Brake Actuator: Installation: Installation

1. Install the No. 3 brake actuator bracket to the brake actuator with the 3 bolts.
   Fig 1: Identifying No. 3 Brake Actuator Bracket With Bolts

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

   NOTE:

   After temporarily installing either bolt A or B, tighten the remaining bolts.

   Fig 2: Locating No. 3 Brake Actuator Bracket And Brake Actuator With Bolts

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2. Install the 3 cushions and 3 spacers to the bracket.
   Fig 3: Identifying Brake Actuator Bracket Cushions And Spacers

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   Fig 4: Identifying Bracket, Cushion And Spacer

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3. Install the brake actuator bracket to the brake actuator with the 3 bolts.
   Fig 5: Identifying Brake Actuator Bracket And Brake Actuator With Bolts

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

1. Install the brake booster pump collar (labeled A) and brake booster pump bush (labeled B) to the brake accumulator pump.
   Fig 6: Locating Brake Accumulator Pump Bush, Collar And Clamp

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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.

   Fig 7: Installing Brake Accumulator Pump To Brake Actuator Bracket

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3. Install the brake booster pump bush (labeled C) and a new brake actuator bracket clamp (labeled D) to the brake accumulator pump.
   Fig 8: Identifying Brake Accumulator Clamp

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   NOTE:

   Make sure to securely insert the brake accumulator pump until the claws of the clamp are attached.

1. Install the No. 4 brake actuator bracket to the brake actuator with the bolt.
   Fig 9: Identifying No. 4 Brake Actuator Bracket Bolt

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

1. Connect the brake accumulator pump connector box as follows:
   Fig 10: Identifying Brake Accumulator Pump Connector Box With Nut And Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Install the connector box with the nut (labeled A).

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

   2. Attach the wiring harness clamp (labeled B).

1. Using a union nut wrench, connect the No. 3 brake actuator tube.
   Fig 11: No. 3 Brake Actuator Tube Connection Area

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   NOTE:

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench. Refer to PRECAUTION .

1. Install the reservoir connector to the No. 2 brake actuator hose with the hose clip as shown in the illustration.
   Fig 12: Identifying Hose Clip And Reservoir Connector

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   Fig 13: Identifying Reservoir Connector

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   Length "A"

   4.0 to 7.0 mm (0.158 to 0.276 in.)

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).

   HINT: 

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

   Fig 14: Identifying No. 2 Brake Actuator Hose Clip

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

1. Install the protector.
   Fig 15: Locating Brake Actuator Protector

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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 16: Identifying No. 1 Brake Actuator Hose And Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 5 brake actuator bracket to the body with the bolt.
   Fig 17: Identifying No. 5 Brake Actuator Bracket Bolt

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

1. Install the brake actuator and brake accumulator pump to the body with the bolt (labeled A) and 2 nuts (labeled B).
   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.

   HINT: 

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

   Fig 18: Locating Brake Actuator And Brake Accumulator Pump With Bolt And Nuts

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   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 19: Identifying No. 1 Brake Actuator Hose From Clamp

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4. Connect the brake actuator connector.
   Fig 20: Connecting Brake Actuator Connector

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   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.

1. Using a union nut wrench, connect the No. 1 (labeled A) and No. 2 (labeled B) brake actuator tubes.
   Fig 21: Disconnect The No. 1 (Labeled A) And No. 2 (Labeled B) Brake Actuator Tubes

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

   NOTE:

   • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench. Refer to PRECAUTION .
   • Do not damage the No. 1 and No. 2 brake actuator tubes.
2. Set each brake tube to the correct positions on the brake actuator as shown in the illustration.
   Fig 22: Make A Note To Identify The Reconnection Locations

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   • *1: To FR RH
   • *2: To FR LH
   • *3: To: RR RH
   • *4: To RR LH
   • *5: From Master Cylinder
   • *6: From Stroke Simulator
3. Using a union nut wrench, connect the 6 brake tubes.
   Fig 23: Identifying Brake Tubes

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   NOTE:

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench. Refer to PRECAUTION .

1. Install the No. 3 relay block to the reservoir bracket.
   Fig 24: Pull Out The No. 3 Relay Block

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   NOTE:

   Check that the claw of the No. 3 relay block is securely attached to the reservoir bracket.

1. Inspect for brake fluid leak. Refer to ON-VEHICLE INSPECTION .

1. Clear the DTCs. Refer to DTC CHECK / CLEAR .

1. When the brake actuator is replaced, perform the linear valve offset learning. Refer to INITIALIZATION .

1. If any DTC is set, perform the troubleshooting for the DTC. Refer to 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 engine switch off.
2. Connect the Techstream to the DLC3.
3. Turn the engine switch on (IG).
4. Operate the Techstream according to the display and select "DATA LIST".

   Skid control ECU

   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 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 25: No. 3 Brake Actuator Tube Connection Area

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   NOTE:

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench. Refer to PRECAUTION .