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Home >> Toyota >> 2009 >> Yaris Base, 2D Hatchback, Automatic >> Repair and Diagnosis >> Brakes >> Traction Control >> Brake Control >> Brake Actuator >> Installation

Brake Actuator: Installation

  1. INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY (for Sedan) 
    1. Install the actuator bracket with the 2 nuts.

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

      NOTE:
      • Do not remove the hole plug before connecting the brake tube. New actuators are filled with brake fluid.
      • Do not carry with the connector part of an actuator.
        Fig 1: Locating Nuts And Brake Actuator Bracket Assembly
        G04832235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY (for Hatchback) 
    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) 

      NOTE:
      • Do not remove the hole plug before connecting the brake tube. New actuators are filled with brake fluid.
      • Do not carry with the connector part of an actuator.
        Fig 2: Locating Bolts And Brake Actuator Bracket Assembly
        G05401276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL BRAKE ACTUATOR (for Sedan) 
    1. Install the brake actuator with bracket with the 3 bolts in the sequence shown in the illustration.

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

      NOTE: Do not damage the brake tubes or wire harness.
      Fig 3: Locating Bolts And Brake Actuator With Bracket
      G04832237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect a new brake tube clamp.
      Fig 4: Locating Brake Tube Clamp
      G04832233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install each brake tube in the correct positions of the brake actuator as shown in the illustration.
      Fig 5: Identifying Front And Rear Wheel Brake Tube
      G06132061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a union nut wrench, install the 6 brake tubes onto the brake actuator.

      Torque: without union nut wrench 

      15 N*m (155 kgf*cm, 11 ft.*lbf) 

      with union nut wrench 

      14 N*m (144 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 GENERAL INFORMATION ).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
        Fig 6: Locating Brake Tubes Onto Brake Actuator
        G06132079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a union nut wrench, install the 2 brake tubes onto the brake master cylinder.

      Torque: without union nut wrench 

      15 N*m (155 kgf*cm, 11 ft.*lbf) 

      with union nut wrench 

      14 N*m (144 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 GENERAL INFORMATION ).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
        Fig 7: Locating Brake Tubes Onto Brake Master Cylinder
        G06132080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a union nut wrench, install the 2 brake tubes onto the brake tube No. 1 way.

      Torque: without union nut wrench 

      15 N*m (155 kgf*cm, 11 ft.*lbf) 

      with union nut wrench 

      14 N*m (144 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 GENERAL INFORMATION ).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
        Fig 8: Locating Brake Tubes Onto Brake Tube No. 1 Way
        G06132081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a union nut wrench, install the brake tube onto the front flexible hose.

      Torque: without union nut wrench 

      15 N*m (155 kgf*cm, 11 ft.*lbf) 

      with union nut wrench 

      14 N*m (144 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 GENERAL INFORMATION ).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
        Fig 9: Locating Brake Tube Onto Front Flexible Hose
        G06132082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the brake actuator connector.
      NOTE:
      • Make sure that the connector is locked securely.
      • Make sure that the actuator connector can be connected smoothly. Do not allow entry of water, oil or dirt.
    9. Engage the clamp.
      Fig 10: Connecting Brake Actuator Connector
      G06132083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL BRAKE ACTUATOR (for Hatchback) 
    1. Install the brake actuator with bracket with the 3 bolts in the sequence shown in the illustration.

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

      NOTE: Do not damage the brake tubes or wire harness.
      Fig 11: Locating Bolts And Brake Actuator With Bracket
      G05401278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect a new brake tube clamp.
      Fig 12: Locating Brake Tube Clamp
      G04832233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install each brake tube in the correct positions of the brake actuator 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 master cylinder
      • *6: From 2nd master cylinder
        Fig 13: Identifying Front And Rear Wheel Cylinder Brake Tube
        G06132069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a union nut wrench, install the 6 brake tubes onto the brake actuator.

      Torque: without union nut wrench 

      15 N*m (155 kgf*cm, 11 ft.*lbf) 

      with union nut wrench 

      14 N*m (144 kgf*cm, 10 ft.*lbf) 

      Fig 14: Locating Brake Tubes Onto Brake Actuator
      G06132087Courtesy 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 22 mm (0.866 in.)

        (See GENERAL INFORMATION ).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
    5. Using a union nut wrench, install the 2 brake tubes onto the brake master cylinder.

      Torque: without union nut wrench 

      15 N*m (155 kgf*cm, 11 ft.*lbf) 

      with union nut wrench 

      14 N*m (144 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 GENERAL INFORMATION ).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
        Fig 15: Locating Brake Tubes Onto Brake Master Cylinder
        G06132080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a union nut wrench, install the 2 brake tubes onto the brake tube No. 1 way.

      Torque: without union nut wrench 

      15 N*m (155 kgf*cm, 11 ft.*lbf) 

      with union nut wrench 

      14 N*m (144 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 GENERAL INFORMATION ).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
        Fig 16: Locating Brake Tubes Onto Brake Tube No. 1 Way
        G06132081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a union nut wrench, install the brake tube onto the front flexible hose.

      Torque: without union nut wrench 

      15 N*m (155 kgf*cm, 11 ft.*lbf) 

      with union nut wrench 

      14 N*m (144 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 GENERAL INFORMATION ).

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
        Fig 17: Locating Brake Tube Onto Front Flexible Hose
        G06132082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the brake actuator connector.
      NOTE:
      • Make sure that the connector is locked securely.
      • Make sure that the actuator connector can be connected smoothly. Do not allow entry of water, oil or dirt.
  5. INSTALL BATTERY CARRIER (See  INSTALLATION  ) 
  6. INSTALL BATTERY TRAY 
    Fig 18: Locating Brake Actuator Connector
    G06132091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL BATTERY (See  INSTALLATION  ) 
  8. FILL RESERVOIR WITH BRAKE FLUID  (See BRAKE FLUID )
  9. BLEED MASTER CYLINDER  (See BRAKE FLUID )
  10. BLEED BRAKE LINE  (See BRAKE FLUID )
  11. CHECK FLUID LEVEL IN RESERVOIR  (See BRAKE FLUID )
  12. CHECK FOR BRAKE FLUID LEAKAGE 
  13. CHECK ACTUATOR WITH TECHSTREAM 

    (See ON-VEHICLE INSPECTION  )

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