BRAKE ACTUATOR(for RHD) INSTALLATION

CAUTION / NOTICE / HINT

Note

While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch is turned on. Therefore, when servicing brake system components, do not depress the brake pedal or open/close the doors while the auxiliary battery is connected.

PROCEDURE


  1. INSTALL NO. 3 BRAKE ACTUATOR BRACKET


    1. B004BJJN01

      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. B004BAL

      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.

      B004BZMC01
      *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. B004B1S

      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. B004BLQ

      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. B004C3PC01
      *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. B004BTH

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

  7. INSTALL BRAKE ACTUATOR WITH BRACKET


    1. B004B40N01

      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. B004BMDC02
      *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. B004CP2

      Temporarily install the 6 brake tube flare nuts.

    3. B0049WM

      Attach the 3 brake tubes with a new clamp.

    4. B004AIKC01
      *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. B004BMDC03
      *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. B004CLY

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

    3. B004CGLC01
      *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. B004A0KC01
      B004B1M Connector Connected
      B004CNL 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 RELAY BLOCK


    1. B004C92

      Install the wire harness clamp bracket with the bolt.

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

    2. Connect the wire harness clamp with the bolt.

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

    3. Attach the 9 claws and install the relay block lower cover.

      B004CSR
    4. B004CND

      Temporarily install the relay block with the 2 bolts and nut.

    5. B004CK7

      Attach the 2 claws and install the Wiring harness protector.

    6. Install the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    7. B004AN5

      Attach the 3 claws and install the No. 2 relay block cover.

    8. B004AD3

      Tighten the 2 bolts and nut.

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

  12. INSTALL FRONT APRON FENDER INSULATOR RH


    1. B004CAC

      Install the front apron fender insulator RH with the 3 bolts.

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

  13. INSTALL AIR CLEANER WITH AIR CLEANER HOSE

    Click here

  14. INSTALL NO. 1 AIR CLEANER INLET

    Click here

  15. INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH

    Click here

  16. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

    Note

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

  17. BLEED BRAKE SYSTEM

    Click here

  18. PERFORM INITIALIZATION AND CALIBRATION OF LINEAR SOLENOID VALVE

    Click here

  19. CHECK AND CLEAR DTC

    Click here