Installation

BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: BRAKE ACTUATOR (w/o VSC): INSTALLATION

INSTALLATION

1. INSTALL BRAKE ACTUATOR





(a) Install the brake actuator to the brake actuator bracket assembly with the 3 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 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 carry the brake actuator assembly by the connector.
- Tighten the 3 bolts in the order shown in the illustration.

2. INSTALL BRAKE ACTUATOR WITH BRACKET





(a) Install the brake actuator with bracket to the body with the 2 bolts and nut.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)

NOTICE:
- Do not damage the brake lines or wire harness.
- Tighten the nut and 2 bolts in the order shown in the illustration.





(b) Temporarily tighten each brake line to the correct position of the brake actuator assembly with bracket as shown in the illustration.

HINT:
- *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 master cylinder
- *6: From 2nd master cylinder





(c) Using a union nut wrench (10 mm), fully tighten each brake line.
without a union nut wrench - Torque: 15 Nm (155 kgf-cm, 11 ft-lbf)
with a union nut wrench - Torque: 14 Nm (143 kgf-cm, 10 ft-lbf)

NOTICE:
- Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
- This torque value is effective when the union nut wrench is parallel to the torque wrench.





(d) Install the brake line clamp with brake line with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)





(e) Connect the actuator connector and lock the lock lever.
NOTE: Make sure that the connector is locked securely.

3. INSTALL RADIATOR RESERVE TANK ASSEMBLY





(a) Install the radiator reserve tank assembly with the 3 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
4. INSTALL WINDSHIELD WASHER JAR ASSEMBLY





(a) Install the windshield washer jar assembly and clamp to the body with the 2 bolts.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)





(b) Install the bolt and clamp connect the washer hoses and motor connectors.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
5. INSTALL FRONT BUMPER ASSEMBLY
HINT: Refer to the instructions for Installation of the front bumper assembly Installation.

6. INSTALL GENERATOR ASSEMBLY (for 2ZR-FE)
HINT: Refer to the instructions for Installation of the generator assembly Installation.

7. INSTALL GENERATOR ASSEMBLY (for 2AZ-FE)
HINT: Refer to the instructions for Installation of the generator assembly Installation.

8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
9. REMOVE CENTER COWL TOP VENTILATOR LOUVER Service and Repair
10. FILL UP BRAKE FLUID RESERVOIR Service and Repair
11. BLEED BRAKE MASTER CYLINDER Service and Repair
12. BLEED BRAKE LINE Service and Repair
13. INSPECT BRAKE FLUID LEVEL Testing and Inspection
14. INSPECT FOR FLUID LEAK
15. INSTALL CENTER COWL TOP VENTILATOR LOUVER Service and Repair
16. INSPECT ACTUATOR USING TECHSTREAM
HINT: Brake Actuator (w/o VSC)

17. PREPARATION FOR FOG LIGHT AIMING (w/ Fog Light) Adjustments
18. INSPECT FOG LIGHT AIMING (w/ Fog Light) Adjustments
19. ADJUST FOG LIGHT AIMING (w/ Fog Light) Adjustments