Brake Actuator: Installation

INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY
1. Install the actuator bracket with the 3 bolts in the sequence shown in the illustration.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
Fig 1: Identifying Brake Actuator Bracket Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE ACTUATOR ASSEMBLY
1. Install the brake actuator with bracket with the 3 nuts in the sequence shown in the illustration.
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
  
  Fig 2: Locating Brake Actuator Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful not to damage the brake tubes and wire harness.
2. Temporarily install each brake tube in the correct positions of the brake actuator as shown in the illustration.
  
  Fig 3: Identifying RR Master Cylinder And FR Master Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a union nut wrench, install the 6 brake tubes onto the brake actuator.
  1. for 12 mm flare nuts :
    Torque: without union nut wrench
    
    20 N*m (199 kgf*cm, 14 ft.*lbf)
    
    with union nut wrench
    
    18 N*m (187 kgf*cm, 13 ft.*lbf)
    
    Fig 4: Identifying Fulcrum Length
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    HINT:
    - This torque value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.8 in.) and a union nut wrench with a fulcrum length of 20 mm (0.787 in.) (See REPAIR INSTRUCTION ).
    - This torque value is effective when the union nut wrench is parallel to the torque wrench.
  2. for 10 mm flare nuts :
    Torque: without union nut wrench
    
    15 N*m (155 kgf*cm, 11 ft.*lbf)
    
    with union nut wrench
    
    14 N*m (145 kgf*cm, 10 ft.*lbf)
  HINT:
  - This torque value can be obtained by using a torque wrench with a fulcrum length of 300 mm (11.8 in.) and a union nut wrench with a fulcrum length of 22 mm (0.866 in.) (See REPAIR INSTRUCTION ).
  - This torque value is effective when the union nut wrench is parallel to the torque wrench.
4. Connect the brake actuator connector.
5. Lock the connector lock lever.
NOTE: Make sure that the lever is locked securely.
INSTALL AIR INJECTION CONTROL DRIVER (for 2TR-FE)
1. Install the air injection control driver with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 5: Locating Air Injection Control Driver And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the 2 connectors.
INSTALL AIR CLEANER CASE (for 2TR-FE) (See INSTALLATION )
INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for 2TR-FE)
INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2TR-FE) (See INSTALLATION )

Fig 6: Locating Connector Location
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
FILL RESERVOIR WITH BRAKE FLUID (See BRAKE FLUID (FOR VACUUM BRAKE BOOSTER) )
BLEED MASTER CYLINDER (See BRAKE FLUID (FOR VACUUM BRAKE BOOSTER) )
BLEED BRAKE LINE (See REPLACEMENT )
BLEED BRAKE ACTUATOR (See REPLACEMENT )
INSPECT FLUID LEVEL IN RESERVOIR (See BRAKE FLUID (FOR VACUUM BRAKE BOOSTER) )
INSPECT FOR BRAKE FLUID LEAK
CHECK BRAKE ACTUATOR WITH TECHSTREAM
(See ON-VEHICLE INSPECTION )
PERFORM YAW RATE AND ACCELERATION SENSOR ZERO POINT CALIBRATION
(See CALIBRATION )
CHECK AND CLEAR DTC
(See DTC CHECK/CLEAR )