BRAKE ACTUATOR(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL BRAKE ACTUATOR BRACKET CUSHION


    1. Install the 3 brake actuator bracket cushions to the brake actuator bracket assembly.

  2. INSTALL NO.1 BRAKE ACTUATOR CASE COLLAR


    1. Install the 3 No. 1 brake actuator case collars to the brake actuator bracket cushions.

      Note

      Make sure the No. 1 brake actuator case collars are in full contact with the brake actuator bracket cushions.

  3. INSTALL NO. 5 BRAKE ACTUATOR BRACKET


    1. B006ACHN01

      Install the No. 5 brake actuator bracket with the 3 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Note


      • Tighten the 3 bolts uniformly in alphabetical order.

      • Be careful not to damage the brake tubes.

  4. INSTALL NO. 4 BRAKE ACTUATOR BRACKET


    1. B006FHM

      Install the No. 4 brake actuator bracket with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Note

      Be careful not to damage the brake tubes.

  5. INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY


    1. B006BB7N01

      Install the brake actuator bracket assembly with the 3 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Note

      Tighten the 3 bolts uniformly in alphabetical order.

  6. INSTALL BRAKE ACTUATOR WITH BRACKET ASSEMBLY


    1. B006CIGN02

      Install the brake actuator with bracket assembly with the 2 bolts and nut.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      Note


      • Tighten the 2 bolts and nuts uniformly in alphabetical order.

      • Be careful not to damage the brake tubes.

    2. B006CMVC01
      *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 Port
      *f from Rear Master Cylinder Port

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

    3. B006DM7C01
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Using a union nut wrench, tighten each 4 brake lines.

      Torque:
      Specified tightening torque
      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.

      Tech Tips


      • 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 (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.378 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

    4. B006AN4C01
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Using a union nut wrench, tighten each 2 brake lines.

      Torque:
      Specified tightening torque
      19.5 N*m  { 199 kgf*cm, 14 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.

      Tech Tips


      • 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 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.378 in.)): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

    5. B006CIJC01
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Using a union nut wrench, tighten each 2 brake lines.

      Torque:
      Specified tightening torque
      19.5 N*m  { 199 kgf*cm, 14 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.

      Tech Tips


      • 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 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.378 in.)): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

    6. Connect the clamp and install the 2 brake lines.

    7. B006FX7C01
      B006DHE Lock Lever Locked
      B006B42 Connector Connected

      Connect the wire harness connector to the brake actuator assembly, and then push up the lock lever to apply the lock.

      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.

  7. CONNECT UNION TO CHECK VALVE HOSE


    1. B006GKL

      Slide the clip and connect the union to check valve hose to the brake booster assembly.

  8. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  10. BLEED BRAKE SYSTEM

    Click here

  11. PERFORM SYSTEM VARIANT LEARNING AND ACCELERATION SENSOR ZERO POINT CALIBRATION

    Click here

  12. INSPECT BRAKE ACTUATOR USING GTS

    Click here

  13. INSTALL FENDER APRON BRACE SUB-ASSEMBLY LH

    Click here

  14. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here