Installation

BRAKE CONTROL: BRAKE ACTUATOR: INSTALLATION

NOTICE:
While the battery is connected, even if the engine switch is off, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal and open/close the doors while the battery is connected.

1. INSTALL BRAKE ACTUATOR

NOTICE:
Do not remove the hole plug before installing a new brake actuator because the brake actuator is filled with brake fluid.

(a) Install the No. 3 brake actuator bracket to the brake actuator with the 3 bolts.

Torque : 9.3 Nm (95 kgf-cm, 82 in-lbf)

NOTICE:
After temporarily installing either bolt A or B, tighten the remaining bolts.

(b) Install the 3 cushions and 3 spacers to the bracket.

Torque : 9.2 Nm (94 kgf-cm, 81 in-lbf)

2. INSTALL BRAKE ACCUMULATOR PUMP

(a) Install the brake booster pump collar (labeled A) and brake booster pump bush (labeled B) to the brake accumulator pump.

(b) Install the brake accumulator pump to the brake actuator bracket.

NOTICE:
After installing the brake accumulator pump, make sure the collar has not fallen off.

(c) Install the brake booster pump bush (labeled C) and a new brake actuator bracket clamp (labeled D) to the brake accumulator pump.

NOTICE:
Make sure to securely insert the brake accumulator pump until the claws of the clamp are attached.

3. INSTALL NO. 4 BRAKE ACTUATOR BRACKET

(a) Install the No. 4 brake actuator bracket to the brake actuator with the bolt.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

4. CONNECT BRAKE ACCUMULATOR PUMP CONNECTOR BOX

(a) Connect the brake accumulator pump connector box as follows:

(1) Install the connector box with the nut (labeled A).

Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)

(2) Attach the wiring harness clamp (labeled B).

5. INSTALL NO. 3 BRAKE ACTUATOR TUBE

NOTICE:
* Do not damage the No. 3 brake actuator tube, brake actuator and brake accumulator pump.
* When installing the No. 3 brake actuator tube, hold the tube, brake actuator and brake accumulator pump securely.
* When tightening the nut, make sure that other parts do not move with the nut.
(a) Using a union nut wrench, connect the No. 3 brake actuator tube.

Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

NOTICE:
Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Part 1.

6. INSTALL NO. 2 BRAKE ACTUATOR HOSE

NOTICE:
Do not remove the cap installed to the reservoir connector until it is connected to the reservoir.

(a) Install the reservoir connector to the No. 2 brake actuator hose with the hose clip as shown in the illustration.

Length "A":

4.0 to 7.0 mm (0.158 to 0.276 in.)

(b) With the paint mark on the hose's tip facing the bottom of the vehicle, install the No. 2 brake actuator hose to the brake accumulator pump with the hose clip.

NOTICE:
When inserting the hose, be careful that there is no excessive weight applied to the union of the brake accumulator pump (especially in the union rotation direction).

HINT
Install the hose clip so that its claws face the rear of the vehicle.

(c) Connect the No. 2 brake actuator hose to the No. 3 brake actuator bracket with the clamp.

7. INSTALL BRAKE ACTUATOR PROTECTOR

(a) Install the protector.

8. INSTALL NO. 1 BRAKE ACTUATOR HOSE

(a) With the paint mark on the hose's tip facing the bottom of the vehicle, install the No. 1 brake actuator hose to the brake actuator with the hose clip.

NOTICE:
When inserting the hose, be careful that there is no excessive weight applied to the union of the brake actuator (especially in the union rotation direction).

HINT
Install the hose clip so that its claws face the rear of the vehicle.

9. INSTALL NO. 5 BRAKE ACTUATOR BRACKET

(a) Install the No. 5 brake actuator bracket to the body with the bolt.

Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

10. INSTALL BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY

(a) Install the brake actuator and brake accumulator pump to the body with the bolt (labeled A) and 2 nuts (labeled B).

NOTICE:
* Do not damage the brake tubes.
* When installing the brake actuator and brake accumulator pump to the vehicle, do not hold the connector, harness, hose or tube parts.
* Do not drop the brake actuator and brake accumulator pump. Do not use parts that have been dropped.
HINT
First insert the bracket bottom's longer stud bolt (vehicle outer side, labeled C) into the body.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

(b) Connect the front fender liner rear side.

(c) Connect the No. 1 brake actuator hose to the body with the clamp.

(d) Connect the brake actuator connector.

NOTICE:
* Before connecting the vehicle wire harnesses, make sure that the connector faces are free of foreign matter.
* Make sure that the connector is locked securely.
11. CONNECT BRAKE TUBE

(a) Using a union nut wrench, connect the No. 1 (labeled A) and No. 2 (labeled B) brake actuator tubes.

Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

NOTICE:
* Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Part 1.
* Do not damage the No. 1 and No. 2 brake actuator tubes.
(b) Set each brake tube to the correct positions on the brake actuator as shown in the illustration.

* *1: To FR RH

* *2: To FR LH

* *3: To: RR RH

* *4: To RR LH

* *5: From Master Cylinder

* *6: From Stroke Simulator

(c) Using a union nut wrench, connect the 6 brake tubes.

Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

NOTICE:
Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Part 1.

12. INSTALL FRONT WHEEL Installation

13. INSTALL RESERVOIR BRACKET Installation

14. INSTALL NO. 1 RESERVOIR HOSE Installation

15. INSTALL BRAKE FLUID RESERVOIR Installation

16. CONNECT NO. 3 RELAY BLOCK

(a) Install the No. 3 relay block to the reservoir bracket.

NOTICE:
Check that the claw of the No. 3 relay block is securely attached to the reservoir bracket.

17. INSTALL SKID CONTROL ECU BRACKET Installation

18. INSTALL SKID CONTROL ECU Installation

19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
* Make sure that the 2 accumulator pump connectors are disconnected.
* When disconnecting the cable, some systems need to be initialized after the cable is reconnected Testing and Inspection.
20. BLEEDING PRECAUTION

CAUTION:
Be sure to read the "PRECAUTION" thoroughly before bleeding Service Precautions.

21. PERFORM ACCUMULATOR ZERO DOWN Procedures

22. FILL RESERVOIR WITH BRAKE FLUID Procedures

23. BLEED BRAKE SYSTEM Procedures

24. PERFORM ACCUMULATOR ZERO DOWN Procedures

25. INSPECT AND ADJUST BRAKE FLUID LEVEL IN RESERVOIR Service and Repair

26. INSPECT FOR BRAKE FLUID LEAK

(a) Inspect for brake fluid leak On-Vehicle Inspection.

27. CLEAR DTC

(a) Clear the DTCs Reading and Clearing Diagnostic Trouble Codes.

28. PERFORM LINEAR VALVE OFFSET LEARNING

(a) When the brake actuator is replaced, perform the linear valve offset learning Initialization.

29. CHECK FOR DTC

(a) If any DTC is set, perform the troubleshooting for the DTC Electronically Controlled Brake System.

30. READ VALUE OF ACCUMULATOR PRESSURE SENSOR OUTPUT VOLTAGE

HINT
If removing and installing the No. 3 brake actuator tube, check for a brake fluid leak from the No. 3 tube connection area by monitoring the accumulator pressure sensor output value from the brake actuator. Directly checking for a brake fluid leak from the No. 3 tube connection area is difficult.

(a) Turn the engine switch off.

(b) Connect the Techstream to the DLC3.

(c) Turn the engine switch on (IG).

(d) Operate the Techstream according to the display and select "DATA LIST".

Skid control ECU:

(e) Depress the brake pedal 4 or 5 times to operate the pump motor, and check the output value on the Techstream with the motor stopped (not braking).

OK:

Accumulator pressure sensor's output voltage drops 0.2 V or less for 30 seconds.

(f) If the voltage drops more than 0.2 V, there may be a brake fluid leak from the No. 3 brake actuator tube connection area. Remove the brake actuator and brake accumulator pump, and then repeat the procedures above from the retightening of the 2 union nuts of the No. 3 brake actuator tube.

Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

NOTICE:
Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Part 1.

31. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

32. INSTALL COWL TOP VENTILATOR LOUVER PROTECTOR LH Installation

33. INSTALL FRONT FENDER TO COWL SIDE SEAL LH Installation

34. INSTALL FRONT FENDER TO COWL SIDE SEAL RH Installation

35. INSTALL HOOD TO COWL TOP SEAL Installation

36. INSTALL FRONT FENDER PROTECTOR UPPER LH Installation

37. INSTALL FRONT FENDER PROTECTOR UPPER RH Installation

38. INSTALL ENGINE ROOM SIDE COVER RH Installation

39. INSTALL ENGINE ROOM SIDE COVER LH Installation

40. INSTALL FRONT WIPER ARM LH Installation

41. INSTALL FRONT WIPER ARM RH Installation

42. INSTALL COWL TOP VENTILATOR LOUVER RH Installation

43. INSTALL V-BANK COVER SUB-ASSEMBLY Installation