Removal and Installation
REMOVALNOTE: While the battery is connected, even if the engine switch is off, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal and open/ close the doors while the battery is connected.
1. REMOVE V-BANK COVER SUB-ASSEMBLY
2. REMOVE COWL TOP VENTILATOR LOUVER RH
3. REMOVE FRONT WIPER ARM LH
4. REMOVE FRONT WIPER ARM RH
5. REMOVE ENGINE ROOM SIDE COVER LH
6. REMOVE ENGINE ROOM SIDE COVER RH
7. REMOVE FRONT FENDER PROTECTOR UPPER LH
8. REMOVE FRONT FENDER PROTECTOR UPPER RH
9. REMOVE HOOD TO COWL TOP SEAL
10. REMOVE FRONT FENDER TO COWL SIDE SEAL LH
11. REMOVE FRONT FENDER TO COWL SIDE SEAL RH
12. REMOVE COWL TOP VENTILATOR LOUVER PROTECTOR LH
13. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
14. PERFORM ACCUMULATOR PRESSURE ZERO DOWN
CAUTION: Be sure to perform this procedure before removing the brake actuator and brake accumulator pump.
a. Connect the intelligent tester or Techstream to the DLC3 with the engine switch off.
b. Turn the engine switch on (IG).
c. Turn the intelligent tester or Techstream ON and perform accumulator zero down by following the prompts displayed on the intelligent tester or Techstream.
HINT: Select "DIAGNOSTIC MENU"->"ABS/VSC"->"ELECTRONICALLY CONTROLLED BRAKE SYSTEM UTILITY"->"ZERO DOWN" on the intelligent tester or Techstream.
d. When the buzzer sounds, turn the engine switch off.
NOTE: Do not push the engine switch on (IG). If the engine switch is pushed on (IG), the brake accumulator pump operates so that the brake accumulator is accumulated with brake fluid.
15. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
16. DRAIN BRAKE FLUID
NOTE: If brake fluid leaks onto any painted surface, wash or remove it completely.
17. REMOVE SKID CONTROL ECU
18. REMOVE SKID CONTROL ECU BRACKET
19. DISCONNECT ENGINE ROOM NO. 3 RELAY BLOCK
a. While pushing the claw of the engine room No. 3 relay block, pull out the engine room No. 3 relay block and disconnect it from the reservoir bracket.
NOTE: Do not allow brake fluid to contact the engine room No. 3 relay block.
20. REMOVE BRAKE FLUID RESERVOIR
21. REMOVE NO.1 RESERVOIR HOSE
22. REMOVE RESERVOIR BRACKET
23. REMOVE FRONT WHEEL
24. DISCONNECT BRAKE TUBE
a. Using SST, disconnect the 6 brake tubes from the actuator.
SST 09023-00101
b. Use tags or make a note to identify the reconnection locations.
c. Using SST, disconnect the No.1 (labeled A) and No.2 (labeled B) brake actuator tubes.
SST 09023-00101
NOTE: Do not damage the No.1 and No.2 brake actuator tubes.
25. REMOVE BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY
a. Release the lock lever and disconnect the brake actuator connector.
NOTE: Do not allow brake fluid to contact the connector face.
b. Disconnect the 2 brake accumulator pump connectors.
NOTE: Do not allow brake fluid to contact the connector faces.
c. Disconnect the No.1 brake actuator hose from the clamp and then remove the clamp.
d. Disconnect the front fender liner rear side and then remove the 2 nuts (labeled A).
e. Remove the bolt (labeled B) and brake actuator and brake accumulator pump.
NOTE:
- Do not damage the brake tubes.
- When removing the brake actuator and brake accumulator pump from the vehicle, do not hold the connector, harness, hose or tube parts.
- Do not drop the brake actuator and brake accumulator pump. Do not use parts that have been dropped.
26. REMOVE NO.5 BRAKE ACTUATOR BRACKET
a. Remove the bolt and No.5 brake actuator bracket.
27. REMOVE NO.1 BRAKE ACTUATOR HOSE
NOTE: When disconnecting the hose, be careful that there is no excessive weight applied to the union of the brake actuator (especially in the union rotation direction).
a. Remove the hose clip and the No.1 brake actuator hose.
28. REMOVE BRAKE ACTUATOR PROTECTOR
a. Remove the protector.
29. REMOVE NO.2 BRAKE ACTUATOR HOSE
NOTE: When disconnecting the hose, be careful that there is no excessive weight applied to the union of the brake accumulator pump (especially in the union rotation direction).
a. Disconnect the No.2 brake actuator hose from the No.3 brake actuator bracket and then remove the clamp.
b. Remove the hose clip and No.2 brake actuator hose.
c. Remove the hose clip and reservoir connector.
30. REMOVE NO. 3 BRAKE ACTUATOR TUBE
NOTE:
- Do not damage the No.3 brake actuator tube, brake actuator and brake accumulator pump.
- When removing the No.3 brake actuator tube, hold the tube, brake actuator and brake accumulator pump securely.
a. Using SST, disconnect the No.3 brake actuator tube.
SST 09023-00101
31. DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTOR BOX
a. Disconnect the brake accumulator pump connector box as follows:
1. Detach the wiring harness clamp (labeled A).
2. Remove the nut (labeled B) and connector box.
32. REMOVE NO.4 BRAKE ACTUATOR BRACKET
a. Remove the bolt and No.4 brake actuator bracket.
33. REMOVE BRAKE ACCUMULATOR PUMP
a. Break and remove the brake actuator bracket clamp (labeled A), and then remove the brake accumulator pump.
b. Remove the brake booster pump bush (labeled B) from the brake actuator bracket.
c. Remove the brake booster pump bush (labeled C) and brake booster pump collar (labeled D) from the brake accumulator pump.
34. REMOVE BRAKE ACTUATOR
a. Remove the 3 bolts, brake actuator bracket and brake actuator.
b. Remove the 3 cushions and 3 spacers from the brake actuator bracket.
c. Remove the 3 bolts and No.3 brake actuator bracket from the brake actuator.
INSTALLATION
NOTE: While the battery is connected, even if the engine switch is off, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on.
Therefore during servicing of the brake system components, do not operate the brake pedal and open/ close the doors while the battery is connected.
1. INSTALL BRAKE ACTUATOR
NOTE: Do not remove the hole plug before installing a new brake actuator because the brake actuator is filled with brake fluid.
a. Install the No. 3 brake actuator bracket to the brake actuator with the 3 bolts.
Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
NOTE: After temporarily installing either bolt A or B, tighten the remaining bolts.
b. Install the 3 cushions and 3 spacers to the bracket.
c. Install the brake actuator bracket to the brake actuator with the 3 bolts.
Torque: 9.2 N.m (94 kgf.cm, 81 in.lbf)
2. INSTALL BRAKE ACCUMULATOR PUMP
a. Install the brake booster pump collar (labeled A) and brake booster pump bush (labeled B) to the brake accumulator pump.
b. Install the brake accumulator pump to the brake actuator bracket.
NOTE: After installing the brake accumulator pump, make sure the collar has not fallen off.
c. Install the brake booster pump bush (labeled C) and a new brake actuator bracket clamp (labeled D) to the brake accumulator pump.
NOTE: Make sure to securely insert the brake accumulator pump until the claws of the clamp are attached.
3. INSTALL NO. 4 BRAKE ACTUATOR BRACKET
a. Install the No. 4 brake actuator bracket to the brake actuator with the bolt.
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
4. CONNECT BRAKE ACCUMULATOR PUMP CONNECTOR BOX
a. Connect the brake accumulator pump connector box as follows:
1. Install the connector box with the nut (labeled A).
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
2. Attach the wiring harness clamp (labeled B).
5. INSTALL NO.3 BRAKE ACTUATOR TUBE
NOTE:
- Do not damage the No.3 brake actuator tube, brake actuator and brake accumulator pump.
- When installing the No.3 brake actuator tube, hold the tube, brake actuator and brake accumulator pump securely.
- When tightening the nut, make sure that other parts do not move with the nut.
a. Using SST, connect the No. 3 brake actuator tube.
SST 09023-00101
Torque:
15 N.m (155 kgf.cm, 11 ft.lbf) without SST
14 N.m (145 kgf.cm, 10 ft.lbf) with SST
HINT:
- Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
- This torque value is effective when SST is parallel to a torque wrench.
6. INSTALL NO.2 BRAKE ACTUATOR HOSE
NOTE: Do not remove the cap installed to the reservoir connector until it is connected to the reservoir.
a. Install the reservoir connector to the No. 2 brake actuator hose with the hose clip as given in the illustration.
Length "A": 4.0 to 7.0 mm (0.158 to 0.276 in.)
b. With the paint mark on the hose's tip facing the bottom of the vehicle, install the No.2 brake actuator hose to the brake accumulator pump with the hose clip.
NOTE: When inserting the hose, be careful that there is no excessive weight applied to the union of the brake accumulator pump (especially in the union rotation direction).
HINT: Install the hose clip so that its claws face the rear of the vehicle.
c. Connect the No.2 brake actuator hose to the No.3 brake actuator bracket with the clamp.
7. INSTALL BRAKE ACTUATOR PROTECTOR
a. Install the protector.
8. INSTALL NO.1 BRAKE ACTUATOR HOSE
a. With the paint mark on the hose's tip facing the bottom of the vehicle, install the No.1 brake actuator hose to the brake actuator with the hose clip.
NOTE: When inserting the hose, be careful that there is no excessive weight applied to the union of the brake actuator (especially in the union rotation direction).
HINT: Install the hose clip so that its claws face the rear of the vehicle.
9. INSTALL NO.5 BRAKE ACTUATOR BRACKET
a. Install the No. 5 brake actuator bracket to the body with the bolt.
Torque: 11 N.m (112 kgf.cm, 8 ft.lbf)
10. INSTALL BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY
a. Install the brake actuator and brake accumulator pump to the body with the bolt (labeled A) and 2 nuts (labeled B).
NOTE:
- Do not damage the brake tubes.
- When installing the brake actuator and brake accumulator pump to the vehicle, do not hold the connector, harness, hose or tube parts.
- Do not drop the brake actuator and brake accumulator pump. Do not use parts that have been dropped.
HINT: First insert the bracket bottom's longer stud bolt (vehicle outer side, labeled C) into the body.
Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
b. Connect the front fender liner rear side.
c. Connect the No.1 brake actuator hose to the body with the clamp.
d. Connect the 2 brake accumulator pump connectors.
NOTE:
- Before connecting the vehicle wire harnesses, make sure that the connector faces are free of foreign matter.
- Make sure that the connectors are locked securely.
e. Connect the brake actuator connector.
NOTE:
- Before connecting the vehicle wire harnesses, make sure that the connector faces are free of foreign matter.
- Make sure that the connector is locked securely.
11. CONNECT BRAKE TUBE
a. Using SST, connect the No.1 (labeled A) and No.2 (labeled B) brake actuator tubes.
SST 09023-00101
Torque:
15 N.m (155 kgf.cm, 11 ft.lbf) without SST
14 N.m (145 kgf.cm, 10 ft.lbf) with SST
HINT:
- Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
- This torque value is effective when SST is parallel to a torque wrench.
NOTE: Do not damage the No.1 and No.2 brake actuator tubes.
b. Set each brake tube to the correct positions on the brake actuator as given in the illustration.
c. Using SST, connect the 6 brake tubes.
SST 09023-00101
Torque:
15 N.m (155 kgf.cm, 11 ft.lbf) without SST
14 N.m (145 kgf.cm, 10 ft.lbf) with SST
HINT:
- Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
- This torque value is effective when SST is parallel to a torque wrench.
12. INSTALL FRONT WHEEL
Torque: 140 N.m (1428 kgf.cm, 103 ft.lbf)
13. INSTALL RESERVOIR BRACKET
14. INSTALL NO. 1 RESERVOIR HOSE
15. INSTALL BRAKE FLUID RESERVOIR
16. CONNECT ENGINE ROOM NO.3 RELAY BLOCK
a. Install the engine room No.3 relay block to the reservoir bracket.
NOTE: Check that the claw of the engine room No.3 relay block is securely attached to the reservoir bracket.
17. INSTALL SKID CONTROL ECU BRACKET
18. INSTALL SKID CONTROL ECU
19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
20. BLEEDING PRECAUTION
CAUTION: Be sure to read the "PRECAUTION" thoroughly before bleeding.
21. DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTORS
22. FILL RESERVOIR WITH BRAKE FLUID
23. DISABLE BRAKE CONTROL
24. BLEED AIR FROM FRONT BRAKE SYSTEM
25. CANCEL DISABLE BRAKE CONTROL
26. CONNECT BRAKE ACCUMULATOR PUMP CONNECTORS
27. BLEED AIR FROM PUMP SUCTION SYSTEM (RR)
28. DISABLE BRAKE CONTROL
29. BLEED AIR FROM REAR BRAKE SYSTEM
30. CANCEL DISABLE BRAKE CONTROL
31. CLEAR DTC
32. PERFORM ACCUMULATOR ZERO DOWN
33. CHECK AND ADJUST BRAKE FLUID LEVEL IN RESERVOIR
34. INSPECT FOR BRAKE FLUID LEAK
35. CLEAR DTC
36. PERFORM LINEAR VALVE OFFSET LEARNING
a. When the brake actuator is replaced, perform the linear valve offset learning.
37. PERFORM INITIALIZATION Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
38. CHECK DTC
a. If any DTC is set, perform the troubleshooting for the DTC.
39. READ VALUE OF ACCUMULATOR PRESSURE SENSOR OUTPUT VOLTAGE
HINT: If removing and installing the No.3 brake actuator tube, check for a brake fluid leak from the No.3 tube connection area by monitoring the accumulator pressure sensor output value from the brake actuator. Directly checking for a brake fluid leak from the No.3 tube connection area is difficult.
a. Turn the engine switch off.
b. Connect the intelligent tester or Techstream to the DLC3.
c. Turn the engine switch on (IG).
d. Operate the intelligent tester or Techstream according to the display and select "DATA LIST".
e. Depress the brake pedal 4 or 5 times to operate the pump motor, and check the output value on the intelligent tester or Techstream with the motor stopped (not braking).
OK: Accumulator pressure sensor's output voltage drops 0.2 V or less for 30 seconds.
If the voltage drops more than 0.2 V, there may be a brake fluid leak from the No. 3 brake actuator tube connection area. Remove the brake actuator and brake accumulator pump, and then repeat the procedures from the retightening of the 2 union nuts of the No. 3 brake actuator tube
SST 09023-00101
Torque:
15 N.m (155 kgf.cm, 11 ft.lbf) without SST
14 N.m (145 kgf.cm, 10 ft.lbf) with SST
HINT:
- Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
- This torque value is effective when SST is parallel to a torque wrench.
40. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
41. INSTALL COWL TOP VENTILATOR LOUVER PROTECTOR LH
42. INSTALL FENDER TO COWL SIDE SEAL LH
43. INSTALL FRONT FENDER TO COWL SIDE SEAL RH
44. INSTALL HOOD TO COWL TOP SEAL
45. INSTALL FRONT FENDER PROTECTOR UPPER LH
46. INSTALL FRONT FENDER PROTECTOR UPPER RH
47. INSTALL ENGINE ROOM SIDE COVER RH
48. INSTALL ENGINE ROOM SIDE COVER LH
49. INSTALL FRONT WIPER ARM LH
50. INSTALL FRONT WIPER ARM RH
51. INSTALL COWL TOP VENTILATOR LOUVER RH
52. INSTALL V-BANK COVER SUB-ASSEMBLY