Installation [09/2017 - ]: Procedure

1. Install the 3 brake actuator bolt cushions to the brake actuator bracket assembly.

1. Install the 3 brake actuator case collars to the brake actuator bolt cushions.
   NOTE:

   Make sure the collars are in full contact with the cushions.

1. Temporarily install the brake actuator bracket assembly to the brake actuator with the 3 bolts.
   Fig 1: Brake Actuator Bracket Assembly Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Do not remove the hole plugs of a new brake actuator before connecting the 6 brake lines because the brake actuator is filled with brake fluid.
   • Do not hold the actuator by the connector.
   • If the actuator is dropped, replace it.
2. Tighten the 3 bolts in the order shown in the illustration.

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

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

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

1. Temporarily install the brake actuator assembly with bracket with the 2 bolts and nut.
   NOTE:

   • Do not damage the brake tubes.
   • Do not hold the brake actuator assembly with bracket by the connector.

   HINT: 

   Install the brake actuator with bracket while avoiding the brake lines.

   Fig 2: Brake Actuator Assembly With Bracket Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tighten the 2 bolts and nut in the order shown in the illustration.

   Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

3. Temporarily connect the 4 brake tubes to the correct positions on the brake actuator assembly as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	From Front Master Cylinder
   *b	From Rear Master Cylinder
   *c	To Front Wheel Cylinder Assembly RH
   *d	To Front Wheel Cylinder Assembly LH
   *e	To Rear Wheel Cylinder Assembly RH
   *f	To Rear Wheel Cylinder Assembly LH

4. Using a union nut wrench, fully tighten each brake tube.

   Specified tightening torque 

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

   NOTE:

   • Do not kink or damage the brake tubes.
   • Do not allow the brake tubes 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 tubes from the connecting parts.

   HINT: 

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

     Refer to PRECAUTION [10/2015 - ]

   • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.378 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Torque Wrench Fulcrum Length

5. Connect the connector to the brake actuator assembly and lock the lock lever.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Lock Lever Locked

   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.

1. Using a union nut wrench, connect the rear No. 1 brake tube to the brake actuator assembly.

   Specified tightening torque 

   Torque: 19.5 N*m (199 kgf*cm, 14 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 [10/2015 - ]

   • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.378 in.)): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Torque Wrench Fulcrum Length

2. Attach the clamp to install the rear 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: 19.5 N*m (199 kgf*cm, 14 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 [10/2015 - ]

   • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.378 in.)): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Torque Wrench Fulcrum Length

2. Attach the clamp to install the front No. 1 brake tube.

1. Install the grommet of the front No. 3 brake tube to the body.
   NOTE:

   Make sure that the grommet is securely attached to the body.

2. Hold the flexible hose in place with a wrench and connect the front No. 3 brake tube to the flexible hose using a union nut wrench.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Torque Wrench Fulcrum Length

   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 and interfere with other parts or 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 [10/2015 - ]

   • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.378 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)
3. Attach the clamp to install the front No. 3 brake tube.

1. Connect the union to check valve hose to the brake booster assembly, and slide the clip to secure it.

Refer to INSTALLATION [09/2017 - ]

1. Install the No. 3 engine room relay block with the bolt and nut.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

Refer to PROCEDURE - Step 2

Refer to BLEEDING [09/2017 - ]

Refer to PROCEDURE - Step 1

1. Engage the guide to install the engine room side cover LH.
2. Install the 2 clips.

Refer to CALIBRATION [09/2017 - ]

Refer to TEST MODE PROCEDURE [09/2017 - ]

Refer to ON-VEHICLE INSPECTION [10/2015 - ] 

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