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Installation [09/2015 - ]: Procedure

  1. INSTALL BRAKE ACTUATOR 
    NOTE:

    Do not remove the hole plug before installing a new brake actuator because the brake actuator is filled with brake fluid.

    1. Install the No. 3 brake actuator bracket to the brake actuator with the 3 bolts.
      GTY121070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

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

      GTY629025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Brake Actuator
      *2 No. 3 Bracket
    2. Install the 3 cushions and 3 spacers to the bracket.
      GTY672890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Cushion
      *2 Spacer
      GTY413313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Bracket
      *2 Cushion
      *3 Spacer
    3. Install the brake actuator bracket to the brake actuator with the 3 bolts.
      GTY679517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  2. INSTALL BRAKE ACCUMULATOR PUMP 
    1. Install the brake booster pump collar (labeled A) and brake booster pump bush (labeled B) to the brake accumulator pump.
      GTY656623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

      GTY648043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Actuator Bracket
      *2 Brake Accumulator Pump
      *3 Collar (A)
    3. Install the brake booster pump bush (labeled C) and a new brake actuator bracket clamp (labeled D) to the brake accumulator pump.
      GTY654440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Brake Accumulator Pump
      *2 Clamp (D)
      *3 Bush (C)
      NOTE:

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

  3. INSTALL NO. 4 BRAKE ACTUATOR BRACKET 
    1. Install the No. 4 brake actuator bracket to the brake actuator with the bolt.
      GTY679518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  4. CONNECT BRAKE ACCUMULATOR PUMP CONNECTOR BOX 
    1. Connect the brake accumulator pump connector box as follows:
      GTY637563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Connector Box
      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).
  5. INSTALL NO. 3 BRAKE ACTUATOR TUBE 
    NOTE:
    • Do not damage the No. 3 brake actuator tube, brake actuator and brake accumulator pump.
    • When installing the No. 3 brake actuator tube, hold the tube, brake actuator and brake accumulator pump securely.
    • When tightening the nut, make sure that other parts do not move with the nut.
    1. Using a union nut wrench, connect the No. 3 brake actuator tube.
      GTY623389Courtesy 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 [09/2015 - ] ).

  6. INSTALL NO. 2 BRAKE ACTUATOR HOSE 
    NOTE:

    Do not remove the cap installed to the reservoir connector until it is connected to the reservoir.

    1. Install the reservoir connector to the No. 2 brake actuator hose with the hose clip as shown in the illustration.
      GTY110822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      GTY673751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Length "A"

      4.0 to 7.0 mm (0.158 to 0.276 in.)

      TEXT IN ILLUSTRATION

      *1 Reservoir Connector
      *a View B
      *b View C
      *c Paint Mark
      *d 30°to 60°
    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.
      GTY640875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Rear

      HINT: 

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

      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).

    3. Connect the No. 2 brake actuator hose to the No. 3 brake actuator bracket with the clamp.
  7. INSTALL BRAKE ACTUATOR PROTECTOR 
    1. Install the protector.
      GTY685722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 1 BRAKE ACTUATOR HOSE 
    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.
      GTY615940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Rear

      HINT: 

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

      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).

  9. INSTALL NO. 5 BRAKE ACTUATOR BRACKET 
    1. Install the No. 5 brake actuator bracket to the body with the bolt.
      GTY674098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  10. INSTALL BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY 
    1. Install the brake actuator and brake accumulator pump to the body with the bolt (labeled A) and 2 nuts (labeled B).

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

      HINT: 

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

      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.
      GTY663347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the front fender liner rear side.
    3. Connect the No. 1 brake actuator hose to the body with the clamp.
      GTY685964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the brake actuator connector.
      GTY121061Courtesy 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 connector is locked securely.
  11. CONNECT BRAKE TUBE 
    1. Using a union nut wrench, connect the No. 1 (labeled A) and No. 2 (labeled B) brake actuator tubes.
      GTY629365Courtesy 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 [09/2015 - ] ).
      • 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.
      GTY680359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • *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.
      GTY623387Courtesy 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 [09/2015 - ] ).

  12. INSTALL FRONT WHEEL 

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

  13. INSTALL RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 5

  14. INSTALL NO. 1 RESERVOIR HOSE 

    Refer to PROCEDURE - Step 6

  15. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 7

  16. CONNECT NO. 3 RELAY BLOCK 
    1. Install the No. 3 relay block to the reservoir bracket.
      GTY613938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

  17. INSTALL SKID CONTROL ECU BRACKET 

    (See step  1)

  18. INSTALL SKID CONTROL ECU 

    (See step  2)

  19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:
    • Make sure that the 2 accumulator pump connectors are disconnected.
    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Refer to INITIALIZATION [09/2015 - ] ).
  20. BLEEDING PRECAUTION 
    WARNING:

    Be sure to read the Precaution thoroughly before bleeding (Refer to PRECAUTION [09/2015 - ] ).

  21. PERFORM ACCUMULATOR ZERO DOWN 

    Refer to PROCEDURE - Step 4

  22. FILL RESERVOIR WITH BRAKE FLUID 

    Refer to PROCEDURE - Step 1

  23. BLEED BRAKE SYSTEM 

    Refer to PROCEDURE - Step 2

  24. PERFORM ACCUMULATOR ZERO DOWN 

    Refer to PROCEDURE - Step 4

  25. INSPECT AND ADJUST BRAKE FLUID LEVEL IN RESERVOIR 

    Refer to PROCEDURE - Step 1

  26. INSPECT FOR BRAKE FLUID LEAK 

    (Refer to ON-VEHICLE INSPECTION [09/2015 - ] )

  27. CLEAR DTC 

    (Refer to DTC CHECK / CLEAR [09/2015 - ] )

  28. PERFORM LINEAR VALVE OFFSET LEARNING 
    1. When the brake actuator is replaced, perform the linear valve offset learning (Refer to INITIALIZATION [09/2015 - ] ).
  29. CHECK FOR DTC 
    1. If any DTC is set, perform the troubleshooting for the DTC (Refer to DIAGNOSTIC TROUBLE CODE CHART [09/2015 - ] ).
  30. READ VALUE OF ACCUMULATOR PRESSURE SENSOR OUTPUT VOLTAGE 

    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.

      GTY623389Courtesy 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 [09/2015 - ] ).

  31. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    (Refer to INSTALLATION [09/2015 - ] )

  32. INSTALL COWL TOP VENTILATOR LOUVER RH 

    Refer to PROCEDURE - Step 17

  33. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

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