Description

Actyon SPORTS II 2013 Technical Manual – Brake System Factory Specs

I have pulled more brake jobs than I care to count. If you are about to open up the brake system on an Actyon SPORTS II, you need the actual factory data, not some third-party reprint that guesses the thread pitch. This Actyon SPORTS II 2013 Technical Manual is 31 pages of genuine OEM specs covering the entire brake system. I have seen what happens when a tech uses the wrong master cylinder bore dimension – a mushy pedal that never bleeds right. That’s why this manual exists.

Brake System Specifications from Page 1

Page 1 lays out every critical dimension for front and rear brakes. Front disc outer diameter is 294 mm (wear limit 25.4 mm). Rear disc is 299 mm solid, 10.4 mm thick (wear limit 8.5 mm). Brake pad area front above 60 cm², rear above 28.8 cm². Master cylinder inner diameter is 26.99 mm – a tandem type with integrated level sensor. Pedal ratio 4:1, free play 3 to 10 mm. Parking brake drum inner diameter 190 mm. Brake fluid must be DOT 4, change every 2 years. If you skip those wear limits, you risk a rotor crack under hard use. The manual does not guess these numbers.

Why Use Factory Torque Specs Instead of Aftermarket Data?

Aftermarket manuals often pull torque values from a different model year or confuse metric with imperial. The Removal and Installation sections of this OEM manual list the exact torque for every bolt – caliper mounting bolts, banjo bolts, booster nuts. I have had to redo jobs where a rookie used a generic spec and snapped a caliper bracket bolt. The factory procedure (references like 4830-01 for front caliper/disc) gives the tightening sequence and angle if required. That is the difference between a brake job that lasts 50,000 miles and one that comes back in 5,000.

Check the Master Cylinder Bore Before Assembly

Section 4850-01 covers the brake master cylinder assembly. The bore diameter, piston travel, and seal part numbers are all specified. You cannot swap in a random master cylinder from another SUV – the Actyon SPORTS II uses a specific tandem circuit with an integrated level sensor. If you install a cylinder with the wrong bore, the pedal ratio changes, and the booster may not provide enough assist. The manual includes the full component illustration and part numbers for seals. Do not rely on a parts-store computer screen alone.

3 Reasons to Stick with OEM Documentation

1. Accuracy of dimensions. The specs come from the Actyon engineering group, not a translator. Disc thickness, pad area, and caliper piston diameters are verified to the production line.
2. Bleeding procedure specific to this model. The air bleeding section (page 2 of the general information) explains the correct sequence for the hydraulic circuit – front right, front left, rear right, rear left – and warns against letting the reservoir run dry.
3. Safety-critical torque. Brake booster mounting (4850-02), caliper bolts, and parking brake hardware have specific torque that prevents failure under panic stops. Without the OEM numbers, you are guessing.

Air Bleeding: Factory Procedure and Fluid Specifications

The general information section includes a full air bleeding procedure. Brake fluid must be DOT 4, with a note on capacity: “as required” but explicitly states change every 2 years. The manual shows the hydraulic circuit layout (section 2 – system layout and hydraulic circuit diagram). It also includes the stop lamp circuit diagram (circuit diagram of stop lamp). If you are dealing with a spongy pedal, you need to follow the exact sequence and check for any leaks at the master cylinder or caliper union. The manual does not assume you know which line is primary vs secondary – it spells it out.

Parking Brake Lining: Replacement Procedure

Section 4910-01 covers the parking brake assembly, and section 4841-15 covers the parking brake lining (shoe). The drum inner diameter is 190 mm – if your drum is worn beyond that, you need a replacement, not just new shoes. The removal procedure includes step-by-step for the hand-operated type. Many shops skip the lining adjustment spec and end up with a parking brake that barely holds on a slope. The manual gives the adjustment specs and the correct tool for retracting the piston.

Related Manuals for Specialized Equipment

If you work on heavy equipment or other vehicles, factory manuals are just as critical. For instance, the Drogobych Crane КТА-16, КТА-25, КТА-28 2004 Installation Manual follows the same philosophy. Similarly, the Injectocean Diablo, Murciélago, Defender, Discovery, Freelander Technical Manual offers OEM-level specs for those platforms. And for older equipment, the Minsk MMVZ-3.11212 Technical Manual – Factory Specs is worth a look.

For a broader context on automotive standards, the Automotive Industry Overview provides background, but this manual gives you the exact specs for the Actyon SPORTS II. Unlike working on a Manual Transmission where gear ratios are the focus, brake hydraulic work demands precision on fluid volumes and piston travel.

Does this manual cover the ABS system?

Yes. Page 2 lists the system overview including ABS, EBD, ESP, HBA, and other electronic aids. However, the detailed ABS diagnosis is minimal – this is primarily a hydraulic brake component manual. For full ABS diagnostics you would need the separate ESP/ABS technical manual.

How many pages is the manual?

31 pages.

What brake fluid does the Actyon SPORTS II require?

DOT 4. Change interval is every 2 years. Capacity is listed as “as required” – bleed until clean fluid appears.

Can I use this manual for engine or transmission work?

No. This is exclusively the brake system manual for the Actyon SPORTS II 2013. It covers master cylinder, calipers, discs, pads, booster, parking brake, and hydraulic circuits. For the engine or transmission, you need the corresponding 2013 service manual.

When you have a brake job on an Actyon SPORTS II, you cannot afford to guess dimensions or torque. This 31-page factory document gives you the same information the dealership techs use. If you want to get this right the first time, access the factory manual through AutoRepairManuals.