BRAKE ACTUATOR (w/o VSC) INSTALLATION


  1. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET


    1. A005SN9E01

      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. A005W7A

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

  2. CONNECT BRAKE LINE


    1. A005S9FE01

      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. A005VMK

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

      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 CONNECTOR


    1. A005W2O

      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 1AZ-FE)


    1. A005S4X

      Install the air cleaner case with the 3 bolts.

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

    2. Connect the engine wire.

  6. 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.

  7. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1AZ-FE)


    1. Install the air cleaner filter element to the air cleaner case.

    2. A005RINE01

      Insert the hinge part of the air cleaner cap into the air cleaner case, and then fasten the 3 hook clamps.

    3. Tighten the air cleaner hose clamp as shown in the illustration.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    4. Connect the mass air flow meter connector.

  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. 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.

  10. 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.

  11. 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.

  12. 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.

  13. 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

  14. INSPECT FOR BRAKE FLUID LEAK

  15. 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.

  16. CHECK BRAKE ACTUATOR ASSEMBLY WITH INTELLIGENT TESTER


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