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Home >> Lexus >> 2019 >> ES 350 Luxury >> Repair and Diagnosis >> Brakes >> Traction Control >> Brake Control System - Service Information >> BRAKE ACTUATOR (for Gasoline Model) >> Installation [08/2021 - ] >> Procedure

Installation [08/2021 - ]: Procedure

  1. INSTALL BRAKE ACTUATOR BRACKET CUSHION 
    1. Install the 3 brake actuator bracket cushions to the brake actuator bracket assembly.
  2. INSTALL NO. 2 BRAKE ACTUATOR CASE COLLAR 
    1. Install the 3 No. 2 brake actuator case collars to the brake actuator bracket cushion.
      NOTE:

      Make sure that the No. 2 brake actuator case collar is in full contact with the brake actuator bracket cushion.

    2. Install the 3 nuts.

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

  3. INSTALL BRAKE ACTUATOR ASSEMBLY 
    1. Install the brake actuator assembly to the brake actuator bracket assembly with the 3 bolts.
      Fig 1: Brake Actuator Assembly To Actuator Bracket Tightening Sequence [08/2021 - ]
      GTY823726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 6.5 N.m (66 kgf/cm, 58 in.lbf) 

      NOTE:
      • Do not remove the hole plugs of a new brake actuator assembly before connecting the brake tubes because the brake actuator assembly is filled with brake fluid.
      • Do not hold the brake actuator assembly by the connector.
      • Do not drop the brake actuator assembly when carrying it.
      • Tighten the 3 bolts in the order shown in the illustration.
  4. INSTALL BRAKE ACTUATOR WITH BRACKET 
    1. Temporarily install the brake actuator with bracket to the vehicle body with the 2 bolts and nut.
      Fig 2: Brake Actuator With Bracket Tightening Sequence [08/2021 - ]
      GTY792466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not kink or damage the brake lines.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.
      • Be careful not to allow any brake fluid to enter the connector.
      • Do not hold the brake actuator assembly by the connector.
      • Do not drop the brake actuator with bracket when carrying it.

      HINT: 

      • Install the brake actuator with bracket while avoiding the brake lines.
      • Install the 2 bolts from the bottom of the vehicle.
    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. Remove the protective tape.
    4. Engage the clamp to install a new brake tube clamp.
      GTY828515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Return the front No. 3 brake tube to its original position.
      NOTE:

      Do not apply excessive force to the front No. 3 brake tube.

    6. Temporarily install the front No. 3 brake tube to the front flexible hose.
      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.
      GTY766265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Engage the clamp to connect the front No. 3 brake tube.
      GTY780746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not kink or damage the front No. 3 brake tube.

    8. Temporarily tighten the brake line to the correct position on the brake actuator assembly as shown in the illustration.
      GTY811993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a To Front Wheel Cylinder Assembly LH
      NOTE:
      • Do not kink or damage the brake line.
      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the connecting parts.
    9. Using a union nut wrench, fully tighten the brake line.

      Specified tightening torque 

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

      GTY832895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
      NOTE:

      Do not kink or damage the brake line.

      HINT: 

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

        Refer to PRECAUTION [06/2018 - ]

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

        13.4 N.m (137 kgf/cm, 10 ft.lbf)

    10. Temporarily tighten the brake line to the correct position on the brake actuator assembly as shown in the illustration.
      GTY820958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a To Rear Wheel Cylinder Assembly RH
      NOTE:
      • Do not kink or damage the brake line.
      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the connecting parts.
    11. Using a union nut wrench, fully tighten the brake line.

      Specified tightening torque 

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

      GTY814674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
      NOTE:

      Do not kink or damage the brake line.

      HINT: 

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

        Refer to PRECAUTION [06/2018 - ]

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

        13.4 N.m (137 kgf/cm, 10 ft.lbf)

    12. Temporarily tighten the 4 brake lines to the correct positions on the brake actuator assembly as shown in the illustration.
      GTY784024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a From 1st Chamber of Brake Master Cylinder Sub-assembly
      *b From 2nd Chamber of Brake Master Cylinder Sub-assembly
      *c To Front Wheel Cylinder Assembly RH
      *d To Rear Wheel Cylinder Assembly LH
      NOTE:
      • Do not kink or damage the brake lines.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.
    13. Using a union nut wrench, fully tighten each brake line.

      Specified tightening torque (A) 

      Torque: 19.5 N.m (199 kgf/cm, 14 ft.lbf) 

      Specified tightening torque (B) 

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

      GTY776937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
      NOTE:

      Do not kink or damage the brake lines.

      HINT: 

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

        Refer to PRECAUTION [06/2018 - ]

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

        (A): 17.4 N.m (177 kgf/cm, 13 ft.lbf)

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

        (B): 13.4 N.m (137 kgf/cm, 10 ft.lbf)

    14. Engage the 2 clamps to install a new No. 4 brake tube clamp to the brake lines.
      GTY792837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. Using a union nut wrench, fully tighten the front No. 3 brake tube while holding the front flexible hose with a wrench.

      Specified tightening torque 

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

      GTY757275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench
      NOTE:

      Do not kink or damage the front No. 3 brake tube.

      HINT: 

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

        Refer to PRECAUTION [06/2018 - ]

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

        13.4 N.m (137 kgf/cm, 10 ft.lbf)

    16. Connect the connector to the brake actuator assembly and lock the lock lever.
      GTY779347Courtesy 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 CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY 
    1. Temporarily install the front center upper suspension brace sub-assembly with the 6 bolts and 4 nuts.
      GTY824446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Fully tighten the 2 nuts (A).

      Torque: 50 N.m (510 kgf/cm, 37 ft.lbf) 

    3. Fully tighten the 6 bolts and 2 nuts (B) to install the front center upper suspension brace sub-assembly.

      Bolt 

      Torque: 8.9 N.m (91 kgf/cm, 79 in.lbf) 

      Nut (B) 

      Torque: 39 N.m (398 kgf/cm, 29 ft.lbf) 

    4. Engage the 2 clamps to install the wire harness.
    5. Connect the connector.
    6. w/ Windshield Deicer System:
      1. Engage the 3 clamps to install the wire harness.
      2. Connect the connector.
  6. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  7. INSTALL FRONT WHEEL RH 

    Refer to PROCEDURE - Step 1

  8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    for 2GR-FKS: Refer to PROCEDURE - Step 2

    for A25A-FKS: Refer to PROCEDURE - Step 2

    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [08/2021 - 09/2022] , or refer to INITIALIZATION [09/2022 - ]

  9. BLEED BRAKE SYSTEM 

    Refer to BLEEDING [08/2021 - ]

  10. ACCELERATION SENSOR ZERO POINT CALIBRATION AND STORE SYSTEM INFORMATION MEMORIZATION 

    Refer to UTILITY [06/2018 - ]

  11. PERFORM TEST MODE INSPECTION 

    Refer to TEST MODE PROCEDURE [08/2020 - ]

  12. INSPECT BRAKE ACTUATOR USING GTS 

    Refer to ON-VEHICLE INSPECTION [06/2018 - ] 

  13. CHECK FOR AND CLEAR DTCS 

    Refer to DTC CHECK / CLEAR [06/2018 - ]

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