BRAKE ACTUATOR(for RHD) INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 FUEL TUBE CLAMP


    1. Engage the claw to install the No. 2 fuel tube clamp to the brake actuator bracket assembly.

  2. INSTALL BRAKE ACTUATOR BRACKET CUSHION


    1. Install the brake actuator bracket cushion to the brake actuator bracket assembly.

  3. INSTALL NO. 1 BRAKE ACTUATOR CASE COLLAR


    1. Install the No. 1 brake actuator case collar to the brake actuator bracket cushion.

  4. INSTALL BRAKE ACTUATOR ASSEMBLY


    1. Temporarily install the brake actuator assembly with the 2 nuts and a new bolt.

    2. B008M5BN01

      Fully tighten the 2 nuts and bolt in the order shown in the illustration.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Note


      • Do not remove the hole plugs of a new brake actuator assembly before connecting the brake tubes because the brake actuator assembly is filled with brake fluid.

      • Do not hold the brake actuator assembly by the connector.

  5. INSTALL BRAKE ACTUATOR WITH BRACKET


    1. Temporarily install the brake actuator with bracket to the vehicle body with the bolt and 2 nuts.

    2. B008L03N01

      Fully tighten the bolt and 2 nuts in the order shown in the illustration.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      Note

      Do not damage the brake tubes.

    3. Engage the 2 clamps to install the fuel main tube and fuel tank to canister tube to the No. 2 fuel tube clamp.

    4. B008LOSC01
      *a From 1st Chamber of Brake Booster with Master Cylinder Assembly
      *b From 2nd Chamber of Brake Booster with Master Cylinder Assembly
      *c To Front Wheel Cylinder Assembly LH
      *d To Rear Wheel Cylinder Assembly RH
      *e To Rear Wheel Cylinder Assembly LH
      *f To Front Wheel Cylinder Assembly RH

      Temporarily tighten each brake tube to the correct position on the brake actuator assembly as shown in the illustration.

    5. B008LPHC01
      *a Torque Wrench Fulcrum Length

      Using a 10 mm and 12 mm union nut wrench, connect the 6 brake tubes to the brake actuator assembly.

      Torque:
      Specified tightening torque (A)
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }
      Specified tightening torque (B)
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note


      • Do not kink or damage the brake tubes.

      • Do not allow the brake tubes to twist or interfere with other parts or the vehicle body during tightening.

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

      Tech Tips


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

        Click here

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)) (A): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)) (B): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

    6. B008KU6C01
      *a Torque Wrench Fulcrum Length

      Using a 10 mm union nut wrench, connect the brake tube to the front flexible hose.

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

      Note


      • Do not kink or damage the brake tubes.

      • Do not allow the brake tubes to twist or interfere with other parts or the vehicle body during tightening.

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

      Tech Tips


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

        Click here

      • 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)

    7. B008LP4C01
      B008LJK Connect the connector
      B008KJ9 Lock the lock lever

      Connect the connector to the brake actuator assembly and lock the lock lever.

      Note


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

      • Make sure that the connector is locked securely.

  6. INSTALL SECURITY HORN ASSEMBLY (w/ Security Horn)

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  7. INSTALL BATTERY

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  8. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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  9. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

    Click here

  10. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

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  11. INSTALL WATER GUARD PLATE LH

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  12. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

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  13. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Click here

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  15. BLEED BRAKE SYSTEM

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  16. INSPECT BRAKE ACTUATOR USING GTS

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  17. PERFORM SYSTEM VARIANT LEARNING

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  18. CHECK FOR AND CLEAR DTCS

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