BRAKE ACTUATOR(for LHD) INSTALLATION

CAUTION / NOTICE / HINT

Note

While the battery is connected, even if the power switch is OFF, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal or open/close the doors while the battery is connected.

PROCEDURE


  1. INSTALL BRAKE ACTUATOR

    Note

    Do not remove the hole plug before installing a new brake actuator because the brake actuator is filled with brake fluid.


    1. Install the No. 3 brake actuator bracket to the brake actuator with the 3 bolts.

      Torque:
      9.3 N*m  { 95 kgf*cm, 82 in.*lbf }
      A000Z61E01
      Text in Illustration
      *1 Brake Actuator
      *2 No. 3 Bracket

      Note

      Temporarily install either bolt A or B first.

    2. Install the 3 cushions and 3 spacers to the bracket.

      A000XS8E01
      Text in Illustration
      *1 Cushion
      *2 Spacer
      *3 Bracket
    3. A000TX7

      Install the brake actuator bracket to the brake actuator with the 3 bolts.

      Torque:
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

  2. INSTALL BRAKE ACCUMULATOR PUMP


    1. Install the brake booster pump collars (labeled A) and brake booster pump bushes (labeled B) to the brake accumulator pump.

      A000WZ5E01
      Text in Illustration
      *1 Brake Accumulator Pump
      *2 Actuator Bracket
      *3 Collar (A)
      *4 Bush (C)
      *5 Clamp (D)

    2. Install the brake accumulator pump to the brake actuator bracket.

      Note

      After installing the brake accumulator pump, make sure the collar has not fallen off.

    3. Install the brake booster pump bush (labeled C) and a new brake actuator bracket clamp (labeled D) to the brake accumulator pump.

      Note

      Make sure to securely insert the brake accumulator pump until the claws of the clamp are attached.

  3. INSTALL NO. 4 BRAKE ACTUATOR BRACKET


    1. A000WI6

      Install the No. 4 brake actuator bracket to the brake actuator with the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  4. CONNECT BRAKE ACCUMULATOR PUMP CONNECTOR BOX


    1. A00106CE07
      Text in Illustration
      *1 Connector Box

      Connect the brake accumulator pump connector box.


      1. Install the connector box with the nut.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      2. Attach the wiring harness clamp.

  5. INSTALL NO. 3 BRAKE ACTUATOR TUBE

    Note


    • Do not damage the No. 3 brake actuator tube, brake actuator and brake accumulator pump.

    • When installing the No. 3 brake actuator tube, hold the tube, brake actuator and brake accumulator pump securely.

    • When tightening the nut, make sure that other parts do not move with the nut.


    1. A000VR2

      Using a union nut wrench, connect the No. 3 brake actuator tube.

      Torque:
      Specified tightening torque
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Tech Tips

      A000X40E04
      Text in Illustration
      *a Torque Wrench Fulcrum Length

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

      • 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).

  6. INSTALL NO. 2 BRAKE ACTUATOR HOSE


    1. Install the reservoir connector to the No. 2 brake actuator hose with the hose clip as shown in the illustration.

      Length "A"
      4.0 to 7.0 mm (0.157 to 0.276 in.)
      A000V8BE01
      Text in Illustration
      *1 Reservoir Connector
      *a Paint Mark
      *b View B
      *c View C
      *d 30°to 60°
    2. A000ZWEE01
      Text in Illustration
      *a Rear

      With the paint mark on the hose's tip facing the bottom of the vehicle, install the No. 2 brake actuator hose to the brake accumulator pump with the hose clip.

      Tech Tips

      Install the hose clip so that its claws face the rear of the vehicle.

      Note

      When inserting the hose, be careful that there is no excessive weight applied to the union of the brake accumulator pump (especially in the union rotation direction).

    3. Connect the No. 2 brake actuator hose to the No. 3 brake actuator bracket with the clamp.

  7. INSTALL BRAKE ACTUATOR PROTECTOR


    1. A000TRW

      Install the protector.

  8. INSTALL NO. 1 BRAKE ACTUATOR HOSE


    1. A000V0SE01
      Text in Illustration
      *a Rear

      With the paint mark on the hose's tip facing the bottom of the vehicle, install the No. 1 brake actuator hose to the brake actuator with the hose clip.

      Tech Tips

      Install the hose clip so that its claws face the rear of the vehicle.

      Note

      When inserting the hose, be careful that there is no excessive weight applied to the union of the brake actuator (especially in the union rotation direction).

  9. INSTALL NO. 5 BRAKE ACTUATOR BRACKET


    1. A000XJB

      Install the No. 5 brake actuator bracket to the body with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  10. INSTALL BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY


    1. A000W02E02

      Install the brake actuator and brake accumulator pump to the body with the bolt and 2 nuts.

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

      Tech Tips

      First insert the bracket bottom's longer stud bolt (vehicle outer side, labeled A) into the body.

      Note


      • Do not damage the brake tubes.

      • When installing the brake actuator and brake accumulator pump to the vehicle, do not hold the connector, harness, hose or tube parts.

      • Do not drop the brake actuator and brake accumulator pump. Do not use parts that have been dropped.

    2. Connect the front fender liner rear side.

    3. A000W5X

      Connect the No. 1 brake actuator hose to the body with the clamp.

  11. CONNECT BRAKE TUBE


    1. A000XP9

      Using a union nut wrench, connect the No. 1 and No. 2 brake actuator tubes.

      Torque:
      Specified tightening torque
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Tech Tips

      A000X40E04
      Text in Illustration
      *a Torque Wrench Fulcrum Length

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

      • 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).

    2. A000Y1XE04

      Set each brake tube to the correct positions on the brake actuator as shown in the illustration.


      • *1: To FR RH

      • *2: To FR LH

      • *3: To: RR RH

      • *4: To RR LH

      • *5: From Brake Master Cylinder

      • *6: From Brake Stroke Simulator Cylinder

    3. A000Y5O

      Using a union nut wrench, connect the 6 brake tubes.

      Torque:
      Specified tightening torque
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Tech Tips

      A000X40E04
      Text in Illustration
      *a Torque Wrench Fulcrum Length

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

      • 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)

    4. A000TL6

      Connect the brake actuator connector.

      Note


      • Before connecting the vehicle wire harnesses, make sure that the connector faces are free of foreign matter.

      • Make sure that the connector is locked securely.

  12. INSTALL FRONT WHEEL

    Torque:
    140 N*m  { 1428 kgf*cm, 103 ft.*lbf }

  13. INSTALL RESERVOIR BRACKET

    Click here

  14. INSTALL NO. 1 RESERVOIR HOSE

    Click here

  15. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

    Click here

  16. CONNECT NO. 3 RELAY BLOCK


    1. A000WPA

      Install the No. 3 relay block to the reservoir bracket.

      Note

      Make sure that the claw of the No. 3 relay block is securely attached to the reservoir bracket.

  17. INSTALL SKID CONTROL ECU BRACKET

    Click here

  18. INSTALL SKID CONTROL ECU

    Click here

  19. CONNECT NO. 1 MOTOR COOLING PIPE

    Click here

  20. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note


    • Make sure that the 2 accumulator pump connectors are disconnected.

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

  21. INSTALL BATTERY SERVICE HOLE COVER LH

    Click here

  22. INSTALL DECK TRIM SIDE BOARD LH (w/o Spare Tire)

    Click here

  23. INSTALL DECK BOARD ASSEMBLY (w/o Spare Tire)

    Click here

  24. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

    Click here

  25. BLEED BRAKE SYSTEM

    Click here

  26. CLEAR THE DTC

    Click here

  27. PERFORM LINEAR VALVE OFFSET LEARNING


    1. When the brake actuator is replaced, perform the linear valve offset learning Click here.

  28. CHECK FOR DTC


    1. Check for DTC. If any DTC is output, perform the troubleshooting for that DTC Click here.

  29. READ VALUE OF ACCUMULATOR PRESSURE SENSOR OUTPUT VOLTAGE

    Tech Tips

    If removing and installing the No. 3 brake actuator tube, check for a brake fluid leak from the No. 3 tube connection area by monitoring the accumulator pressure sensor output value from the brake actuator. Directly checking for a brake fluid leak from the No. 3 tube connection area is difficult.


    1. Turn the power switch OFF.

    2. Connect the intelligent tester to the DLC3.

    3. Turn the power switch ON (IG).

    4. Operate the intelligent tester according to the display and select "DATA LIST".

      Skid control ECU:
      Tester Display Measurement Item/Range Normal Condition Diagnostic Note
      Accumulator Pressure Sensor Accumulator pressure sensor / min.: 0 V, max.: 5 V Specified value: 2.6 to 3.8 V -
    5. A000VR2

      Depress the brake pedal 4 or 5 times to operate the pump motor, and check the output value on the intelligent tester with the motor stopped (not braking).

      OK
      Accumulator pressure sensor's output voltage drops 0.2 V or less for 30 seconds.

      If the voltage drops more than 0.2 V, there may be a brake fluid leak from the No. 3 brake actuator tube connection area. Remove the brake actuator and brake accumulator pump, and then repeat the procedures above from the retightening of the 2 union nuts of the No. 3 brake actuator tube.

      Torque:
      Specified tightening torque
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Tech Tips

      A000X40E04
      Text in Illustration
      *a Torque Wrench Fulcrum Length

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

      • 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)

  30. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  31. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here