BRAKE ACTUATOR (w/o VSC): Installation

1. Install the brake actuator to the brake actuator bracket assembly with the 3 bolts.

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

   NOTE:

   • 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.
   • Do not carry the brake actuator assembly by the connector.
   • Tighten the 3 bolts in the order shown in the illustration.
     Fig 1: Tightening Order Of Brake Actuator Mounting Bolts

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.
   • Tighten the nut and 2 bolts in the order shown in the illustration.
     Fig 2: Tightening Order Of Nut And Bolts For Installing Brake Actuator With Bracket

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily tighten each brake line to the correct position 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 1st master cylinder
   • *6: From 2nd master cylinder
     Fig 3: Identifying Brake Lines

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a union nut wrench (10 mm), fully tighten each brake line.

   Torque: without a union nut wrench 

   15 N*m (155 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 4: Tightening Brake Line

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the brake line clamp with brake line with the bolt.

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

   Fig 5: Locating Brake Line Clamp Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the actuator connector and lock the lock lever.
   NOTE: Make sure that the connector is locked securely.
   Fig 6: Locating Actuator Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the radiator reserve tank assembly with the 3 bolts.

   Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

   Fig 7: Locating Radiator Reserve Tank Assembly Mounting Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the windshield washer jar assembly and clamp to the body with the 2 bolts.

   Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

   Fig 8: Locating Windshield Washer Jar Assembly Bolt And Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the bolt and clamp connect the washer hoses and motor connectors.

   Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

HINT:

Refer to the instructions for Installation of the front bumper assembly (See INSTALLATION ).

HINT:

Refer to the instructions for Installation of the generator assembly (See INSTALLATION ).

Fig 9: Locating Washer Hoses And Motor Connectors Bolt And Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Refer to the instructions for Installation of the generator assembly (See INSTALLATION ).

HINT:

(See ON-VEHICLE INSPECTION  )