Brake Actuator Installation

Install the 2 brake actuator bolt cushions and 2 bolts to the brake actuator assembly.

Install the brake actuator bolt cushion with the actuator bracket assembly.

Install the brake actuator to the actuator bracket assembly with the 2 nuts.

Torque:

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

Install the actuator assembly with bracket to the body with the 2 bolts and nut.

Torque:

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

NOTICE:

Do not to damage the brake tubes.

Install the grommet to the body.

NOTICE:

Make sure that the grommet is installed correctly.

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

HINT:

1. *1: To Front Wheel Cylinder RH
   
2. *2: To Front Wheel Cylinder LH
   
3. *3: To Rear Wheel Cylinder RH
   
4. *4: To Rear Wheel Cylinder LH
   
5. *5: From Front Master Cylinder
   
6. *6: From Rear Master Cylinder
   

Using SST, fully tighten each brake tube.

SST

09023-00101

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

Connect the actuator connector.

NOTICE:

Make sure that the connector is locked securely.

Using SST, connect the No. 3 front brake tube to the flexible hose.

SST

09023-00101

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

Using SST, connect the No. 2 front brake tube to the flexible hose.

SST

09023-00101

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

Install a new O-ring to the brake master cylinder sub-assembly.

Install the brake master cylinder sub-assembly to the booster assembly with the 2 nuts.

Torque:

12.5 N*m{127 kgf*cm, 9 ft.*lbf}

Install the brake actuator assembly to the actuator bracket with the 2 cap nuts.

Torque:

5.5 N*m{55 kgf*cm, 48 in.*lbf}

Using SST, connect the 2 brake lines to the brake master cylinder sub-assembly.

SST

09023-00101

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

Engage the clamp and connect the warning switch connector.

Install the No. 3 engine room relay block with the bolt and nut.

Torque:

12.5 N*m{127 kgf*cm, 9 ft.*lbf}

Fill the reservoir with brake fluid.

Fluid:

SAE J1703 or FMVSS No. 116 DOT3

Disconnect the 2 brake lines from the master cylinder.

Slowly depress the brake pedal and hold it (*1).

Cover the 2 outer holes with fingers, and release the brake pedal (*2).

Repeat (*1) and (*2) 3 or 4 times.

Using SST, connect the brake lines to the master cylinder.

SST

09023-00101

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

Connect the vinyl tube to the bleeder plug.

Depress the brake pedal several times, then loosen the bleeder plug with the pedal depressed (*3).

When fluid no longer comes out, tighten the bleeder plug, then release the brake pedal (*4).

Repeat (*3) and (*4) until all the air in the fluid is completely bled out.

Using SST, tighten the bleeder plug completely.

SST

09023-00101

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

Repeat the above procedures for each wheel to bleed the air from the brake line.

Depress the brake pedal more than 20 times with the engine switch off.

Connect the intelligent tester to the DLC3, then turn the engine switch on (IG).

NOTICE:

Do not start the engine.

Turn the intelligent tester power on and select "AIR BLEEDING" on the screen.

NOTICE:

1. Refer to the intelligent tester operator's manual for further details.
   
2. Bleed the brake actuator assembly by following the steps displayed on the intelligent tester.
   

Bleed the air from the actuator according to "Step 1: Increase" on the intelligent tester display.

NOTICE:

Make sure that the master cylinder reservoir tank does not become empty of brake fluid.

1. Connect a vinyl tube to either one of the bleeder plugs.
   

2. Depress the brake pedal several times, then loosen the bleeder plug connected to the vinyl tube with the pedal depressed (*5).
   





3. When fluid no longer comes out, tighten the bleeder plug, then release the brake pedal (*6).
   

4. Repeat (*5) and (*6) until all the air in the fluid is completely bled.
   

5. Using SST, tighten the bleeder plug completely.
   

   SST

   09023-00101
   

   Torque:

   11 N*m{110 kgf*cm, 8 ft.*lbf}

6. Repeat the above procedures for the rest of the wheels to bleed the air from the brake lines.
   

Bleed the air from the suction line according to "Step 2: Inhalation" on the intelligent tester display.

NOTICE:

1. Bleed the suction line by following the steps displayed on the intelligent tester.
   
2. Make sure that the master cylinder reservoir tank does not become empty of brake fluid.
   

1. Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel and loosen the bleeder plug.
   

2. Operate the brake actuator assembly to bleed the air using the intelligent tester (*7).
   

   NOTICE:

   1. The operation stops automatically in 4 seconds.
      
   2. At this time, be sure to release the brake pedal.
      




3. Check that the operation has stopped by referring to the intelligent tester display and tighten the bleeder plug (*8).
   

4. Repeat (*7) and (*8) until all the air in the fluid is completely bled out.
   

5. Using SST, tighten the bleeder plug completely.
   

   SST

   09023-00101
   

   Torque:

   11 N*m{110 kgf*cm, 8 ft.*lbf}

6. For the rest of the wheels, bleed the air in the same way as stated in the above procedures.
   

Bleed the air from the pressure reduction line according to "Step 3: Decrease" on the intelligent tester display.

NOTICE:

1. Bleed the pressure reduction line by following the steps displayed on the intelligent tester.
   
2. Make sure that the master cylinder reservoir tank does not become empty of brake fluid.
   

1. Connect a vinyl tube to either one of the bleeder plugs.
   

2. Loosen the bleeder plug (*9).
   

3. Using the intelligent tester, operate the brake actuator assembly, completely depress the brake pedal and hold it.
   

   NOTICE:

   1. The operation stops automatically after 4 seconds. When this operation will be repeated continuously, allow an interval of at least 20 seconds between each bleeding operation.
      
   2. When the operation is completed, the brake pedal will go down slightly. This is a normal phenomenon due to the opening of the solenoid.
      
   3. During this procedure, the brake pedal will seem heavy. It is necessary to completely depress it, so that brake fluid will come out of the bleeder plug.
      
   4. Be sure to keep the brake pedal depressed. Never depress and release the pedal repeatedly.
      




4. Tighten the bleeder plug, then release the brake pedal (*10).
   

5. Repeat steps (*9) to (*10) until all the air in the fluid is completely bled out.
   

6. Using SST, tighten the bleeder plug completely.
   

   SST

   09023-00101
   

   Torque:

   11 N*m{110 kgf*cm, 8 ft.*lbf}

7. Repeat the above procedures for the rest of the brakes to bleed the air from the brake line.
   

Bleed the air from the brake line again according to "Step 4: Increase" on the intelligent tester display.

NOTICE:

1. Bleed the brake line by following the steps displayed on the intelligent tester.
   
2. Make sure that the master cylinder reservoir tank does not become empty of brake fluid.
   

1. Connect a vinyl tube to either one of the bleeder plugs.
   

2. Depress the brake pedal several times, then loosen the bleeder plug connected to the vinyl tube with the pedal depressed (*11).
   





3. When fluid no longer comes out, tighten the bleeder plug, then release the brake pedal (*12).
   

4. Repeat (*11) and (*12) until all the air in the fluid is completely bled out.
   

5. Using SST, tighten the bleeder plug completely.
   

   SST

   09023-00101
   

   Torque:

   11 N*m{110 kgf*cm, 8 ft.*lbf}

6. Repeat the above procedures for each brake to bleed the air from the brake line.
   

Finish "AIR BLEEDING" on the intelligent tester and turn off the power.

Disconnect the intelligent tester from the DLC3.

Turn the engine switch off.

Check the fluid level.
If brake fluid level is lowered, check for leakage and inspect the disc brake pad. If necessary, refill the reservoir with brake fluid after repair and replacement.

Fluid:

SAE J1703 or FMVSS No. 116 DOT 3

Engage the 11 claws.

Install the cowl top ventilator louver sub-assembly with the 2 clips.

Operate the wiper, and stop the windshield wiper motor at the automatic stop position.

Clean the wiper arm serrations.

Clean the wiper pivot serrations with a wire brush (when reinstalling).

Install the front wiper arm and blade assembly LH with the nut at the position as shown in the illustration.

Torque:

22 N*m{224 kgf*cm, 16 ft.*lbf}

HINT:

Hold the arm hinge by hand to fasten the nut.

Operate the wiper, and stop the windshield wiper motor at the automatic stop position.

Clean the wiper arm serrations.

Clean the wiper pivot serrations with a wire brush (when reinstalling).

Install the front wiper arm and blade assembly RH with the nut at the position as shown in the illustration.

Torque:

22 N*m{224 kgf*cm, 16 ft.*lbf}

HINT:

Hold the arm hinge by hand to fasten the nut.

Operate the front wipers while spraying washer fluid on the windshield glass. Make sure that the front wipers function properly and there is no interference with the vehicle body.

Install the front wiper arm head cap.

HINT:

Use the same procedures for the RH side and the LH side.

Engage the claw and the 3 clips, then install the front upper fender protector LH.

Engage the clip on the rubber portion of the cowl top ventilator louver sub-assembly to the front fender protector upper LH.

Install the side cover with the 2 clips.

Install the side cover with the 5 clips.

Install the intake duct seal with the 11 clips.