Brake Actuator (W/O Vsc) -- Installation |
| 1. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET |
- NOTICE:
- Do not remove the hole plug before connecting the brake tube. New actuators are filled with brake fluid.
Install the actuator with bracket with the 3 nuts.
- Torque:
- 19 N*m{194 kgf*cm, 14 ft.*lbf}
- HINT:
- The nuts should be tightened in order from 1 to 3 as shown in the illustration.
- NOTICE:
- Be careful not to damage the brake tubes.
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Connect the brake tube clamp to the bracket.
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Connect the actuator connector.
| 2. CONNECT BRAKE LINE |
Using a union nut wrench, connect the 6 brake lines to the correct locations on the actuator, as shown in the illustration.
- Torque:
- without union nut wrench:
- 15 N*m{155 kgf*cm, 11 ft.*lbf}
- with union nut wrench:
- 14 N*m{145 kgf*cm, 10 ft.*lbf}
- HINT:
- Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
- This torque value is effective when the union nut wrench is parallel to the torque wrench.
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| 3. FILL RESERVOIR WITH BRAKE FLUID |
- Fluid:
- SAE J1703 or FMVSS No. 116 DOT3
- NOTICE:
- Make sure there is sufficient brake fluid in the can.
- After adding braking fluid, make sure the reservoir is sufficiently full.
| 4. BLEED AIR FROM BRAKE MASTER CYLINDER |
- HINT:
- If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.
Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.
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Slowly depress and hold the brake pedal.
Block the outer holes with your fingers, and release the pedal.
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Repeat the 2 previous steps 3 or 4 times.
Using a union nut wrench, connect the 2 brake lines to the master cylinder.
- Torque:
- without union nut wrench:
- 15.2 N*m{155 kgf*cm, 11 ft.*lbf}
- with union nut wrench:
- 14 N*m{144 kgf*cm, 10 ft.*lbf}
- HINT:
- Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
- This torque value is effective when the union nut wrench is parallel to the torque wrench.
| 5. BLEED AIR FROM BRAKE LINE |
Remove the bleeder plug cap.
Connect the vinyl tube to the bleeder plugs.
Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.
When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.
Repeat the 2 previous steps until all the air in the brake fluid is gone.
Tighten the bleeder plug.
- Torque:
- 8.3 N*m{85 kgf*cm, 73 in.*lbf}
Install the cap.
Bleed air from the brake line for each wheel by repeating the above procedures.
| 6. BLEED AIR FROM CLUTCH LINE (for Manual Transaxle) |
Fill the brake reservoir with brake fluid and bleed the clutch system.
- Torque:
- 8.3 N*m{85 kgf*cm, 73 in.*lbf}
| 7. CHECK BRAKE FLUID LEVEL IN RESERVOIR |
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Check the fluid level and add fluid if necessary.
- Fluid:
- SAE J1703 or FMVSS No. 116 DOT3
- HINT:
- Add fluid to a level between the reservoir's MIN and MAX lines.
| 8. CHECK FOR BRAKE FLUID LEAKAGE |
| 9. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1AZ-FE) |
Install the air cleaner case (RAV4_ACA30 RM000001BC100NX.html).
| 10. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2AZ-FE) |
Install the air cleaner case (RAV4_ACA30 RM000001BC100OX.html).
| 11. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 3ZR-FAE) |
Install the air cleaner case (RAV4_ACA30 RM000003PXK003X.html).
| 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL |
| 13. CHECK BRAKE ACTUATOR ASSEMBLY WITH INTELLIGENT TESTER |
Check the brake actuator with the intelligent tester (RAV4_ACA30 RM000001XV501BX.html).