PARKING BRAKE LEVER INSTALLATION


  1. INSTALL PARKING BRAKE SWITCH ASSEMBLY


    1. Install the parking brake switch with the screw.

      Torque:
      0.9 N*m  { 9 kgf*cm, 8 in.*lbf }

  2. INSTALL PARKING BRAKE LEVER SUB-ASSEMBLY


    1. A01EOL6

      Install the parking brake lever with the 2 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    2. Install the parking brake lever support with the 2 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    3. Install the straight pin to the parking brake lever.

    4. A01EN2Y

      Connect the No. 2 parking brake cable and No. 3 parking brake cable to the No. 1 parking brake pull rod.

    5. A01ENKT

      Install the bush, compression spring and No. 1 parking brake pull rod to the parking brake lever with the adjusting nut.

    6. Install the parking brake return spring.

    7. Connect the parking brake switch connector.

  3. INSPECT PARKING BRAKE LEVER TRAVEL


    1. Fully pull the parking brake lever to engage the parking brake.

    2. Release the lever to disengage the parking brake.

    3. Slowly pull the parking brake lever all the way, and count the number of clicks.

      Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf)
      5 to 7 clicks

      If the parking brake lever travel is not as specified, adjust the parking brake shoe clearance and parking brake lever travel.

  4. ADJUST PARKING BRAKE LEVER TRAVEL


    1. Remove the console cup holder box sub-assembly Click here.

    2. Completely release the parking brake lever.

    3. A01ENKT

      Loosen the adjusting nut to completely release the parking brake cable.

    4. Temporarily install the hub nuts.

    5. Remove the hole plug.

    6. A01EOAXE01

      Insert an adjustment tool into the adjustment hole of the disc. Rotate the adjustment wheel in the "X" direction until the shoes are locked. Then rotate the adjustment wheel in the "Y" direction 8 notches.

    7. Check that the disc can be rotated lightly. If not, rotate the adjustment wheel in the "Y" direction and check again.

    8. Install the hole plug.

    9. Remove the hub nuts.

    10. A01ENKT

      Turn the adjusting nut until the parking brake lever travel becomes correct.

      Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf)
      5 to 7 clicks

    11. Operate the parking brake lever 3 to 4 times, and check the parking brake lever travel.

      Standard Parking Brake Lever Travel when Pulled with a Force of 200 N (20 kgf, 45 lbf)
      5 to 7 clicks

    12. Check whether the parking brake drags or not.

    13. When operating the parking brake lever, check that the brake warning light comes on.

      Standard Condition
      The brake warning light always illuminates at the first click.

    14. Install the console cup holder box sub-assembly Click here.

  5. INSTALL REAR CONSOLE BOX SUB-ASSEMBLY (w/o Cool Box)


    1. Install the rear console box sub-assembly Click here.

  6. INSTALL COOLING BOX ASSEMBLY (w/ Cool Box)


    1. Install the cooling box assembly Click here.

  7. INSTALL FRONT SEAT ASSEMBLY LH (w/ Cool Box)


    1. Install the front seat assembly LH Click here.

  8. CHARGE REFRIGERANT (w/ Cool Box)

    SST
    09985-20010   ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )

    1. Perform vacuum purging using a vacuum pump.

    2. Charge refrigerant HFC-134a (R134a).

      Standard:
      Condenser Core Thickness Cool Box Refrigerant Charging Amount
      22 mm (0.866 in.) w/ Cool Box 1010 +/-30 g (35.6 +/-1.1 oz.)
      w/o Cool Box 970 +/-30 g (34.2 +/-1.1 oz.)
      16 mm (0.630 in.) w/ Cool Box 970 +/-30 g (34.2 +/-1.1 oz.)
      w/o Cool Box 920 +/-30 g (32.5 +/-1.1 oz.)
      A01EPR4E25

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.

      • Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.

  9. WARM UP ENGINE (w/ Cool Box)


    1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

      Note

      Be sure to warm up the compressor when turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  10. CHECK FOR REFRIGERANT GAS LEAK (w/ Cool Box)


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation under these conditions:


      • Stop the engine.

      • Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).

    3. A01EOLRE21

      Using a halogen leak detector, check the refrigerant line for leakage.

    4. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

    5. Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.

  11. INSTALL UPPER RADIATOR SUPPORT SEAL (w/ Cool Box)


    1. Install the upper radiator support seal with the 3 clips.

  12. INSTALL ENGINE ROOM SIDE COVER RH (w/ Cool Box)


    1. Install the engine room side cover RH with the 7 clips.

  13. INSTALL ENGINE ROOM SIDE COVER LH (w/ Cool Box)


    1. Install the engine room side cover LH with the 7 clips.