BRAKE ACTUATOR (for RHD) INSTALLATION

Note

While the battery is connected, even if the power 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 or 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. A01GX8DE02
      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

      Temporarily install either bolt A or B first.

    2. A01GWOFE02
      Text in Illustration
      *1 Cushion
      *2 Spacer
      *3 Bracket

      Install the 3 cushions and 3 spacers to the bracket.

    3. A01H2AD

      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. A01GYX2E02
      Text in Illustration
      *1 Brake Accumulator Pump
      *2 Actuator Bracket
      *3 Collar (A)
      *4 Bush (C)
      *5 Clamp (D)

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

    2. 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. 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. A01H22H

      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. A01GWY5E06
      Text in Illustration
      *1 Connector Box

      Connect the brake accumulator pump connector box.


      1. Install the connector box with the nut.

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

      2. Attach the 2 wiring harness clamps.

  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. A01GZQM

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

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

      Tech Tips

      A01GXLHE04
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13 N*m (137 kgf*cm, 10 ft.*lbf).

  6. INSTALL NO. 2 BRAKE ACTUATOR HOSE


    1. A01GZF3E02
      Text in Illustration
      *1 Reservoir Connector
      *a Paint Mark
      *b View B
      *c View C
      *d 30°to 60°

      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 (0.157 to 0.276 in.)
    2. A01GYY0E02
      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. A01H0XW

      Install the protector.

  8. INSTALL NO. 1 BRAKE ACTUATOR HOSE


    1. A01H18TE03
      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. A01GX3Y

      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. A01H0NFE03

      Install the brake actuator and brake accumulator pump to the body with the bolt and 2 nuts.

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

      Tech Tips

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

    2. Connect the front fender liner rear side.

    3. A01H18N

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

    4. A01GWFF

      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. A01H1YC

      Using a union nut wrench, connect the No. 1 and No. 2 brake actuator tubes.

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

      Note

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

      Tech Tips

      A01GXLHE04
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13 N*m (137 kgf*cm, 10 ft.*lbf).

    2. A01GXCIE04

      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 Brake Master Cylinder

      • *6: From Brake Stroke Simulator Cylinder

    3. A01GZK0

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

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

      Tech Tips

      A01GXLHE04
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13 N*m (137 kgf*cm, 10 ft.*lbf).

  12. INSTALL FRONT WHEEL

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

  13. INSTALL RESERVOIR BRACKET


    1. A01GX2S

      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. A01GZX4E02
      Text in Illustration
      *1 Reservoir Connector
      *a View B
      *b Upper
      *c Paint Mark
      *d 75°to 105°
      *e 30°to 60°

      Install the reservoir connector to the No. 1 reservoir hose with the hose clip as shown in the illustration.

      Length "A"
      4.0 to 7.0 mm (0.157 to 0.276 in.)

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

      Tech Tips

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

  15. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A01H2C3E02
      Text in Illustration
      *1 Reservoir
      *2 Rib
      *3 Claw
      *4 Lock
      *a Upper

      Connect the No. 1 reservoir hose (labeled A) and No. 2 brake actuator hose (labeled B) 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. 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. 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 C) 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, and then attach the connector clamp 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 to the reservoir.

  16. CONNECT NO. 3 RELAY BLOCK


    1. A01GZMJ

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

      Note

      Make sure 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 NO. 2 INVERTER COOLING PIPE


    1. A01GYTN

      Connect the No. 2 inverter cooling pipe with the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  20. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE 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.

  21. INSTALL BATTERY SERVICE HOLE COVER LH


    1. A01GZIME02
      Text in Illustration
      *A for Standard
      *B for Ottoman

      Attach the battery service hole cover LH with the clip and fastening tape.

  22. INSTALL DECK TRIM SIDE BOARD LH (w/o Spare Tire)


    1. A01GXQQ

      Attach the 2 clips to install the deck trim side board LH.

  23. INSTALL DECK BOARD ASSEMBLY (w/o Spare Tire)

    A01GZ3P

  24. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

    A01GWKI

  25. BLEED BRAKE SYSTEM

    Click here

  26. CLEAR THE DTC

    Click here

  27. PERFORM LINEAR VALVE OFFSET LEARNING


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

  28. CHECK FOR DTC


    1. Check for DTC. If any DTC is output, perform the troubleshooting for that DTC Click here.

  29. 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 power switch OFF.

    2. Connect the intelligent tester to the DLC3.

    3. Turn the power 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. A01GZQM

      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:
      Specified tightening torque
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Tech Tips

      A01GXLHE04
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13 N*m (137 kgf*cm, 10 ft.*lbf)

  30. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  31. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A01GZ6XE01

      After sliding the V-bank cover sub-assembly from the vehicle front to the rear to attach the 2 clips labeled A, attach the 4 clips labeled B and install the V-bank cover sub-assembly.

      CAUTION:


      • Make sure the clips are attached securely.

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