BRAKE ACTUATOR(for RHD) INSTALLATION

PROCEDURE

1. INSTALL BRAKE ACTUATOR BOLT CUSHION

   
   

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

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

      Note

      Make sure the brake actuator case collars are in full contact with the brake actuator bolt cushions.

2. INSTALL BRAKE ACTUATOR ASSEMBLY

   
   

   1. 

      Temporarily install the brake actuator assembly to the brake actuator bracket assembly with the 3 bolts.

      Note

      
      

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

      • Do not hold the brake actuator assembly by the connector.

   2. Tighten the 3 bolts in the order shown in the illustration.

      Torque:

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

3. INSTALL BRAKE ACTUATOR WITH BRACKET

   
   

   1. 

      Temporarily install the brake actuator with bracket with the 2 bolts and nut.

      Note

      
      

      • Do not damage the brake lines.

      • Do not hold the brake actuator with bracket by the connector.

      Tech Tips

      Install the brake actuator with bracket while avoiding the brake lines.

   2. Tighten the 2 bolts and nut in the order shown in the illustration.

      Torque:

      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

   3. 

      *a	From 1st Chamber of Brake Master Cylinder Sub-assembly
      *b	From 2nd Chamber of Brake Master Cylinder Sub-assembly
      *c	To Front Wheel Cylinder Assembly LH
      *d	To Rear Wheel Cylinder Assembly RH
      *e	To Rear Wheel Cylinder Assembly LH

      Temporarily tighten the 5 brake lines to the correct position on the brake actuator assembly as shown in the illustration.

   4. Using a union nut wrench, fully tighten each brake line.

      Torque:

      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      
      

      • Do not kink or damage the brake lines.

      • Do not allow the brake lines to twist and interfere with other parts or vehicle body during tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

        Click here

   5. 

      	Connect the connector
      	Lock the lock lever

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

      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 the connector.

4. INSTALL FRONT NO. 2 BRAKE TUBE

   
   
   1. 

      *1	Front Flexible Hose
      *2	Grommet

      Install the front No. 2 brake tube to the vehicle body, and engage the grommet.

      Note

      
      

      • Do not kink or damage the front No. 2 brake tube.

      • Do not allow any foreign matter such as dirt or dust to enter the front No. 2 brake tube from the connecting parts.

      • Ensure that the front No. 2 brake tube passes through the center of the grommet.

   2. Using a union nut wrench, connect the front No. 2 brake tube to the front flexible hose while holding the flexible hose with a wrench.

      Torque:

      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      
      

      • Do not allow the front No. 2 brake tube to twist and interfere with other parts or vehicle body during tightening.

      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

        Click here

   3. Engage the clamp to install the front No. 2 brake tube.

   4. Using a union nut wrench, connect the front No. 2 brake tube to the brake actuator assembly.

      Torque:

      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      
      

      • Do not allow the front No. 2 brake tube to twist and interfere with other parts or vehicle body during tightening.

      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

        Click here

5. INSTALL BRAKE MASTER CYLINDER O-RING

   Click here

6. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

   Click here

7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

   Note

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

   Click here

8. BLEED BRAKE SYSTEM

   Click here

9. INSTALL FRONT WHEEL RH

   Torque:

   103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

10. PERFORM YAW RATE AND ACCELERATION SENSOR ZERO POINT CALIBRATION AND STORE SYSTEM INFORMATION

    Click here

11. PERFORM TEST MODE INSPECTION

    Click here

12. INSPECT BRAKE ACTUATOR USING GTS

    Click here

13. CHECK FOR AND CLEAR DTCS

    Click here