BRAKE ACTUATOR INSTALLATION

Bleed air from the brake system.

1. 

   Remove the 2 ABS motor relays.

   Tech Tips

   If the ABS motor relays are already removed, this procedure is unnecessary.

2. With the power switch off, connect the GTS to the DLC3.

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

4. Adjust the brake fluid amount so that the brake fluid level is at the MIN level of the brake fluid reservoir.

5. Turn the power switch on (IG), turn the GTS on, and enter the following menus: Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Utility / Zero Down.

   Tech Tips

   Using the GTS to perform zero down causes the pressurized fluid in the accumulator to be returned to the brake fluid in the accumulator to be returned to the brake fluid reservoir.

6. Confirm the sounds of the buzzer and turn the power switch off.

7. Add brake fluid so that the fluid level is between the MIN and MAX lines of the brake fluid reservoir.

8. Turn the power switch on (IG), turn the GTS on, and enter the following menus: Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Invalid.

9. Bleed air from the No. 1 brake actuator tube.

   Tech Tips

   If the No. 1 brake actuator tube (between the master cylinder and brake actuator) is disconnected, bleed air using the following procedure.

   
   

   1. Add brake fluid so that the fluid level is between the MIN and MAX lines of the brake fluid reservoir.

   2. Remove the cover from the top of the brake master cylinder reservoir filler cap assembly.

   3. Set the vacuum pump to pressurized state (discharge) and install the small diameter attachment to the hose.

   4. 

      Insert the small diameter attachment into the air hole of the reservoir cap to install it.

      Text in Illustration

      *1	Vacuum Pump
      *2	Small Diameter Attachment

   5. Connect a vinyl tube to the bleeder plug of the brake actuator.

   6. Loosen the bleeder plug of the brake actuator.

   7. Using the vacuum pump, increase the pressure inside the brake fluid reservoir.

   8. Drain the air and brake fluid inside the tube and tighten the bleeder plug.

   9. With the bleeder plug tightened, maintain the pressure in the brake fluid reservoir at 0.08 MPa, and then loosen the bleeder plug to bleed air.

      NOTICE
      Perform this procedure 5 times or more.

   10. Tighten the bleeder plug all the air between the brake fluid reservoir and brake actuator is bled.

       Torque
       8.3 N*m (85 kgf*cm, 73 in.*lbf)

   11. Release the pressure in the brake fluid reservoir and remove the vinyl tube, vacuum pump and small diameter attachment.

   12. Install the cover on the top of the brake master cylinder reservoir filler cap assembly.

10. Repeatedly depress the brake pedal to bleed the air from the bleeder plug of the front disc brake cylinder RH.

    Tech Tips

    Repeatedly depress the brake pedal 30 times or more, as air often remains inside the brake stroke simulator cylinder.

    Note

    Add fluid so that the fluid level does not drop below the MIN line on the brake fluid reservoir.

11. After bleeding the air, depress and hold the brake pedal, and tighten the bleeder plug.

    Torque:

    11 N*m  { 110 kgf*cm, 8 ft.*lbf }

12. In the same way as the RH side, bleed air from the bleeder plug of the front disc brake cylinder LH.

13. Follow the GTS screen, to end ECB (Electronically Controlled Brake system) Invalid.

14. Install the 2 ABS motor relays with the power switch off.

15. Turn the power switch on (IG), turn the GTS on, and enter the following menus: Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Utility / ECB (Electronically controlled Brake system) Invalid.

16. While depressing the brake pedal, loosen the bleeder plug of the rear disc brake cylinder LH. While the pump motor and solenoid are operating, bleed the air.

    Note

    Add fluid so that the fluid level does not drop below the MIN line on the brake fluid reservoir.

17. After bleeding the air, tighten the bleeder plug and release the brake pedal.

    Torque:

    8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

18. In the same way as the LH side, bleed air from the bleeder plug of the rear disc brake cylinder RH.

19. Follow the GTS screen, to end ECB (Electronically Controlled Brake system) Invalid.

20. Adjust the brake fluid amount so that the brake fluid level is at the MIN level of the brake fluid reservoir.

21. Turn the power switch on (IG), turn the GTS on, and enter the following menus: Chassis / ABS/VSC/TRC / Utility / ECB (Electronically controlled Brake system) Utility / Zero Down.

22. Confirm the sounds of the buzzer and turn the power switch off.

23. Turn the power switch on (IG), and then after confirming that the pump motor stops operating, perform zero down again.

    Tech Tips

    The operation of the pump motor can be confirmed by listening to the operating sound.

24. In order to circulate the fluid inside the accumulator, perform "Zero Down" a total of 5 times.