BRAKE ACTUATOR(for RHD) INSTALLATION

CAUTION / NOTICE / HINT

Note

While the battery is connected, even if the engine switch is off, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal and open/close the doors while the battery is connected.

PROCEDURE


  1. INSTALL NO. 3 BRAKE ACTUATOR BRACKET


    1. B000WVMN01

      Install the No. 3 brake actuator bracket to the body with the 4 bolts.

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

      Note

      Tighten the 4 bolts uniformly in alphabetical order.

  2. INSTALL NO. 1 BRAKE ACTUATOR BRACKET


    1. B000WUV

      Install the No. 1 brake actuator bracket to the brake actuator assembly with the 3 bolts.

      Torque:
      9.3 N*m  { 95 kgf*cm, 82 in.*lbf }

  3. INSTALL NO. 2 BRAKE ACTUATOR BRACKET


    1. Install the 3 brake actuator bracket cushions to the No. 2 brake actuator bracket.

      B000WS8C01
      *1 Brake Actuator Bracket Cushion *2 Brake Actuator Bracket Spacer

    2. Install the 3 brake actuator bracket spacers to the brake actuator bracket cushion.

    3. B000XD1

      Install the No. 2 brake actuator bracket to the brake actuator assembly with the 3 nuts.

      Torque:
      9.3 N*m  { 95 kgf*cm, 82 in.*lbf }

  4. INSTALL NO. 1 BRAKE ACTUATOR WAY


    1. B000U1O

      Install the No. 1 brake actuator way to the brake actuator assembly with the 2 bolts.

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

  5. INSTALL NO. 3 BRAKE ACTUATOR TUBE


    1. B000UOQC01
      *a Torque Wrench Fulcrum Length

      Temporarily install the No. 3 brake actuator tube to the brake actuator assembly and No. 1 brake actuator way.

    2. Using a union nut wrench, tighten the No. 3 brake actuator tube.

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

      Note


      • Do not kink or damage the No. 3 brake actuator tube.

      • Do not allow any foreign matter such as dirt or dust to enter the No. 3 brake actuator 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 (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

  6. INSTALL BRAKE ACTUATOR HOSE


    1. B000WPG

      Connect the brake actuator hose to the brake actuator assembly, and slide the clamp to secure it.

  7. INSTALL BRAKE ACTUATOR WITH BRACKET


    1. B000XQ4N01

      Install the brake actuator with bracket with the bolt and 2 nuts.

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

      Note


      • Tighten the bolt and 2 nuts uniformly in alphabetical order.

      • Do not kink or damage the brake tube.

      • Do not hold the brake actuator with bracket by the connector, hose or union.

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

      • Do not drop the brake actuator assembly. Do not use parts that have been dropped.

      Tech Tips

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

    2. Connect the brake actuator hose to the brake master cylinder reservoir, and slide the clamp to secure it

  8. INSTALL BRAKE TUBE


    1. B000X1LC02
      *a From Brake Stroke Simulator Cylinder Sub-assembly
      *b From Brake Master Cylinder Sub-assembly

      Tighten the 3 brake lines to the correct positions on the brake actuator assembly as shown in the illustration.

    2. B000TSJ

      Temporarily install the 6 brake tube flare nuts.

    3. B000VLG

      Attach the 3 brake tubes with a new clamp.

    4. B000TOZC01
      *a Torque Wrench Fulcrum Length

      Using a union nut wrench, tighten the 6 brake tube flare nuts.

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

      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 (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

  9. CONNECT BRAKE TUBE


    1. B000X1LC03
      *a To Rear Wheel Cylinder Assembly RH
      *b To Rear Wheel Cylinder Assembly LH
      *c To Front Wheel Cylinder Assembly LH

      Tighten the 3 brake lines to the correct positions on the brake actuator assembly as shown in the illustration.

    2. B000WGN

      Attach the claws and connect the 3 upper side brake tubes to the clam.

    3. B000YNZC01
      *a Torque Wrench Fulcrum Length

      Temporarily install the 4 brake tube flare nuts.

    4. Connect the No. 2 brake actuator tube with the bolt.

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

    5. Using a union nut wrench, tighten the 4 brake tube flare nuts.

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

      Note


      • Do not kink or damage the brake tube.

      • Do not allow any foreign matter such as dirt or dust to enter the 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 (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

  10. CONNECT WIRE HARNESS


    1. B000YL3C01
      B000WYJ Connector Connected
      B000YNM Lock Lever Locked

      Connect the 2 clips.

    2. Connect the brake actuator 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.

  11. INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH

    Click here

  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Click here

    Note

    Make sure that the 2 brake booster pump connectors are disconnected.

  13. BLEED BRAKE SYSTEM

    Click here

  14. PERFORM INITIALIZATION AND CALIBRATION OF LINEAR SOLENOID VALVE

    Click here

  15. CHECK AND CLEAR DTC

    Click here