Installation

INSTALLATION PROCEDURE

1. INSTALL BRAKE ACTUATOR ASSEMBLY

(a) Install the brake actuator assembly to the brake actuator bracket assembly with the 2 nuts. Torque: 8 N·m {82 kgf·cm, 71 in·lbf} NOTICE: Do not remove the hole plugs of a new brake actuator before connecting the 6 brake lines because the brake actuator is filled with brake fluid. Do not hold the actuator by the connector. Set the actuator down with the pin being set securely as shown in the illustration. Text in Illustration *1 Pin *2 Cushion

2. INSTALL BRAKE ACTUATOR WITH BRACKET

(a) Install the brake actuator with bracket to the body with the nut and 2 bolts. Torque: 19 N·m {194 kgf·cm, 14 ft·lbf} NOTICE: Do not damage the brake lines or wire harness. Tighten the nut and 2 bolts in order from 1 to 3.

(b) Connect the brake actuator connector. NOTICE: Make sure that the connector is locked securely. Make sure that the actuator connector can be connected smoothly. Do not allow water, oil or dirt to enter.

(c) Temporarily tighten each brake line to the correct positions of the brake actuator with bracket as shown in the illustration. Text in Illustration *1 To Front Wheel Cylinder RH *2 To Front Wheel Cylinder LH *3 To Rear Wheel Cylinder RH *4 To Rear Wheel Cylinder LH *5 From 1st of Master Cylinder *6 From 2nd of Master Cylinder

(d) Using a union nut wrench, fully tighten 4 brake lines (A).

Text in Illustration

*a	Torque Wrench Fulcrum Length
	Flare Nut A (10 mm)
	Flare Nut B (12 mm)

Torque:

Specified Tightening Torque :

15 N·m {155 kgf·cm, 11 ft·lbf}

HINT:

• Calculate the torque wrench reading when changing the fulcrum length for the torque wrench (See page ).
• When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 250 mm (9.84 in.)):

  14 N*m (142 kgf*cm, 10 ft.*lbf)

(e) Using a union nut wrench, fully tighten 2 brake lines (B).

Torque:

Specified Tightening Torque :

20 N·m {199 kgf·cm, 14 ft·lbf}

HINT:

• Calculate the torque wrench reading when changing the fulcrum length for the torque wrench (See page ).
• When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 250 mm (9.84 in.)):

  18 N*m (184 kgf*cm, 13 ft.*lbf)

(f) Install the clamp of the suction hose sub-assembly to the brake actuator bracket assembly.

3. INSTALL RADIATOR RESERVE TANK ASSEMBLY

(a) Install the radiator reserve tank assembly.

(b) Install the radiator reserve tank cap assembly.

4. FILL RESERVOIR WITH BRAKE FLUID

5. BLEED BRAKE MASTER CYLINDER

6. BLEED BRAKE LINE

7. INSPECT FLUID LEVEL IN RESERVOIR

8. INSPECT FOR BRAKE FLUID LEAK

9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See page ).

10. PERFORM ENGINE VARIANT LEARNING

(See page )

11. INSPECT BRAKE ACTUATOR USING TECHSTREAM

(See page )