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Brake Actuator: Installation

  1. INSTALL BRAKE ACTUATOR BOLT CUSHION 
    1. Install the 2 brake actuator bolt cushions and 2 brake actuator bolt holders to the brake actuator.
      NOTE:
      • Do not hold the actuator by the connector.
      • Do not remove the hole plugs of a new brake actuator before connecting the 6 brake lines because the brake actuator is filled with brake fluid.
        Fig 1: Identifying Brake Actuator Bolt Holders And Brake Actuator Bolt Cushions
        G05752688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL BRAKE ACTUATOR 
    1. Install the brake actuator bolt cushion to the brake actuator bracket assembly.
    2. Install the brake actuator to the brake actuator bracket assembly with the 2 nuts

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  3. TEMPORARILY INSTALL BRAKE ACTUATOR WITH BRACKET 
    1. Temporarily install the brake actuator with bracket
      Fig 2: Identifying Brake Actuator Bolt Cushion And Brake Actuator Bracket Assembly
      G05752687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 3 front brake tube and grommet.
  4. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY  (See INSTALLATION )
    Fig 3: Locating No. 3 Front Brake Tube And Grommet
    G05752686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL BRAKE ACTUATOR WITH BRACKET 
    1. Install the brake actuator with bracket to the body with the 2 bolts and nut

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

      NOTE: Do not damage the brake lines or wire harness.
      Fig 4: Locating Brake Actuator Bolts And Nut
      G05297144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a union nut wrench, connect the No 3 front brake tube to the brake flexible hose

      Torque: without a union nut wrench 

      15 N*m (153 kgf*cm, 11 ft.*lbf) 

      with a union nut wrench 

      14 N*m (143 kgf*cm, 10 ft.*lbf) 

      NOTE:
      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
    3. Install the grommet to the body
      NOTE: Make sure that the grommet is installed correctly.
      Fig 5: Connecting No 3 Front Brake Tube To Brake Flexible Hose
      G05752693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily tighten each brake line to the correct positions of the brake actuator assembly with bracket as shown in the illustration.

      HINT

      • *1. To front wheel cylinder RH
      • *2 To front wheel cylinder LH
      • *3 To rear wheel cylinder RH
      • *4: To rear wheel cylinder LH
      • *5: From front of master cylinder
      • *6 From rear of master cylinder
        Fig 6: Identifying Brake Line Correct Positions
        G05752683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a union nut wrench, fully tighten each brake line.

      Torque: without a union nut wrench 

      15 N*m (153 kgf*cm, 11 ft.*lbf) 

      with a union nut wrench 

      14 N*m (143 kgf*cm, 10 ft.*lbf) 

      NOTE:
      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
        Fig 7: Tightening Brake Line
        G05752695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the brake actuator connector
      NOTE:
      • Make sure that the actuator connector can be connected smoothly. Do not allow water, oil or dirt to enter.
      • Make sure that the connector is locked securely.
  6. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK  (See INSTALLATION )
    Fig 8: Connecting Brake Actuator Connector
    G05752696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  8. FILL RESERVOIR WITH BRAKE FLUID  (See REPLACEMENT )
  9. BLEED BRAKE MASTER CYLINDER  (See BLEEDING )
  10. BLEED BRAKE LINE  (See REPLACEMENT )
  11. BLEED BRAKE ACTUATOR  (See BLEEDING )
  12. CHECK FOR DTC 

    HINT.

    (See DTC CHECK / CLEAR  )

  13. INSPECT FOR BRAKE FLUID LEAK 
  14. INSPECT FOR FLUID LEVEL IN RESERVOIR  (See ON-VEHICLE INSPECTION )
  15. INSTALL FRONT WHEEL 

    Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 

  16. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  17. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  18. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  19. INSTALL FRONT WIPER ARM HEAD CAP  (See INSTALLATION )
  20. INSTALL ROOF DRIP SIDE FINISH MOULDING LH  (See INSTALLATION )
  21. INSTALL ROOF DRIP SIDE FINISH MOULDING RH  (See INSTALLATION )
  22. INSTALL FRONT UPPER FENDER PROTECTOR LH  (See INSTALLATION )
  23. INSTALL FRONT UPPER FENDER PROTECTOR RH  (See INSTALLATION )
  24. INSTALL ENGINE ROOM SIDE COVER RH  (See INSTALLATION )
  25. INSTALL ENGINE ROOM SIDE COVER LH  (See INSTALLATION )
  26. INSTALL COOL AIR INTAKE DUCT SEAL  (See INSTALLATION )
  27. INSPECT ACTUATOR WITH TECHSTREAM 

    HINT:

    (See ON-VEHICLE INSPECTION  )

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