GSIC - Global Service Information Center

# BRAKE BOOSTER > INSTALLATION

## for Preparation Click here

1. INSTALL BRAKE BOOSTER ASSEMBLY

1. Install a new gasket to the brake booster.

1. Install the booster with the 4 nuts.

   Torque:
     14.2 N*m{ 145 kgf*cm , 10 ft.*lbf }

1. Install the push rod clevis.

1. Apply lithium soap base glycol grease to the clevis pin.

1. Install the clevis pin and clip.

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

1. Install the return spring.

2. CHECK AND ADJUST BRAKE BOOSTER PUSH ROD

NOTICE:

  The brake booster interior must not be a vacuum when adjusting the booster. Stop the engine and depress the brake pedal several times until there is no vacuum in the booster.

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 booster is replaced with a new one.

1. Apply chalk to the tip of an accessory tool.

   HINT:
     An accessory tool is included with each new master cylinder.

1. Place the accessory tool on the booster.

1. Confirm that the clearance between the booster push rod and accessory tool is equal to zero.
   If there is clearance between the tool and shell of the booster, the rod is protruding too far. If chalk does not transfer from the tool to the rod, the rod is not protruding far enough. In both cases, adjust the rod in the next step.

1. To adjust the clearance of the rod, first depress the pedal so that the rod protrudes. Then fix the rod in place using SST and rotate the hexagon cap nut to adjust the clearance.

   SST
     09737-00020

3. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

1. Install the brake master cylinder (Click here).

4. FILL RESERVOIR WITH BRAKE FLUID

Fluid:
  SAE J1703 or FMVSS No. 116 DOT3

5. BLEED AIR FROM BRAKE MASTER CYLINDER

HINT:

  If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.

1. Using SST, disconnect the 2 brake lines from the master cylinder.

   SST
     09023-00101

1. Slowly depress and hold the brake pedal.

1. Cover the outer holes with your finger, and release the pedal.

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

1. Using SST, connect the 2 brake lines to the master cylinder.

   SST
     09023-00101

   Torque:
     15.2 N*m{ 155 kgf*cm , 11 ft.*lbf } without SST
     14 N*m{ 143 kgf*cm , 10 ft.*lbf } with SST

   HINT:
     Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

6. BLEED AIR FROM BRAKE LINE

1. Remove the bleeder plug cap.

1. Connect the vinyl tube to the bleeder plugs.

1. Depress the 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:
     10.8 N*m{ 110 kgf*cm , 8 ft.*lbf } for front brake
     11 N*m{ 112 kgf*cm , 8 ft.*lbf } for rear brake (2WD)
     10 N*m{ 102 kgf*cm , 7 ft.*lbf } for rear brake (4WD)

1. Install the cap.

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

7. BLEED AIR FROM CLUTCH LINE (M/T)

1. Remove the bleeder plug cap.

1. Connect the vinyl tube to the bleeder plug.

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

1. At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

1. Repeat the previous 2 steps until all the air in the fluid is completely bled out.

1. Tighten the bleeder plug.

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

1. Install the bleeder plug cap.

1. Check that all the air has been bled out of the clutch line.

8. CHECK AND ADJUST BRAKE PEDAL HEIGHT

1. Check the pedal height.

   Pedal height from dash panel:

     Model | Specified Condition
     LHD (M/T) | 152.9 to 162.9 mm (6.020 to 6413 in.)
     LHD (A/T) | 154.1 to 1164.1 mm (6.067 to 6.461 in.)
     RHD (M/T) | 156.9 to 166.9 mm (6.177 to 6.571 in.)
     RHD (A/T) | 158.1 to 168.1 mm (6.224 to 6.618 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. Insert the switch into the adjuster until it slightly touches the pedal.

      NOTICE:
        Do not depress the pedal.

   7. 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.

   8. Connect the connector to the switch.

   9. Check the switch clearance.

      Stop light switch clearance:
        1.5 to 2.5 mm (0.059 to 0.098 in.)

9. CHECK BRAKE PEDAL FREE PLAY

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's free play by measuring the distance between the position in the previous step and the pedal's released position.

   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.

   Stop light switch clearance:
     1.5 to 2.5 mm (0.059 to 0.098 in.)
   If the clearance is not as specified, adjust the clearance 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.

10. 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 shown in the illustration.

      Pedal reserve distance:

        Model | Specified Condition
        LHD (2WD) | 78.0 mm (3.071 in.)
        LHD (4WD) | 85.0 mm (3.347 in.)
        RHD (2WD) | 82.0 mm (3.228 in.)
        RHD (4WD) | 89.0 mm (3.504 in.)

      If the distance is not as specified, troubleshoot the brake system.

11. CHECK BRAKE FLUID LEVEL IN RESERVOIR

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

   Fluid:
     SAE J1703 or FMVSS No. 116 DOT3

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

12. CHECK FOR BRAKE FLUID LEAKAGE