BRAKE ACTUATOR INSTALLATION


  1. INSTALL BRAKE ACTUATOR BRACKET (for LHD)


    1. A0163I3E02

      Install the 3 brake actuator bolt case cushions and 3 brake actuator bolt collars to the brake actuator bracket.

  2. INSTALL BRAKE ACTUATOR BRACKET (for RHD)


    1. A015ZHQE01

      Install the 3 brake actuator bolt case cushions and 3 brake actuator collars to the brake actuator bracket assembly.

  3. INSTALL BRAKE ACTUATOR ASSEMBLY (for LHD)


    1. A015YVKE03

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

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

      Note


      • If installing a new brake actuator, do not remove the hole plugs before connecting the 6 brake lines because the brake actuator is filled with brake fluid.

      • Do not carry the brake actuator assembly by the connector.

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

  4. INSTALL BRAKE ACTUATOR ASSEMBLY (for RHD)


    1. A015YOWE01

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

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

      Note


      • If installing a new brake actuator, do not remove the hole plugs before connecting the 6 brake lines because the brake actuator is filled with brake fluid.

      • Do not carry the brake actuator assembly by the connector.

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

  5. TEMPORARILY INSTALL BRAKE ACTUATOR WITH BRACKET (for LHD)


    1. A01614GE03

      Temporarily install the brake actuator with bracket.

  6. TEMPORARILY INSTALL BRAKE ACTUATOR WITH BRACKET (for RHD)


    1. A0162BLE02

      Temporarily install the brake actuator with bracket.

  7. INSTALL BRAKE ACTUATOR WITH BRACKET (for LHD)


    1. A0162O3E01

      Install the brake actuator with bracket to the body with the 2 bolts and nut.

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

      Note


      • Do not damage the brake lines or wire harness.

      • Tighten the 2 bolts and nut in the order shown in the illustration.

    2. A015ZOVE02
      Text in Illustration
      *1 Front No. 1 Brake Line
      *2 Rear No. 1 Brake Line

      Install the front No. 1 brake line and rear No. 1 brake line to the clamp.

    3. A01619C

      Connect the vacuum hose to the check valve with the clip.

    4. A0160OQE03
      Text in Illustration
      *1 Clamp
      *2 Vacuum Hose
      *3 Mark

      Engage the clamps and inspect the condition of the vacuum hose.

      Note

      Align the vacuum hose matchmarks and the clamp as shown in the illustration.

    5. A0163E7E05
      Text in Illustration
      *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 Master Cylinder Chamber
      *6 from 2nd Master Cylinder Chamber

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

    6. A01615R

      Using a union nut wrench, fully tighten each brake line.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

      Note


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

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

    7. A01611NE04
      Text in Illustration
      *1 Lock Lever

      Connect the brake actuator connector.

      Note


      • Make sure that the actuator connector can be connected smoothly. Do not allow water, oil or dirt to enter.

      • Make sure that the connector is locked securely.

  8. INSTALL BRAKE ACTUATOR WITH BRACKET (for RHD)


    1. A0162BLE01

      Temporarily install the brake actuator assembly with bracket.

    2. A015YRVE01

      Install the brake actuator with bracket to the body with the 2 bolts and nut.

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

      Note


      • Do not damage the brake lines or wire harness.

      • Tighten the 2 bolts and nut in the order shown in the illustration.

    3. A0163GHE04
      Text in Illustration
      *1 Grommet
      *2 Front No. 2 Brake Line

      Install the front No. 2 brake line and grommet.

      Note

      Make sure that the grommet is installed correctly.

    4. A015ZQSE03
      Text in Illustration
      *1 Turn
      *2 Hold
      *3 Fulcrum Length

      Using a union nut wrench (10 mm), connect the brake line to the front flexible hose while holding the flexible hose with a wrench.

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

      Note


      • Do not kink or damage the brake lines.

      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the clip or bracket.

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

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

    5. A0160LFE02
      Text in Illustration
      *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 Master Cylinder Chamber
      *6 from 2nd Master Cylinder Chamber

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

    6. A0160LFE03

      Using a union nut wrench, fully tighten each brake line.

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

      Note


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

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

    7. A0161HR

      Connect the brake actuator connector.

      Note


      • Make sure that the actuator connector can be connected smoothly. Do not allow water, oil or dirt to enter.

      • Make sure that the connector is locked securely.

  9. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (for LHD)

    Tech Tips

    Refer to the procedure from Install Brake Master Cylinder Sub-assembly Click here.

  10. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (for RHD)

    Tech Tips

    Refer to the procedure from Install Brake Master Cylinder Sub-assembly Click here.

  11. OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR

    Tech Tips

    Obtain zero point of the yaw rate and acceleration sensor Click here.

  12. CHECK FOR SENSOR SIGNAL

    Tech Tips

    Check for sensor signal Click here.

  13. INSPECT ACTUATOR USING INTELLIGENT TESTER

    Tech Tips

    Click here