BRAKE ACTUATOR (w/o VSC) INSTALLATION


  1. INSTALL BRAKE ACTUATOR ASSEMBLY


    1. A003HXZ

      Install the brake actuator assembly to the actuator bracket with the 2 nuts.

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

      Note


      • Do not remove the hole plug until the new actuator assembly is connected because it already contains brake fluid.

      • Insert the protrusion of the actuator bolt holder between the positioning claws of the actuator bracket No.1.

      • Insert the positioning pin of the actuator bracket No.1 into the cushion of the actuator assembly.

  2. INSTALL BRAKE ACTUATOR COVER


    1. A003I3N

      Install the actuator cover to the brake actuator assembly with the 2 nuts.

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

  3. INSTALL BRAKE TUBE


    1. A003GZ6

      Using a union nut wrench, install the 5 brake tubes and brake way No.1 to the brake actuator assembly.

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

  4. INSTALL BRAKE ACTUATOR ASSEMBLY WITH FRONT BRAKE TUBE WAY NO. 1


    1. A003HM9

      Install the brake actuator assembly with front brake tube way No. 1 and the brake tube to the body with the 5 bolts.

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

      Note

      Do not bend or damage the brake tube.

    2. A003CVG

      Using a union nut wrench, connect the 6 brake tubes to the front brake tube way No. 1.

      Torque:
      15 N*m  { 155 kgf*cm, 11 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. A003D2P

      Connect the connector and lock the lock lever.

      Note

      Check that the lock lever is securely locked.

  5. INSTALL FRONT MUDGUARD


    1. A003CTN

      Install the front mudguard with the 3 clips.

  6. INSTALL FRONT BUMPER

    for Standard Body
    (See page Click here)
    for Wide Body
    (See page Click here)

  7. INSTALL FRONT WHEEL

    Torque:
    100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

  8. ADD BRAKE FLUID

    Fluid
    SAE J1703 or FMVSS No. 116 DOT3 or equivalent

  9. 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:
        10.8 N*m  { 110 kgf*cm, 8 ft.*lbf }

      2. Rear bleeder plug:

        Torque:
        11.0 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.

  10. INSPECT BRAKE FLUID LEVEL


    1. Check the fluid level and add fluid if necessary.

      Fluid
      SAE J1703 or FMVSS No.116 DOT3 or equivalent