BRAKE ACTUATOR 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. B006L9A

      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.

  3. INSTALL BRAKE ACTUATOR WITH BRACKET


    1. B006MP1

      Install the brake actuator with bracket to the vehicle body with the 2 nuts.

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

      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.

      • for 2AR-FE:

        Hold the engine wire to insert the tool from the bottom of the vehicle.

    2. for 2AR-FE:


      1. B006MMLC02
        *a Torque Wrench Fulcrum Length

        Using a union nut wrench, install the engine wire to the engine assembly with transaxle with the bolt.

        Torque:
        Specified tightening torque
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }

        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.)):

          11.5 N*m (117 kgf*cm, 8 ft.*lbf)

    3. B006NT9

      Engage the clamp to the brake actuator bracket assembly.

    4. B006QWFC01
      *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 LH
      *d To Rear Wheel Cylinder Assembly RH
      *e To Rear Wheel Cylinder Assembly LH
      *f To Front Wheel Cylinder Assembly RH

      Temporarily tighten each brake line to the correct position on the brake actuator assembly as shown in the illustration.

    5. B006PL5C02
      *a Torque Wrench Fulcrum Length

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

      Torque:
      Specified tightening torque (A)
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }
      Specified tightening torque (B)
      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 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        (A): 17.36 N*m (177 kgf*cm, 13 ft.*lbf)

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

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

    6. B006MTCC01
      B006QOD Connect the connector
      B006LKF 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 AIR CLEANER CASE SUB-ASSEMBLY (for 2AR-FE)

    Click here

  5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2AR-FE)

    Click here

  6. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2GR-FE)

    Click here

  7. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (for 2GR-FE)

    Click here

  8. INSTALL V-BANK COVER SUB-ASSEMBLY (for 2GR-FE)

    Click here

  9. INSTALL BATTERY

    for 2AR-FE: Click here

    for 2GR-FE: Click here

  10. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    for LHD: Click here

    for RHD: Click here

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

    for LHD: Click here

    for RHD: Click here

  12. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL

    for LHD: Click here

    for RHD: Click here

  13. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  14. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  15. INSPECT WASHER NOZZLE

    Click here

  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  17. BLEED BRAKE SYSTEM

    Click here

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

    Click here

  19. PERFORM TEST MODE INSPECTION

    Click here

  20. INSPECT BRAKE ACTUATOR USING GTS

    Click here

  21. CHECK FOR AND CLEAR DTCS

    Click here