RX400h · Service Manual BRAKE

INSTALLATION

Removal / installation


1. INSTALL BRAKE ACTUATOR ASSEMBLY

  1. C108786
    Install the brake actuator assembly with bracket to the body with the 3 nuts.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }

    NOTICE:
    Do not damage the brake tubes.

  1. C113080E01
    Connect the brake actuator connector.

    NOTICE:
    Make sure that the connector is locked securely.

  1. Install the brake tube bracket with the bolt.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. C108787E06
    Using SST, connect the front brake No.8 tube to the front flexible hose.
    SST
    09023-00101  

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

  1. C111533E06
    Using SST, connect each brake tube to the correct positions on top of the actuator assembly with bracket as shown in the illustration.
    SST
    09023-00101  

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

  1. C112901E03
    Install the brake actuator bracket No.7 with clamp with the bolt.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }


2. INSTALL FRONT WHEEL RH

Torque:
103 N*m{ 1,050 kgf*cm , 76 ft.*lbf }


3. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

  1. C108791
    Install the brake master cylinder reservoir assembly with the 2 bolts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

  1. C108790E04
    Install the 2 reservoir tubes with the 2 clips.

  1. C108792E08
    Install the brake actuator hose with the 2 clips.

  1. Install the brake actuator hose to the clamp.

    NOTICE:
    Install the brake actuator hose with the edges of the protector and clamp aligned.

  1. Connect the warning switch connector.


4. INSTALL COWL PANEL SUB-ASSEMBLY

  1. Remove the 4 shock absorber nuts.

  1. A112528E01
    Install the 4 bolts, 2 nuts and cowl top panel sub-assembly.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Install the 4 shock absorber nuts (B).

    Torque:
    80 N*m{ 815 kgf*cm , 59 ft.*lbf }

  1. Install the wire harness clamp and grommet (A).


5. INSTALL WIND SHIELD WIPER MOTOR ASSEMBLY

  1. E110471
    Install the windshield wiper motor and link assembly with the 5 bolts.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

  1. Connect the connector.


6. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

  1. Remove the 4 shock absorber nuts.

  1. A112528E01
    Install the 4 bolts, 2 nuts and cowl top panel sub-assembly.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Install the 4 shock absorber nuts (B).

    Torque:
    80 N*m{ 815 kgf*cm , 59 ft.*lbf }

  1. Install the wire harness clamp and grommet (A).


7. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

  1. B108016E03
    Clean the wiper arm serrations.

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

  1. E069046E01
    Install the front wiper arm and blade assembly RH with the 2 nuts at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.

  1. Operate the front wipers while spraying water or washer fluid on the windshield.

  1. Make sure that the wipers function properly and there is no interference with the vehicle body.


8. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

  1. B108016E03
    Operate the front wiper, and stop the front wiper motor at the automatic stop position.

  1. Clean the wiper arm serrations.

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

  1. E069045E01
    Install the front wiper arm and blade assembly LH with the nut at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.


9. INSTALL FRONT FENDER TO COWL SIDE SEAL LH

10. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

11. FILL RESERVOIR WITH BRAKE FLUID

  1. Add brake fluid to the MAX line in the reservoir.

    Fluid:
    SAE J1703 or FMVSS No. 116 DOT3

    CAUTION:
    1. Add brake fluid carefully and check that the reservoir level remains between the MIN and MAX lines while bleeding the brakes.
    2. Do not stand the fluid can on the reservoir inlet when bleeding the brake actuator. Doing so will cause brake fluid to overflow.


12. BLEED BRAKE ACTUATOR HOSE

  1. C108423E01
    Connect SST to the reservoir with the brake reservoir pressure adapter.
    SST
    09992-00242  
    09992-00350  

  1. Using SST, loosen the bleeder plug of the actuator.

    SST
    09023-00101  

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

  1. Use the SST to boost 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 (50 to 80 kPa (0.5 to 0.8 kgf/cm2)). Then, loosen the bleeder plug and bleed the brake actuator hose.

    NOTICE:
    Repeat this procedure at least 5 times.

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

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


13. BLEED FRONT BRAKE SYSTEM

HINT:
Air can be easily bled from the front brake system if air has been bled from the master cylinder when replacing the brake master cylinder assembly.

NOTICE:
  1. If brake fluid leaks onto any painted surface of the vehicle, wash or otherwise remove it completely.
  2. Bleed the air by following the steps displayed on the intelligent tester.

  1. Depress the brake pedal several times and bleed the front brake system from the bleeder plugs on the front brake cylinder RH and LH.

    HINT:
    Repeat the procedure until air is completely bled from the front brake system.

  1. Tighten the bleeder plugs after bleeding.

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


14. INSTALL ABS MOTOR RELAY

  1. C108426
    Install the 2 ABS motor relays.


15. CLEAR DTC
(Click here)

16. BLEED REAR BRAKE SYSTEM

CAUTION:
Never bleed air from the brake hydraulic system without using the intelligent tester. Failure to use the intelligent tester could cause serious injury or an accident.

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

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

  1. Check that the parking brake is applied and turn the ignition switch to the ON position.

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

  1. With the brake pedal depressed, bleed the rear brake system from the bleeder plug on the rear disc brake cylinder LH while the pump motor and solenoid are operating.

    CAUTION:
    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:
    8.3 N*m{ 85 kgf*cm , 74 in.*lbf }

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

  1. With the brake pedal depressed, bleed the rear brake system from the bleeder plug on the rear disc brake cylinder RH while the pump motor and solenoid are operating.

    CAUTION:
    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:
    8.3 N*m{ 85 kgf*cm , 74 in.*lbf }


17. PERFORM ACCUMULATOR ZERO DOWN

CAUTION:
  1. Never bleed air from the brake hydraulic system without using the intelligent tester. Failure to use the intelligent tester could cause serious injury or an accident.
  2. Be sure to perform this procedure before replacement, removal, or installation of the actuator.

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

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

  1. Depressurize the accumulator.

    1. Check that the parking brake is applied and turn the ignition switch to the ON position.

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

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

  1. Circulate the fluid in the accumulator.

    1. Depressurize the accumulator 5 times.

      HINT:
      1. Accumulator pressure is released and accumulated repeatedly, which circulates the fluid inside the accumulator, when repeating accumulator zero down.
      2. The pump motor rotates and the accumulator is pressurized every time the ignition switch is turned from off to on.


18. CHECK BRAKE FLUID LEVEL

  1. After performing accumulator zero down (accumulator depressurizing), return the fluid in the accumulator back to the reservoir and then 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 ignition switch to the ON position and the fluid level of the reservoir 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.


19. CHECK AND CLEAR DTC
(Click here)

20. PERFORM LINEAR VALVE OFFSET LEARNING
(Click here)

21. CHECK FOR BRAKE FLUID LEAKAGE
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