BRAKE ACTUATOR (w/ VSC) INSTALLATION


  1. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET


    1. except CVT:


      1. A005V9NE01

        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


        • Be careful not to damage the brake tubes.

        • Do not drop the actuator. If dropped, replace it.

    2. for CVT:


      1. A005T98E01

        Install the brake actuator with bracket with the 2 nuts and bolt. Tighten the 2 nuts and bolt uniformly in alphabetical order.

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

        Note


        • Be careful not to damage the brake tubes.

        • Do not drop the actuator. If dropped, replace it.

    3. except CVT:


      1. A005W7A

        Connect a new brake tube clamp to the brake actuator bracket.

    4. for CVT:


      1. A005RLU

        Connect a new brake tube clamp to the brake actuator bracket.

  2. CONNECT BRAKE LINE


    1. A005VIVE01

      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 master cylinder

    2. A005WLKE01

      Using a union nut wrench, connect the 6 brake lines to the brake actuator.

      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.

  3. CONNECT CONNECTOR


    1. A005ULJ

      Connect the connector and push the lock lever downward.

  4. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1ZR-FAE)


    1. A00DQ1D

      Install the air cleaner case with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Attach the wire harness clamp to the air cleaner case.

  5. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2ZR-FAE)


    1. A00DQ1D

      Install the air cleaner case with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Attach the wire harness clamp to the air cleaner case.

  6. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 3ZR-FE)


    1. A00DQ1D

      Install the air cleaner case with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Attach the wire harness clamp to the air cleaner case.

  7. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 3ZR-FAE)


    1. A00DQ1D

      Install the air cleaner case with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Attach the wire harness clamp to the air cleaner case.

  8. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1ZR-FAE)


    1. A005SIR

      Connect the air cleaner cap with the band.

    2. Connect the ventilation hose.

    3. A005UHW

      Connect the 2 clamps.

    4. A005SHE

      Attach the wire harness to the 2 clamps.

    5. Connect the mass air flow meter connector.

  9. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FAE)


    1. A005SIR

      Connect the air cleaner cap with the band.

    2. Connect the ventilation hose.

    3. A005UHW

      Connect the 2 clamps.

    4. A005SHE

      Attach the wire harness to the 2 clamps.

    5. Connect the mass air flow meter connector.

  10. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 3ZR-FE)


    1. A005W5Q

      Connect the air cleaner cap with the band.

    2. Connect the ventilation hose.

    3. A005U5E

      Connect the 2 clamps.

    4. A005UEV

      Attach the wire harness to the 2 clamps.

    5. Connect the mass air flow meter connector.

  11. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 3ZR-FAE)


    1. A005SIR

      Connect the air cleaner cap with the band.

    2. Connect the ventilation hose.

    3. A005UHW

      Connect the 2 clamps.

    4. A005SHE

      Attach the wire harness to the 2 clamps.

    5. Connect the mass air flow meter connector.

  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. REMOVE CENTER COWL TOP VENTILATOR LOUVER


    1. A010K8X

      Slide the hood to cowl top seal and detach the clip as shown in the illustration.

    2. A010GT5

      Detach the 5 claws and remove the center cowl top ventilator louver.

  14. FILL RESERVOIR WITH BRAKE FLUID


    1. Fill the reservoir with brake fluid.

      Brake Fluid
      SAE 1704 or FMVSS No. 116 DOT 4

      Note

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

  15. BLEED AIR FROM BRAKE MASTER CYLINDER

    Note


    • If the master cylinder is reinstalled or if the reservoir becomes empty, bleed the master cylinder.

    • To prevent brake fluid from damaging painted surfaces, cover any surrounding parts with a piece of cloth.


    1. A005UWXE01

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

    2. A005TEX

      Slowly depress the brake pedal and hold it.*1

    3. A005T8P

      Cover the 2 outer holes with fingers and release the brake pedal.*2

    4. Repeat *1 and *2 3 or 4 times.

    5. A005UWXE01

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

      Torque:
      without VSC
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }
      with VSC
      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.

  16. BLEED AIR FROM BRAKE LINE

    Note


    • Bleed the brake line of the wheel farthest from the master cylinder first.

    • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


    1. Connect a vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1

    3. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2

    4. Repeat *1 and *2 until all the air in the fluid is completely bled out.

    5. Tighten the bleeder plug completely.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    6. Repeat the above procedure for each wheel to bleed the brake line.

  17. BLEED AIR FROM BRAKE ACTUATOR

    Note

    After bleeding the brake system, if the specified height or feel of the brake pedal cannot be obtained, bleed the brake actuator assembly with the intelligent tester by following the procedure below.


    1. Depress the brake pedal more than 20 times with the ignition switch off.

    2. Connect the intelligent tester to the DLC3.

    3. Turn the ignition switch to ON.

      Note

      Do not start the engine.

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

      Tech Tips

      Refer to the intelligent tester operator's manual for further details.

    5. Bleed the front right brake line.

      Note


      • Make sure that the master cylinder reservoir tank does not run out of brake fluid.

      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


      1. Select "FR Line" on the intelligent tester.

      2. Depress the brake pedal and hold it.

        Note

        The actuator operation stops automatically in 4 seconds.

      3. Tighten the bleeder plug completely.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      4. Wait 20 seconds.

      5. Repeat the steps above until there are no more air bubbles in the fluid.

    6. Bleed the front left brake line.

      Note


      • Make sure that the master cylinder reservoir tank does not run out of brake fluid.

      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


      1. Select "FL Line" on the intelligent tester.

      2. Depress the brake pedal and hold it.

        Note

        The actuator operation stops automatically in 4 seconds.

      3. Tighten the bleeder plug completely.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      4. Wait 20 seconds.

      5. Repeat the steps above until there are no more air bubbles in the fluid.

    7. Bleed the rear right brake line.

      Note


      • Make sure that the master cylinder reservoir tank does not run out of brake fluid.

      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

      • The actuator operation stops automatically in 4 seconds.


      1. Select "RR Line" on the intelligent tester.

      2. Depress the brake pedal and hold it.

      3. Tighten the bleeder plug completely.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      4. Wait 20 seconds.

      5. Repeat the steps above until there are no more air bubbles in the fluid.

    8. Bleed the rear left brake line.

      Note


      • Make sure that the master cylinder reservoir tank does not run out of brake fluid.

      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

      • The actuator operation stops automatically in 4 seconds.


      1. Select "RL Line" on the intelligent tester.

      2. Depress the brake pedal and hold it.

      3. Tighten the bleeder plug completely.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      4. Wait 20 seconds.

      5. Repeat the steps above until there are no more air bubbles in the fluid.

    9. Disconnect the intelligent tester from the DLC3.

    10. Clear the DTCs Click here.

  18. CHECK BRAKE FLUID LEVEL IN RESERVOIR


    1. A010LQYE01

      Check the fluid level.

      If the brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Brake Fluid
      SAE J1704 or FMVSS No. 116 DOT 4

  19. INSPECT FOR BRAKE FLUID LEAK

  20. INSTALL CENTER COWL TOP VENTILATOR LOUVER


    1. A010GT5

      Attach the 5 claws to install the center cowl top ventilator louver.

    2. A010HT8E01

      Push and attach the clip, and slide and attach the claw of the hood to cowl top seal as shown in the illustration.

  21. CHECK BRAKE ACTUATOR ASSEMBLY WITH INTELLIGENT TESTER


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