BRAKE ACTUATOR(for RHD) INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

The parking brake indicator light blinks (red) when the ignition switch is turned to ON after replacing the brake actuator assembly. Operate the electric parking brake switch assembly to turn off the parking brake indicator light.

PROCEDURE


  1. INSTALL BRAKE ACTUATOR BOLT CUSHION


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

  2. INSTALL NO. 2 BRAKE ACTUATOR CASE COLLAR


    1. Install the No. 2 brake actuator case collar to the brake actuator bolt cushion.

      Note

      Make sure that the No. 2 brake actuator case collar is in full contact with the brake actuator bolt cushion.

  3. INSTALL BRAKE ACTUATOR ASSEMBLY


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

    2. B006XS1N01

      Tighten the 2 nuts and install the bolt.

      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.

      • Do not drop the brake actuator assembly when carrying it.

      • Tighten the bolt and 2 nuts in the order shown in the illustration.

  4. INSTALL BRAKE ACTUATOR WITH BRACKET


    1. B006YG2C01
      *a Stud Bolt
      *b Cushion
      *c Side Member

      Temporarily install the brake actuator with bracket to the vehicle body.

      Note


      • Do not kink or damage the brake lines.

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

      • Be careful not to allow any brake fluid to enter the connector.

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

      • Do not drop the brake actuator with bracket when carrying it.

      Tech Tips


      • Install the brake actuator with bracket while avoiding the brake lines.

      • After temporarily installing the brake actuator with bracket to the vehicle body, confirm that the cushion is contacting the upper side of the side member.

    2. B006Y8YN01

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

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

    3. Remove the protective tape.

    4. B006Y8Q

      Engage the clamp to install a new brake tube clamp.

    5. Return the front No. 5 brake tube to its original position.

      Note

      Do not apply excessive force to the front No. 5 brake tube.

    6. B0071JN

      Temporarily install the front No. 5 brake tube to the front flexible hose.

      Note


      • Do not kink or damage the front No. 5 brake tube.

      • Do not allow any foreign matter such as dirt or dust to enter the front No. 5 brake tube from the connecting parts.

    7. B006WZ0

      Engage the clamp to connect the front No. 5 brake tube.

      Note

      Do not kink or damage the front No. 5 brake tube.

    8. B007127C01
      *a To Front Wheel Cylinder Assembly RH
      *b To Rear Wheel Cylinder Assembly LH
      *c To Rear Wheel Cylinder Assembly RH
      *d To Front Wheel Cylinder Assembly LH

      Temporarily tighten the 4 brake lines to the correct positions on the brake actuator assembly as shown in the illustration.

      Note


      • Do not kink or damage the brake lines.

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

    9. B0070KAC01
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

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

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

      Note

      Do not kink or damage the brake lines.

      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)

    10. B006ZXSC01
      *a From 1st Chamber of Brake Master Cylinder Sub-assembly
      *b From 2nd Chamber of Brake Master Cylinder Sub-assembly

      Temporarily tighten the 2 brake lines to the correct positions on the brake actuator assembly as shown in the illustration.

      Note


      • Do not kink or damage the brake lines.

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

    11. B006WT1C01
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

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

      Torque:
      Specified tightening torque
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note

      Do not kink or damage the brake lines.

      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 (6.38 in.)):

        17.4 N*m (177 kgf*cm, 13 ft.*lbf)

    12. B006XI7C01
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Using a union nut wrench, fully tighten the front No. 5 brake tube while holding the front flexible hose with a wrench.

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

      Note

      Do not kink or damage the front No. 5 brake tube.

      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)

    13. B006XXFC01
      B006ZFL Connect the connector
      B006WSJ 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 BATTERY CLAMP SUB-ASSEMBLY


    1. B006YEA

      Install the battery clamp sub-assembly with the 3 bolts and nut.

      Torque:
      Bolt
      18.5 N*m  { 189 kgf*cm, 14 ft.*lbf }
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Engage the 5 clamps to the battery clamp sub-assembly.

  6. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE (for 2AR-FE)

    Click here

  7. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE (for 2GR-FKS)

    Click here

  8. INSTALL FRONT WHEEL LH

    Click here

  9. INSTALL BATTERY

    for 2AR-FE: Click here

    for 2GR-FKS: Click here

  10. BLEED BRAKE SYSTEM

    Click here

  11. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY


    1. B006XVGN02

      Temporarily install the front center upper suspension brace sub-assembly with the 6 bolts and 4 nuts.

    2. Fully tighten the 2 nuts (A).

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    3. Fully tighten the 6 bolts and 2 nuts (B) to install the front center upper suspension brace sub-assembly.

      Torque:
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Nut (B)
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    4. Engage the 3 clamps to install the wire harness.

    5. Connect the connector.

  12. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  13. PERFORM SYSTEM VARIANT LEARNING AND ACCELERATION SENSOR ZERO POINT CALIBRATION

    Click here

  14. PERFORM TEST MODE INSPECTION

    Click here

  15. INSPECT BRAKE ACTUATOR USING GTS

    Click here

  16. CHECK FOR AND CLEAR DTCS

    Click here