actuator assembly with bracket as shown in the illustration.

SST

09023-00101

Torque:

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

Connect the actuator connector.

NOTICE:

Make sure that the connector is locked securely.

Install a new O-ring to the brake master cylinder sub-assembly.

Install the brake master cylinder sub-assembly to the booster assembly with the 2 nuts.

Torque:

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

Using SST, connect the 2 brake tubes to the brake master cylinder sub-assembly.

SST

09023-00101

Torque:

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

Engage the clamp and connect the warning switch connector.

Install the relay block No.3 with the bolt and nut.

Torque:

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

Push the ventilator louver in the direction indicated by the arrow in the illustration. Attach the 10 claws to install the ventilator louver.

Attach the 5 claws and 2 clips to install the ventilator louver.

Push the cowl side seal in the direction indicated by the arrow in the illustration. Attach the 2 claws to install the cowl side seal.

Stop the wiper motor at the automatic stop position.

Clean the wiper arm serration with a round file or equivalent.

Clean the wiper pivot serration with a wire brush.

Install the wiper arm and blade with the nut. Make sure that the wiper arm and blade comes to the position shown in the illustration.

Torque:

22 N*m{224 kgf*cm, 16 ft.*lbf}

HINT:

Hold down the wiper arm hinge with your hand while tightening the nut.

Specification:

Area	Measurement
A (for LHD)	25.3 mm (0.996 in.)
B (for LHD)	26.2 mm (1.031 in.)
C (for RHD)	21.8 mm (0.858 in.)
D (for RHD)	28.9 mm (1.138 in.)

Stop the wiper motor at the automatic stop position.

Clean the wiper arm serration with a round file or equivalent.

Clean the wiper pivot serration with a wire brush.

Install the wiper arm and blade with the nut. Make sure that the wiper arm and blade comes to the position shown in the illustration.

Torque:

22 N*m{224 kgf*cm, 16 ft.*lbf}

HINT:

Hold down the wiper arm hinge with your hand while tightening the nut.

Specification:

Area	Measurement
A (for LHD)	28.9 mm (1.138 in.)
B (for LHD)	21.8 mm (0.858 in.)
C (for RHD)	26.2 mm (1.031 in.)
D (for RHD)	25.3 mm (0.996 in.)

Operate the front wipers while spraying washer fluid on the windshield glass. Make sure that the front wipers function properly and there is no interference with the vehicle body.

Attach the 3 clips to install the side seal.

Fill reservoir with brake fluid.

Fluid:

SAE J1703 or FMVSS No. 116 DOT3

Disconnect the 2 brake lines from the master cylinder.

Slowly depress the brake pedal and hold it.

Cover the 2 outer holes with fingers, and release the brake pedal.

Repeat (b) and (c) 3 or 4 times.

Using SST, connect the brake lines to the master cylinder.

SST

09023-00101

Torque:

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

Connect a vinyl tube to the bleeder plug.

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

When fluid stops coming out, tighten the bleeder plug, then release the brake pedal.

Repeat (b) and (c) until all the air in the fluid is completely bled out.

Using SST, tighten the bleeder plug completely.

SST

09023-00101

Torque:

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

Repeat the above procedures for each wheel to bleed the air from the brake line.

Depress the brake pedal more than 20 times with the engine switch off.

Connect the intelligent tester to the DLC3, then turn the engine switch on (IG).

NOTICE:

Do not start the engine.

Turn the intelligent tester on and select "AIR BLEEDING" on the screen.

NOTICE:

1. Refer to the intelligent tester operator's manual for further details.
   
2. Bleed the air by following the prompts displayed on the intelligent tester.
   

Bleed the air according to "Step 1: Increase" on the intelligent tester display.

NOTICE:

Make sure that the master cylinder reservoir tank does not become empty of brake fluid.

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

2. Depress the brake pedal several times, then loosen the bleeder plug connected to the vinyl tube with the pedal depressed.
   





3. When fluid stops coming out, tighten the bleeder plug, then release the brake pedal.
   

4. Repeat (2) and (3) until all the air in the fluid is completely bled out.
   

5. Using SST, tighten the bleeder plug completely.
   

   Torque:

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

   SST

   09023-00101
   

6. Repeat the above procedures for the rest of the wheels to bleed the air from the brake line.
   

Bleed the air from the suction line according to "Step 2: Inhalation" on the intelligent tester display.

NOTICE:

1. Bleed the suction line by following the prompts displayed on the intelligent tester.
   
2. Make sure that the master cylinder reservoir tank does not become empty of brake fluid.
   

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

2. Operate the ABS and TRACTION actuator assembly to bleed the air using the intelligent tester.
   

   NOTICE:

   1. The operation stops automatically in 4 seconds.
      
   2. At this time, be sure to release the brake pedal.
      

3. Check that the operation has stopped by referring to the intelligent tester display and tighten the bleeder plug.
   

4. Repeat (2) and (3) until all the air in the fluid is completely bled out.
   

5. Using SST, tighten the bleeder plug completely.
   

   Torque:

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

   SST

   09023-00101
   

6. For the rest of the wheels, bleed the air in the same way as stated in the above procedures.
   

Bleed the air from the pressure reduction line according to "Step 3: Decrease" on the intelligent tester display.

NOTICE:

1. Bleed the pressure reduction line by following the prompts displayed on the intelligent tester.
   
2. Make sure that the master cylinder reservoir tank does not become empty of brake fluid.
   

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

2. Loosen the bleeder plug.
   





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

   NOTICE:

   1. The operation stops automatically in 4 seconds. When performing this procedure continuously, an interval of at least 20 seconds is required.
      
   2. When the operation is completed, the brake pedal slightly goes down. This is a normal phenomenon when the solenoid opens.
      
   3. During this procedure, the pedal seems heavy, but completely depress it so that the brake fluid comes out from the bleeder plug.
      
   4. Be sure to keep the brake pedal depressed. Never depress and release the pedal repeatedly.
      

4. Tighten the bleeder plug, then release the brake pedal.
   

5. Repeat (2) to (4) until all the air in the fluid is completely bled out.
   

6. Using SST, tighten the bleeder plug completely.
   

   Torque:

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

   SST

   09023-00101
   

7. Repeat the above procedures for the rest of the brakes to bleed the air from the brake line.
   

Bleed the air from the brake line again according to "Step 4: Increase" on the intelligent tester display.

NOTICE:

1. Bleed the air from the brake line again according to "Step 4: Increase" on the intelligent tester display.
   
2. Make sure that the master cylinder reservoir tank does not become empty of brake fluid.
   

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





2. Depress the brake pedal several times, then loosen the bleeder plug connected to the vinyl tube with the pedal depressed.
   





3. When fluid stops coming out, tighten the bleeder plug, then release the brake pedal.
   

4. Repeat (2) and (3) until all the air in the fluid is completely bled out.
   

5. Using SST, tighten the bleeder plug completely.
   

   Torque:

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

   SST

   09023-00101
   

6. Repeat the above procedures for each brake to bleed the air from the brake line.
   

Finish "AIR BLEEDING" on the intelligent tester and turn off the power.

Disconnect the intelligent tester from the DLC3.

Turn the engine switch off.

Check the fluid level and add fluid if necessary.

Fluid:

SAE J1703 or FMVSS No. 116 DOT3

Install the intake duct seal with the 7 clips.

Check the brake pedal height.

Pedal height from tibia pad :

120.5 to 130.5 mm (4.744 to 5.138 in.)

Adjust brake pedal height.

1. Disconnect the connector from the stop light switch assembly.
   

2. Remove the stop light switch lock nut. Turn the switch in order to give the pedal some free play.
   

3. for VSC :
   Remove the brake booster assembly.
   

4. for ECB :
   Remove brake master cylinder with simulator assembly.
   





5. for VSC :
   Loosen the push rod lock nut, turn the push rod clevis and adjust length "A" shown in the illustration.
   

   Length "A":

   146.2 to 147.2 mm (5.756 to 5.795 in.)
   





6. for ECB :
   Loosen the push rod lock nut, turn the push rod clevis and adjust length "A" shown in the illustration.
   

   Length "A":

   147.5 to 148.5 mm (5.807 to 5.846 in.)
   

7. Tighten the push rod lock nut.
   

   Torque:

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

8. for VSC :
   Install the brake booster assembly.
   

9. for ECB :
   Install the brake master cylinder with simulator assembly.
   





10. Turn the stop light switch assembly so that the clearance between the switch and the area where the pedal makes contact is between 0.5 and 2.4 mm (0.020 to 0.095 in.). Tighten the lock nut.
    

    Torque:

    17 N*m{170 kgf*cm, 12 ft.*lbf}

11. Connect the connector to the stop light switch assembly.
    

Adjust the brake pedal stroke sensor.

1. Connect the intelligent tester to the DLC3.
   

2. Loosen the 2 nuts. (for LHD)
   

3. Loosen the 2 bolts. (for RHD)
   





4. Turn the engine switch on (IG). Reading the stroke sensor 1 value shown on the data monitor, turn the stroke sensor slowly to the right and left to adjust it to the standard voltage.
   

   Standard voltage:

   0.8 to 1.2 V
   

   NOTICE:

   Do not depress the brake pedal after turning the engine switch on (IG).

5. Tighten the 2 nuts. (for LHD)
   

   Torque:

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

6. Tighten the 2 bolts. (for RHD)
   

   Torque:

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

Perform system initialization.

Stop the engine and depress the brake pedal several times until no vacuum is left in the booster.

Press the pedal until a slight resistance is felt. Measure the distance as shown in the illustration.

Pedal free play:

1.0 to 2.0 mm (0.039 to 0.079 in.)

Protrusion of the stop light switch assembly shaft:

0.5 to 2.4 mm (0.020 to 0.095 in.)

Release the parking brake pedal.

With the engine running, depress the pedal and measure the pedal reserve distance as shown in the illustration.

Pedal reserve distance from tibia pad at 490 N (50 kgf, 110 lbf) for VSC:

More than 69 mm (2.71 in.)

Pedal reserve distance from tibia pad at 196 N (20 kgf, 44 lbf) for ECB:

More than 86 mm (3.38 in.)

Connect the connector.

NOTICE:

When handling the airbag connector, take care not to damage the airbag wire harness.

Install the driver side knee airbag assembly with the 4 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install the hood lock control cable to the safety pad.

Attach the 8 clips and claw to install the safety pad.

Connect the connectors.

Attach the 2 claws to install the under cover.

Install the 2 screws.

Attach the 2 claws and 4 clips to install the side panel.

Attach the 2 claws and 4 clips to install the side panel.

Attach the 3 claws to install the trim cover.

Pull out the folded lip of the weatherstrip.

Attach the 5 claws to install the scuff plate.

Pull out the folded lip of the weatherstrip.

Attach the 4 clips and 3 claws to install the finish panel end.

Install the screw.

Attach the 3 clips and 3 claws to install the finish panel end.

Install the screw.

Connect the connector.

Attach the 9 clips to install the ash receptacle.

Install the shift lever knob and twist it in the direction indicated by the arrow.

Attach the claws to install the garnish.

Install the side cover with the 2 clips and nut.

Install the side cover with the 2 clips and nut.