BRAKE ACTUATOR INSTALLATION

PROCEDURE

1. INSTALL BRAKE ACTUATOR BOLT CUSHION

   1. Install the 4 brake actuator bolt cushions to the brake actuator bracket assembly.

2. INSTALL BRAKE ACTUATOR CASE COLLAR

   1. Install the 4 brake actuator case collars to the brake actuator bolt cushions.

      Note:

      Make sure the brake actuator case collars are in full contact with the brake actuator bolt cushions.

3. INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY

   1. 

      Install the brake actuator with bracket with the 3 nuts.

      19 N*m

      194 kgf*cm

      14 ft.*lbf

      Note:

      • Tighten the 3 nuts uniformly in alphabetical order.

      • Be careful not to damage the brake tubes.

   2. 

      Connect the 3 clamps to the brake actuator bracket assembly.

4. INSTALL BRAKE ACTUATOR ASSEMBLY

   1. 

      Install the brake actuator bracket assembly to the brake actuator assembly with the 4 bolts.

      5.4 N*m

      55 kgf*cm

      48 in.*lbf

      Note:

      • Tighten the 4 bolts uniformly in alphabetical order.

      • A new brake actuator is filled with brake fluid. Therefore, make sure to connect the brake tube before removing the hole plug.

   2. Connect the 3 clamps to the brake actuator bracket assembly.

   3. 

      *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 Front Master Cylinder
      *f	from Rear Master Cylinder

      Temporarily install each brake line to the correct positions of the brake actuator assembly with bracket as shown in the illustration.

   4. 

      *a	Torque Wrench Fulcrum Length

      Using a union nut wrench, tighten each 6 brake lines.

      Specified tightening torque

      15.2 N*m

      155 kgf*cm

      11 ft.*lbf

      Tip:

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 22 mm (0.8661 in.)) + torque wrench (fulcrum length of 162 mm (6.3779 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

   5. 

      Connect the clamp to the brake actuator bracket assembly.

   6. Connect the connector to the brake actuator assembly and lock the lock lever.

      Note:

      • Before connecting the wire harness connector, make sure that the surfaces of the wire harness connector are free of foreign matter.

      • After connecting the wire harness connector, make sure that the lock lever is securely locked.

5. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET (for Automatic Transmission)

   1. 

      Attach the clamp.

   2. Install the No. 1 transmission control cable bracket to the automatic transaxle assembly with the 2 bolts.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

6. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transmission)

   1. 

      Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

   2. Connect the transmission control cable assembly to the transmission control shaft lever with the nut.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

7. CONNECT ENGINE WIRE

   1. except 2WW:

      1. 

         Install the wire harness clamp bracket with the bolt.

         7.7 N*m

         79 kgf*cm

         68 in.*lbf

      2. 

         Connect the engine wire to the body with the bolt.

         8.4 N*m

         86 kgf*cm

         74 in.*lbf

      3. Attach the 2 clamps.

   2. 

      for CVT

      1. Connect the connector.

      2. Connect the engine wire with the bolt.

         7.7 N*m

         79 kgf*cm

         68 in.*lbf

8. INSTALL AIR CLEANER BRACKET

   1. for 2AD-FHV:

      Click here

   2. for 2AD-FTV:

      Click here

9. INSTALL FUEL FILTER SUPPORT (for 2WW)

   Click here

10. INSTALL FUEL FILTER ASSEMBLY

    1. for 2AD-FHV:

       Click here

    2. for 2AD-FTV:

       Click here

    3. for 2WW:

       Click here

11. INSTALL AIR CLEANER SUPPORT

    1. for 2AD-FHV:

       Click here

    2. for 2AD-FTV:

       Click here

12. INSTALL NO. 3 COWL TOP PANEL INSULATOR (for 2WW)

    1. 

       Install the No. 3 cowl top panel insulator with the 4 nuts.

       5.5 N*m

       56 kgf*cm

       49 in.*lbf

13. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    1. for 2AD-FHV:

       Click here

    2. for 2AD-FTV:

       Click here

    3. for 2AR-FE:

       Click here

    4. for 3ZR-FAE:

       Click here

    5. for 3ZR-FE:

       Click here

    6. for 2WW:

       Click here

14. INSTALL REAR ENGINE UNDER COVER LH

    1. for 2AD-FHV:

       Click here

    2. for 2AD-FTV:

       Click here

    3. for 2AR-FE:

       Click here

    4. for 3ZR-FAE:

       Click here

    5. for 3ZR-FE:

       Click here

    6. for 2WW:

       Click here

15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

16. BLEED BRAKE SYSTEM

    Click here

17. INSPECT BRAKE ACTUATOR WITH GTS

    Click here