Hydraulic Brake Booster (For Rhd) Reassembly

Apply lithium soap base glycol grease to a new piston.

Install the piston.

NOTICE:

When installing, be careful not to damage the seals, etc.

Install the plug.

Using 2 screwdrivers, install a new C-ring while pressing on the piston.

HINT:

Tape the screwdriver tip before use.

Install the brake master cylinder side lock nut and rod operating adapter to the brake master cylinder.

Torque:

26 N*m{260 kgf*cm, 19 ft.*lbf}

Install the lock nut and master cylinder push rod clevis to the rod operating adapter.

Torque:

26 N*m{260 kgf*cm, 19 ft.*lbf}

Install a new gasket.

NOTICE:

Keep all surfaces of the master cylinder solenoid, master cylinder and gasket, especially contact surfaces, away from water and dust.

Install the master cylinder solenoid with 6 new bolts.

Torque:

32 N*m{325 kgf*cm, 24 ft.*lbf}

Install the brake booster accumulator pipe and compression spring.

NOTICE:

Ensure that no foreign matter enters the pump.

Install a new O-ring to the brake booster accumulator.

Install the brake booster accumulator.

Torque:

57 N*m{585 kgf*cm, 42 ft.*lbf}

Install the brake booster pump bush to the No. 1 brake booster pump bracket.

Using a 5 mm hexagon wrench, install the No. 1 brake booster pump bracket with the 2 bolts.

Torque:

7.8 N*m{80 kgf*cm, 69 in.*lbf}

Using a 4 mm hexagon wrench, install the 2 pins to the brake master cylinder.

Torque:

7.8 N*m{80 kgf*cm, 69 in.*lbf}

Install 2 new brake booster pump collars and 2 brake booster pump bushes to the brake booster with accumulator pump assembly.

Install the brake booster with accumulator pump assembly to the brake master cylinder.

Install a new clip.

Connect the wire harnesses with the 2 screws.

Torque:

2.9 N*m{30 kgf*cm, 26 in.*lbf}

Install 2 new plugs.

Using a union nut wrench, install the No. 1 brake actuator tube.

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. The torque value for use with a union nut wrench is effective when the union nut wrench is parallel to the torque wrench.
   

Using needle nose pliers, install the brake actuator hose with the 2 clips.

Apply lithium soap base glycol grease to 3 new reservoir grommets.

Install the 3 reservoir grommets to the brake master cylinder.

NOTICE:

Be careful of the size of each grommet.

Install the brake master cylinder reservoir sub-assembly with the screw.

Torque:

1.7 N*m{17 kgf*cm, 15 in.*lbf}

Install the master cylinder reservoir filler cap.

Using a pin punch and hammer, install a new pin to the brake master cylinder reservoir.

Install the brake fluid level warning switch connector to the No. 1 brake actuator bracket.

Using a 5 mm hexagon wrench, install the No. 1 brake actuator bracket with the bolt.

Torque:

7.8 N*m{80 kgf*cm, 69 in.*lbf}