Except For Electric Brake Booster Model

CAUTION:

Before handling the airbag system components, refer to "CAUTION" of "General Description" in "AIRBAG SYSTEM". Ref. to AIRBAG SYSTEM>GENERAL DESCRIPTION>CAUTION .

Check the operating rod of the vacuum booster assembly.

Check the length (a) between the vacuum booster assembly mounting surface and clevis pin hole.

Specification:

136.3 mm (5.37 in)

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If the inspection result is not within the standard value, loosen the lock nuts of operating rod, and rotate the rod to adjust the length within the specification.
Tighten the lock nut.

NOTE:

Check the brake pedal height. When adjusting, also adjust the stop light switch assembly.

Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)

Apply grease to the cylinder seal assembly, vacuum booster assembly, and master cylinder assembly.

CAUTION:

Be careful not to mix up application locations of each grease.

Apply fluorine grease to the entire outer diameter of a new cylinder seal assembly and the entire contact surface of the vacuum booster assembly with the master cylinder assembly.

CAUTION:

Apply fluorine grease to the entire circumference. Areas where application was missed may cause rust.

Preparation items:

Grease: An item contained in the seal kit (fluorine grease) or equivalent

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Apply silicone grease to the entire circumference on the piston rod of the master cylinder assembly and the entire inner diameter of a new cylinder seal assembly.
Preparation items:

Grease: An item contained in the seal kit (silicone grease) or equivalent

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Install a new cylinder seal assembly to the master cylinder assembly.
CAUTION:
Be careful not to install the cylinder seal assembly in the wrong location.

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Install the vacuum booster assembly.
CAUTION:
- Replace the gasket booster with a new part.
- Use a wobble extension for torque tightening to prevent interference with the column assembly steering.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)
Install the master cylinder assembly. Ref. to BRAKE>MASTER CYLINDER>INSTALLATION>EXCEPT FOR ELECTRIC BRAKE BOOSTER MODEL .

Install the operating rod to the pedal COMPL brake.

Apply a thin coat of grease to the new clevis pin.

Preparation items:

Grease: NIPPON GREASE NIGTIGHT LTS No. 2 or equivalent

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Using a clevis pin and a snap pin, install the operating rod to the pedal COMPL brake.

Install the duct foot driver. Ref. to AIR CONDITIONER>AIR VENT DUCT>INSTALLATION>FOOT DUCT .
Install the knee airbag module. Ref. to AIRBAG SYSTEM>KNEE AIRBAG MODULE>INSTALLATION .
Install the cover LWR driver. Ref. to EXTERIOR/INTERIOR TRIM>INSTRUMENT PANEL LOWER COVER>INSTALLATION .
Install the pipe assembly front ABS using a flare nut wrench and a crowfoot wrench.
NOTE:
If the work can be performed with the front and back sides reversed, it is also possible to use a 6-point crowfoot wrench.

Tightening torque:

Calculation formula

T = 19 N.m (1.9 kgf-m, 14.0 ft-lb) x L1/(L1 + L2)

T: Reading of the torque wrench

L1: Effective length of the torque wrench

L2: Effective length of the crowfoot wrench

NOTE:
If the effective length of the tool used is unknown, consult the manufacturer of the tool.

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Install the clutch pipe. Ref. to CLUTCH SYSTEM>CLUTCH PIPE AND HOSE>INSTALLATION .
Connect the vacuum sensor assembly connector.
Install the vacuum hose COMPL.
Install the engine control module (ECM). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>ENGINE CONTROL MODULE (ECM)>INSTALLATION .
Install the intercooler. Ref. to INTAKE (INDUCTION) (H4DOTC)>INTERCOOLER>INSTALLATION .
Bleed air from the brake system and clutch system. Ref. to BRAKE>AIR BLEEDING>PROCEDURE .
Connect the ground terminal to battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
Perform a road test to make sure the brakes do not drag.