Brake Actuator: Installation

1. Install the No. 3 brake actuator bracket to the brake actuator with the 3 bolts.

   Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf) 

   NOTE: Temporarily install either bolt A or B first.
   Fig 1: Locating Brake Actuator Bracket To Brake Actuator With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 3 cushions and 3 spacers to the bracket.
   Fig 2: Identifying Cushions And Spacers To Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the brake actuator bracket to the brake actuator with the 3 bolts.

   Torque: 9.2 N*m (94 kgf*cm, 81 in.*lbf) 

   Fig 3: Identifying Brake Actuator Bracket And Brake Actuator With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the brake booster pump collars (labeled A) and brake booster pump bushes (labeled B) to the brake accumulator pump.
2. Install the brake accumulator pump to the brake actuator bracket.
   NOTE: After installing the brake accumulator pump, make sure the collar has not fallen off.
3. Install the brake booster pump bush (labeled C) and a new brake actuator bracket clamp (labeled D) to the brake accumulator pump.
   NOTE: Make sure to securely insert the brake accumulator pump until the claws of the clamp are attached.
   Fig 4: Identifying Brake Accumulator Pump Collar And Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 4 brake actuator bracket to the brake actuator with the bolt.

   Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

   Fig 5: Identifying Brake Actuator Bracket And Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the brake accumulator pump connector box.
   1. Install the connector box with the nut.

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

   2. Attach the wiring harness clamp.
      Fig 6: Identifying Brake Accumulator Pump Connector Box And Nut

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a union nut wrench, connect the No 3 brake actuator tube.

   Torque: without union nut wrench 

   15 N*m (155 kgf*cm, 11 ft.*lbf) 

   with union nut wrench 

   14 N*m (145 kgf*cm, 10 ft.*lbf) 

   NOTE:

   • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
   • The torque value for use with a union nut wrench is effective when the union nut wrench is parallel to the torque wrench.
   Fig 7: Identifying Brake Actuator Hose And Union Nut Wrench With Fulcrum Length

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the reservoir connector to the No. 2 brake actuator hose with the hose clip as shown in the illustration

   Length "A": 

   4.0 to 7.0 mm (0.157 to 0.276 in.) 

   Fig 8: Identifying Reservoir Connector To Brake Actuator Hose With Hose Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. With the paint mark on the hose's tip facing the bottom of the vehicle, install the No. 2 brake actuator hose to the brake accumulator pump with the hose clip.
   NOTE: When inserting the hose, be careful that there is no excessive weight applied to the union of the brake accumulator pump (especially in the union rotation direction).
   Fig 9: Identifying Brake Actuator Hose And Hose Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Install the hose clip so that its claws face the rear of the vehicle.

3. Connect the No. 2 brake actuator hose to the No. 3 brake actuator bracket with the clamp.

1. Install the protector.
   Fig 10: Identifying Brake Actuator Protector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. With the paint mark on the hose's tip facing the bottom of the vehicle, install the No. 1 brake actuator hose to the brake actuator with the hose clip.
   NOTE: When inserting the hose, be careful that there is no excessive weight applied to the union of the brake actuator (especially in the union rotation direction).

   HINT:

   Install the hose clip so that its claws face the rear of the vehicle.

   Fig 11: Identifying Brake Actuator Hose And Hose Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 5 brake actuator bracket to the body with the bolt.

   Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

   Fig 12: Identifying Brake Actuator Bracket And Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the brake actuator and brake accumulator pump to the body with the bolt and 2 nuts
   NOTE:

   • Do not damage the brake tubes.
   • When installing the brake actuator and brake accumulator pump to the vehicle, do not hold the connector, harness, hose or tube parts.
   • Do not drop the brake actuator and brake accumulator pump. Do not use parts that have been dropped.
     Fig 13: Locating Brake Actuator And Brake Accumulator Pump With Bolt And Nuts

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   First insert the bracket bottom's longer stud bolt (vehicle outer side, labeled A) into the body.

   Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

2. Connect the front fender liner rear side.
3. Connect the No 1 brake actuator hose to the body with the clamp.
   Fig 14: Identifying No 1 Brake Actuator Hose From Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a union nut wrench, connect the No. 1 (labeled A) and No 2 (labeled B) brake actuator tubes.

   Torque: without union nut wrench 

   15 N*m (155 kgf*cm, 11 ft.*lbf) 

   with union nut wrench 

   14 N*m (145 kgf*cm, 10 ft.*lbf) 

   NOTE:

   • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
   • The torque value for use with a union nut wrench is effective when the union nut wrench is parallel to the torque wrench.
   • Do not damage the No. 1 and No. 2 brake actuator tubes.
     Fig 15: Identifying Union Nut Wrench With Fulcrum Length

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set each brake tube to the correct positions on the brake actuator as shown in the illustration
   Fig 16: Identifying Brake Tube To Correct Positions On Brake Actuator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a union nut wrench, connect the 6 brake tubes

   Torque: without union nut wrench 

   15 N*m (155 kgf*cm, 11 ft.*lbf) 

   with union nut wrench 

   14 N*m (145 kgf*cm, 10 ft.*lbf) 

   NOTE:

   • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
   • The torque value for use with a union nut wrench is effective when the union nut wrench is parallel to the torque wrench.
     Fig 17: Identifying Brake Tubes And Union Nut Wrench With Fulcrum Length

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

   • Before connecting the vehicle wire harnesses, make sure that the connector faces are free of foreign matter.
   • Make sure that the connector is locked securely.
     Fig 18: Locating Brake Actuator Connector

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 140 N*m (1428 kgf*cm, 103 ft.*lbf) 

1. Install the No. 3 relay block to the reservoir bracket.
   NOTE: Make sure that the claw of the No. 3 relay block is securely attached to the reservoir bracket.
   Fig 19: Locating No 3 Relay Block To Reservoir Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the 2 brake accumulator pump connectors.
   Fig 20: Locating Brake Accumulator Pump Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Before connecting the vehicle wire harnesses, make sure that the connector faces are free of foreign matter.
   • Make sure that the connectors are locked securely.

1. When the brake actuator is replaced, perform the linear valve offset learning (see INITIALIZATION  ).

1. Check for DTC If any DTC is output, perform the troubleshooting for that DTC (see DIAGNOSTIC TROUBLE CODE CHART  ).

HINT:

If removing and installing the No. 3 brake actuator tube, check for a brake fluid leak from the No. 3 tube connection area by monitoring the accumulator pressure sensor output value from the brake actuator. Directly checking for a brake fluid leak from the No. 3 tube connection area is difficult.

1. Turn the power switch OFF.
2. Connect the Intelligent tester or Techstream to the DLC3.
3. Turn the power switch ON (IG).
4. Operate the Intelligent tester or Techstream according to the display and select "DATA LIST".

   Skid control ECU 

   Intelligent tester 

   SKID CONTROL ECU REFERENCE
   
   

   Tester Display	Measurement Item/Range	Normal Condition	Diagnostic Note
   ACC PRESS SENS	Accumulator pressure sensor/ min.: 0 V, max.. 5 V	Specified value. 2.6 to 3 8 V	-

   Techstream 

   VOLTAGE SPECIFICATION
   
   

   Tester Display	Measurement Item/Range	Normal Condition	Diagnostic Note
   Accumulator Pressure Sensor	Accumulator pressure sensor/ min.. 0 V, max.: 5 V	Specified value 2 6 to 3 8 V	-

5. Depress the brake pedal 4 or 5 times to operate the pump motor, and check the output value on the Intelligent tester or Techstream with the motor stopped (not braking).

   OK: Accumulator pressure sensor's output voltage drops 0.2 V or less for 30 seconds. 

   If the voltage drops more than 0.2 V, there may be a brake fluid leak from the No 3 brake actuator tube connection area. Remove the brake actuator and brake accumulator pump, and then repeat the procedures above from the retightening of the 2 union nuts of the No 3 brake actuator tube.

   Fig 21: Identifying Brake Actuator Tube And Union Nut Wrench With Fulcrum Length

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: without union nut wrench 

   15 N*m (155 kgf*cm, 11 ft.*lbf) 

   with union nut wrench 

   14 N*m (145 kgf*cm, 10 ft.*lbf) 

   NOTE:

   • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
   • The torque value for use with a union nut wrench is effective when the union nut wrench is parallel to the torque wrench.