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 BRAKE ACTUATOR CASE COLLAR


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

      Note

      Make sure the collars are in full contact with the cushions.

  3. INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY


    1. B002CS3E02

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

      Note


      • Do not remove the hole plugs of a new brake actuator before connecting the 6 brake lines because the brake actuator is filled with brake fluid.

      • Do not hold the actuator by the connector.

      • If the actuator is dropped, replace it.

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

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

  4. 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 }

  5. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET


    1. B002F1VC03

      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. B002DQKC04
      *a From Front Master Cylinder
      *b From Rear Master Cylinder
      *c To Front Wheel Cylinder Assembly RH
      *d To Front Wheel Cylinder Assembly RH
      *e To Rear Wheel Cylinder Assembly RH
      *f To Rear Wheel Cylinder Assembly LH

      Temporarily connect the 3 brake tubes to the correct positions on the brake actuator assembly as shown in the illustration.

    4. B002CY5C02
      *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 162 mm (6.378 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

    5. B002F0HC02
      B002C8N Lock Lever Locked

      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.

  6. INSTALL REAR NO. 1 BRAKE TUBE


    1. B002CPAC02
      *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
      19.5 N*m  { 199 kgf*cm, 14 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 and interfere with other parts or 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 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.378 in.)): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

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

  7. INSTALL FRONT NO. 1 BRAKE TUBE


    1. B002E4MC03
      *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
      19.5 N*m  { 199 kgf*cm, 14 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 and interfere with other parts or 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 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.378 in.)): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

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

  8. CONNECT VACUUM HOSE ASSEMBLY


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

  9. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  10. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK


    1. B002EOR

      Install the No. 3 engine room relay block with the bolt and nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  11. 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

  12. BLEED BRAKE SYSTEM

    Click here

  13. INSTALL FRONT WHEEL RH

    Click here

  14. REMOVE ENGINE ROOM SIDE COVER


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

    2. Install the 2 clips.

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

    Click here

  16. PERFORM TEST MODE INSPECTION

    Click here

  17. INSPECT BRAKE ACTUATOR USING GTS

    Click here

  18. CHECK FOR AND CLEAR DTCS

    Click here