BRAKE ACTUATOR (w/o VSC): Installation

1. INSTALL BRAKE ACTUATOR 
   1. Install the brake actuator assembly 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 assembly by the connector.
      • Tighten the 3 bolts in the order shown in the illustration.
      Fig 1: Locating Brake Actuator Assembly Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 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 assembly 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 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
3. INSTALL RADIATOR RESERVE TANK ASSEMBLY 
   1. Install the radiator reserve tank assembly with the 3 bolts.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

      Fig 7: Locating Radiator Reserve Tank Assembly Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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 8: Locating Windshield Washer Jar Assembly Clamp And Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Install the bolt and connect the washer hoses and 2 connectors.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 9: Locating Bolt, Washer Hoses And Motor Connectors

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. INSTALL FRONT BUMPER ASSEMBLY  (See INSTALLATION )
6. INSTALL RADIATOR GRILLE PROTECTOR  (See INSTALLATION )
7. INSTALL NO. 4 ENGINE UNDER COVER (for 2AZ-FE)  (See INSTALLATION )
8. INSTALL GENERATOR ASSEMBLY (for 2ZR-FE)  (See INSTALLATION )
9. INSTALL GENERATOR ASSEMBLY (for 2AZ-FE)  (See INSTALLATION )
10. INSTALL V-RIBBED BELT (for 2ZR-FE)  (See INSTALLATION )
11. INSTALL V-RIBBED BELT (for 2AZ-FE)  (See ON-VEHICLE INSPECTION )
12. ADJUST V-RIBBED BELT (for 2ZR-FE)  (See INSTALLATION )
13. INSPECT V-RIBBED BELT (for 2ZR-FE)  (See ON-VEHICLE INSPECTION )
14. INSTALL ENGINE UNDER COVER RH 
15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
16. REMOVE CENTER COWL TOP VENTILATOR LOUVER  (See BRAKE FLUID )
17. FILL BRAKE FLUID RESERVOIR  (See REPLACEMENT )
18. BLEED BRAKE MASTER CYLINDER  (See BLEEDING )
19. BLEED BRAKE LINE  (See REPLACEMENT )
20. INSPECT BRAKE FLUID LEVEL  (See BRAKE FLUID )
21. INSPECT FOR FLUID LEAK 
22. INSTALL CENTER COWL TOP VENTILATOR LOUVER  (See REPLACEMENT )
23. INSPECT ACTUATOR WITH TECHSTREAM 

(See ON-VEHICLE INSPECTION )