BRAKE ACTUATOR INSTALLATION


  1. INSTALL BRAKE ACTUATOR BOLT CUSHION


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

  2. INSTALL BRAKE ACTUATOR CASE COLLAR


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

      Note

      Make sure the collars are in full contact with the cushions.

  3. INSTALL BRAKE ACTUATOR BRACKET


    1. A00K1N3E01

      Install the brake actuator bracket to the brake actuator with the 3 bolts. Tighten the 3 bolts uniformly in alphabetical order.

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

      Note


      • Do not remove the hole plugs of a new brake actuator before connecting the 6 brake lines because the brake actuator is filled with brake fluid.

      • Do not hold the actuator by the connector.

      • If the actuator is dropped, replace it.

  4. INSTALL BRAKE ACTUATOR ASSEMBLY


    1. A00JZYEE01

      Install the brake actuator with bracket with the 3 nuts. Tighten the 3 nuts uniformly in alphabetical order.

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

      Note


      • Do not damage the brake lines or wire harness.

      • Do not hold the actuator by the connector.

      • If the actuator is dropped, replace it.

    2. A00JV9UE01

      Set each brake line in the correct position on the brake actuator as shown in the illustration.

      Tech Tips


      • *1: To front wheel cylinder RH

      • *2: To front wheel cylinder LH

      • *3: To rear wheel cylinder RH

      • *4: To rear wheel cylinder LH

      • *5: From front master cylinder

      • *6: From rear master cylinder

    3. A00JVUKE01

      Using a union nut wrench, tighten each brake line.

      Torque:
      for flare nut A
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      for flare nut B
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note

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

    4. Connect the brake actuator connector.

      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.

  5. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2TR-FE)

    Click here

  6. INSTALL AIR CLEANER CASE ASSEMBLY (for 5L-E)

    Click here

  7. BLEED BRAKE SYSTEM

    CAUTION:

    If air is bled without using the intelligent tester, damage or accidents may result. Therefore, always use the intelligent tester when bleeding air.


    1. Remove the brake master cylinder reservoir filler cap assembly.

    2. Add brake fluid until the fluid level is between the MIN and MAX lines of the reservoir.

    3. Using a union nut wrench, disconnect the 2 brake tube from the master cylinder.

    4. Slowly depress and hold the brake pedal.

    5. Block the tube holes with your fingers, and then release the brake pedal.

    6. Remove your fingers, slowly depress and hold the brake pedal, block the tube holes with your fingers again, and then release the brake pedal. Repeat this step 3 or 4 times.

    7. Using a union nut wrench, connect the 2 brake tubes to the brake master cylinder assembly.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note

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

    8. Loosen the bleeder plug of the front brake cylinder RH.

    9. Repeatedly depress the brake pedal and bleed the air from the bleeder plug of the front brake cylinder RH.

      Note

      Add fluid as necessary so that the fluid in reservoir does not decrease below the MIN level.

    10. After air is completely bled out, tighten the bleeder plug while depressing the brake pedal.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }
    11. Bleed the air from the bleeder plug of the front disc brake cylinder LH using the same procedure as for the RH side.

    12. Loosen the bleeder plug of the rear brake cylinder RH.

    13. Repeatedly depress the brake pedal and bleed the air from the bleeder plug of the rear brake cylinder RH.

      Note

      Add fluid as necessary so that the fluid in the reservoir does not decrease below the MIN level.

    14. After the air is completely bled out, tighten the bleeder plug while depressing the brake pedal.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }
    15. Bleed the air from the bleeder plug of the rear disc brake cylinder LH using the same procedure as for the RH side.

    16. Turn the ignition switch off and connect the intelligent tester to the DLC3.

    17. Turn the ignition switch to on and turn the tester on.

      Note

      Do not start the engine.

    18. Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Air Bleeding.

    19. Select and run "Inhalation" from the Air Bleeding screen on the intelligent tester.

      Note

      Follow the prompts on the tester screen to bleed the air for both wheels (front and rear) on the right side.

    20. Loosen the bleeder plug of the right front wheel.*1

    21. Using the intelligent tester, operate the actuator.

      Tech Tips


      • To protect the actuator, the operation stops automatically.

      • Make sure the brake pedal is released.

    22. Check the intelligent tester screen to confirm that the operation stopped.

    23. Tighten the bleeder plug.*2

    24. Repeat the procedures above from *1 to *2 until the air is completely bled out.

    25. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }
    26. Bleed the air for the right rear wheel using the same procedure as for the right front wheel.

    27. Select and run "Decrease" from the Air Bleeding screen on the intelligent tester.

      Note

      Follow the prompts on the tester screen to bleed the air for all 4 wheels.

    28. Loosen the bleeder plug of the right front wheel.*3

    29. Using the intelligent tester, operate the actuator and at the same time fully depress and hold the brake pedal.

      Tech Tips

      To protect the solenoids, the actuator operation stops automatically in 4 seconds. When operating the actuator repeatedly, follow the prompts on the tester screen and wait for 20 seconds or more between each operation.

      Note


      • At this time, the brake pedal becomes difficult to depress. However, be sure to hold the brake pedal in the fully depressed position until brake fluid comes out of the bleeder plug.

      • Do not repeatedly depress the brake pedal, hold the brake pedal in the fully depressed position.

    30. Tighten the bleeder plug and release the brake pedal.*4

    31. Repeat the procedures above from *3 to *4 until the air in completely bled out.

    32. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }
    33. Bleed the air for the other 3 wheels using the same procedure as for the right front wheel.

    34. Repeat the procedure in which air is bled from the brake line by repeatedly depressing the brake pedal.

      Note

      Repeat this step for each wheel until air is completely bled out.

    35. Inspect for brake fluid leaks.

    36. Inspect fluid level in reservoir Click here.

    37. Check and clear the DTCs Click here for VSC).

  8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  9. INSPECT BRAKE ACTUATOR WITH INTELLIGENT TESTER

    Click here

  10. PERFORM YAW RATE AND ACCELERATION SENSOR ZERO POINT CALIBRATION

    Click here