FRONT BRAKE FLEXIBLE HOSE INSTALLATION

Note

Because the left and right hoses are not interchangeable, verify the part number when installing the flexible hoses.
If the hoses are to be reused, connect them after checking the identification marks placed when each hose was disconnected.

INSTALL FRONT FLEXIBLE HOSE
1. Connect the front flexible hose to the disc brake cylinder assembly with a new union bolt and a new gasket.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
2. Install the front flexible hose with a new clip.
  
  Note
  
  Install the clip as far as it will go.
3. Using a union nut wrench (10 mm), connect the brake line to the front flexible hose while holding the front flexible hose with a wrench.
  
  Torque:
  
  without union nut wrench
  
  15 N*m { 155 kgf*cm, 11 ft.*lbf }
  
  with union nut wrench
  
  14 N*m { 143 kgf*cm, 10 ft.*lbf }
  Note
  
  Do not bend or damage the brake line.
  
  Do not allow any foreign matter such as dirt and dust to enter the brake line.
  
  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. Install the front flexible hose to the absorber bracket with the bolt.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
FILL BRAKE FLUID RESERVOIR
1. 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.
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. 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. 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.
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. 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. 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. 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. 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. 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. 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. 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. 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.
INSPECT FLUID LEVEL
1. 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
INSPECT FOR BRAKE FLUID LEAK
INSTALL FRONT WHEEL

Torque:

103 N*m { 1050 kgf*cm, 76 ft.*lbf }