RM3660EC _54 Brake _080770 BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS _0392396 BRAKE ACTUATOR(for Gasoline Model) A

BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS BRAKE ACTUATOR(for Gasoline Model) INSTALLATION

CAUTION / NOTICE / HINT

HINT:: The parking brake indicator light blinks (red) when the ignition switch is turned to ON after replacing the brake actuator assembly. Operate the electric parking brake switch assembly to turn off the parking brake indicator light.

PROCEDURE

Hide Display 44547B 1.INSTALL BRAKE ACTUATOR BRACKET CUSHION

Install the 3 brake actuator bracket cushions to the brake actuator bracket assembly.

Install the 3 No. 1 brake actuator case collars to the brake actuator bracket cushion.

NOTICE:: Make sure that the No. 1 brake actuator case collar is in full contact with the brake actuator bracket cushion.

Install the brake actuator bracket assembly with the 3 nuts.

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

Hide Display 44510 2.INSTALL BRAKE ACTUATOR ASSEMBLY

Temporarily install the brake actuator assembly with the 3 bolts.

1.656,1.844 1.813,2.021 0.156,0.177 10 true 1 2.052,1.5 2.208,1.677 0.156,0.177 10 true 2 2.708,1.427 2.865,1.604 0.156,0.177 10 false 3

Fully tighten the 3 bolts in the order shown in the illustration.

Torque:: 6.5 N*m (66 kgf*cm, 58 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.

Hide Display 3.INSTALL BRAKE ACTUATOR WITH BRACKET

0.656,0.115 0.792,0.292 0.135,0.177 10 true 1 1.156,1.854 1.292,2.031 0.135,0.177 10 true 2 2.365,1.948 2.5,2.125 0.135,0.177 10 true 3

Temporarily install the brake actuator with bracket to the vehicle body with the bolt and 2 nuts.

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.

Fully tighten the bolt and 2 nuts in the order shown in the illustration.

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

for NR Series Engine:

Engage the 5 clamps to install a new No. 1 brake tube clamp to the brake lines.

ii.

Engage the clamp and install a new No. 2 brake tube clamp to the vehicle body.

iii.

Engage the 5 clamps to install the No. 2 brake tube clamp to the brake lines.

Engage the 5 clamps to install a new No. 1 brake tube clamp to the brake lines.

NOTICE:: Do not kink or damage the brake lines.

1.948,0.771 2.302,0.344 2.302,0.344 2.396,0.344 true 1.156,1.781 1.26,1.781 1.26,1.781 1.604,1.354 true 2.021,1.146 2.49,0.906 2.49,0.906 2.583,0.906 true 0.625,0.844 0.729,0.844 0.729,0.844 1.323,1.083 true 0.979,0.406 1.083,0.406 1.083,0.406 1.521,0.99 true 1.76,0.906 1.885,0.198 1.885,0.198 1.979,0.198 true 0.979,1.698 1.146,1.854 0.167,0.156 10 true *a 2.594,0.823 2.76,0.979 0.167,0.156 10 true *b 2.406,0.26 2.573,0.417 0.167,0.156 10 true *c 1.99,0.115 2.156,0.271 0.167,0.156 10 true *d 0.813,0.333 0.979,0.49 0.167,0.156 10 true *e 0.458,0.76 0.625,0.917 0.167,0.156 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 each brake line to the correct position on the brake actuator assembly as shown in the illustration.

NOTICE:: ·

Do not kink or damage the brake line.

·

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

2.719,2.656 2.802,3.052 2.802,3.052 2.896,3.052 false 1.771,2.948 2.083,3.104 0.313,0.156 10 false *a 2.938,2.969 3.25,3.125 0.313,0.156 10 false *b 1.146,1.427 1.292,1.583 0.146,0.156 10 true B 2.375,1.052 2.521,1.208 0.146,0.156 10 true B 2.208,0.448 2.354,0.604 0.146,0.156 10 true A 1.813,1.281 1.958,1.438 0.146,0.156 10 true A 1.198,0.583 1.344,0.74 0.146,0.156 10 true A 0.885,0.844 1.031,1 0.146,0.156 10 true A

*a	Torque Wrench Fulcrum Length
*b	Union Nut Wrench

Using a union nut wrench, connect the 6 brake lines to the brake actuator assembly.

Torque:: Specified tightening torque (A) : 15.2 N*m (155 kgf*cm, 11 ft.*lbf); Specified tightening torque (B) : 19.5 N*m (199 kgf*cm, 14 ft.*lbf)

NOTICE:: ·

Do not kink or damage the brake lines.

·

Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.

·

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>PRECAUTION201906,999999,_V1,_080724,_0393249,RM100000001HWSK,

·

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

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

·

When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

(B): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

0,0 0,0 false

	Connect the connector
	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.

for NR Series Engine:

Return the suction pipe sub-assembly and cooler refrigerant liquid pipe A to its original position.

NOTICE:: Do not apply excessive force to the suction pipe sub-assembly and cooler refrigerant liquid pipe A.

Hide Display 88716A 4.INSTALL COOLER REFRIGERANT LIQUID PIPE A (for NR Series Engine)

Remove the vinyl tape from the cooler refrigerant liquid pipe A.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler refrigerant liquid pipe A.

Compressor Oil:: ND-OIL 8 or equivalent

Install the O-ring to the cooler refrigerant liquid pipe A.

NOTICE:: Keep the O-ring and O-ring fitting surfaces free of foreign matter.

0,0 0,0 false

Install in this Direction

Connect the cooler refrigerant liquid pipe A to the air conditioning unit assembly.

Engage the 2 clamps to install the cooler refrigerant liquid pipe A.

Hide Display 88707 5.INSTALL SUCTION PIPE SUB-ASSEMBLY (for NR Series Engine)

Remove the vinyl tape from the suction pipe sub-assembly.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe sub-assembly.

Compressor Oil:: ND-OIL 8 or equivalent

Install the O-ring to the suction pipe sub-assembly.

NOTICE:: Keep the O-ring and O-ring fitting surfaces free of foreign matter.

Connect the suction pipe sub-assembly to the air conditioning unit assembly.

Engage the 2 clamps to install the suction pipe sub-assembly.

0,0 0,0 false

Rotate in this Direction

Rotate the hook connector as shown in the illustration.

Insert the hose joint into the fitting hole securely and install the bolt.

Torque:: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

Hide Display 55225C 6.INSTALL DASH PANEL HEAT INSULATOR (for NR Series Engine)

2.167,0 2.313,0.156 0.146,0.156 10 true A 2.948,0.135 3.094,0.292 0.146,0.156 10 true A

Temporarily install the dash panel heat insulator to the vehicle body with the 2 nuts (A).

1.927,1.125 2.073,1.281 0.146,0.156 10 true B

Install the nut (B).

Torque:: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

Tighten the 2 nuts (A).

Torque:: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

Hide Display 55225C 7.INSTALL DASH PANEL HEAT INSULATOR (except NR Series Engine)

2.219,0.292 2.365,0.448 0.146,0.156 10 true A 3.26,0.521 3.406,0.677 0.146,0.156 10 true A

Temporarily install the dash panel heat insulator to the vehicle body with the 2 nuts (A).

2.031,1.208 2.219,1.406 0.188,0.198 10 true B

Install the nut (B).

Torque:: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

Tighten the 2 nuts (A).

Torque:: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

Hide Display 51410 8.INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

for NR Series Engine: Click hereEngine / Hybrid System>NR Series (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202304,999999,_51,_080739,_0391935,RM100000002BCNA_01_0452,

for M15B-FKS: Click hereEngine / Hybrid System>M15B-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202304,999999,_51,_096197,_0454892,RM100000002BBF1_01_0389,

for M15C-FKS: Click hereEngine / Hybrid System>M15C-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202304,999999,_51,_096206,_0454902,RM100000002BBQF_01_0389,

for M20A-FKS: Click hereEngine / Hybrid System>M20A-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202304,999999,_51,_101145,_0470307,RM100000002BFCZ_01_0389,

for M20C-FKS: Click hereEngine / Hybrid System>M20C-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202304,999999,_51,_105191,_0481157,RM100000002BFD2_01_0389,

for M20E-FKS: Click hereEngine / Hybrid System>M20E-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202304,999999,_51,_101154,_0476817,RM100000002BFD9_01_0389,

Hide Display 55701J 9.INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

Click hereSuspension>FRONT SUSPENSION>FRONT SHOCK ABSORBER>INSTALLATION202304,202307,_53,_080764,_0392681,RM100000002BA6W_01_0037,202307,999999,_53,_080764,_0392681,RM100000002CW5I_01_0037,

Hide Display 55737B 10.INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (w/ No. 1 Heater Air Duct Splash Shield Seal)

Click hereSuspension>FRONT SUSPENSION>FRONT SHOCK ABSORBER>INSTALLATION202304,202307,_53,_080764,_0392681,RM100000002BA6W_01_0048,202307,999999,_53,_080764,_0392681,RM100000002CW5I_01_0048,

Hide Display 11.INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click hereVehicle Exterior>WIPER / WASHER>FRONT WIPER MOTOR>INSTALLATION202304,202307,_59,_080767,_0392873,RM100000002AYHL,202307,999999,_59,_080767,_0392873,RM100000002CL7R,

Hide Display 12.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

for NR Series Engine: Click hereGeneral>MAINTENANCE>NR Series BATTERY>INSTALLATION202304,999999,_V1,_080956,_0392375,RM100000002BCCN_03_0002,

for M15B-FKS: Click hereGeneral>MAINTENANCE>M15B-FKS BATTERY>INSTALLATION202304,999999,_V1,_080956,_0453685,RM100000002BCCF_03_0002,

for M15C-FKS: Click hereGeneral>MAINTENANCE>M15C-FKS BATTERY>INSTALLATION202304,999999,_V1,_080956,_0453686,RM100000002BCCG_03_0002,

for M20A-FKS: Click hereGeneral>MAINTENANCE>M20A-FKS BATTERY>INSTALLATION202304,999999,_V1,_080956,_0470107,RM100000002BCCI_03_0002,

for M20C-FKS: Click hereGeneral>MAINTENANCE>M20C-FKS BATTERY>INSTALLATION202304,999999,_V1,_080956,_0484846,RM100000002BCCJ_03_0002,

for M20E-FKS: Click hereGeneral>MAINTENANCE>M20E-FKS BATTERY>INSTALLATION202304,999999,_V1,_080956,_0474497,RM100000002BCCK_03_0002,

Hide Display 13.BLEED BRAKE SYSTEM

Click hereBrake>BRAKE SYSTEM (OTHER)>BRAKE FLUID (for Gasoline Model)>BLEEDING202007,999999,_54,_080771,_0392409,RM100000001NQLF,

Hide Display 14. ACCELERATION SENSOR ZERO POINT CALIBRATION AND STORE SYSTEM INFORMATION MEMORIZATION

for NR Series: Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for Gasoline Model (NR Series))>UTILITY202304,999999,_54,_080770,_0599814,RM100000002BA8F,

except NR Series: Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for Gasoline Model (except NR Series))>UTILITY202304,999999,_54,_080770,_0599811,RM100000002B9XU,

Hide Display 15.PERFORM TEST MODE INSPECTION

for NR Series: Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for Gasoline Model (NR Series))>TEST MODE PROCEDURE202304,999999,_54,_080770,_0599814,RM100000002BA8E,

except NR Series: Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for Gasoline Model (except NR Series))>TEST MODE PROCEDURE202304,999999,_54,_080770,_0599811,RM100000002B9YL,

Hide Display 16.INSPECT BRAKE ACTUATOR USING GTS

Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>BRAKE ACTUATOR (for Gasoline Model)>ON-VEHICLE INSPECTION201906,999999,_54,_080770,_0392396,RM100000001HQEY,

Hide Display 17. CHECK FOR AND CLEAR DTCS

for NR Series: Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for Gasoline Model (NR Series))>DTC CHECK / CLEAR202304,999999,_54,_080770,_0599814,RM100000002BA8I,

except NR Series: Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for Gasoline Model (except NR Series))>DTC CHECK / CLEAR202304,999999,_54,_080770,_0599811,RM100000002B9X4,

Hide Display 18.CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for NR Series Engine)

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>REPLACEMENT202304,999999,_58,_080733,_0393725,RM100000002B1HP_01_0002,

Hide Display 19.WARM UP ENGINE (for NR Series Engine)

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>REPLACEMENT202304,999999,_58,_080733,_0393725,RM100000002B1HP_01_0005,

Hide Display 20.INSPECT FOR REFRIGERANT LEAK (for NR Series Engine)

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>REPLACEMENT202304,999999,_58,_080733,_0393725,RM100000002B1HP_01_0004,