BRAKE ACTUATOR(w/ VSC) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET


    1. except CVT:


      1. A00582LE01

        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 and wire harness.

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

    2. for CVT:


      1. A0052H1E01

        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 and wire harness.

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

    3. except CVT:


      1. Install 2 new tube clamps to the tubes, and then attach the 2 clamps to the brake actuator bracket.

    4. for CVT:


      1. Install 2 new tube clamps to the tubes, and then attach the 2 clamps to the brake actuator bracket.

  2. CONNECT BRAKE LINE


    1. A0053NGE01
      Text in Illustration
      *a To Front Wheel Cylinder RH
      *b To Front Wheel Cylinder LH
      *c To Rear Wheel Cylinder RH
      *d To Rear Wheel Cylinder LH
      *e From Master Cylinder

      Set each brake line in the correct position on the brake actuator as shown in the illustration.

    2. A0053ANE02
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      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 }

      Tech Tips


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

      • for flare nut A

        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).

      • for flare nut B

        When using a union nut wrench (fulcrum length of 20 mm (0.7874 in.)) + torque wrench (fulcrum length of 180 mm (7.0866 in.)): 18 N*m (179 kgf*cm, 13 ft.*lbf).

  3. CONNECT CONNECTOR


    1. A0056MQE01
      Text in Illustration
      *A except CVT
      *B for CVT
      A0054CA Lock Lever Locked

      Connect the connector to the brake actuator assembly and lock the lock lever.

  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 GTS


    1. Check the brake actuator with the GTS Click here.