BRAKE ACTUATOR INSTALLATION


  1. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET


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      Install the actuator with bracket with the 3 bolts.

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

      Note


      • Tighten the 3 nuts uniformly in alphabetical order.

      • Be careful not to damage the brake tubes.

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      Using a union nut wrench, connect the 5 brake lines to the correct locations on the actuator, as shown in the illustration.

      Torque:
      15 N*m  { 155 kgf*cm, 11 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.

    3. Connect the actuator connector.

  2. FILL RESERVOIR WITH BRAKE FLUID

    Fluid
    SAE J1703 or FMVSS No. 116 DOT3

  3. BLEED AIR FROM BRAKE MASTER CYLINDER

    Tech Tips

    If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.


    1. Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.

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      Slowly depress and hold the brake pedal.

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      Cover the outer holes with your fingers, and release the pedal.

    4. Repeat the 2 previous steps 3 or 4 times.

    5. Using a union nut wrench, connect the 2 brake lines to the master cylinder.

      Torque:
      15 N*m  { 155 kgf*cm, 11 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. BLEED AIR FROM BRAKE LINE

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    1. Remove the bleeder plug cap.

    2. Connect the vinyl tube to the bleeder plugs.

    3. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.

    4. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

    5. Repeat the 2 previous steps until all the air in the brake fluid is gone.

    6. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf, for front brake }
      10 N*m  { 102 kgf*cm, 7 ft.*lbf, for rear brake }

    7. Install the cap.

    8. Bleed air from the brake line for each wheel by repeating the above procedures.

  5. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)


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

    2. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the clutch line.

      Fluid
      SAE J1703 or FMVSS No. 116 DOT3

    3. Remove the bleeder plug cap.

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      Connect a vinyl tube to the bleeder plug.

    5. Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

    6. At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

    7. Repeat the previous 2 steps until all the air in the fluid is completely bled out.

    8. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    9. Install the bleeder plug cap.

    10. Check that all the air has been bled out of the clutch line.

    11. Check for brake fluid leaks.

    12. Check the brake fluid level in the reservoir Click here.

    13. Install the brake master cylinder reservoir filler cap assembly.

  6. CHECK BRAKE FLUID LEVEL IN RESERVOIR

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    1. Check the fluid level and add fluid if necessary.

      Fluid
      SAE J1703 or FMVSS No. 116 DOT3

      Tech Tips

      Add fluid to a level between the reservoir's MIN and MAX lines.

  7. CHECK FOR BRAKE FLUID LEAKAGE

  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. CHECK BRAKE ACTUATOR WITH INTELLIGENT TESTER


    1. Check the brake actuator with the intelligent tester Click here.