INSTALLATION

CAUTION / NOTICE / HINT

HINT:

The parking brake indicator light (red) blinks when the ignition switch is turned to ON after replacing the brake actuator assembly. Operate the electric parking brake switch assembly to turn off the parking brake indicator light.

PROCEDURE

1. INSTALL BRAKE ACTUATOR BOLT CUSHION

HINT:

Perform this procedure only when replacement of the brake actuator bolt cushions is necessary.

(a) Install the 3 brake actuator bolt cushions to the brake actuator bracket assembly.

2. INSTALL NO. 1 BRAKE ACTUATOR CASE COLLAR

HINT:

Perform this procedure only when replacement of the No. 1 brake actuator case collars is necessary.

(a) Install the 3 No. 1 brake actuator case collars to the brake actuator bolt cushion.

NOTICE:

Make sure that the No. 1 brake actuator case collar is in full contact with the brake actuator bolt cushion.

3. INSTALL BRAKE ACTUATOR ASSEMBLY

(a) Temporarily install the brake actuator assembly with the 3 bolts.

(b) Tighten the 3 bolts in the order shown in the illustration. Torque: 6.5 N·m {66 kgf·cm, 58 in·lbf} NOTICE: 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. Do not drop the brake actuator assembly when carrying it.

4. INSTALL BRAKE ACTUATOR WITH BRACKET

(a) Temporarily install the brake actuator with bracket with the 2 bolts and nut. NOTICE: Do not kink or damage the brake lines. Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts. Be careful not to allow any brake fluid to enter the connector. Do not hold the brake actuator with bracket by the connector. Do not drop the brake actuator with bracket when carrying it. HINT: Install the brake actuator with bracket while avoiding the brake lines.

(b) Tighten the 2 bolts and nut in the order shown in the illustration.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

(c) Engage the clamp to install a new brake tube clamp.

(d) Return the front brake tube to its original position.

NOTICE:

Do not apply excessive force to the front brake tube.

(e) Temporarily install the front brake tube to the front flexible hose. NOTICE: Do not kink or damage the front brake tube. Do not allow any foreign matter such as dirt or dust to enter the front brake tube from the connecting parts.

(f) Engage the clamp to connect the front brake tube. NOTICE: Do not kink or damage the front brake tube.

(g) Temporarily tighten the 2 brake lines to the correct position on the brake actuator assembly as shown in the illustration. NOTICE: Do not kink or damage the brake lines. Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

*a From 1st Chamber of Brake Booster with Master Cylinder Assembly *b From 2nd Chamber of Brake Booster with Master Cylinder Assembly

(h) Using a union nut wrench, fully tighten the 2 brake lines. Torque: Specified tightening torque : 19.5 N·m {199 kgf·cm, 14 ft·lbf} NOTICE: Do not kink or damage the brake lines. HINT: 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 (6.38 in.)): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

*a Torque Wrench Fulcrum Length *b Union Nut Wrench

(i) Temporarily tighten the 4 brake lines to the correct position on the brake actuator assembly as shown in the illustration. NOTICE: Do not kink or damage the brake lines. Do not allow any foreign matter such as dirt or dust to enter the brake line from the connecting parts.

*a To Front Disc Brake Cylinder Assembly RH *b To Front Disc Brake Cylinder Assembly LH *c To Rear Disc Brake Cylinder Assembly RH *d To Rear Disc Brake Cylinder Assembly LH

(j) Using a union nut wrench, fully tighten the 4 brake lines. Torque: Specified tightening torque : 15.2 N·m {155 kgf·cm, 11 ft·lbf} NOTICE: Do not kink or damage the brake lines. HINT: 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 (6.38 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

*a Torque Wrench Fulcrum Length *b Union Nut Wrench

(k) Using a union nut wrench, fully tighten the front brake tube while holding the front flexible hose with a wrench. Torque: Specified tightening torque : 15.2 N·m {155 kgf·cm, 11 ft·lbf} NOTICE: Do not kink or damage the front brake tube. HINT: 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 (6.38 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

*a Torque Wrench Fulcrum Length *b Union Nut Wrench

(l) Install the brake lines with the 2 bolts. Torque: 7.0 N·m {71 kgf·cm, 62 in·lbf}

(m) Connect the connector to the brake actuator assembly and lock the lock lever.

	Connect the connector
	Lock the lock lever

5. CONNECT BRAKE BOOSTER WITH ACCUMULATOR PUMP CONNECTOR

HINT:

Perform this operation only when the accumulator pressure zero down could not be performed using the GTS.

(a) Connect the brake booster with accumulator pump connector. NOTICE: Do not allow water, oil or dirt to enter the connector.

6. FILL RESERVOIR WITH BRAKE FLUID

7. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

Click here

NOTICE:

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

Click here

8. BLEED BRAKE SYSTEM

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9. INSTALL COWL VENTILATOR PANEL SUB-ASSEMBLY

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10. INSTALL COWL VENTILATOR SPLASH SHIELD

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11. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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12. PERFORM INITIALIZATION AND CALIBRATION

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13. CHECK AND CLEAR DTC

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