BRAKE ACTUATOR INSTALLATION


  1. INSTALL BRAKE ACTUATOR


    1. A017E5TE02

      Install the brake actuator to the brake actuator bracket assembly with the 3 bolts.

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

      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 with the actuator by the connector.

      • Tighten the 3 bolts in order the from shown in the illustration.

    2. A017DZU

      Install the piping clamp to the brake actuator bracket assembly.

  2. INSTALL BRAKE ACTUATOR WITH BRACKET (for LHD)


    1. A017BRKE01

      Install the brake actuator with bracket to the body with the 3 bolts.

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

      Note


      • Do not damage the brake lines or wire harness.

      • Tighten the 3 bolts in order the from shown in the illustration.

    2. A017CHDE01

      Temporarily tighten each brake line to the correct positions of the brake actuator with bracket as shown in the illustration.

      Tech Tips


      • *1: To front wheel cylinder RH

      • *2: To front wheel cylinder LH

      • *3: To rear wheel cylinder RH

      • *4: To rear wheel cylinder LH

      • *5: From 1st of master cylinder

      • *6: From 2nd of master cylinder

    3. A017FEZE01

      Using a union nut wrench (10 mm and 12 mm), fully tighten each brake line.

      Torque:
      Flare Nut A (M10) without union nut wrench
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      Flare Nut A (M10) with union nut wrench
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
      Flare Nut B (M12) without union nut wrench
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Flare Nut B (M12) with union nut wrench
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

    4. A017BPH

      Connect the brake actuator connector.

      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.

    5. A017G3W

      Install the No. 1 cooler refrigerant suction tube to the 2 clamps.

    6. A017D0T

      Install the suction hose bracket to the brake actuator bracket assembly with the nut and bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    7. A017CM5

      Install the relay box.

  3. INSTALL BRAKE ACTUATOR WITH BRACKET (for RHD)


    1. A017BRKE01

      Install the brake actuator with bracket to the body with the 3 bolts.

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

      Note


      • Do not damage the brake lines or wire harness.

      • Tighten the 3 bolts in order the from shown in the illustration.

    2. A017CHDE01

      Temporarily tighten each brake line to the correct position of the brake actuator with bracket as shown in the illustration.

      Tech Tips


      • *1: To front wheel cylinder RH

      • *2: To front wheel cylinder LH

      • *3: To rear wheel cylinder RH

      • *4: To rear wheel cylinder LH

      • *5: From 1st of master cylinder

      • *6: From 2nd of master cylinder

    3. A017FEZE01

      Using a union nut wrench (10 mm and 12 mm), fully tighten each brake line.

      Torque:
      Flare Nut A (M10) without union nut wrench
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      Flare Nut A (M10) with union nut wrench
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
      Flare Nut B (M12) without union nut wrench
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Flare Nut B (M12) with union nut wrench
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

    4. A017BPH

      Connect the brake actuator connector.

      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.

    5. A017G3W

      Install the No. 1 cooler refrigerant suction tube to the 2 clamps.

    6. A017D0T

      Install the suction hose bracket to the brake actuator bracket assembly with the nut and bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  4. FILL RESERVOIR WITH BRAKE FLUID


    1. A017E1Q

      Fill the reservoir with brake fluid.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

      Note

      Make sure that there is sufficient brake fluid in the reservoir.

  5. BLEED BRAKE MASTER CYLINDER

    Note


    • If the master cylinder is reinstalled or if the reservoir becomes empty, bleed the master cylinder.

    • To prevent brake fluid from adhering, cover the painted surfaces with a shop rag or a piece of cloth.


    1. A017CMV

      Using a union nut wrench (12 mm), disconnect the 2 brake lines from the master cylinder.

    2. A017B31

      Slowly depress the brake pedal and hold it (*1).

    3. A017D7B

      Cover the 2 outer holes with fingers, and release the brake pedal (*2).

    4. Repeat (*1) and (*2) 3 or 4 times.

    5. A017EQPE01

      Using a union nut wrench (12 mm), connect the 2 brake lines to the master cylinder.

      Torque:
      w/o union nut wrench
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      w/ union nut wrench
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

  6. BLEED BRAKE LINE

    Note


    • Bleed the brake line of the wheel farthest from the master cylinder first.

    • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


    1. A017DDG

      Connect a vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed (*3).

    3. A017CQE

      When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal (*4).

    4. Repeat (*3) and (*4) until all the air in the fluid is completely bled out.

    5. Tighten the bleeder plug completely.

      Torque:
      8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

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

  7. BLEED BRAKE ACTUATOR

    Note

    After bleeding the brake system, if the specified height or feel of the brake pedal cannot be obtained, bleed the brake actuator assembly with the intelligent tester by following the procedure below.


    1. Depress the brake pedal more than 20 times with the ignition switch off.

    2. Connect the intelligent tester to the DLC3, and then turn the ignition switch on (IG).

      Note

      Do not start the engine.

    3. Turn the intelligent tester on and select "AIR BLEEDING" on the screen.

      Note


      • Refer to the intelligent tester operator's manual for further details.

      • Bleed the air by following the steps displayed on the intelligent tester.

    4. Bleed the air according to "Step 1: Increase" on the intelligent tester display.

      Note


      • Make sure that the master cylinder reservoir tank does not run out of brake fluid.

      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


      1. A017DDG

        Connect a vinyl tube to either one of the bleeder plugs.

      2. Depress the brake pedal several times, and then loosen the bleeder plug connected to the vinyl tube with the pedal depressed (*5).

      3. A017CQE

        When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal (*6).

      4. Repeat (*5) and (*6) until all the air in the fluid is completely bled out.

      5. Tighten the bleeder plug completely.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

      6. Repeat the above procedure for the rest of the wheels to bleed the brake lines.

    5. Bleed the suction line according to "Step 2: Inhalation" on the intelligent tester display.

      Note


      • Bleed the suction line by following the steps displayed on the intelligent tester.

      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


      1. A017C8D

        Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel and loosen the bleeder plug.

      2. Operate the brake actuator assembly to bleed the air using the intelligent tester (*7).

        Note


        • During this step, be sure to release the brake pedal.

        • The actuator operation stops automatically in 4 seconds.

      3. A017BW2

        Check that the actuator operation has stopped by referring to the intelligent tester display, and tighten the bleeder plug (*8).

      4. Repeat (*7) and (*8) until all the air in the fluid is completely bled out.

      5. Tighten the bleeder plug completely.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

      6. For the rest of the wheels, bleed the air in the same way as stated in the above procedure.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

    6. Bleed the pressure reduction line according to "Step 3: Decrease" on the intelligent tester display.

      Note


      • Bleed the pressure reduction line by following the steps displayed on the intelligent tester.

      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


      1. A017D3G

        Connect a vinyl tube to either one of the bleeder plugs.

      2. Loosen the bleeder plug (*9).

      3. While keeping the brake pedal fully depressed, operate the brake actuator assembly using the intelligent tester.

        Note


        • The actuator operation stops automatically in 4 seconds. When performing this procedure continuously, an interval of at least 20 seconds is required.

        • After the operation is completed, the brake pedal goes down slightly. This is a normal phenomenon when the solenoid opens.

        • During this procedure, the pedal seems heavy, but completely depress it so that the brake fluid comes out from the bleeder plug.

        • Be sure to keep the brake pedal depressed. Never depress and release the pedal repeatedly.

      4. A017CQE

        Tighten the bleeder plug, and then release the brake pedal (*10).

      5. Repeat steps (*9) to (*10) until all the air in the fluid is completely bled out.

      6. Tighten the bleeder plug completely.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

      7. Repeat the above procedures for the rest of the brakes to bleed the brake line.

    7. Bleed the brake lines again according to "Step 4: Increase" on the intelligent tester display.

      Note


      • Bleed the air by following the steps displayed on the intelligent tester.

      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


      1. A017D3G

        Connect a vinyl tube to either one of the bleeder plugs.

      2. Depress the brake pedal several times, and then loosen the bleeder plug connected to the vinyl tube with the pedal depressed (*11).

      3. A017CQE

        When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal (*12).

      4. Repeat (*11) and (*12) until all the air in the fluid is completely bled out.

      5. Tighten the bleeder plug completely.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

      6. Repeat the above procedures for each brake to bleed the brake lines.

    8. Finish "AIR BLEEDING" on the intelligent tester, and then turn off the tester.

    9. Disconnect the intelligent tester from the DLC3.

    10. Turn the ignition switch off.

  8. INSPECT FLUID LEVEL IN RESERVOIR


    1. A017FVOE01

      Check the fluid level.

      If brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  9. INSPECT FOR BRAKE FLUID LEAK

  10. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A017EFM

      Fit the 3 retainers and install the V-bank cover.

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Click here

  12. INSPECT BRAKE ACTUATOR WITH INTELLIGENT TESTER

    Click here

  13. PERFORM YAW RATE AND ACCELERATION SENSOR ZERO POINT CALIBRATION

    Click here

  14. CHECK AND CLEAR DTCS

    Click here