BRAKE ACTUATOR (w/ VSC): Installation

INSTALL BRAKE ACTUATOR
1. Install the brake actuator to the brake actuator bracket assembly with the 3 bolts.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  NOTE:
  - Do not remove the hole plugs before installing a new brake actuator because the brake actuator is filled with brake fluid.
  - Do not carry the brake actuator by the connector.
  - Tighten the 3 bolts in the order shown in the illustration.
  Fig 1: Identifying Brake Actuator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE ACTUATOR WITH BRACKET
1. Install the brake actuator with bracket to the body with the 2 bolts and nut.
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
  NOTE:
  - Do not damage the brake lines or wire harness.
  - Tighten the 2 bolts and nut in the order shown in the illustration.
  Fig 2: Locating Brake Actuator Bolts And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily tighten each brake line to the correct positions of the brake actuator with bracket as shown in the illustration.
  HINT:
  - *1: To front wheel cylinder RH
  - *2: To front wheel cylinder LH
  - *3: To rear wheel cylinder RH
  - *4: To rear wheel cylinder LH
  - *5: From 1st of master cylinder
  - *6: From 2nd of master cylinder
  Fig 3: Identifying Brake Line Tags Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a union nut wrench (10 mm), fully tighten each brake line.
  Torque: without a union nut wrench
  
  15 N*m (155 kgf*cm, 11 ft.*lbf)
  
  with a union nut wrench
  
  14 N*m (143 kgf*cm, 10 ft.*lbf)
  NOTE:
  - Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
  - This torque value is effective when the union nut wrench is parallel to the torque wrench.
  Fig 4: Tightening Brake Line Using Union Nut Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the brake line clamp with the bolt.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 5: Locating Brake Line Clamp With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the actuator connector.
  NOTE: Make sure that the connector is locked securely.
  
  Fig 6: Connecting Actuator Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WINDSHIELD WASHER JAR ASSEMBLY
1. Install the windshield washer jar assembly and clamp to the body with the 2 bolts.
  Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
  
  Fig 7: Locating Windshield Washer Jar Assembly Clamp And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the bolt and connect the washer hoses and motor connectors.
  Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
  
  Fig 8: Locating Bolt, Connect Washer Hoses And Motor Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR RESERVE TANK SUB-ASSEMBLY
1. Install the radiator reserve tank sub-assembly with the 3 bolts.
  Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
INSTALL FRONT BUMPER ASSEMBLY (See INSTALLATION )
INSTALL RADIATOR GRILLE PROTECTOR (See INSTALLATION )
INSTALL NO. 4 ENGINE UNDER COVER (See INSTALLATION )

Fig 9: Locating Radiator Reserve Tank Sub-Assembly With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT WHEEL RH
INSTALL GENERATOR ASSEMBLY (for 2ZR-FE) (See INSTALLATION )
INSTALL GENERATOR ASSEMBLY (for 2AZ-FE) (See INSTALLATION )
INSTALL V-RIBBED BELT (for 2ZR-FE) (See INSTALLATION )
ADJUST V-RIBBED BELT (for 2ZR-FE) (See INSTALLATION )
INSPECT V-RIBBED BELT (for 2ZR-FE) (See ON-VEHICLE INSPECTION )
INSTALL V-RIBBED BELT (for 2AZ-FE) (See ON-VEHICLE INSPECTION )
INSTALL ENGINE UNDER COVER RH
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
REMOVE CENTER COWL TOP VENTILATOR LOUVER (See BRAKE FLUID )
FILL UP BRAKE FLUID RESERVOIR (See REPLACEMENT )
BLEED BRAKE MASTER CYLINDER (See BLEEDING )
BLEED BRAKE LINE (See REPLACEMENT )
BLEED BRAKE ACTUATOR (See BLEEDING )
INSPECT BRAKE FLUID LEVEL (See BRAKE FLUID )
INSPECT FOR BRAKE FLUID LEAK
INSTALL CENTER COWL TOP VENTILATOR LOUVER (See REPLACEMENT )
INSPECT ACTUATOR WITH TECHSTREAM

(See ON-VEHICLE INSPECTION )