BRAKE ACTUATOR INSTALLATION

PROCEDURE


  1. INSTALL BRAKE ACTUATOR BOLT CUSHION


    1. Install the 3 brake actuator bolt cushions to the brake actuator bracket.

  2. INSTALL BRAKE ACTUATOR CASE COLLAR


    1. Install the 3 brake actuator case collars to the brake actuator bolt cushions.

      Note

      Make sure the collars are in full contact with the cushions.

  3. INSTALL BRAKE ACTUATOR BRACKET


    1. B001CHPE01

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

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

      Note


      • Do not remove the hole plugs of a new brake actuator before connecting the 6 brake lines because the brake actuator is filled with brake fluid.

      • Do not hold the actuator by the connector.

      • If the actuator is dropped, replace it.

  4. INSTALL BRAKE ACTUATOR ASSEMBLY


    1. B001HYYE01

      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


      • Do not damage the brake lines or wire harness.

      • Do not hold the actuator by the connector.

      • If the actuator is dropped, replace it.

    2. B001DMME02

      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 front master cylinder

      • *6: From rear master cylinder

    3. B001ER9E02

      Using a union nut wrench, tighten each brake line.

      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.

    4. Connect the brake actuator connector.

      Note


      • Make sure that the connector is locked securely.

      • Make sure that the actuator connector can be connected smoothly. Do not allow water, oil or dirt to enter.

  5. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2TR-FE)

    Click here

  6. INSTALL AIR CLEANER CASE ASSEMBLY (for 5L-E)

    Click here

  7. BLEED BRAKE SYSTEM

    Click here

  8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  9. INSPECT BRAKE ACTUATOR WITH INTELLIGENT TESTER

    Click here

  10. PERFORM YAW RATE AND ACCELERATION SENSOR ZERO POINT CALIBRATION

    Click here