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Brake Actuator: Installation

  1. INSTALL BRAKE ACTUATOR ASSEMBLY 
    1. Install the brake actuator assembly with bracket to the body with the 3 nuts.

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

      NOTE: Do not damage the brake tubes.
      Fig 1: Locating Nuts And Brake Actuator Assembly
      G05202798Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    2. Connect the brake actuator connector.
      NOTE: Make sure that the connector is locked securely.
    3. Install the brake tube bracket with the bolt.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      Fig 2: Installing Brake Tube Bracket With Bolt
      G05276961Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    4. Connect the front brake No. 8 tube to the front flexible hose.

      SST 09023-00101 

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

      Fig 3: Connecting Front Brake No.8 Tube To Front Flexible Hose
      G05276962Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    5. Using SST, connect each brake tube to the correct positions on top of the actuator assembly with bracket as shown in the illustration.

      SST 09023-00101 

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

      Fig 4: Identifying Brake Tube Correct Positions On Top Of Actuator Assembly With Bracket
      G05276963Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    6. Install the brake actuator bracket No. 7 with clamp with the bolt.

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

      Fig 5: Locating Brake Actuator Bracket No.7 With Clamp And Bolt
      G05276964Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  2. INSTALL FRONT WHEEL RH 

    Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 

  3. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Install the brake master cylinder reservoir assembly with the 2 bolts.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      Fig 6: Locating Brake Master Cylinder Reservoir Assembly Bolts
      G05202792Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    2. Install the 2 reservoir tubes with the 2 clips.
      Fig 7: Locating Reservoir Tubes With Clips
      G05276966Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Install the brake actuator hose with the 2 clips.
      4. Fig 8: Identifying Warning Switch Connector, Clips And Brake Actuator Hose
      G05276948Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    4. Install the brake actuator hose to the clamp.
      NOTE: Install the brake actuator hose with the edges of the protector and clamp aligned.
    5. Connect the warning switch connector.
  4. INSTALL COWL PANEL SUB-ASSEMBLY  (See INSTALLATION )
  5. INSTALL WIND SHIELD WIPER MOTOR ASSEMBLY  (See INSTALLATION )
  6. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 
  7. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  8. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  9. INSTALL FRONT FENDER TO COWL SIDE SEAL LH 
  10. INSTALL FRONT FENDER TO COWL SIDE SEAL RH 
  11. FILL RESERVOIR WITH BRAKE FLUID  (See BLEEDING )
  12. BLEED BRAKE ACTUATOR HOSE  (See BLEEDING )
  13. BLEED FRONT BRAKE SYSTEM  (See BLEEDING )
  14. INSTALL ABS MOTOR RELAY 
    1. Install the 2 ABS motor relays.
      2. Fig 9: Locating ABS Motor Relays
      G05202789Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  15. CLEAR DTC  (See BLEEDING )
  16. BLEED REAR BRAKE SYSTEM  (See BLEEDING )
  17. PERFORM ACCUMULATOR ZERO DOWN  (See BLEEDING )
  18. CHECK BRAKE FLUID LEVEL  (See BLEEDING )
  19. CLEAR DTC  (See BLEEDING )
  20. PERFORM LINEAR VALVE OFFSET LEARNING  (See BLEEDING )
  21. INSPECT FOR BRAKE FLUID LEAK 
  22. PERFORM INITIALIZATION 

    Some systems need initialization after reconnecting the cable to the negative battery terminal.

    (See INITIALIZATION )

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