BRAKE ACTUATOR(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE ACTUATOR BOLT CUSHION


    1. Install the 3 brake actuator bolt cushions to the brake actuator bracket assembly.

    2. Install the 3 brake actuator case collars to the brake actuator bolt cushions.

      Note

      Make sure the brake actuator case collars are in full contact with the brake actuator bolt cushions.

  2. INSTALL BRAKE ACTUATOR ASSEMBLY


    1. A01XQ6UN01

      Temporarily install the brake actuator assembly to the brake actuator bracket assembly with the 3 bolts.

      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.

    2. Tighten the 3 bolts in the order shown in the illustration.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  3. INSTALL NO. 5 BRAKE ACTUATOR BRACKET


    1. Install the No. 5 brake actuator bracket with the bolt.

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

  4. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET


    1. Temporarily install the brake actuator assembly with bracket with the 2 bolts and nut.

      Note


      • Do not damage the brake tubes.

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

      Tech Tips


      • Install the brake actuator assembly with bracket while avoiding the brake tubes.

      • Fully tighten the 2 bolts and nut of the brake actuator assembly with bracket after installing the brake master cylinder sub-assembly.

    2. A01XQUDC01
      *a To Front Wheel Cylinder Assembly RH
      *b To Front Wheel Cylinder Assembly LH
      *c To Rear Wheel Cylinder Assembly RH
      *d To Rear Wheel Cylinder Assembly LH

      Temporarily connect the 4 brake tubes to the correct positions on the brake actuator assembly as shown in the illustration.

    3. A01XR34C02
      *a Torque Wrench Fulcrum Length

      Using a union nut wrench, fully tighten each brake tube.

      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 250 mm (9.84 in.)):

        13.97 N*m (142 kgf*cm, 10 ft.*lbf)

    4. A01XRG6C02
      B002DP3 Connect the connector
      B002CU5 Lock the lock lever

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

      Note


      • Make sure that the connector is locked securely.

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

  5. INSTALL REAR NO. 1 BRAKE TUBE


    1. A01XRNWC02
      *a Torque Wrench Fulcrum Length

      Using a union nut wrench, connect the rear No. 1 brake tube to the brake actuator assembly.

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

      Note


      • Do not kink or damage the rear No. 1 brake tube.

      • Do not allow the rear No. 1 brake tube 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 rear No. 1 brake tube 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 250 mm (9.84 in.)):

        13.97 N*m (142 kgf*cm, 10 ft.*lbf)

    2. Engage the clamp to install the rear No. 1 brake tube.

  6. INSTALL FRONT NO. 1 BRAKE TUBE


    1. A01XQ5QC02
      *a Torque Wrench Fulcrum Length

      Using a union nut wrench, connect the front No. 1 brake tube to the brake actuator assembly.

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

      Note


      • Do not kink or damage the front No. 1 brake tube.

      • Do not allow the front No. 1 brake tube 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 front No. 1 brake tube 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 250 mm (9.84 in.)):

        13.97 N*m (142 kgf*cm, 10 ft.*lbf)

    2. Engage the clamp to install the front No. 1 brake tube.

  7. SEPARATE BRAKE ACTUATOR ASSEMBLY WITH BRACKET


    1. Remove the 2 bolts and nut, and separate the brake actuator assembly with bracket.

      Note


      • Do not damage the brake tubes.

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

  8. CONNECT UNION TO CHECK VALVE HOSE


    1. Connect the union to check valve hose to the brake booster assembly, and slide the clip to secure it.

  9. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  10. 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

  11. BLEED BRAKE SYSTEM

    Click here

  12. INSTALL FRONT WHEEL LH

    Click here

  13. INSTALL ENGINE ROOM SIDE COVER LH


    1. Engage the guide to install the engine room side cover LH.

    2. Install the 2 clips.

  14. PERFORM YAW RATE AND ACCELERATION SENSOR AND ROLL RATE AND VERTICAL ACCELERATION SENSOR ZERO POINT CALIBRATION

    Click here

  15. PERFORM TEST MODE INSPECTION

    Click here

  16. INSPECT BRAKE ACTUATOR USING GTS

    Click here

  17. CHECK FOR AND CLEAR DTCS

    Click here