BRAKE ACTUATOR (w/ VSC) INSTALLATION

INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET
1. except CVT:
  1. 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 and wire harness.
    
    Do not drop the actuator. If dropped, replace it.
2. for CVT:
  1. 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 and wire harness.
    
    Do not drop the actuator. If dropped, replace it.
3. except CVT:
  1. Install 2 new tube clamps to the tubes, and then attach the 2 clamps to the brake actuator bracket.
4. for CVT:
  1. Install 2 new tube clamps to the tubes, and then attach the 2 clamps to the brake actuator bracket.
CONNECT BRAKE LINE
1. 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. 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.

CONNECT CONNECTOR

Text in Illustration
*A	for 1ZR-FAE, 2ZR-FAE
*B	for 1AD-FTV, 2AD-FHV

Connect the connector, attach the harness clamp and push the lock lever downward.

INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1ZR-FAE)
1. 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.
INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2ZR-FAE)
1. 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.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1ZR-FAE)
1. Connect the air cleaner cap with the band.
2. Connect the PCV hose.
3. Connect the 2 clamps.
4. Attach the 2 clamps and connect the wire harness.
5. Connect the mass air flow meter connector.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FAE)
1. Connect the air cleaner cap with the band.
2. Connect the PCV hose.
3. Connect the 2 clamps.
4. Attach the 2 clamps and connect the wire harness.
5. Connect the mass air flow meter connector.
INSTALL FUEL FILTER ASSEMBLY
1. for 1AD-FTV:
  
  Install the fuel filter assembly Click here.
2. for 2AD-FHV:
  
  Install the fuel filter assembly Click here.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
REMOVE CENTER COWL TOP VENTILATOR LOUVER
1. Slide the hood to cowl top seal and detach the clip as shown in the illustration.
2. Detach the 5 claws and remove the center cowl top ventilator louver.
BLEED BRAKE SYSTEM
1. Bleed 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. 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 brakes.
    
    Brake fluid
    
    SAE J1704 or FMVSS No, 116 DOT 4
  3. Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.
  4. Slowly depress the brake pedal and hold it.*1
  5. Cover the 2 outer holes with fingers and release the brake pedal.*2
  6. Repeat *1 and *2 3 or 4 times.
  7. Using a union nut wrench, connect the 2 brake lines to the master cylinder.
    
    Torque:
    
    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.
2. Bleed brake line
  1. Remove the bleeder plug cap.
  2. Connect a vinyl tube to the bleeder plug.
  3. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1
  4. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
  5. Repeat *1 and *2 until all the air in the fluid is completely bled out.
  6. Tighten the bleeder plug completely.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  7. Install the bleeder plug cap.
  8. Repeat the above procedure for each wheel to bleed the brake line.
3. Bleed brake actuator (w/ VSC)
  
  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 does not run out of brake fluid.
    
    1. Select "FR Line" on the intelligent tester.
    
    2. Loosen the bleeder plug.
    
    3. Depress the brake pedal and hold it.
    
    Note
    
    The actuator operation stops automatically in 4 seconds.
    
    4. Tighten the bleeder plug completely.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
    
    5. Release the brake pedal.
    
    6. Wait 20 seconds.
    
    7. 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 does not run out of brake fluid.
    
    1. Select "FL Line" on the intelligent tester.
    
    2. Loosen the bleeder plug.
    
    3. Depress the brake pedal and hold it.
    
    Note
    
    The actuator operation stops automatically in 4 seconds.
    
    4. Tighten the bleeder plug completely.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
    
    5. Release the brake pedal.
    
    6. Wait 20 seconds.
    
    7. 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 does not run out of brake fluid.
    
    1. Select "RR Line" on the intelligent tester.
    
    2. Loosen the bleeder plug.
    
    3. Depress the brake pedal and hold it.
    
    Note
    
    The actuator operation stops automatically in 4 seconds.
    
    4. Tighten the bleeder plug completely.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
    
    5. Release the brake pedal.
    
    6. Wait 20 seconds.
    
    7. 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 does not run out of brake fluid.
    
    1. Select "RL Line" on the intelligent tester.
    
    2. Loosen the bleeder plug.
    
    3. Depress the brake pedal and hold it.
    
    Note
    
    The actuator operation stops automatically in 4 seconds.
    
    4. Tighten the bleeder plug completely.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
    
    5. Release the brake pedal.
    
    6. Wait 20 seconds.
    
    7. Repeat the steps above until there are no more air bubbles in the fluid.
  9. Disconnect the intelligent tester from the DLC3.
4. Clear the DTCs Click here.
5. Inspect for brake fluid leak.
6. Inspect fluid level in reservoir Click here.
BLEED AIR FROM CLUTCH LINE (for 1ZR-FAE with Manual Transaxle)
Text in Illustration

*1 Bleeder Plug Cap

*2 Bleeder Plug
1. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
  
  Brake fluid
  
  SAE J1704 or FMVSS No, 116 DOT 4
2. Remove the bleeder plug cap.
3. Connect a vinyl tube to the bleeder plug.
4. Depress the clutch pedal 5 times, and then loosen the bleeder plug while the pedal is depressed.
5. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.
6. Repeat both of the previous 2 steps 6 times.
7. Tighten the bleeder plug.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
8. Depress the clutch pedal 10 times or more and confirm its operation.
  
  Note
  
  This must be performed before the engine is started.
9. Install the bleeder plug cap.
10. Check that all the air has been bled from the clutch line.
BLEED AIR FROM CLUTCH LINE (for 2ZR-FAE with Manual Transaxle)
Text in Illustration

*1 Bleeder Plug Cap

*2 Bleeder Plug
1. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
  
  Brake fluid
  
  SAE J1704 or FMVSS No, 116 DOT 4
2. Remove the bleeder plug cap.
3. Connect a vinyl tube to the bleeder plug.
4. Depress the clutch pedal 5 times, and then loosen the bleeder plug while the pedal is depressed.
5. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.
6. Repeat both of the previous 2 steps 6 times.
7. Tighten the bleeder plug.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
8. Depress the clutch pedal 10 times or more and confirm its operation.
  
  Note
  
  This must be performed before the engine is started.
9. Install the bleeder plug cap.
10. Check that all the air has been bled from the clutch line.
BLEED AIR FROM CLUTCH LINE (for 1AD-FTV with Manual Transaxle)
Text in Illustration

*1 Bleeder Plug Cap

*2 Bleeder Plug
1. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
  
  Brake fluid
  
  SAE J1704 or FMVSS No, 116 DOT 4
2. Remove the bleeder plug cap.
3. Connect a vinyl tube to the bleeder plug.
4. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.
5. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.
6. Repeat the previous 2 steps until all the air in the fluid is completely bled.
7. Tighten the bleeder plug.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
8. Install the bleeder plug cap.
9. Check that all the air has been bled from the clutch line.
BLEED AIR FROM CLUTCH LINE (for 2AD-FHV with Manual Transaxle)
Text in Illustration

*1 Bleeder Plug Cap

*2 Bleeder Plug
1. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
  
  Brake fluid
  
  SAE J1704 or FMVSS No, 116 DOT 4
2. Remove the bleeder plug cap.
3. Connect a vinyl tube to the bleeder plug.
4. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.
5. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.
6. Repeat the previous 2 steps until all the air in the fluid is completely bled.
7. Tighten the bleeder plug.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
8. Install the bleeder plug cap.
9. Check that all the air has been bled from the clutch line.
INSTALL CENTER COWL TOP VENTILATOR LOUVER
1. Attach the 5 claws to install the center cowl top ventilator louver.
2. Push the clip to attach it, and then slide the hood to cowl top seal as shown in the illustration to attach the claw.
CHECK BRAKE ACTUATOR ASSEMBLY WITH INTELLIGENT TESTER
1. Check the brake actuator with the intelligent tester Click here.

Text in Illustration
*1	Bleeder Plug Cap
*2	Bleeder Plug

Text in Illustration
*1	Bleeder Plug Cap
*2	Bleeder Plug

Text in Illustration
*1	Bleeder Plug Cap
*2	Bleeder Plug

Text in Illustration
*1	Bleeder Plug Cap
*2	Bleeder Plug