Installation

BRAKE: BRAKE MASTER CYLINDER: INSTALLATION

INSTALLATION
NOTE: While the battery is connected, even if the power 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 or open/close the doors while the battery is connected.

1. INSTALL BRAKE BOOSTER GASKET






(a) Install a new brake booster gasket to the brake master cylinder with simulator.
2. INSTALL BRAKE MASTER CYLINDER WITH SIMULATOR ASSEMBLY






(a) Install the brake master cylinder with simulator with the 4 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft-lbf)
(b) Connect the brake stroke simulator connector.
3. INSTALL PUSH ROD PIN Installation

4. INSTALL BRAKE PEDAL RETURN SPRING Installation

5. INSTALL BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY Installation

6. CONNECT BRAKE TUBE Installation

7. INSTALL RESERVOIR BRACKET






(a) Install the reservoir bracket with the 3 bolts.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)
8. INSTALL NO. 1 RESERVOIR HOSE






(a) Install the reservoir connector to the No. 1 reservoir hose with the hose clip as shown in the illustration.
Length "A":
4.0 to 7.0 mm (0.157 to 0.276 in.)
(b) With the paint mark on the hose's tip facing the top of the vehicle, install the No. 1 reservoir hose to the master cylinder with the hose clip.
HINT: Install the hose clip so that its claws face the top of the vehicle.

9. INSTALL SKID CONTROL ECU BRACKET Installation

10. INSTALL BRAKE FLUID RESERVOIR






(a) Connect the No. 1 reservoir hose (labeled A) and No. 2 brake actuator hose (labeled B) to the reservoir. The reservoir connector connecting procedure must be followed as described below:
(1) Remove the foreign matter entry prevention plastic bags.
NOTE: Check that there is no damage or foreign objects on the connected part of the reservoir and reservoir connectors.
(2) Insert the reservoir connector to the reservoir until the reservoir connector makes a "click" sound, so that the reservoir connector tip's groove is aligned with the reservoir's rib.
(3) Securely set the lock of the reservoir connector.
(4) Check that the reservoir connector lock's claw is securely attached.
(b) With the paint mark on the hose's tip facing the top of the vehicle, connect the No. 1 brake actuator hose (labeled C) to the reservoir with the hose clip.
HINT: Install the hose clip so that its claws face the top of the vehicle.

(c) Connect the brake fluid level warning switch connector, and then attach the connector clamp to the reservoir bracket.
(d) Install the brake fluid reservoir with the 2 bolts.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)
(e) Connect the wire harness clamp to the reservoir.
11. CONNECT NO. 3 RELAY BLOCK Installation

12. INSTALL SKID CONTROL ECU Installation

13. CONNECT NO. 1 MOTOR COOLING PIPE Installation

14. INSTALL SERVICE PLUG GRIP Installation

15. INSTALL BATTERY SERVICE HOLE COVER Hybrid Battery Service Switch

16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

17. INSTALL BATTERY SERVICE HOLE COVER LH Battery

18. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY

19. BLEEDING PRECAUTION
CAUTION: Be sure to read the "PRECAUTION" thoroughly before bleeding Service Precautions.

20. CONNECT BRAKE ACCUMULATOR PUMP CONNECTORS






(a) Connect the 2 brake accumulator pump connectors.
- 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.

21. PERFORM ACCUMULATOR ZERO DOWN Service and Repair

22. FILL RESERVOIR WITH BRAKE FLUID Service and Repair

23. BLEED BRAKE SYSTEM Service and Repair

24. PERFORM ACCUMULATOR ZERO DOWN Service and Repair

25. INSPECT AND ADJUST BRAKE FLUID LEVEL IN RESERVOIR Testing and Inspection

26. INSPECT FOR BRAKE FLUID LEAK
27. CHECK AND ADJUST BRAKE PEDAL HEIGHT Adjustments

28. ADJUST BRAKE PEDAL STROKE SENSOR Adjustments

29. CHECK BRAKE PEDAL FREE PLAY Adjustments

30. CHECK BRAKE PEDAL RESERVE DISTANCE Adjustments

31. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY Installation

32. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation

33. INSTALL NO. 1 INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY Installation

34. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY Installation

35. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY Installation

36. INSTALL STEERING COLUMN COVER (w/o Driver Monitor Camera) Installation

37. INSTALL STEERING COLUMN COVER (w/ Driver Monitor Camera) Installation

38. INSTALL NO. 1 INSTRUMENT CLUSTER MOULDING Installation

39. INSTALL INSTRUMENT SIDE PANEL LH Installation

40. INSTALL INSTRUMENT PANEL FINISH PANEL END LH Installation

41. INSTALL FRONT WHEEL
Torque: 140 Nm (1428 kgf-cm, 103 ft-lbf)
42. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

43. INSTALL COWL TOP VENTILATOR LOUVER PROTECTOR LH Installation

44. INSTALL FRONT FENDER TO COWL SIDE SEAL LH Installation

45. INSTALL FRONT FENDER TO COWL SIDE SEAL RH Installation

46. INSTALL HOOD TO COWL TOP SEAL Installation

47. INSTALL FRONT UPPER FENDER PROTECTOR LH Installation

48. INSTALL FRONT UPPER FENDER PROTECTOR RH Installation

49. INSTALL ENGINE ROOM SIDE COVER RH Installation

50. INSTALL ENGINE ROOM SIDE COVER LH Installation

51. INSTALL FRONT WIPER ARM LH Installation

52. INSTALL FRONT WIPER ARM RH Installation

53. INSTALL COWL TOP VENTILATOR LOUVER RH Installation

54. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

55. CLEAR DTC
(a) Clear the DTCs Reading and Clearing Diagnostic Trouble Codes.
56. PERFORM LINEAR VALVE OFFSET LEARNING
(a) When the brake master cylinder with simulator assembly is replaced, perform the linear valve offset learning Programming and Relearning.
57. CHECK BRAKE ACTUATOR WITH TESTER
(a) Check the brake actuator and pressure sensor On-Vehicle Inspection.
58. CHECK BRAKE MASTER CYLINDER WITH TESTER
(a) Check the brake master cylinder and stroke simulator On-Vehicle Inspection.
59. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light Diagnosis System.
60. RESET CUSTOMIZE PROGRAM
NOTE: Reset the AUTO TILT AWAY function setting to the previous condition by changing the customize parameter Repair Instruction - Customize Parameters.

61. CHECK MASTER CYLINDER PRESSURE SENSOR SIGNAL
(a) Check the pressure sensor signal Test Mode Procedure.
62. CHECK FOR DTC
(a) Check for DTC. If any DTC is output, perform the troubleshooting for that DTC Electronically Controlled Brake System.
63. READ VALUE OF ACCUMULATOR PRESSURE SENSOR OUTPUT VOLTAGE Installation