BRAKE ACTUATOR(w/ VSC) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET


    1. except CVT:


      1. A00559YE01

        Install the brake actuator with bracket with the 3 nuts. Tighten the 3 nuts uniformly in alphabetical order.

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

        Note


        • Be careful not to damage the brake tubes.

        • Do not drop the actuator. If dropped, replace it.

    2. for CVT:


      1. A0053CME01

        Install the brake actuator with bracket with the 2 nuts and bolt. Tighten the 2 nuts and bolt uniformly in alphabetical order.

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

        Note


        • Be careful not to damage the brake tubes.

        • Do not drop the actuator. If dropped, replace it.

    3. except CVT:


      1. A0055K6

        Connect a new brake tube clamp to the brake actuator bracket.

    4. for CVT:


      1. A0054A1

        Connect a new brake tube clamp to the brake actuator bracket.

  2. CONNECT BRAKE LINE


    1. A00556FE01

      Set each brake line in the correct position on the brake actuator 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 master cylinder

    2. A0055CVE02

      Using a union nut wrench, connect the 6 brake lines to the brake actuator.

      Torque:
      for flare nut A
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      for flare nut B
      20 N*m  { 199 kgf*cm, 14 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.

  3. CONNECT CONNECTOR


    1. A0053XV

      Connect the connector and push the lock lever downward.

  4. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1ZR-FAE)

    Click here

  5. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2ZR-FAE)

    Click here

  6. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 3ZR-FE)

    Click here

  7. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 3ZR-FAE)

    Click here

  8. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1ZR-FAE)

    Click here

  9. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FAE)

    Click here

  10. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 3ZR-FE)

    Click here

  11. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 3ZR-FAE)

    Click here

  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  13. REMOVE CENTER COWL TOP VENTILATOR LOUVER

    Click here

  14. FILL RESERVOIR WITH BRAKE FLUID

    Click here

  15. BLEED AIR FROM BRAKE MASTER CYLINDER

    Click here

  16. BLEED AIR FROM BRAKE LINE

    Click here

  17. CHECK BRAKE FLUID LEVEL IN RESERVOIR

    Click here

  18. INSPECT FOR BRAKE FLUID LEAK

  19. INSTALL CENTER COWL TOP VENTILATOR LOUVER

    Click here

  20. CHECK BRAKE ACTUATOR ASSEMBLY WITH INTELLIGENT TESTER


    1. Check the brake actuator with the intelligent tester Click here.