BRAKE ACTUATOR (w/ VSC) INSTALLATION

INSTALL BRAKE TUBE

Text in Illustration
*a	From Front Master Cylinder
*b	From Rear Master Cylinder
*c	To Front Wheel Cylinder Assembly RH
*d	To Front Wheel Cylinder Assembly LH
*e	To Rear Wheel Cylinder Assembly RH
*f	To Rear Wheel Cylinder Assembly LH

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

Text in Illustration

*a Torque Wrench Fulcrum Length

Using a union nut wrench, install the 6 brake tubes and front No. 1 brake tube way to the brake actuator assembly.

Torque:

Flare nut A

25 N*m { 255 kgf*cm, 18 ft.*lbf }

Flare nut B

15 N*m { 155 kgf*cm, 11 ft.*lbf }
Tech Tips
- Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.
- Flare nut A:
  
  When using a union nut wrench (fulcrum length of 20 mm (0.7874 in.)) + torque wrench (fulcrum length of 180 mm (7.0866 in.)): 23 N*m (229 kgf*cm, 17 ft.*lbf).
- Flare nut B:
  
  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).

INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET
1. Temporarily install the brake actuator assembly with bracket and the brake tube to the body with the 3 bolts.
  
  Note
  
  Do not bend or damage the brake tube.
2. Tighten the 3 bolts in the order shown in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
3. Connect the connector and lock the lock lever.
  
  Note
  
  Check that the lock lever is securely locked.
CONNECT FRONT NO. 1 BRAKE TUBE
1. Connect the front No. 1 brake tube to the clamp.
CONNECT REAR NO. 1 BRAKE TUBE
1. Connect the rear No. 1 brake tube to the clamp.
CONNECT FRONT NO. 1 BRAKE TUBE WAY
1. Connect the front No. 1 brake tube way to the body with the 2 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Text in Illustration
  
  *a Torque Wrench Fulcrum Length
  
  Using a union nut wrench, connect the 6 brake tubes to the front No. 1 brake tube way.
  
  Torque:
  
  Flare nut A
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Flare nut B
  
  15 N*m { 155 kgf*cm, 11 ft.*lbf }
  Tech Tips
  - Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.
  - Flare nut A:
    
    When using a union nut wrench (fulcrum length of 20 mm (0.7874 in.)) + torque wrench (fulcrum length of 180 mm (7.0866 in.)): 23 N*m (229 kgf*cm, 17 ft.*lbf).
  - Flare nut B:
    
    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).
INSTALL FRONT MUDGUARD
1. Install the front mudguard with the 3 clips.
INSTALL FRONT BUMPER

for Standard Body

(See page Click here)

for Wide Body

(See page Click here)
INSTALL FRONT WHEEL

Torque:

100 N*m { 1020 kgf*cm, 74 ft.*lbf }
ADD BRAKE FLUID

Fluid

SAE J1703 or FMVSS No. 116 DOT3 or equivalent

Note

Do not remove the filter from the brake master cylinder reservoir and be sure to fill with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.
BLEED BRAKE LINE
1. Connect the vinyl tube to the bleeder plug.
2. Depress the brake pedal several times and loosen the bleeder plug with the pedal held down.
3. At the point where the fluid stops coming out, tighten the bleeder plug and release the brake pedal.
4. Repeat this procedure until the air in the brake fluid is completely bled out.
5. Tighten the bleeder plug.
  1. Front bleeder plug:
    
    Torque:
    
    11 N*m { 110 kgf*cm, 8 ft.*lbf }
  2. Rear bleeder plug:
    
    Torque:
    
    11 N*m { 112 kgf*cm, 8 ft.*lbf }
6. Repeat the above procedure to bleed the air out of the brake line for each wheel.
INSPECT BRAKE FLUID LEVEL
1. Check the fluid level and add fluid if necessary.
  
  Fluid
  
  SAE J1703 or FMVSS No.116 DOT3 or equivalent
  
  Note
  
  Do not remove the filter from the brake master cylinder reservoir and be sure to fill with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.