BRAKE ACTUATOR (w/ ECB) > INSTALLATION

for Preparation Click here



1. INSTALL BRAKE ACTUATOR WITH ACTUATOR BRACKET


  1. 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 damage the brake tubes.



    C113027E01

  1. Connect the actuator connector.

    NOTICE:
    Make sure that the connector is locked securely.



    C113026E01

  1. Using SST, connect the brake No.1 and No.2 tubes.

    SST
    09023-00101  

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

    NOTICE:
    Do not damage the brake No.1 and No.2 tubes.



  1. Using SST, connect each brake tube to the correct positions of the actuator assembly with bracket as shown in the illustration.

    SST
    09023-00101  

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



    C113024E01

  1. Connect the reservoir No.1 tube with the clip.



2. INSTALL SKID CONTROL ECU ASSEMBLY


3. INSTALL ENGINE ROOM RELAY NO.3 BLOCK

  1. Install the engine room relay No.3 block.



4. INSTALL FRONT WHEEL LH


5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


6. DISABLE BRAKE CONTROL

  1. Move the shift lever to the P position and apply the parking brake.



    C105695E01

  1. Connect the intelligent tester to the DLC3 with the engine switch off.



  1. Remove the 2 ABS motor relays with the engine switch off from the engine room relay block No.3.


    C113037E01

  1. Turn the engine switch on (IG).

    NOTICE:
    Do not start the engine.

  1. Turn the intelligent tester on and select "DIAGNOSTIC MENU"→"ABS/VSC"→"ECB UTILITY"→"ECB INVALID".



7. FILL RESERVOIR WITH BRAKE FLUID

NOTICE:
If brake fluid leaks onto any painted surface, clean it off completely.



    I038739

  1. Add brake fluid into the reservoir.

    Fluid:
    SAE J1703 or FMVSS No.116 DOT3



8. BLEED BRAKE RESERVOIR TUBE NO.1 HOSE


  1. Connect SST to the reservoir with the brake reservoir pressure adapter.

    SST
    09992-00242  
    09992-00350  


    C113038E01

  1. Connect the vinyl tube to the bleeder plug of the actuator.

  1. Loosen the bleeder plug of the actuator.

  1. Use the SST to boost the pressure in the reservoir.

    Standard:
    50 to 80 kPa (0.5 to 0.8 kgf/cm2,7.3 to 11.6 psi)

  1. Drain approximately 100 cc of fluid.

  1. Tighten the bleeder plug and boost the pressure in the reservoir again. Then loosen the bleeder plug to bleed air.

    NOTICE:
    Repeat the above procedures 5 times or more.

  1. When air is completely bled from the hose between the reservoir and the actuator, tighten the bleeder plug.

    Torque:
    8.3 N*m{ 85 kgf*cm , 74 ft.*lbf }



9. BLEED MASTER CYLINDER

HINT:
If the master cylinder has been reinstalled or if the reservoir becomes empty, bleed the air from the master cylinder.



    I038740

  1. Disconnect the brake lines from the master cylinder.

  1. Slowly depress and hold the brake pedal.



    I038741

  1. Cover the outer holes with fingers, and release the brake pedal.

  1. Repeat (b) and (c) 3 or 4 times.

  1. Connect the brake lines to the master cylinder.

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



10. BLEED FRONT BRAKE SYSTEM

NOTICE:
Bleed the air from the wheel furthest from the master cylinder.



    I039673

  1. Connect the vinyl tube to the bleeder plug.

  1. Depress the brake pedal several times, then loosen the bleeder plug with the pedal depressed.



    I039674

  1. When fluid stops coming out, tighten the bleeder plug, then release the brake pedal.

  1. Repeat (b) and (c) until all the air in the fluid is completely bled out.

  1. Using SST, tighten the bleeder plug completely.

    Torque:
    11 N*m{ 112 kgf*cm , 8 ft.*lbf }

  1. Repeat the above procedures for other wheels to bleed the air from the brake line.



11. BLEED REAR BRAKE SYSTEM

NOTICE:
Bleed the air by following the prompts displayed on the intelligent tester.

  1. Turn the engine switch off.

  1. Install the 2 ABS motor relays to the engine room relay block No.3.

    NOTICE:
    Install ABS motor relays before bleeding the air from the rear brake system.

  1. Turn the engine switch on (IG) and turn the intelligent tester on.

  1. Cancel "DISABLE BRAKE CONTROL" on the intelligent tester.

    HINT:
    If the brake control has been disabled by the tester.

  1. Clear the DTC.

  1. Turn the intelligent tester on and select "DIAGNOSTIC MENU"→"ABS/VSC"→"ECB UTILITY"→"ECB INVALID".

  1. With the brake pedal depressed, bleed air from the bleeder plug on the rear disc brake cylinder LH.

    NOTICE:
    Keep the fluid inside the reservoir above the LOW level by replenishing.

    HINT:
    1. Depress and hold the brake pedal.
    2. After the solenoid operates for approximately 30 seconds, release the brake pedal to stop the solenoid.
    3. Repeat the procedures until air is completely bled from the rear brake system.
    4. The ECB warning light comes on and the buzzer sounds while bleeding, but they do not indicate a malfunction.

    Torque:
    11 N*m{ 112 kgf*cm , 8 ft.*lbf }

  1. Tighten the bleeder plug after bleeding.

  1. With the brake pedal depressed, bleed air from the bleeder plug on the rear disc brake cylinder RH.

    NOTICE:
    Keep the fluid inside the reservoir above the LOW level by replenishing.

    HINT:
    1. Depress and hold the brake pedal.
    2. After the solenoid operates for approximately 30 seconds, release the brake pedal to stop the solenoid
    3. Repeat the procedures until air is completely bled from the rear brake system.
    4. The ECB warning light comes on and the buzzer sounds while bleeding, but they do not indicate a malfunction.

  1. Tighten the bleeder plug after bleeding.

    Torque:
    11 N*m{ 112 kgf*cm , 8 ft.*lbf }

  1. Cancel "DISABLE BRAKE CONTROL" on the intelligent tester.



12. PERFORM ACCUMULATOR ZERO DOWN

CAUTION:
Be sure to perform this procedure before removing of the actuator.

NOTICE:
Perform accumulator zero down by following the prompts displayed on the intelligent tester.

  1. Connect the intelligent tester to the DLC3 with the engine switch off.

  1. Turn the intelligent tester on and repeat the following steps 5 times.

    1. Turn the engine switch on (IG).

    2. Turn the intelligent tester on and select "DIAGNOSTIC MENU" → "ABS/VSC" → "ECB UTILITY" → "ZERO DOWN" on the intelligent tester.

    3. When the buzzer sounds, turn the engine switch off.

      NOTICE:
      Keep the fluid inside the reservoir above the LOW level by replenishing.

      HINT:
      1. Accumulator pressure is released and accumulated repeatedly, which circulates the fluid inside the accumulator every time accumulator zero down (accumulator depressurizing) is performed.
      2. The pump motor rotates and accumulator is pressurized every time the engine switch is turned from off to on (IG).



13. CHECK BRAKE FLUID LEVEL

  1. After performing accumulator zero down (accumulator depressurizing), adjust the fluid level in the master cylinder reservoir to the MAX level.

    HINT:
    1. After performing accumulator zero down (accumulator depressurizing), fluid is built up in the accumulator by turning the engine switch on (IG) and the fluid level lowers.
    2. If the fluid level is adjusted without performing accumulator zero down (accumulator depressurizing), fluid is sent from the accumulator to the reservoir. The fluid level may exceed the MAX level, but it is normal.



14. INSPECT BRAKE FLUID LEAKAGE


15. CLEAR DTC
(Click here)


16. PERFORM INITIALIZATION
(Click here)
Some systems need initialization after reconnecting the cable to the negative battery terminal.


17. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    B111089E01

  1. Push the ventilator louver in the direction indicated by the arrow in the illustration. Attach the 10 claws to install the ventilator louver.



    B111074E01

  1. Attach the 5 claws and 2 clips to install the ventilator louver.



18. INSTALL FRONT FENDER TO COWL SIDE SEAL LH


    B108984E02

  1. Push the cowl side seal in the direction indicated by the arrow in the illustration. Attach the 2 claws to install the cowl side seal.



19. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

HINT:
Use the same procedures described for the LH side.



20. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


B108016E01

  1. Stop the wiper motor at the automatic stop position.

  1. Clean the wiper arm serration with a round file or equivalent.

  1. Clean the wiper pivot serration with a wire brush.



    B111120E01

  1. Install the wiper arm and blade with the nut. Make sure that the wiper arm and blade comes to the position shown in the illustration.

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

    HINT:
    Hold down the wiper arm hinge with your hand while tightening the nut.

    Specification:
    Area
    		Measurement
    A (for LHD)
    		25.3 mm (0.996 in.)
    B (for LHD)
    		26.2 mm (1.031 in.)
    C (for RHD)
    		21.8 mm (0.858 in.)
    D (for RHD)
    		28.9 mm (1.138 in.)



21. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


B108016E01

  1. Stop the wiper motor at the automatic stop position.

  1. Clean the wiper arm serration with a round file or equivalent.

  1. Clean the wiper pivot serration with a wire brush.



    B111121E01

  1. Install the wiper arm and blade with the nut. Make sure that the wiper arm and blade comes to the position shown in the illustration.

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

    HINT:
    Hold down the wiper arm hinge with your hand while tightening the nut.

    Specification:
    Area
    		Measurement
    A (for LHD)
    		28.9 mm (1.138 in.)
    B (for LHD)
    		21.8 mm (0.858 in.)
    C (for RHD)
    		26.2 mm (1.031 in.)
    D (for RHD)
    		25.3 mm (0.996 in.)

  1. 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.



22. INSTALL ENGINE ROOM SIDE COVER LH


    A110867E01

  1. Install the side cover with the 3 clips.



23. INSTALL ENGINE SIDE ROOM COVER RH


    A110866E01

  1. Install the side cover with the 2 clips and nut.



24. INSTALL FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY LH


B108983E02

  1. Attach the 3 clips to install the side seal.



25. INSTALL FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY RH

HINT:
Use the same procedures described for the LH side.



26. INSTALL COOL AIR INTAKE DUCT SEAL


A105932E01

  1. Install the intake duct seal with the 7 clips.