RM35X0E _54 Brake _078667 BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS _0381523 BRAKE ACTUATOR A

BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS  BRAKE ACTUATOR  INSTALLATION  


PROCEDURE

Hide 44547B 1.INSTALL BRAKE ACTUATOR BRACKET CUSHION

a.
C409115

Install the brake actuator bracket cushion and brake actuator case collar to the brake actuator bracket assembly.

NOTICE:

Make sure that the brake actuator case collar is in full contact with the brake actuator bracket cushion.



Hide 44510 2.INSTALL BRAKE ACTUATOR ASSEMBLY

a.

Temporarily install the brake actuator assembly to the brake actuator bracket assembly.


b.
C413287N01
1.208,1.542 1.365,1.74 0.156,0.198 10 true 1 1.927,1.458 2.083,1.656 0.156,0.198 10 true 2 1.698,1.854 1.854,2.052 0.156,0.198 10 true 3

Install the brake actuator assembly to the brake actuator bracket assembly with the bolt and 2 nuts.

Torque:
7.0 N*m (71 kgf*cm, 62 in.*lbf)

NOTICE:
·

Do not remove the hole plugs of a new brake actuator assembly before connecting the brake tubes because the brake actuator assembly is filled with brake fluid.

·

Do not hold the brake actuator assembly by the connector.

·

Do not drop the brake actuator assembly when carrying it.

·

Tighten the bolt and 2 nuts in the order shown in the illustration.




Hide 3.INSTALL BRAKE ACTUATOR WITH BRACKET

a.
C409111C02
2.313,1.656 2.917,1.885 0.604,0.229 10 true 1 (*a), 4 0.302,0.698 0.896,0.958 0.594,0.26 10 true 2 (*a), 5 2.375,0.313 2.542,0.479 0.167,0.167 10 true 3
*a Temporarily Tighten


Install the 3 bolts in the order shown in the illustration.

Torque:
19 N*m (194 kgf*cm, 14 ft.*lbf)

NOTICE:
·

Do not kink or damage the brake lines.

·

Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

·

Be careful not to allow any brake fluid to enter the connector.

·

Do not hold the brake actuator assembly by the connector.

·

Do not drop the brake actuator with bracket when carrying it.



HINT:

Install the brake actuator with bracket while avoiding the brake lines.



b.
C409103C02
0.76,0.74 0.865,0.74 0.865,0.74 1.25,1.115 true 1.052,0.396 1.146,0.396 1.146,0.396 1.385,0.865 true 1.792,0.813 2.24,0.583 2.24,0.583 2.344,0.583 true 1.135,1.833 1.229,1.833 1.229,1.833 1.438,1.417 true 1.583,1.979 1.667,1.979 1.667,1.979 1.813,1.479 true 1.938,1.135 2.354,1.854 2.354,1.854 2.604,1.854 true 2.677,1.74 2.865,1.917 0.188,0.177 10 true *a 1.375,1.896 1.552,2.063 0.177,0.167 10 true *b 0.927,1.719 1.104,1.896 0.177,0.177 10 true *c 0.573,0.625 0.75,0.792 0.177,0.167 10 true *d 0.844,0.292 1.01,0.469 0.167,0.177 10 true *e 2.417,0.5 2.583,0.667 0.167,0.167 10 true *f
*a From 1st Chamber of Brake Master Cylinder Sub-assembly
*b From 2nd Chamber of Brake Master Cylinder Sub-assembly
*c To Front Wheel Cylinder Assembly RH
*d To Rear Wheel Cylinder Assembly LH
*e To Rear Wheel Cylinder Assembly RH
*f To Front Wheel Cylinder Assembly LH


Temporarily tighten the 6 brake lines to the correct positions on the brake actuator assembly as shown in the illustration.

NOTICE:
·

Do not kink or damage the brake lines.

·

Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.




c.
C409107C01
2.719,2.646 2.813,3.01 2.813,3.01 2.896,3.01 false 1.771,2.948 2.083,3.104 0.313,0.156 10 false *a 2.938,2.927 3.25,3.083 0.313,0.156 10 false *b 1.615,1.813 1.771,1.969 0.156,0.156 10 true A 1.427,0.458 1.583,0.656 0.156,0.198 10 true B 1.917,1.24 2.073,1.396 0.156,0.156 10 true B 2.042,0.615 2.198,0.771 0.156,0.156 10 true A 1.104,1.635 1.26,1.792 0.156,0.156 10 true B 1.906,0.344 2.063,0.5 0.156,0.156 10 true B
*a Torque Wrench Fulcrum Length
*b Union Nut Wrench


w/ VSC:

i.

Using a union nut wrench, fully tighten each brake line.

Torque:
Specified tightening torque (A) : 25 N*m (255 kgf*cm, 18 ft.*lbf)
Specified tightening torque (B) : 15.2 N*m (155 kgf*cm, 11 ft.*lbf)

NOTICE:
·

Do not kink or damage the brake lines.

·

Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.



HINT:
·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 180 mm (7.087 in.)):

(A): 22.5 N*m (229 kgf*cm, 17 ft.*lbf)

·

When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

(B): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)





d.
C409107C02
2.917,3.052 2.833,3.052 2.833,3.052 2.729,2.677 false 1.76,2.979 2.073,3.135 0.313,0.156 10 false *a 2.99,2.969 3.25,3.208 0.26,0.24 10 false *b
*a Torque Wrench Fulcrum Length
*b Union Nut Wrench


w/o VSC:

i.

Using a union nut wrench, fully tighten each brake line.

Torque:
Specified tightening torque : 15.2 N*m (155 kgf*cm, 11 ft.*lbf)

NOTICE:
·

Do not kink or damage the brake lines.

·

Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.



HINT:
·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

13.4 N*m (137 kgf*cm, 10 ft.*lbf)





e.
C545163

Engage the 2 clamps to install a new brake tube clamp to the brake lines.

NOTICE:

Do not kink or damage the brake lines.



f.
C409109

Engage the 2 clamps to install a new brake tube clamp to the brake lines.

NOTICE:

Do not kink or damage the brake lines.



g.
C409117C01
0,0 0,0 false
V113147

Connect the connector
V113148

Lock the lock lever


Connect the connector to the brake actuator assembly and lock the lock lever.

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 the connector.




Hide 4.INSTALL WIRE HARNESS CLAMP BRACKET (for 1GD-FTV)

a.
C413286

Install the bolt and wire harness clamp bracket.

Torque:
13 N*m (133 kgf*cm, 10 ft.*lbf)


b.

Engage the clamp and connect the engine wire.


Hide 8. ACCELERATION SENSOR ZERO POINT CALIBRATION AND STORE SYSTEM INFORMATION MEMORIZATION (w/ VSC OFF Switch)

Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>ELECTRONICALLY CONTROLLED BRAKE SYSTEM (w/ VSC OFF Switch)>UTILITY