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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 Brake Actuator Assembly Nuts
      G05202798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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, LICENSE AGREEMENT TMS1002
    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) 

    5. Using SST, connect each brake tube to the correct positions on top of the actuator assembly with bracket as shown in the illustration.
      Fig 3: Connecting Front Brake No.8 Tube To Front Flexible Hose
      G05276962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09023-00101 

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

      Fig 4: Connecting Brake Tube To Actuator Assembly With Bracket
      G05276963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 Bolt
      G05276964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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, LICENSE AGREEMENT TMS1002
    2. Install the 2 reservoir tubes with the 2 clips.
      Fig 7: Locating Reservoir Tubes Clips
      G05276966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the brake actuator hose with the 2 clips.
    4. Install the brake actuator hose to the clamp.
      NOTE: Install the brake actuator hose with the edges of the protector and clamp aligned.
      Fig 8: Identifying Warning Switch Connector, Brake Actuator Hose, Clamp And Protector
      G05276948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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, LICENSE AGREEMENT TMS1002
  15. CLEAR DTC  (See DTC CHECK / CLEAR )
  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 DTC CHECK / CLEAR )
  20. PERFORM LINEAR VALVE OFFSET LEARNING  (See INITIALIZATION )
  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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