Hydraulic Control Assembly - Antilock Brakes: Service and Repair
BRAKE ACTUATOR ASSYREPLACEMENT
1. REMOVE FR WIPER ARM LH
2. REMOVE FR WIPER ARM RH
3. REMOVE HOOD TO COWL TOP SEAL
4. REMOVE COWL TOP VENTILATOR LOUVER LH
5. REMOVE COWL TOP VENTILATOR LOUVER RH
6. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY
7. PERFORM ACCUMULATOR PRESSURE DOWN
NOTICE: Carry out accumulator zero down and lower the internal pressure before removing the brake actuator.
a) Move the shift lever to the P position. Apply the parking brake and connect the hand-held tester to the DLC3.
b) Turn the power switch on (IG).
c) Turn on the hand-held tester. Select "ZERO DOWN".
NOTICE: Keep the fluid inside the reservoir above the "LOW" level by replenishing.
HINT:
^ Accumulator pressure is released and accumulated repeatedly, which circulates the fluid inside the accumulator when performing this procedure.
^ The pump motor rotates and the accumulator is pressurized every time turning the power switch from off to on (IG).
d) Turn the power switch off.
8. BRAKE CONTROL (ECB) OFF
NOTICE:
^ Prohibit the brake control (ECB) certainly before air bleeding.
^ Be sure to remove the motor relays No.1 and No.2 first, then the brake actuator.
a) With the power switch off to prohibit brake control, remove the motor relays No.1 and No.2.
NOTICE: If the pump motor operates while there is air remaining inside the brake actuator hose, the air will enter the actuator, resulting in difficulty in air bleeding.
9. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT
10. REMOVE W/CONVERTER INVERTER ASSY
HINT: Refer to the procedures from the removal of the engine under cover LH up until the removal of the inverter assy with converter.
11. DRAIN BRAKE FLUID
NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.
12. SEPARATE WATER W/MOTOR & BRACKET PUMP ASSY
a) Remove the 2 bolts and connector, separate the heater water pump assy from the gusset assy.
b) Remove the 2 clamps and bolt, and remove the heater hose bracket from the gusset assy.
13. REMOVE BRAKE ACTUATOR WITH BRACKET
a) Release the lock and separate the connector from the brake actuator assy.
b) Remove the clip and separate the brake actuator hose No.2 from the brake actuator assy.
c) Using SST, separate the front brake tube No.5 from the brake actuator assy and front brake flexible hose.
SST 09023-00100
d) Remove the bolt and front brake tube No.5 from the bracket of the brake actuator assy.
e) Using SST, separate the front brake tube No. 1.
SST 09023-00100
f) Remove the bolt and the front brake tube No.1 from the bracket of the brake actuator assy.
g) Remove the 3 nuts and the brake actuator tubes assy from the brake stroke simulator and brake actuator assy.
h) Using SST, remove the bolt and the 4 brake tubes from the brake stroke simulator and brake actuator assy.
SST 09023-00100
i) Remove the bolt, 2 nuts and the brake actuator assy with gusset assy.
14. REMOVE BRAKE ACTUATOR ASSY
a) Remove the 2 bolts and brake actuator damper.
b) Remove the bolt, nut, and the bracket from the brake actuator assy.
c) Remove the 2 nuts, bolt, and the brake actuator assy from the gusset assy.
d) Remove the bolt and brake actuator bracket No.2 from the brake actuator assy.
15. DISPOSE OF BRAKE ACTUATOR ASSY
a) Using a drill, slowly make a hole at the radius indicated at the middle of A in the illustration and bleed the charged gas.
NOTICE: Be sure to wear protective glasses as fragments may fly out due to pressure.
HINT:
^ The hole may be drilled up to approximately 5mm to 10mm away from the point indicated by A without problem
^ The gas is nitrogen, which is colorless, odorless, and harmless.
16. INSTALL BRAKE ACTUATOR ASSY
a) Aligning the positioning pin, install the brake actuator bracket No.2 to the brake actuator assy with the bolt.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
b) Aligning the positioning pin, install the brake actuator assy to gusset assy with the 2 nuts and bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
NOTICE: Tighten the nuts and bolt in the order shown in the illustration.
c) Install the bracket to the brake actuator assy with the bolt and nut.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
NOTICE: Tighten the nuts and bolt in the order shown in the illustration.
d) Install the brake actuator damper to the brake actuator assy with the 2 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
NOTICE: Tighten the bolts in the order shown in the illustration.
17. INSTALL BRAKE ACTUATOR WITH BRACKET
a) Install the brake actuator assy and the gusset assy with the bolt and 2 nuts.
Torque: 20 Nm (200 kgf-cm, 15 ft. lbs.)
b) Using SST, install the 4 brake tube to the brake stroke simulator and brake actuator assy.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
c) Set the brake tube with the clamp bracket bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
d) Install the brake actuator tube assy with the 2 nuts.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
e) Set the brake actuator tube assy with the nut.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
NOTICE: Press the brake actuator tube assy so that there is no clearance between the bracket and the actuator tube assy as shown in the illustration, and tighten the nut.
f) Using SST, install the front brake tube No.1 to the brake actuator and 2 way.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
g) Install the bolt and the front brake tube No.1 to the bracket of the brake actuator assy.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
h) Using SST, install the front brake tube No. 5.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
i) Install the bracket of front brake tube No.5 with the bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
j) Install the connector to the brake actuator assy, and fix it with the lock.
k) Install the brake actuator hose No.2 to the brake actuator assy with the clip.
18. CONNECT WATER W/MOTOR & BRACKET PUMP ASSY
a) Install the heater hose bracket to the gusset assy with the 2 clamps and bolt.
b) Install the heater water pump assy with 2 bolts.
NOTICE: Tighten bolt A and then bolt B.
c) Connect the connector to the heater water pump assy.
19. INSTALL W/CONVERTER INVERTER ASSY
HINT: Refer to the procedures from the installation of the inverter assy with converter up until the installation of the engine under cover LH.
20. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT
21. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY
22. INSTALL FR WIPER ARM LH
23. INSTALL FR WIPER ARM RH
24. FILL RESERVOIR WITH BRAKE FLUID
25. BLEED BRAKE ACTUATOR
26. CHECK BRAKE FLUID LEAKAGE
27. CHECK FLUID LEVEL IN RESERVOIR
28. CHECK AND CLEAR DTC
29. SYSTEM INITIALIZATION
30. ACTIVE TEST