Brake Actuator: Installation

1. Install the brake actuator assembly to the brake actuator bracket assembly with the 2 nuts.

   Torque: 8.0 N*m (82 kgf*cm, 71 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 hold the actuator by the connector.
   • Set the actuator down with the pin being set securely as shown in the illustration.

     Text in Illustration 

     ILLUSTRATION LEGEND
     
     

     *1	Pin
     *2	Cushion

     Fig 1: Locating Brake Actuator Bracket Assembly Nuts

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the brake actuator with bracket to the body with the nut and 2 bolts.

   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 order from 1 to 3.
     Fig 2: Identifying Brake Actuator With Bracket Nut And Bolt Tightening Sequence

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the brake actuator connector.
   NOTE:

   • Make sure that the connector is locked securely.
   • Make sure that the actuator connector can be connected smoothly. Do not allow water, oil or dirt to enter.
     Fig 3: Connecting Brake Actuator Connector

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Temporarily tighten each brake line to the correct positions of the brake actuator with bracket as shown in the illustration.

   Text in Illustration 

   ILLUSTRATION LEGEND
   
   

   *1	To front wheel cylinder RH
   *2	To front wheel cylinder LH
   *3	To front wheel cylinder RH
   *4	To front wheel cylinder LH
   *5	From 1st of master cylinder
   *6	From 2nd of master cylinder

   Fig 4: Identifying Correct Installation Positions Of Brake Actuator With Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using union nut wrenches (10 mm and 12 mm), fully tighten each brake line.

   Torque: Flare nut A (10 mm) 

   15 N*m (155 kgf*cm, 11 ft.*lbf) 

   Flare nut B (12 mm) 

   20 N*m (199 kgf*cm, 14 ft.*lbf) 

   NOTE: Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (See REPAIR INSTRUCTION ).

   Text in Illustration 

   ILLUSTRATION LEGEND
   
   

   *1	Flare Nut A (10 mm)
   *2	Flare Nut B (12 mm)

   Fig 5: Identifying Brake Lines Nuts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the clamp of the suction hose sub-assembly to the brake actuator bracket assembly.
   Fig 6: Identifying Suction Hose Sub-Assembly With Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the radiator reserve tank assembly.
2. Install the radiator reserve tank cap assembly.
Fig 7: Identifying Radiator Reserve Tank Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

(See CALIBRATION  ).

HINT:

(See ON-VEHICLE INSPECTION  ).