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Installation [10/2016 - 09/2020]: 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 [10/2016 - 09/2020]
      GTY663662Courtesy 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.
      Fig 2: Brake Actuator With Bracket Tightening Sequence [10/2016 - 09/2020]
      GTY641230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.

    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 tighten the 3 brake lines to the correct position on the brake actuator assembly as shown in the illustration.
      GTY658649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a To Front Wheel Cylinder Assembly RH
      *b To Rear Wheel Cylinder Assembly RH
      *c To Rear Wheel Cylinder Assembly LH
    4. 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 vehicle body during tightening.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.
      GTY620766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      HINT: 

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

        Refer to PRECAUTION [10/2016 - 10/2017] , or refer to PRECAUTION [10/2017 - 09/2020]

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        13.38 N.m (136 kgf/cm, 10 ft.lbf)

    5. Type A:
      1. Connect the connector to the brake actuator assembly and lock the lock lever.
        GTY627067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        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.
    6. Type B:
      1. Connect the connector to the brake actuator assembly and lock the lock lever.
        GTY835135Courtesy 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 FRONT NO. 5 BRAKE TUBE 
    1. Engage the clamp to install the front No. 5 brake tube.
      GTY671650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
    2. Using a union nut wrench, connect the front No. 5 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. 5 brake tube.
      • Do not allow the front No. 5 brake tube to twist or interfere with other parts or vehicle body during tightening.
      • Do not allow any foreign matter such as dirt or dust to enter the front No. 5 brake tube from the connecting parts.

      HINT: 

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

        Refer to PRECAUTION [10/2016 - 10/2017] , or refer to PRECAUTION [10/2017 - 09/2020]

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        17.36 N.m (177 kgf/cm, 13 ft.lbf)

  6. INSTALL FRONT NO. 1 BRAKE TUBE 
    1. Engage the clamp to install the front No. 1 brake tube.
      GTY654170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
    2. 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 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 [10/2016 - 10/2017] , or refer to PRECAUTION [10/2017 - 09/2020]

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        17.36 N.m (177 kgf/cm, 13 ft.lbf)

  7. INSTALL FRONT NO. 3 BRAKE TUBE 
    1. Install the front No. 3 brake tube to the vehicle body, and engage the grommet.
      GTY618707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Flexible Hose
      *2 Grommet
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
      NOTE:
      • Do not kink or damage the front No. 3 brake tube.
      • Do not allow any foreign matter such as dirt or dust to enter the front No. 3 brake tube from the connecting parts.
      • Ensure that the front No. 3 brake tube passes through the center of the grommet.
    2. Using a union nut wrench, connect the front No. 3 brake tube to the front flexible hose.

      Specified tightening torque 

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

      NOTE:

      Do not allow the front No. 3 brake tube to twist or interfere with other parts or vehicle body during tightening.

      HINT: 

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

        Refer to PRECAUTION [10/2016 - 10/2017] , or refer to PRECAUTION [10/2017 - 09/2020]

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        13.38 N.m (136 kgf/cm, 10 ft.lbf)

    3. Engage the clamp.
      GTY636161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
    4. Using a union nut wrench, connect the front No. 3 brake tube to the brake actuator assembly.

      Specified tightening torque 

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

      NOTE:

      Do not allow the front No. 3 brake tube to twist or interfere with other parts or vehicle body during tightening.

      HINT: 

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

        Refer to PRECAUTION [10/2016 - 10/2017] , or refer to PRECAUTION [10/2017 - 09/2020]

      • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        13.38 N.m (136 kgf/cm, 10 ft.lbf)

  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 2

  10. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  11. INSTALL WIRING HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 4

  12. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK ASSEMBLY 

    Refer to PROCEDURE - Step 5

  13. 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 [10/2016 - 10/2017] , or refer to INITIALIZATION [10/2017 - 09/2020]

  14. BLEED BRAKE SYSTEM 

    Refer to BLEEDING [10/2016 - 09/2020]

  15. INSTALL FRONT WHEEL LH 

    Torque: 103 N.m (1050 kgf/cm, 76 ft.lbf) 

  16. PERFORM YAW RATE AND ACCELERATION SENSOR ZERO POINT CALIBRATION AND STORE SYSTEM INFORMATION 

    Refer to CALIBRATION [10/2016 - 09/2020]

  17. PERFORM TEST MODE INSPECTION 

    Refer to TEST MODE PROCEDURE [10/2016 - 09/2020]

  18. INSPECT BRAKE ACTUATOR USING TECHSTREAM 

    Refer to ON-VEHICLE INSPECTION [04/2013 - 09/2020] 

  19. CHECK FOR AND CLEAR DTCS 

    Refer to DTC CHECK / CLEAR [10/2016 - 09/2020]

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