BRAKE ACTUATOR(for LHD) 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.

      • Do not apply excessive force to the brake lines or refrigerant lines.

      • Be careful not to allow any brake fluid to enter the connector.

      • Do not drop the brake actuator assembly when carrying it.

  2. INSTALL BRAKE BOOSTER PUMP ASSEMBLY


    1. B004Q6HC01
      *1 Brake Booster Pump Collar
      *2 Brake Booster Pump Bushing
      *3 Brake Actuator Case Collar
      B004PI4 Install in this Direction

      Install the brake booster pump assembly to the brake actuator bracket assembly with the nut.

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

      Note


      • Be careful not to allow any brake fluid to enter the connector.

      • When installing the brake booster pump assembly to the brake actuator bracket assembly, confirm that the brake booster pump bushing and brake actuator case collar are on the brake actuator bracket assembly, and 2 brake booster pump bushings and 2 brake booster pump collars are on the brake booster pump assembly.

      • Do not drop the brake booster pump assembly when carrying it.

    2. Engage the claw and clamp to install the brake booster pump assembly wire harness to the brake actuator bracket assembly.

  3. INSTALL ACCUMULATOR TO BRAKE MASTER CYLINDER TUBE


    1. Temporarily tighten the accumulator to brake master cylinder tube to the brake booster pump assembly.

    2. B004QYKC01
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Install the accumulator to brake master cylinder tube with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    3. Using a union nut wrench, tighten the accumulator to brake master cylinder tube.

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

      Note


      • Do not kink or damage the accumulator to brake master cylinder tube.

      • Do not allow the accumulator to brake master cylinder tube 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 accumulator to brake master cylinder tube from the connecting parts.

      Tech Tips


      • 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 (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        13.38 N*m (136 kgf*cm, 10 ft.*lbf)

  4. CONNECT BRAKE LINE


    1. B004PJ2C01
      *a From 1st Chamber of Brake Booster with Master Cylinder Assembly
      *b From 2nd Chamber of Brake Booster with Master Cylinder Assembly
      *c To Front Wheel Cylinder Assembly LH
      *d To Rear Wheel Cylinder Assembly RH
      *e To Rear Wheel Cylinder Assembly LH
      *f To Front Wheel Cylinder Assembly RH

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

    2. B004QRBC01
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Using a union nut wrench, fully tighten the 6 brake lines.

      Torque:
      Specified tightening 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 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.

      Tech Tips


      • 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 (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        13.38 N*m (136 kgf*cm, 10 ft.*lbf)

  5. INSTALL NO. 1 BRAKE ACTUATOR HOSE


    1. B004QL4C01
      *1 Brake Actuator Hose Clamp
      *a Protector
      *b Identification Mark
      *c Contacts

      Install the No. 1 brake actuator hose to the brake actuator hose clamp.

      Note


      • Make sure to install the No. 1 brake actuator hose so that the protector on the brake booster pump assembly side contacts the brake actuator hose clamp.

      • Make sure to install the No. 1 brake actuator hose so that its identification mark can be seen.

    2. B004QYEC01
      *a Identification Mark
      B004P9H Front of the vehicle

      Connect the No. 1 brake actuator hose to the No. 1 brake actuator tube to install it, and slide the clip to secure it.

      Note


      • Make sure to connect the No. 1 brake actuator hose with its identification mark facing the front of the vehicle.

      • Install the clip within the range shown in the illustration.

  6. CONNECT ENGINE ROOM MAIN WIRE


    1. B004QFGC01
      B004PI4 Connect the connector
      B004OIV Lock the lock lever

      Connect the connector to the brake booster pump assembly and lock the lock lever as shown in the illustration.

      Note


      • Make sure that the connector is locked securely.

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

    2. B004QJNC01
      B004PI4 Connect the connector
      B004OIV Lock the lock lever

      Connect the connector to the brake actuator assembly and lock the lock lever as shown in the illustration.

      Note


      • Make sure that the connector is locked securely.

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

    3. Engage the clamp to install the engine room main wire.

  7. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. Remove the vinyl tape from the air conditioner tube and accessory assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioner tube and accessory assembly.

      Compressor Oil
      ND-OIL 11 or equivalent

    3. Install the O-ring to the air conditioner tube and accessory assembly.

      Note

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. B004PSK

      Insert the air conditioner tube and accessory assembly to the air conditioning unit assembly.

    5. Engage the 2 clamps to install the air conditioner tube and accessory assembly.

  8. CONNECT SUCTION PIPE SUB-ASSEMBLY


    1. Remove the vinyl tape from the suction pipe sub-assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe sub-assembly.

      Compressor Oil
      ND-OIL 11 or equivalent

    3. Install the O-ring to the suction pipe sub-assembly.

      Note

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. Insert the suction pipe sub-assembly to the air conditioning unit assembly.

    5. B004P2R

      Rotate the hook connector as shown in the illustration.

    6. Insert the hose joint into the fitting hole securely and install the bolt.

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

    7. Engage the 2 clamps to install the suction pipe sub-assembly.

  9. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  10. BLEED NO. 1 BRAKE ACTUATOR TUBE

    Click here

  11. FILL RESERVOIR WITH BRAKE FLUID

  12. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  13. BLEED BRAKE SYSTEM

    Click here

  14. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    for HFC-134a(R134a): Click here

    for HFO-1234yf(R1234yf): Click here

  15. WARM UP COMPRESSOR

    for HFC-134a(R134a): Click here

    for HFO-1234yf(R1234yf): Click here

  16. INSPECT FOR REFRIGERANT LEAK

    for HFC-134a(R134a): Click here

    for HFO-1234yf(R1234yf): Click here

  17. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  18. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  19. INSTALL WATER GUARD PLATE LH

    Click here

  20. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

    Click here

  21. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here