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Installation [09/2014 - 11/2017]: Procedure

  1. INSTALL BRAKE ACTUATOR BOLT CUSHION 
    1. Install the 3 brake actuator bolt cushions to the brake actuator bracket assembly.
    2. Install the 3 brake actuator case collars to the brake actuator bolt cushions.
      NOTE:

      Make sure the brake actuator case collars are in full contact with the brake actuator bolt cushions.

  2. INSTALL BRAKE ACTUATOR ASSEMBLY 
    1. Temporarily install the brake actuator assembly to the brake actuator bracket assembly with the 3 bolts.
      Fig 1: Brake Actuator Assembly Tightening Sequence
      GTY514677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not remove the hole plugs of a new brake actuator assembly before connecting the brake lines because the brake actuator assembly is filled with brake fluid.
      • Do not hold the brake actuator assembly by the connector.
    2. Tighten the 3 bolts in the order shown in the illustration.

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

  3. INSTALL NO. 5 BRAKE ACTUATOR BRACKET 
    1. Install the No. 5 brake actuator bracket with the bolt.

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

  4. INSTALL BRAKE ACTUATOR WITH BRACKET 
    1. Temporarily install the brake actuator with bracket with the 2 bolts and nut.
      NOTE:
      • Do not damage the brake lines.
      • Do not hold the brake actuator with bracket by the connector.

      HINT: 

      • Install the brake actuator with bracket while avoiding the brake lines.
      • Fully tighten the 2 bolts and nut of the brake actuator with bracket after installing the brake master cylinder sub-assembly.
    2. Temporarily connect the 4 brake lines to the correct positions on the brake actuator assembly as shown in the illustration.
      GTY499127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a To Front Wheel Cylinder Assembly RH
      *b To Front Wheel Cylinder Assembly LH
      *c To Rear Wheel Cylinder Assembly RH
      *d To Rear Wheel Cylinder Assembly LH
    3. Using a union nut wrench, fully tighten each brake line.

      Specified tightening torque 

      Torque: 15.2 N.m (155 kgf/cm, 11 ft.lbf) 

      NOTE:
      • Do not kink or damage the brake lines.
      • Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [09/2014 - 11/2017]

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 250 mm (9.84 in.)):

        13.97 N.m (142 kgf/cm, 10 ft.lbf)

      GTY519146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
    4. Connect the connector to the brake actuator assembly and lock the lock lever.
      GTY510835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Connect the connector
      Lock the lock lever
      NOTE:
      • Make sure that the connector is locked securely.
      • Make sure that the actuator connector can be connected smoothly. Do not allow water, oil or dirt to enter the connector.
  5. INSTALL REAR NO. 1 BRAKE TUBE 
    1. Using a union nut wrench, connect the rear No. 1 brake tube to the brake actuator assembly.

      Specified tightening torque 

      Torque: 15.2 N.m (155 kgf/cm, 11 ft.lbf) 

      NOTE:
      • Do not kink or damage the rear No. 1 brake tube.
      • Do not allow the rear No. 1 brake tube to twist or interfere with other parts or the vehicle body during tightening.
      • Do not allow any foreign matter such as dirt or dust to enter the rear No. 1 brake tube from the connecting parts.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [09/2014 - 11/2017]

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 250 mm (9.84 in.)):

        13.97 N.m (142 kgf/cm, 10 ft.lbf)

      GTY515170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
    2. Engage the clamp to install the rear No. 1 brake tube.
  6. INSTALL FRONT NO. 1 BRAKE TUBE 
    1. Using a union nut wrench, connect the front No. 1 brake tube to the brake actuator assembly.

      Specified tightening torque 

      Torque: 15.2 N.m (155 kgf/cm, 11 ft.lbf) 

      NOTE:
      • Do not kink or damage the front No. 1 brake tube.
      • Do not allow the front No. 1 brake tube to twist or interfere with other parts or the vehicle body during tightening.
      • Do not allow any foreign matter such as dirt or dust to enter the front No. 1 brake tube from the connecting parts.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [09/2014 - 11/2017]

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 250 mm (9.84 in.)):

        13.97 N.m (142 kgf/cm, 10 ft.lbf)

      GTY497341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
    2. Engage the clamp to install the front No. 1 brake tube.
  7. SEPARATE BRAKE ACTUATOR WITH BRACKET 
    1. Remove the 2 bolts and nut, and separate the brake actuator with bracket.
      NOTE:
      • Do not damage the brake lines.
      • Do not hold the brake actuator assembly by the connector.
  8. CONNECT UNION TO CHECK VALVE HOSE 
    1. Connect the union to check valve hose to the brake booster assembly, and slide the clip to secure it.
  9. INSTALL BRAKE MASTER CYLINDER O-RING 

    Refer to PROCEDURE - Step 1

  10. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  11. INSTALL WIRING HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 3

  12. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK ASSEMBLY 

    Refer to PROCEDURE - Step 4

  13. INSTALL FRONT UPPER SUSPENSION TO COWL BRACE LH 

    Refer to PROCEDURE - Step 4 [09/2014 - 08/2016] , or refer to PROCEDURE - Step 4 [08/2016 - 11/2017]

  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [09/2014 - 08/2016] , or refer to INITIALIZATION [08/2016 - 11/2017]

  15. BLEED BRAKE SYSTEM 

    Refer to BLEEDING [09/2014 - 11/2017]

  16. INSTALL FRONT WHEEL LH 

    Refer to PROCEDURE - Step 1

  17. PERFORM YAW RATE AND ACCELERATION SENSOR AND ROLL RATE AND VERTICAL ACCELERATION SENSOR ZERO POINT CALIBRATION 

    Refer to CALIBRATION [09/2014 - 11/2017]

  18. PERFORM TEST MODE INSPECTION 

    Refer to TEST MODE PROCEDURE [09/2014 - 11/2017]

  19. INSPECT BRAKE ACTUATOR USING TECHSTREAM 

    Refer to ON-VEHICLE INSPECTION [09/2014 - 03/2019] 

  20. CHECK FOR AND CLEAR DTCS 

    Refer to DTC CHECK / CLEAR [09/2014 - 11/2017]

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