BRAKE ACTUATOR(for RHD) 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. B0072LXN02

      Temporarily install the brake actuator assembly to the brake actuator bracket assembly with the 3 bolts.

      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.

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

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

  3. INSTALL BRAKE ACTUATOR WITH BRACKET


    1. B0074GON02

      Temporarily install the brake actuator with bracket with the 2 bolts and nut.

      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.

    2. Tighten the 2 bolts and nut in the order shown in the illustration.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    3. B0076PRC01
      *a To Front Wheel Cylinder Assembly LH
      *b To Rear Wheel Cylinder Assembly RH
      *c To Rear Wheel Cylinder Assembly LH

      Temporarily connect the 3 brake lines to the correct positions on the brake actuator assembly as shown in the illustration.

    4. B0077HRC02
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

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

      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.)):

        13.4 N*m (137 kgf*cm, 10 ft.*lbf)

    5. B0072MIC01
      B0077CY Connect the connector
      B0075ZY 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 REAR NO. 1 BRAKE TUBE


    1. B0074AEC02
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Engage the clamp to install the rear No. 1 brake tube.

    2. Using a union nut wrench, connect the rear No. 1 brake tube to the brake actuator assembly.

      Torque:
      Specified tightening torque
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note


      • Do not kink or damage the rear No. 1 brake tube.

      • Do not allow the rear No. 1 brake tube to twist or interfere with other parts or vehicle body during tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the rear No. 1 brake 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 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        17.4 N*m (177 kgf*cm, 13 ft.*lbf)

  5. INSTALL FRONT NO. 1 BRAKE TUBE


    1. B0075TOC02
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Engage the clamp to install the front No. 1 brake tube.

    2. Using a union nut wrench, connect the front No. 1 brake tube to the brake actuator assembly.

      Torque:
      Specified tightening torque
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Note


      • Do not kink or damage the front No. 1 brake tube.

      • Do not allow the front No. 1 brake tube to twist or interfere with other parts or vehicle body during tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the front No. 1 brake 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 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        17.4 N*m (177 kgf*cm, 13 ft.*lbf)

  6. CONNECT UNION TO CHECK VALVE HOSE


    1. Connect the union to check valve hose to the brake booster assembly and slide the clip to secure it.

  7. INSTALL FRONT NO. 2 BRAKE TUBE


    1. B0077OZC03
      *1 Front Flexible Hose
      *2 Grommet
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Install the front No. 2 brake tube to the vehicle body, and engage the grommet.

      Note


      • Do not kink or damage the front No. 2 brake tube.

      • Do not allow any foreign matter such as dirt or dust to enter the front No. 2 brake tube from the connecting parts.

      • Ensure that the front No. 2 brake tube passes through the center of the grommet.

    2. Using a union nut wrench, connect the front No. 2 brake tube to the front flexible hose while holding the flexible hose with a wrench.

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

      Note

      Do not allow the front No. 2 brake tube to twist or interfere with other parts or the vehicle body during tightening.

      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.)):

        13.4 N*m (137 kgf*cm, 10 ft.*lbf)

    3. B0077BUC02
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Engage the clamp to install the front No. 2 brake tube.

    4. Using a union nut wrench, connect the front No. 2 brake tube to the brake actuator assembly.

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

      Note

      Do not allow the front No. 2 brake tube to twist or interfere with other parts or the vehicle body during tightening.

      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.)):

        13.4 N*m (137 kgf*cm, 10 ft.*lbf)

  8. INSTALL BRAKE MASTER CYLINDER O-RING

    Click here

  9. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  10. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  11. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK ASSEMBLY

    Click here

  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  13. BLEED BRAKE SYSTEM

    Click here

  14. INSTALL FRONT WHEEL RH

    Click here

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

    Click here

  16. PERFORM TEST MODE INSPECTION

    Click here

  17. INSPECT BRAKE ACTUATOR USING GTS

    Click here

  18. CHECK FOR AND CLEAR DTCS

    Click here