BRAKE ACTUATOR INSTALLATION

PROCEDURE

1. INSTALL BRAKE ACTUATOR ASSEMBLY

   1. 

      *a

      Pin

      Install a new brake actuator assembly to the brake actuator bracket assembly and engage the pin.

      Note:

      • Do not remove the hole plugs of a new brake actuator assembly before connecting the brake lines because the brake actuator assembly is filled with brake fluid.

      • Do not hold the brake actuator assembly by the connector.

      • Be sure to insert the pin of the brake actuator assembly to the cushion of the brake actuator bracket assembly.

   2. Tighten the 2 nuts to secure the brake actuator assembly to the brake actuator bracket assembly.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

      Note:

      Tighten the 2 nuts in the order shown in the illustration.

2. INSTALL BRAKE ACTUATOR WITH BRACKET

   1. 

      Install the brake actuator with bracket with the 3 bolts.

      19 N*m

      194 kgf*cm

      14 ft.*lbf

      Note:

      • Do not damage the brake lines.

      • Do not hold the brake actuator with bracket by the connector.

      • Tighten the 3 bolts in the order shown in the illustration.

      Tip:

      Install the brake actuator with bracket while avoiding the brake lines.

   2. Engage the clamp to install the No. 3 fuel tube clamp to the brake actuator bracket assembly.

   3. 

      *a	for LHD: From 1st Chamber of Brake Master Cylinder Sub-assembly for RHD: From 2nd Chamber of Brake Master Cylinder Sub-assembly
      *b	for LHD: From 2nd Chamber of Brake Master Cylinder Sub-assembly for RHD: From 1st Chamber of Brake Master Cylinder Sub-assembly
      *c	To Front Wheel Cylinder Assembly RH
      *d	To Rear Wheel Cylinder Assembly LH
      *e	To Rear Wheel Cylinder Assembly RH
      *f	To Front Wheel Cylinder Assembly LH

      Temporarily tighten the 6 brake lines to the correct positions on the brake actuator assembly as shown in the illustration.

   4. Using a union nut wrench, fully tighten each brake line.

      *a, *b (w/o VSC)

      15.2 N*m

      155 kgf*cm

      11 ft.*lbf

      *a, *b (w/ VSC)

      19.5 N*m

      199 kgf*cm

      14 ft.*lbf

      *c, *d, *e, *f

      15.2 N*m

      155 kgf*cm

      11 ft.*lbf

      Note:

      • Do not kink or damage the brake lines.

      • Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

        Click hereClick here

   5. Connect the connector to the brake actuator assembly.

      

   6. Pull the lock lever down and engage the claw of the lock lever to engage the connector lock.

      Note:

      • Make sure that the connector is locked securely.

      • Make sure that the actuator connector can be connected smoothly. Do not allow water, oil or dirt to enter the connector.

   7. Engage the wire harness clamp.

   8. for 1KR-FE RHD:

      1. 

         Connect the connector to the ECM and lower the lever.

         Note:

         • When connecting the connector to the ECM, make sure that dirt, water or other foreign matter does not contact the connecting part of the connector.

         • Be sure to securely connect the connector.

3. INSTALL CLUTCH RELEASE CABLE CLAMP (for 1PP)

   1. Install the clutch release cable clamp with the bolt.

      7 N*m

      71 kgf*cm

      62 in.*lbf

4. INSTALL RELAY BLOCK BRACKET

   1. Install the relay block bracket with the bolt.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

   2. Install the ground wire to the relay block bracket with the bolt.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

5. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY (for LHD)

   Click here

6. INSTALL BATTERY CLAMP SUB-ASSEMBLY

   for 1KR-FE:Click hereClick here

   for 1PP:Click here

7. INSTALL BATTERY

   for 1KR-FE:Click hereClick here

   for 1PP:Click here

8. INSTALL OUTER COWL TOP PANEL

   for LHD:Click here

   for RHD:Click here

9. INSTALL FRONT NO. 1 VENTILATOR SEAL

   for LHD:Click here

   for RHD:Click here

10. INSTALL FRONT AIR SHUTTER SEAL RH

    for LHD:Click here

    for RHD:Click here

11. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click hereClick here

13. BLEED BRAKE SYSTEM

    Click here

14. PERFORM SYSTEM VARIANT LEARNING AND ACCELERATION SENSOR ZERO POINT CALIBRATION (w/ VSC)

    Click here

15. PERFORM TEST MODE INSPECTION

    w/o VSC:Click here

    w/ VSC:Click here

16. INSPECT BRAKE ACTUATOR USING GTS

    Click here

17. CHECK FOR AND CLEAR DTCS

    w/o VSC:Click here

    w/ VSC:Click here