BRAKE ACTUATOR (for RHD) INSTALLATION

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.


  1. INSTALL BRAKE ACTUATOR

    Note

    Do not remove the hole plug before installing a new brake actuator because the brake actuator is filled with brake fluid.


    1. A01GLCK
      Text in Illustration
      *1 Brake Actuator
      *2 No. 3 Bracket

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

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

      Note

      After temporarily installing either bolt A or B, tighten the remaining bolts.

      A01GNA7E03
    2. A01GI3OE02
      Text in Illustration
      *1 Cushion
      *2 Spacer
      A01GKGFE02
      Text in Illustration
      *1 Bracket
      *2 Cushion
      *3 Spacer

      Install the 3 cushions and 3 spacers to the bracket.

    3. A01GI48

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

      Torque:
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

  2. INSTALL BRAKE ACCUMULATOR PUMP


    1. A01GN05E02

      Install the brake booster pump collars (labeled A) and brake booster pump bushes (labeled B) to the brake accumulator pump.

    2. A01GJMLE02
      Text in Illustration
      *1 Actuator Bracket
      *2 Brake Accumulator Pump
      *3 Collar (A)

      Install the brake accumulator pump to the brake actuator bracket.

      Note

      After installing the brake accumulator pump, make sure the collar has not fallen off.

    3. A01GJE5E03
      Text in Illustration
      *1 Brake Accumulator Pump
      *2 Clamp (D)
      *3 Bush (C)

      Install the brake booster pump bush (labeled C) and a new brake actuator bracket clamp (labeled D) to the brake accumulator pump.

      Note

      Make sure to securely insert the brake accumulator pump until the claws of the clamp are attached.

  3. INSTALL NO. 4 BRAKE ACTUATOR BRACKET


    1. A01GLI0

      Install the No. 4 brake actuator bracket to the brake actuator with the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  4. CONNECT BRAKE ACCUMULATOR PUMP CONNECTOR BOX


    1. A01GIW0E05
      Text in Illustration
      *1 Connector Box

      Connect the brake accumulator pump connector box as follows:


      1. Install the connector box with the nut (labeled A).

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      2. Attach the 2 wiring harness clamps (labeled B).

  5. INSTALL NO. 3 BRAKE ACTUATOR TUBE

    Note


    • Do not damage the No. 3 brake actuator tube, brake actuator and brake accumulator pump.

    • When installing the No. 3 brake actuator tube, hold the tube, brake actuator and brake accumulator pump securely.

    • When tightening the nut, make sure that other parts do not move with the nut.


    1. A01GK8O

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

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  6. INSTALL NO. 2 BRAKE ACTUATOR HOSE


    1. A01GK24
      A01GIEHE02

      Install the reservoir connector to the No. 2 brake actuator hose with the hose clip as shown in the illustration.

      Length "A"
      4.0 to 7.0 mm (0.158 to 0.276 in.)
      Text in Illustration
      *1 Reservoir Connector
      *a View B
      *b View C
      *c Paint Mark
      *d 30°to 60°
    2. A01GMR7E02
      Text in Illustration
      *a Front

      With the paint mark on the hose's tip facing the bottom of the vehicle, install the No. 2 brake actuator hose to the brake accumulator pump with the hose clip.

      Tech Tips

      Install the hose clip so that its claws face the front of the vehicle.

      Note

      When inserting the hose, be careful that there is no excessive weight applied to the union of the brake accumulator pump (especially in the union rotation direction).

  7. INSTALL BRAKE ACTUATOR PROTECTOR


    1. A01GINX

      Install the protector.

  8. INSTALL NO. 1 BRAKE ACTUATOR HOSE


    1. A01GJY0E03
      Text in Illustration
      *a Rear

      With the paint mark on the hose's tip facing the bottom of the vehicle, install the No. 1 brake actuator hose to the brake actuator with the hose clip.

      Tech Tips

      Install the hose clip so that its claws face the rear of the vehicle.

      Note

      When inserting the hose, be careful that there is no excessive weight applied to the union of the brake actuator (especially in the union rotation direction).

  9. INSTALL NO. 5 BRAKE ACTUATOR BRACKET


    1. A01GJ8F

      Install the No. 5 brake actuator bracket to the body with the bolt.

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

  10. INSTALL BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY


    1. A01GN9EE02

      Install the brake actuator and brake accumulator pump to the body with the bolt (labeled A) and 2 nuts (labeled B).

      Tech Tips

      First insert the bracket bottom's longer stud bolt (vehicle outer side, labeled C) into the body.

      Note


      • Do not damage the brake tubes.

      • When installing the brake actuator and brake accumulator pump to the vehicle, do not hold the connector, harness, hose or tube parts.

      • Do not drop the brake actuator and brake accumulator pump. Do not use parts that have been dropped.

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

    2. Connect the front fender liner rear side.

    3. A01GJPL

      Connect the No. 1 brake actuator hose to the body with the clamp.

    4. A01GK6K

      Connect the brake actuator connector.

      Note


      • Before connecting the vehicle wire harnesses, make sure that the connector faces are free of foreign matter.

      • Make sure that the connector is locked securely.

  11. CONNECT BRAKE TUBE


    1. A01GN1XE01

      Using a union nut wrench, connect the No. 1 (labeled A) and No. 2 (labeled B) brake actuator tubes.

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

      Note


      • Do not damage the No. 1 and No. 2 brake actuator tubes.

      • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    2. A01GJ4QE04

      Set each brake tube to the correct positions on the brake actuator as shown in the illustration.


      • *1: To FR RH

      • *2: To FR LH

      • *3: To RR RH

      • *4: To RR LH

      • *5: From Master Cylinder

      • *6: From Stroke Simulator

    3. A01GNOP

      Using a union nut wrench, connect the 6 brake tubes.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  12. INSTALL FRONT WHEEL

    Torque:
    140 N*m  { 1428 kgf*cm, 103 ft.*lbf }

  13. INSTALL RESERVOIR BRACKET


    1. A01GK8N

      Install the reservoir bracket with the 3 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  14. INSTALL NO. 1 RESERVOIR HOSE


    1. A01GJI6E02
      A01GHN6E02

      Install the reservoir connector (labeled A) to the No. 1 reservoir hose (labeled B) with the hose clip (labeled C) as shown in the illustration.

      Length "A"
      4.0 to 7.0 mm (0.158 to 0.276 in.)
      Text in Illustration
      *1 Reservoir Connector
      *a View B
      *b Paint Mark
      *c 75° to 105°
      *d 30° to 60°

    2. With the paint mark on the hose's tip facing the top of the vehicle, install the No. 1 reservoir hose (labeled B) to the master cylinder with the hose clip (labeled D).

      Tech Tips

      Install the hose clip so that its claws face the top of the vehicle.

  15. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A01GLXTE01

      Connect the No. 1 reservoir hose (labeled F) and No. 2 brake actuator hose (labeled E) to the reservoir. The reservoir connector connecting procedure must be followed as described below:


      1. Remove the foreign matter entry prevention plastic bags.

        Note

        Check that there is no damage or foreign objects on the connected part of the reservoir and reservoir connectors.

      2. A01GJXUE02
        Text in Illustration
        *1 Reservoir
        *2 Rib

        Insert the reservoir connector to the reservoir until the reservoir connector makes a "click" sound, so that the reservoir connector tip's groove is aligned with the reservoir's rib.

      3. A01GII2E02
        Text in Illustration
        *1 Claw
        *2 Lock

        Securely set the lock of the reservoir connector.

      4. Check that the reservoir connector lock's claw is securely attached.

    2. With the paint mark on the hose's tip facing the top of the vehicle, connect the No. 1 brake actuator hose (labeled D) to the reservoir with the hose clip.

      Tech Tips

      Install the hose clip so that its claws face the top of the vehicle.

    3. Connect the brake fluid level warning switch connector (labeled C), and then attach the connector clamp (labeled B) to the reservoir bracket.

    4. Install the brake fluid reservoir with the 2 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    5. Connect the wire harness clamp (labeled A) to the reservoir.

  16. CONNECT NO. 3 RELAY BLOCK


    1. A01GIQR

      Install the No. 3 relay block to the reservoir bracket.

      Note

      Check that the claw of the No. 3 relay block is securely attached to the reservoir bracket.

  17. INSTALL SKID CONTROL ECU BRACKET

    Click here

  18. INSTALL SKID CONTROL ECU

    Click here

  19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note


    • Make sure that the 2 accumulator pump connectors are disconnected.

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

  20. BLEED BRAKE SYSTEM

    Click here

  21. CLEAR THE DTC

    Click here

  22. PERFORM LINEAR VALVE OFFSET LEARNING


    1. When the brake actuator is replaced, perform the linear valve offset learning Click here.

  23. CHECK FOR DTC


    1. If any DTC is set, perform the troubleshooting for the DTC Click here.

  24. READ VALUE OF ACCUMULATOR PRESSURE SENSOR OUTPUT VOLTAGE

    Tech Tips

    If removing and installing the No. 3 brake actuator tube, check for a brake fluid leak from the No. 3 tube connection area by monitoring the accumulator pressure sensor output value from the brake actuator. Directly checking for a brake fluid leak from the No. 3 tube connection area is difficult.


    1. Turn the engine switch off.

    2. Connect the intelligent tester to the DLC3.

    3. Turn the engine switch on (IG).

    4. Operate the intelligent tester according to the display and select "DATA LIST".

      Skid control ECU:
      Tester Display Measurement Item/Range Normal Condition Diagnostic Note
      Accumulator Pressure Sensor Accumulator pressure sensor / min.: 0 V, max.: 5 V Specified value: 2.6 to 3.8 V -
    5. A01GK8O

      Depress the brake pedal 4 or 5 times to operate the pump motor, and check the output value on the intelligent tester with the motor stopped (not braking).

      OK
      Accumulator pressure sensor's output voltage drops 0.2 V or less for 30 seconds.

      If the voltage drops more than 0.2 V, there may be a brake fluid leak from the No. 3 brake actuator tube connection area. Remove the brake actuator and brake accumulator pump, and then repeat the procedures above from the retightening of the 2 union nuts of the No. 3 brake actuator tube.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  25. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  26. INSTALL COWL TOP VENTILATOR LOUVER LH


    1. A01GM4S

      for LHD:

      Install the 6 clips and cowl top ventilator louver RH.

      Note

      If the cowl top ventilator louver RH is not properly installed, water may leak into the engine room and cause malfunctions. Therefore, make sure the cowl top ventilator louver RH is installed properly.

    2. A01GI9P

      for RHD:

      Install the 6 clips and cowl top ventilator louver LH.

      Note

      If the cowl top ventilator louver LH is not properly installed, water may leak into the engine room and cause malfunctions. Therefore, make sure the cowl top ventilator louver LH is installed properly.

  27. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A01GMKRE01

      Slide the cover from the vehicle front toward the rear of the vehicle to attach the 2 clips labeled A, and then attach the 4 clips labeled B to install the V bank cover sub-assembly.

      Note


      • Make sure the clips are attached securely.

      • Attaching the clips forcefully or hitting the top of the clips may damage them.

      • When attaching the clips labeled A, be sure to slide the cover from the front of the vehicle toward the rear of the vehicle.