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Brake Actuator: Installation: Installation

  1. INSTALL BRAKE ACTUATOR (for 2AZ-FE) 
    1. Install the brake actuator to the brake actuator bracket assembly with the 3 bolts.
      Fig 1: Identifying Bolts For Installing Brake Actuator To Brake Actuator Bracket Assembly
      GTY244719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:
      • If installing a new brake actuator, do not remove the hole plugs before connecting the 6 brake lines because the brake actuator is filled with brake fluid.
      • Do not carry the brake actuator by the connector.
      • Tighten the 3 bolts in the order shown in the illustration.
  2. INSTALL BRAKE ACTUATOR (for 2ZR-FE) 
    1. Install the brake actuator to the brake actuator bracket assembly with the 3 bolts.
      Fig 2: Identifying Brake Actuator Bracket Assembly Bolts
      GTY225723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:
      • If installing a new brake actuator, do not remove the hole plugs before connecting the 6 brake lines because the brake actuator is filled with brake fluid.
      • Do not carry the brake actuator by the connector.
      • Tighten the 3 bolts in the order shown in the illustration.
  3. INSTALL BRAKE ACTUATOR WITH BRACKET (for 2AZ-FE) 
    1. Install the brake actuator with bracket to the body with the 2 bolts and nut.
      Fig 3: Locating Bolts For Installing Brake Actuator With Bracket
      GTY220963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:
      • Do not damage the brake lines or wire harness.
      • Tighten the 2 bolts and nut in the order shown in the illustration.
    2. Temporarily tighten each brake line to the correct position of the brake actuator with bracket as shown in the illustration.
      Fig 4: Identifying Brake Line Tags Location
      GTY226188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 chamber
      • *6: From 2nd master cylinder chamber
    3. Using a union nut wrench (10 mm), fully tighten each brake line.
      Fig 5: Tightening Brake Line Using Union Nut Wrench
      GTY233347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      without a union nut wrench 

      Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) 

      with a union nut wrench 

      Torque: 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.
    4. Install the brake line clamp with the bolt.
      Fig 6: Locating Brake Line Clamp Bolt
      GTY212220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    5. Connect the actuator connector and lock the lock lever.
      Fig 7: Connecting Actuator Connector
      GTY169882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that the connector is locked securely.

  4. INSTALL BRAKE ACTUATOR WITH BRACKET (for 2ZR-FE) 
    1. Install the brake actuator with bracket to the body with the 2 bolts and nut.
      Fig 8: Locating Brake Actuator Fasteners (For 2ZR-FE)
      GTY220921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:
      • Do not damage the brake lines or wire harness.
      • Tighten the 2 bolts and nut in the order shown in the illustration.
    2. Temporarily tighten each brake line to the correct positions of the brake actuator with bracket as shown in the illustration.
      Fig 9: Identifying Brake Line Tags Location
      GTY223101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 chamber
      • *6: From 2nd master cylinder chamber
    3. Using a union nut wrench (10 mm) and union nut wrench (12 mm), fully tighten each brake line.
      Fig 10: Tightening Brake Line Using Union Nut Wrench
      GTY236851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      without a union nut wrench (10 mm) 

      Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) 

      with a union nut wrench (10 mm) 

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

      without a union nut wrench (12 mm) 

      Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

      with a union nut wrench (12 mm) 

      Torque: 18 N*m (178 kgf*cm, 13 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.
    4. Install the brake line clamp with the bolt.
      Fig 11: View Of Brake Line Mount And Bolt
      GTY186671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    5. Connect the actuator connector.
      Fig 12: Connecting Actuator Connector (For 2ZR-FE)
      GTY220739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that the connector is locked securely.

  5. INSTALL WINDSHIELD WASHER JAR ASSEMBLY 
    1. Install the windshield washer jar assembly and clamp to the body with the 2 bolts.
      Fig 13: Locating Windshield Washer Jar Assembly Bolt And Clamp
      GTY204980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Install the bolt and clamp, and connect the washer hoses and motor connectors.
      Fig 14: Locating Washer Hoses And Motor Connectors Bolt And Clamp
      GTY218759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  6. INSTALL RADIATOR RESERVE TANK SUB-ASSEMBLY 
    1. Install the radiator reserve tank sub-assembly with the 3 bolts.
      Fig 15: Locating Radiator Reserve Tank Sub-Assembly Mounting Bolts
      GTY244720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  7. INSTALL FRONT BUMPER ASSEMBLY 

    HINT: 

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

  8. INSTALL GENERATOR ASSEMBLY (for 2ZR-FE) 

    HINT: 

    Refer to the instructions for Installation of the generator assembly. Refer to INSTALLATION - Step 1 .

  9. INSTALL GENERATOR ASSEMBLY (for 2AZ-FE) 

    HINT: 

    Refer to the instructions for Installation of the generator assembly. Refer to INSTALLATION - Step 1 .

  10. INSTALL FRONT WHEEL RH 

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

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  12. REMOVE CENTER COWL TOP VENTILATOR LOUVER  . Refer to REPLACEMENT - Step 1
  13. FILL RESERVOIR WITH BRAKE FLUID  . Refer to REPLACEMENT - Step 2
  14. BLEED BRAKE MASTER CYLINDER  . Refer to BLEEDING - Step 3
  15. BLEED BRAKE LINE  . Refer to REPLACEMENT - Step 3
  16. BLEED BRAKE ACTUATOR  . Refer to BLEEDING - Step 5
  17. INSPECT BRAKE FLUID LEVEL  . Refer to ON-VEHICLE INSPECTION - Step 1
  18. INSPECT FOR BRAKE FLUID LEAK 
  19. INSTALL CENTER COWL TOP VENTILATOR LOUVER  . Refer to REPLACEMENT - Step 6
  20. INSPECT ACTUATOR USING TECHSTREAM 

    Refer to ON-VEHICLE INSPECTION 

  21. PERFORM YAW RATE AND ACCELERATION SENSOR ZERO POINT CALIBRATION 
  22. CHECK FOR SENSOR SIGNAL 
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