BRAKE ACTUATOR (for LHD with VSC) INSTALLATION


  1. INSTALL NO. 3 BRAKE ACTUATOR BRACKET


    1. A01DV56E01

      Install the No. 3 brake actuator bracket with the bolt.

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Note

      Do not install the bolt for the hole labeled A as it is installed together with the actuator with bracket.

  2. INSTALL BRAKE ACTUATOR ASSEMBLY


    1. A01DXDOE01

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

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Note


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

      • Be careful not to damage the brake tubes.

      • Do not drop the actuator. If dropped, replace the actuator.

    2. A01DVBAE01

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

    3. A01E2OK

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

      Torque:
      15 N*m  { 155 kgf*cm, 11 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.

    4. Connect the actuator connector.

  3. FILL RESERVOIR WITH BRAKE FLUID

    Fluid
    Item Specified Condition
    except TSAM Made SAE J1703 or FMVSS No. 116 DOT 3
    for TSAM Made SAE J1704 or FMVSS No. 116 DOT 4

  4. BLEED AIR FROM BRAKE MASTER CYLINDER

    Tech Tips

    If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.


    1. A01DYWH

      Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.

    2. Slowly depress and hold the brake pedal.

    3. A01DXKZ

      Block the tube holes with your fingers, and then release the brake pedal.

    4. Remove the your fingers, slowly depress and hold the brake pedal, block the tube holes with your fingers again, and then release the brake pedal. Repeat this step 3 or 4 times.

    5. Using a union nut wrench, connect the 2 brake tubes to the brake master cylinder.

      Torque:
      15 N*m  { 155 kgf*cm, 11 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.

  5. BLEED AIR FROM BRAKE LINE


    1. Remove the bleeder plug cap.

    2. Connect a vinyl tube to the bleeder plugs.

    3. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.

    4. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

    5. Repeat the 2 previous steps until all the air in the brake fluid is gone.

    6. Tighten the bleeder plug.

      Torque:
      for front brake
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }
      for rear brake
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    7. Install the cap.

    8. A01E31B

      Bleed air from the brake line for each wheel by repeating the above procedures.

  6. BLEED AIR FROM BRAKE ACTUATOR

    Note

    After bleeding the brae 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 ON.

      Note

      Do not start the engine.

    4. Turn the intelligent tester on and enter the following menus: Chassis / ABS/VSC/TRC / Utility / Air Bleeding.

    5. Bleed the brake actuator by following the instructions on the intelligent tester.

    6. After bleeding air, tighten each bleeder plug.

      Torque:
      for front brake
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }
      for rear brake
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    7. Turn the intelligent tester off and disconnect the intelligent tester from the DLC3.

    8. Turn the ignition switch off.

  7. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)

    A01E1RYE01

    1. Remove the bleeder plug cap.

    2. Connect the vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

    4. At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled out.

    6. Tighten the bleeder plug.

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

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled out of the clutch line.

  8. CHECK BRAKE FLUID LEVEL IN RESERVOIR


    1. A01E2XS

      Check the fluid level.

      If the brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Fluid
      Item Specified Condition
      except TSAM Made SAE J1703 or FMVSS No. 116 DOT 3
      for TSAM Made SAE J1704 or FMVSS No. 116 DOT 4

  9. CHECK FOR BRAKE FLUID LEAKAGE

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  11. CHECK BRAKE ACTUATOR WITH INTELLIGENT TESTER


    1. Check the brake actuator with the intelligent tester Click here.