BRAKE ACTUATOR(for RHD) 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. A01XQKTN01

      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. A01XQCKN02

      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.

    2. Tighten the 2 bolts and nut in the order shown in the illustration.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    3. A01XQPNC01
      *a From 1st Chamber of Brake Master Cylinder Sub-assembly
      *b From 2nd Chamber of Brake Master Cylinder Sub-assembly
      *c To Front Wheel Cylinder Assembly LH
      *d To Rear Wheel Cylinder Assembly RH
      *e To Rear Wheel Cylinder Assembly LH

      Temporarily connect the 5 brake tubes to the correct positions on the brake actuator assembly as shown in the illustration.

    4. A01XQS5C02
      *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)

    5. A01XQITC02
      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 FRONT NO. 2 BRAKE TUBE


    1. A01XRHEC01
      *1 Front Flexible Hose
      *2 Grommet
      *a Torque Wrench Fulcrum Length

      Install the front No. 2 brake tube to the vehicle body, and engage the grommet.

      Note


      • Do not kink or damage the front No. 2 brake tube.

      • Do not allow any foreign matter such as dirt or dust to enter the front No. 2 brake tube from the connecting parts.

      • Ensure that the front No. 2 brake tube passes through the center of the grommet.

    2. Using a union nut wrench, connect the front No. 2 brake tube to the front flexible hose while holding the flexible hose with a wrench.

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

      Note

      Do not allow the front No. 2 brake tube to twist or interfere with other parts or the vehicle body during tightening.

      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)

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

    4. A01XR05C02
      *a Torque Wrench Fulcrum Length

      Using a union nut wrench, connect the front No. 2 brake tube to the brake actuator assembly.

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

      Note

      Do not allow the front No. 2 brake tube to twist or interfere with other parts or the vehicle body during tightening.

      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)

  6. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  7. 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

  8. BLEED BRAKE SYSTEM

    Click here

  9. INSTALL FRONT WHEEL RH

    Click here

  10. REMOVE ENGINE ROOM SIDE COVER


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

    2. Install the 2 clips.

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

    Click here

  12. PERFORM TEST MODE INSPECTION

    Click here

  13. INSPECT BRAKE ACTUATOR USING GTS

    Click here

  14. CHECK FOR AND CLEAR DTCS

    Click here