BRAKE ACTUATOR INSTALLATION


  1. INSTALL BRAKE ACTUATOR ASSEMBLY


    1. A01BCCM

      Install the brake actuator assembly to the actuator bracket with the 2 nuts.

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

      Note


      • Do not remove the hole plug until the new actuator assembly is connected because it already contains brake fluid.

      • Insert the protrusion of the actuator bolt holder between the positioning claws of the actuator bracket No.1.

      • Insert the positioning pin of the actuator bracket No.1 into the cushion of the actuator assembly.

  2. INSTALL BRAKE ACTUATOR COVER


    1. A01BB6R

      Install the actuator cover to the brake actuator assembly with the 2 nuts.

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

  3. INSTALL BRAKE TUBE


    1. A01BAMG

      Using SST, install the 5 brake tubes and brake way No.1 to the brake actuator assembly.

      SST
      09023-00101
      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

  4. INSTALL BRAKE ACTUATOR ASSEMBLY WITH FRONT BRAKE TUBE WAY NO.1


    1. A01BB33

      Install the brake actuator assembly with front brake tube way No.1 and the brake tube to the body with the 5 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

      Do not bend or damage the brake tube.

    2. A01BFVW

      Using SST, connect the 6 brake tubes to the front brake tube way No.1.

      SST
      09023-00101
      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
    3. A01BF67

      Connect the connector and lock the lock lever.

      Note

      Check that the lock lever is securely locked.

  5. INSTALL FRONT MUDGUARD


    1. A01BBWJ

      Install the front mudguard with the 3 clips.

  6. INSTALL SUB RADIATOR ASSEMBLY


  7. INSTALL HIGH PITCHED HORN ASSEMBLY

  8. INSTALL WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY


    1. Connect the connector and hose.

    2. A01BD06

      Install the wind washer jar assembly with the 2 bolts.

      Torque:
      4.9 N*m  { 50 kgf*cm, 43 in.*lbf }

  9. INSTALL RADIATOR RESERVE TANK ASSEMBLY


    1. Connect the water by-pass hose No.2 with the clip.

    2. Connect the water by-pass hose No.1 with the clip.

    3. A01BHM3

      Place the reserve tank in the 2 grommets of the radiator upper support, and install the radiator reserve tank assembly with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  10. INSTALL RADIATOR SUPPORT UPPER


    1. A01BFVV

      Install the radiator upper support with the 6 bolts and 2 screws.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

      Tech Tips

      If the position of the radiator upper support goes out of alignment while installing it, remove the front bumper and adjust the hood lock brace and bumper stay.

  11. INSTALL HOOD LOCK ASSEMBLY


    1. Connect the hood lock cable assembly to the hood lock assembly.

    2. A01BBWB

      Temporarily tighten the hood lock assembly with the 3 bolts from the radiator upper support.

    3. A01BAUN

      Check the hood position and adjust the hood lock assembly position.

    4. Tighten the hood lock assembly with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  12. INSTALL FRONT BUMPER REINFORCEMENT


    1. A01BBEZ

      Install the front bumper reinforcement with the 6 bolts.

      Torque:
      61 N*m  { 622 kgf*cm, 45 ft.*lbf }

  13. INSTALL HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY

  14. INSTALL AIR INLET DUCT NO.1 (LHD (W/ INTERCOOLER ASSEMBLY))

  15. INSTALL AIR INLET DUCT NO.2 (LHD (W/ INTERCOOLER ASSEMBLY))

  16. INSTALL RADIATOR SUPPORT SEAL UPPER (LHD (W/O INTERCOOLER ASSEMBLY))


    1. A01BBFP

      Install the air inlet duct No.1 with the 6 clamps.

  17. INSTALL FRONT BUMPER

  18. INSTALL STEP PLATE COVER RH

  19. INSTALL STEP PLATE COVER LH

  20. INSTALL RADIATOR GRILLE

  21. INSTALL ENGINE UNDER COVER NO.1

  22. INSTALL FRONT WHEEL

    Torque:
    100 N*m  { 1,020 kgf*cm, 74 ft.*lbf }

  23. ADD BRAKE FLUID

    A01BB0E
    Fluid
    SAE J1703 or FMVSS No. 116 DOT3 or equivalent

  24. BLEED BRAKE LINE


    1. Connect the vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times and loosen the bleeder plug with the pedal held down.

    3. At the point where the fluid stops coming out, tighten the bleeder plug and release the brake pedal.

    4. Repeat this procedure until the air in the brake fluid is completely bled out.

    5. Tighten the bleeder plug.


      1. Front bleeder plug:

        Torque:
        10.8 N*m  { 110 kgf*cm, 8 ft.*lbf }

      2. Rear bleeder plug:

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

    6. Repeat the above procedure to bleed the air out of the brake line for each wheel.

  25. INSPECT BRAKE FLUID LEVEL


    1. Check the fluid level and add fluid if necessary.

      Fluid
      SAE J1703 or FMVSS No.116 DOT3 or equivalent

  26. ADD ENGINE COOLANT