BRAKE ACTUATOR INSTALLATION

PROCEDURE

  1. REMOVE BRAKE ACTUATOR COVER (for 1WW)

    1. Install a new brake actuator cover to the brake actuator assembly.

  2. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET

    1. for Manual Transaxle:

      1. C321309E01

        Install the brake actuator with bracket with the 3 nuts. Tighten the 3 nuts uniformly in alphabetical order.

        19 N*m

        194 kgf*cm

        14 ft.*lbf

        Note:

        • Be careful not to damage the brake tubes and wire harness.

        • Do not drop the actuator. If dropped, replace it.

    2. for CVT:

      1. C321310E01

        Install the brake actuator with bracket with the 2 nuts and bolt. Tighten the 2 nuts and bolt uniformly in alphabetical order.

        19 N*m

        194 kgf*cm

        14 ft.*lbf

        Note:

        • Be careful not to damage the brake tubes and wire harness.

        • Do not drop the actuator. If dropped, replace it.

    3. for Manual Transaxle:

      1. Install 2 new tube clamps to the tubes, and then attach the 2 clamps to the brake actuator bracket.

    4. for CVT:

      1. Install 2 new tube clamps to the tubes, and then attach the 2 clamps to the brake actuator bracket.

  3. CONNECT BRAKE LINE

    1. C321308E01

      Set each brake line in the correct position on the brake actuator as shown in the illustration.

      Table 1. Text in Illustration

      *a

      to Front Wheel Cylinder RH

      *b

      to Front Wheel Cylinder LH

      *c

      to Rear Wheel Cylinder RH

      *d

      to Rear Wheel Cylinder LH

      *e

      From Master Cylinder
    2. U123586E01

      Using a union nut wrench, connect the 6 brake lines to the brake actuator.

      for flare nut A

      15 N*m

      155 kgf*cm

      11 ft.*lbf

      for flare nut B

      20 N*m

      199 kgf*cm

      14 ft.*lbf

      Table 2. Text in Illustration

      *a

      Torque Wrench Fulcrum Length
      Tip:

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (Click here).

      • for flare nut A

        When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13 N*m (137 kgf*cm, 10 ft.*lbf).

      • for flare nut B

        When using a union nut wrench (fulcrum length of 20 mm (0.7874 in.)) + torque wrench (fulcrum length of 180 mm (7.0866 in.)): 18 N*m (179 kgf*cm, 13 ft.*lbf).

  4. CONNECT CONNECTOR

    1. C321312E01

      Connect the connector, attach the harness clamp and push the lock lever downward.

      Table 3. Text in Illustration

      *A

      for Manual Transaxle

      *B

      for CVT

  5. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    1. for 1ZR-FAE:

      Install the air cleaner case sub-assembly (Click here).

    2. for 2ZR-FAE:

      Install the air cleaner case sub-assembly (Click here).

  6. INSTALL FUEL FILTER ASSEMBLY (for 1WW)

    1. Install the fuel filter assembly (Click hereClick here).

  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

  8. REMOVE CENTER COWL TOP VENTILATOR LOUVER

    Click here

  9. BLEED BRAKE SYSTEM

    (Click here)

  10. BLEED AIR FROM CLUTCH LINE (for 1ZR-FAE with Manual Transaxle)

    (Click here)

  11. BLEED AIR FROM CLUTCH LINE (for 2ZR-FAE with Manual Transaxle)

    (Click here)

  12. BLEED AIR FROM CLUTCH LINE (for 1WW with Manual Transaxle)

    (Click here)

  13. INSTALL CENTER COWL TOP VENTILATOR LOUVER

    Click here

  14. CHECK BRAKE ACTUATOR ASSEMBLY WITH GTS

    (Click here)