BRAKE ACTUATOR INSTALLATION

PROCEDURE

1. INSTALL BRAKE ACTUATOR ASSEMBLY

   
   

   1. 

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

      Torque:

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

      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.

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

   2. Engage the 2 claws to install the piping clamp.

2. INSTALL BRAKE ACTUATOR WITH BRACKET

   
   

   1. 

      Engage the claw to temporarily install the brake actuator with bracket.

      Note

      
      

      • Do not damage the brake lines.

      • Do not deform the refrigerant 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 and refrigerant lines.

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

      Torque:

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

   3. 

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

      Temporarily tighten the 6 brake lines to the correct positions on the brake actuator assembly as shown in the illustration.

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

      Torque:

      *a, *b

      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

      *c, *d, *e, *f

      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 or interfere with other parts or the 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.

3. INSTALL AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY

   
   

   1. Install the air conditioner tube and accessory assembly with the bolt.

      Torque:

      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note

      
      

      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

   2. Engage the clamp to install the air conditioner tube and accessory assembly to the piping clamp.

      Note

      
      

      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

4. INSTALL SUCTION HOSE SUB-ASSEMBLY

   
   

   1. for 1AR-FE:

      
      

      1. Install the suction hose sub-assembly to the brake actuator bracket assembly with the bolt.

         Torque:

         9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

         Note

         
         

         • Do not deform the refrigerant lines.

         • Do not damage the clamp.

   2. for 2GR-FE:

      
      

      1. Install the suction hose sub-assembly to the suction hose clamp and engage the claw.

         Note

         
         

         • Do not deform the refrigerant lines.

         • Do not damage the clamp.

   3. Engage the clamp to install the suction hose sub-assembly to the piping clamp.

      Note

      
      

      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

5. INSTALL NO. 6 BRAKE TUBE CLAMP

   
   

   1. Install the No. 6 brake tube clamp with the bolt.

      Torque:

      4.9 N*m  { 50 kgf*cm, 43 in.*lbf }

6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

   Note

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

   Click here

7. BLEED BRAKE SYSTEM

   Click here

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

   Click here

9. PERFORM TEST MODE INSPECTION

   Click here

10. INSPECT BRAKE ACTUATOR USING GTS

    Click here

11. CHECK FOR AND CLEAR DTCS

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