RM38T0EC _54 Brake _113942 BRAKE SYSTEM (OTHER) _0604484 BRAKE BOOSTER(for HEV Model) A

BRAKE SYSTEM (OTHER)  BRAKE BOOSTER(for HEV Model)  INSTALLATION  


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
C507164N01
5.75,4.417 6.5,4.583 0.75,0.167 5.708,4.375 6.542,4.625 0.833,0.25 1.49,2.083 2.323,2.417 0.833,0.333 1.448,2.042 2.365,2.458 0.917,0.417 1.875,1.813 1.875,2.083 false 1.604,1.813 1.604,1.958 1.604,1.958 1.875,1.958 false 5.573,5.104 5.76,5.448 5.76,5.448 5.99,5.448 false 3.156,2.646 3.896,2.646 false 0.771,4.552 1.688,4.552 false 4.552,4.854 4.854,4.854 false 6.094,4.417 6.094,4.208 false 5.385,3.583 5.74,3.583 false 5.833,1.365 6.26,1.365 false 2.75,2.01 3.323,2.427 0.573,0.417 18 false 5 6.292,5.344 6.865,5.76 0.573,0.417 18 false 4 4.177,2.521 4.75,2.938 0.573,0.417 18 false 3 0.563,4.385 1.135,4.802 0.573,0.417 18 false 2 5.948,3.448 6.521,3.865 0.573,0.417 18 false 1 5.813,3.5 6.385,3.917 0.573,0.417 10 false ● 4.385,4.729 4.958,5.146 0.573,0.417 10 false ● 6.156,4.115 6.729,4.531 0.573,0.417 10 false x4 5.813,4.427 6.823,4.677 1.01,0.25 8 false 12.7 (130, 9) 1.552,2.104 2.563,2.354 1.01,0.25 8 false 19.5 (199, 14) 1.531,2.25 2.542,2.5 1.01,0.25 8 false 17.4 (177, 13)* 6.323,1.229 6.896,1.646 0.573,0.417 18 false 6 5.188,0.313 5.552,0.51 0.365,0.198 10 false x2

Procedure Part Name Code
Z101186

Z101188

Z101187

1 BRAKE BOOSTER GASKET 44785 - - -
2 BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY 47210L (Click here) - -
3 PUSH ROD PIN 47264A (Click here) - -
4 BRAKE PEDAL RETURN SPRING 47101A (Click here) - -
5 CONNECT BRAKE LINE - (Click here) - -
6 NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY 55606 - - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf) * For use with a union nut wrench
● Non-reusable part
V100135

Lithium soap base glycol grease

C507158N02
0.906,0.521 1.74,0.854 0.833,0.333 0.865,0.479 1.781,0.896 0.917,0.417 6.083,3.583 6.917,3.917 0.833,0.333 6.042,3.542 6.958,3.958 0.917,0.417 4.656,0.302 4.76,0.156 4.76,0.156 4.979,0.156 false 3.396,1.781 3.25,1.594 3.25,1.594 3.063,1.594 false 1.656,3.823 2.01,3.823 false 1.542,4.854 1.708,4.854 false 5.625,3.177 6.052,3.177 false 4.979,0.583 5.188,0.427 5.188,0.427 5.406,0.427 false 6.313,1.156 6.5,1.156 false 1.75,0.708 2.167,0.708 false 5.542,3.75 6.073,3.75 false 5.74,0.792 6,0.792 false 2.729,1.438 3.26,1.802 0.531,0.365 18 false 10 6.865,1.031 7.115,1.396 0.25,0.365 18 false 9 6.396,0.646 6.771,1 0.375,0.354 18 false 8 6.333,3.031 6.75,3.417 0.417,0.385 18 false 7 5.771,0.281 6.177,0.698 0.406,0.417 18 false 9 5.375,0.031 5.781,0.396 0.406,0.365 18 false 9 1.333,3.667 2.073,4.281 0.74,0.615 18 false 10 1.229,4.698 1.76,5.156 0.531,0.458 18 false 10 0.948,0.531 1.802,0.708 0.854,0.177 8 false 15.2 (155, 11) 0.938,0.688 1.792,0.865 0.854,0.177 8 false 13.4 (137, 10)* 6.115,3.615 6.969,3.792 0.854,0.177 8 false 15.2 (155, 11) 6.115,3.75 6.969,3.927 0.854,0.177 8 false 13.4 (137, 10)* 6.75,1.094 7.146,1.448 0.396,0.354 10 false ● 6.271,0.698 6.667,1.063 0.396,0.365 10 false ● 5.667,0.333 6.094,0.708 0.427,0.375 10 false ● 5.25,0.083 5.677,0.438 0.427,0.354 10 false ●

Procedure Part Name Code
Z101186

Z101188

Z101187

7 FRONT NO. 5 BRAKE TUBE 47315 (Click here) - -
8 NO. 2 BRAKE TUBE CLAMP 47372 (Click here) - -
9 NO. 1 BRAKE TUBE CLAMP 47371A (Click here) - -
10 ENGINE ROOM MAIN WIRE 82111 (Click here) - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf) * For use with a union nut wrench
● Non-reusable part - -

C507165N01
1.26,0.177 1.927,0.344 0.667,0.167 1.219,0.135 1.969,0.385 0.75,0.25 1.906,1.281 2.625,1.448 0.719,0.167 2.594,0.604 2.979,0.604 false 2.896,3.375 3.281,3.375 false 5.073,4.052 5.458,4.052 false 5.427,2.615 5.813,2.615 false 6.417,0.688 6.802,0.688 false 6.427,0.302 6.813,0.302 false 1.26,0.26 1.094,0.26 1.094,0.26 1.01,1.188 false 1.458,1.354 1.906,1.354 false 5.156,0.167 6.531,0.51 1.375,0.344 18 false 11, 17 - 20 6.063,0.563 6.635,0.958 0.573,0.396 18 false 16 4.74,3.927 5.323,4.458 0.583,0.531 18 false 15 5.094,2.49 5.802,3.083 0.708,0.594 18 false 14 3.021,0.469 3.656,1.031 0.635,0.563 18 false 13 2.563,3.25 3.198,3.802 0.635,0.552 18 false 12 1.292,1.417 1.573,1.771 0.281,0.354 10 false x8 1.031,1.25 1.313,1.604 0.281,0.354 10 false x4 1.927,1.281 2.75,1.479 0.823,0.198 8 false 12 (122, 9) 1.292,0.188 2.115,0.385 0.823,0.198 8 false 50 (510, 37)

Procedure Part Name Code
Z101186

Z101188

Z101187

11 BLEED BRAKE LINE - - - (Click here)
12 OUTER COWL TOP PANEL SUB-ASSEMBLY 55701J - - -
13 NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL 55737B - - -
14 WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY - - - -
15 FRONT WHEEL LH - - - -
16 CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL - - - -
17 UPDATE ECU SECURITY KEY - - (Click here)
18 INSPECT AND ADJUST BRAKE PEDAL - - - (Click here)
19 PERFORM BRAKE SYSTEM CALIBRATION - - - (Click here)
20 INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL - - - (Click here)

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

For use with a union nut wrench

CAUTION / NOTICE / HINT

NOTICE:
·

After replacing the brake booster with master cylinder assembly, make sure to perform update ECU security key.

·

After performing the update ECU security key procedure, make sure to perform the initialization procedure for when the cable has been disconnected and reconnected to the negative (-) auxiliary battery terminal.



PROCEDURE

Hide 44785 1.INSTALL BRAKE BOOSTER GASKET

Hide 47210L 2.INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

a.
C497831N03
0.563,0.135 0.844,0.49 0.281,0.354 18 false i 2.896,0.292 3.052,0.49 0.156,0.198 10 true 3 2.938,1.375 3.094,1.573 0.156,0.198 10 true 1 4.177,0.354 4.333,0.552 0.156,0.198 10 true 2 4.135,1.365 4.292,1.563 0.156,0.198 10 true 4

i.

Install the brake booster with master cylinder assembly with the 4 nuts.

Torque:
12.7 N*m (130 kgf*cm, 9 ft.*lbf)

NOTICE:
·

Tighten the nuts in the order shown in the illustration.

·

Do not kink or damage the brake lines.

·
C507162C01
0.354,0.708 0.552,0.708 false 2.677,0.792 2.677,0.542 2.677,0.542 2.844,0.542 false 1.104,1.552 1.125,1.813 1.125,1.813 1.958,0.604 true 2.521,1.031 2.521,1.448 false 1.042,1.833 1.354,2.031 0.313,0.198 10 false *a 2.448,1.469 2.76,1.667 0.313,0.198 10 false *b 2.885,0.479 3.198,0.677 0.313,0.198 10 false *c 0.177,0.635 0.49,0.833 0.313,0.198 10 false *d
*a Connectors
*b Boot
*c Brake Master Cylinder Push Rod Clevis
*d Brake Master Cylinder Reservoir Assembly


Do not carry the brake booster with master cylinder assembly by the parts shown in the illustration.

·

Be careful not to allow brake fluid to enter the connector.

·

If installing a new brake booster with master cylinder assembly, do not remove the hole plugs before connecting the brake lines because the brake booster with master cylinder is filled with brake fluid.





Hide 47264A 3.INSTALL PUSH ROD PIN

Z101186

Click here(Click here)

Hide 47101A 4.INSTALL BRAKE PEDAL RETURN SPRING

Z101186

Click here(Click here)

Hide 55606 6.INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

Hide 47315 7.CONNECT FRONT NO. 5 BRAKE TUBE

a.
C507169C01
2.323,3.063 2.635,3.26 0.313,0.198 10 false *a 0.51,0.115 0.823,0.49 0.313,0.375 18 false i 3.958,0.104 4.271,0.479 0.313,0.375 18 false ii 4.125,2 4.417,2.313 0.292,0.313 18 true iii
*a Torque Wrench Fulcrum Length - -
V113147

Connect in this direction - -


i.

Using a union nut wrench, connect the front No. 5 brake tube to the brake actuator assembly.

Torque:
Specified tightening torque : 15.2 N*m (155 kgf*cm, 11 ft.*lbf)

NOTICE:
·

Do not kink or damage the brake lines.

·

Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.



HINT:
·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

13.4 N*m (137 kgf*cm, 10 ft.*lbf)




ii.

Connect the front brake tube grommet to the vehicle body.


iii.

Using a union nut wrench, connect the front No. 5 brake tube to the front flexible hose LH.

Torque:
Specified tightening torque : 15.2 N*m (155 kgf*cm, 11 ft.*lbf)

NOTICE:
·

Do not kink or damage the brake lines.

·

Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.



HINT:
·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

13.4 N*m (137 kgf*cm, 10 ft.*lbf)





Hide 47372 8.INSTALL NO. 2 BRAKE TUBE CLAMP

Z101186

NOTICE:
·

Do not damage the No. 2 brake tube clamp.

·

Do not kink or damage the brake lines.




Hide 47371A 9.INSTALL NO. 1 BRAKE TUBE CLAMP

Z101186

NOTICE:
·

Do not damage the No. 1 brake tube clamp.

·

Do not kink or damage the brake lines.




Hide 82111 10.INSTALL ENGINE ROOM MAIN WIRE

a.
C507167C01
0.365,0.031 0.646,0.385 0.281,0.354 18 false i
V113147

Connect the connector
V113148

Lock the lock lever


i.

Connect the connector to the brake booster assembly as shown in the illustration.

NOTICE:
·

Make sure that the connector is locked securely.

·

Make sure that the connector can be connected smoothly. Do not allow water, oil or dirt to enter the connector.





b.
C507168C01
3.917,0.24 4.135,0.521 0.219,0.281 18 true i 0.24,0.073 0.833,0.417 0.594,0.344 18 false ii, iii 0.99,0.229 1.198,0.469 0.208,0.24 10 true A 0.885,1.229 1.094,1.469 0.208,0.24 10 true B
V113147

Connect the connector in this direction
V113148

Connect the connector in this direction


i.

Connect the connector (B) to the brake master cylinder reservoir assembly as shown in the illustration


ii.

Engage the clamp to the brake master cylinder reservoir assembly.


iii.

Connect the connector (A) to the brake booster assembly.



Hide 55737B 13.INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

Hide 17. UPDATE ECU SECURITY KEY

HINT:

Perform this procedure only when replacement of the brake booster with master cylinder assembly is necessary.


Click hereGeneral>SETUP>WHEN REPLACING OR REMOVING/INSTALLING PARTS>UPDATE ECU SECURITY KEY

Hide 20. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART