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BRAKE ACTUATOR (w/ VSC) INSTALLATION

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  1. Click here

    REMOVE BRAKE ACTUATOR COVER (for 1WW)


    1. Install a new brake actuator cover to the brake actuator assembly.

  2. Click here

    INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET


    1. for Manual Transaxle:


      1. A01ISI0E01

        Install the brake actuator with bracket with the 3 nuts. Tighten the 3 nuts uniformly in alphabetical order.

        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. A01IOZTE01

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

        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. for Manual Transaxle:


      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.

  3. Click here

    CONNECT BRAKE LINE


    1. A01INZWE01

      Set each brake line in the correct position on the brake actuator as shown in the illustration.

      Table 1. Text in Illustration
      *a to Front Wheel Cylinder RH
      *b to Front Wheel Cylinder LH
      *c to Rear Wheel Cylinder RH
      *d to Rear Wheel Cylinder LH
      *e From Master Cylinder
    2. A01IU1KE01

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

      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
      Table 2. Text in Illustration
      *a Torque Wrench Fulcrum Length
      Tip:

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (Click here).

      • for flare nut A

        When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13 N*m (137 kgf*cm, 10 ft.*lbf).

      • for flare nut B

        When using a union nut wrench (fulcrum length of 20 mm (0.7874 in.)) + torque wrench (fulcrum length of 180 mm (7.0866 in.)): 18 N*m (179 kgf*cm, 13 ft.*lbf).

  4. Click here

    CONNECT CONNECTOR


    1. A01IRCUE01

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

      Table 3. Text in Illustration
      *A for Manual Transaxle
      *B for CVT
  5. Click here

    INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. for 1ZR-FAE:

      Install the air cleaner case sub-assembly (Click here).

    2. for 2ZR-FAE:

      Install the air cleaner case sub-assembly (Click here).

  6. Click here

    INSTALL FUEL FILTER ASSEMBLY (for 1WW)


    1. Install the fuel filter assembly (Click here).

  7. 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).

  8. Click here

    REMOVE CENTER COWL TOP VENTILATOR LOUVER


    1. A01IN40E02

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

    2. A01IT64

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

  9. Click here

    BLEED BRAKE SYSTEM

    (Click here)

  10. Click here

    BLEED AIR FROM CLUTCH LINE (for 1ZR-FAE with Manual Transaxle)

    (Click here)

  11. Click here

    BLEED AIR FROM CLUTCH LINE (for 2ZR-FAE with Manual Transaxle)

    (Click here)

  12. Click here

    BLEED AIR FROM CLUTCH LINE (for 1WW with Manual Transaxle)

    (Click here)

  13. Click here

    INSTALL CENTER COWL TOP VENTILATOR LOUVER


    1. A01IT64

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

    2. A01IUP1E01

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

  14. Click here

    CHECK BRAKE ACTUATOR ASSEMBLY WITH GTS

    (Click here)