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Home >> Lexus >> 2020 >> RX 450h Base >> Repair and Diagnosis >> Brakes >> Traction Control >> Brake Control System (Service Information) >> Brake Actuator >> Installation [10/2015 - 03/2018] >> Procedure

Installation [10/2015 - 03/2018]: Procedure

  1. INSTALL NO. 2 BRAKE ACTUATOR HOSE 
    1. Connect the No. 2 brake actuator hose to the brake booster pump assembly to install it, and slide the clip to secure it.
      GTY653060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Union
      *b Identification Mark
      NOTE:
      • When connecting the No. 2 brake actuator hose to the brake booster pump assembly, make sure that there is no excessive weight applied to the union of the brake booster pump assembly (especially in the vertical direction).
      • When connecting the No. 2 brake actuator hose, face the identification mark up.
  2. INSTALL BRAKE BOOSTER PUMP ASSEMBLY 
    1. Install the brake actuator bracket cushion to the brake actuator bracket assembly.
      GTY635054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the brake booster pump assembly to the brake actuator bracket assembly.
      GTY625976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Booster Pump Bushing
      *2 Brake Booster Pump Collar
      *a Pin
      NOTE:
      • When installing the brake booster pump assembly to the brake actuator bracket assembly, confirm that the 2 brake booster pump bushings and 2 brake booster pump collars are on the brake booster pump assembly.
      • Securely insert the 2 pins of the brake actuator bracket assembly to the 2 brake booster pump bushings, and the pin of the brake booster pump assembly to the hole of the brake actuator bracket assembly.
    3. Install the brake booster pump bushing and a new brake actuator bracket clamp to secure the brake booster pump assembly.
      GTY685313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Actuator Bracket Clamp
      *2 Brake Booster Pump Bushing
      NOTE:

      Make sure to install the brake actuator bracket clamp until its claws are engaged securely.

    4. Install the 2 brake actuator bracket cushions to the brake actuator bracket assembly.
      GTY635065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the brake actuator bracket assembly to the brake booster pump assembly with bracket with the bolt and nut.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

    6. Engage the clamp to install the wire harness.
  3. TEMPORARILY INSTALL NO. 1 BRAKE ACTUATOR TUBE 
    1. Temporarily install the No. 1 brake actuator tube to the brake booster pump assembly.
      GTY635264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not kink or damage the brake lines.
      • Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.
  4. INSTALL BRAKE BOOSTER PUMP ASSEMBLY WITH BRACKET 
    1. Temporarily install the brake booster pump assembly with bracket to the vehicle body with the bolt and 2 nuts.
      NOTE:
      • Do not kink or damage the brake lines.
      • Do not hold the brake booster pump assembly with bracket by the connector, hose, brake tube, union or wire harness.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.
      • Do not damage the vehicle body.
      • Do not drop the brake booster pump assembly. Do not use parts that have been dropped.
      • Do not apply excessive force to the refrigerant lines.
    2. Tighten the bolt and 2 nuts.

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

    3. Engage the clamp to install the wire harness to the brake booster pump assembly with bracket.
    4. Install the No. 2 brake actuator hose to the brake actuator hose clamp.
      GTY644609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Actuator Hose Clamp
      *a Painted Surface
      NOTE:

      Make sure to install the No. 2 brake actuator hose so that the painted surface of the No. 2 brake actuator hose does not protrude from the brake actuator hose clamp.

    5. Install the washer inlet to the windshield washer jar sub-assembly.
      GTY622677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the washer inlet with the bolt.

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

  5. INSTALL AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 
    1. Install the air conditioner tube and accessory assembly with the bolt.

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

      NOTE:

      Do not deform the refrigerant lines.

  6. INSTALL NO. 3 ECM BRACKET 
    1. Install the No. 3 ECM bracket to the vehicle body with the 2 bolts.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

  7. INSTALL SUCTION PIPE SUB-ASSEMBLY 
    1. Engage the clamp to install the suction pipe sub-assembly.
      NOTE:
      • Do not deform the refrigerant lines.
      • Do not damage the clamp.
  8. INSTALL BRAKE ACTUATOR ASSEMBLY 
    1. Install the 2 brake actuator bracket cushions and 2 brake actuator bracket spacers to the brake actuator bracket assembly as shown in the illustration.
      GTY622680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the brake actuator assembly to the brake actuator bracket assembly with the 3 bolts.

      Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf) 

  9. INSTALL BRAKE ACTUATOR HOSE 
    1. Connect the brake actuator hose to the brake actuator assembly to install it, and slide the clip to secure it.
      GTY637445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Union
      *b Identification Mark
      NOTE:
      • When inserting the brake actuator hose to the brake actuator assembly, make sure that there is no excessive weight applied to the union of the brake actuator assembly (especially in the vertical direction).
      • When connecting the brake actuator hose, face the identification mark up.
  10. INSTALL BRAKE ACTUATOR WITH BRACKET 
    1. Install the brake actuator with bracket with the 2 nuts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

      NOTE:
      • Do not kink or damage the brake lines.
      • Do not hold the brake actuator with bracket by the connector, hose or union.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.
      • Do not drop the brake actuator assembly. Do not use parts that have been dropped.

      HINT: 

      Install the brake actuator with bracket while avoiding the brake lines.

    2. Install the brake actuator bracket cushion and brake actuator bracket spacer to the No. 1 brake actuator bracket.
      GTY674737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the No. 1 brake actuator bracket assembly with the bolt and nut.
      GTY635269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt 

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

      Nut 

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    4. Temporarily install the No. 1 brake actuator tube to the brake actuator assembly.
      GTY635267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Temporarily install the No. 1 brake tube clamp with the bolt to secure the No. 1 brake actuator tube to the No. 1 brake actuator bracket.
      GTY635270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a union nut wrench, fully tighten the No. 1 brake actuator tube.
      GTY676912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Specified tightening torque 

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

      NOTE:
      • Do not kink or damage the No. 1 brake actuator tube.
      • Do not allow the No. 1 brake actuator tube to twist or interfere with other parts or the vehicle body during tightening.
      • Do not allow any foreign matter such as dirt or dust to enter the No. 1 brake actuator tube from the connecting parts.

      HINT: 

    7. Fully tighten the bolt.
      GTY635270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    8. Engage the claw to set the connector box to the brake actuator bracket assembly.
      GTY680226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw
    9. Install the nut to secure the connector box.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    10. Install the brake tube clamp to the vehicle body with the bolt.
      GTY635265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) 

    11. Temporarily tighten the 6 brake lines to the correct positions on the brake actuator assembly as shown in the illustration.
      GTY635133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a From Brake Stroke Simulator Cylinder Sub-assembly
      *b From Brake Master Cylinder Sub-assembly
      *c To Front Wheel Cylinder Assembly LH
      *d To Rear Wheel Cylinder Assembly RH
      *e To Rear Wheel Cylinder Assembly LH
      *f To Front Wheel Cylinder Assembly RH
    12. Using a union nut wrench, fully tighten each brake line.
      GTY656423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Union Nut Wrench

      Specified tightening torque 

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

      NOTE:
      • Do not kink or damage the brake lines.
      • Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

      HINT: 

    13. Connect the connector to the brake actuator assembly and lock the lock lever.
      GTY669037Courtesy 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.
  11. INSTALL RESERVOIR BRACKET 
    1. Install the reservoir bracket with the bolt and 2 nuts.

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

    2. Engage the clamp to install the wire harness to the reservoir bracket.
  12. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Install the brake master cylinder reservoir assembly to the reservoir bracket with the 2 nuts.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

    2. Connect the brake actuator hose and No. 2 brake actuator hose to the brake master cylinder reservoir assembly, and slide the 2 clips to secure them.
      GTY671363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Actuator Hose
      *2 No. 2 Brake Actuator Hose
      *a Identification Mark
      NOTE:

      When connecting the brake actuator hose and No. 2 brake actuator hose to the brake master cylinder reservoir assembly, face their identification marks up.

    3. Engage the 2 clamps to install the wire harness to the brake master cylinder reservoir assembly.
    4. Connect the 2 connectors to the brake master cylinder reservoir assembly and air conditioner tube and accessory assembly.
  13. INSTALL NO. 2 RESERVOIR HOSE 
    1. Connect the No. 2 reservoir hose to the reservoir tube, and slide the clip to secure it.
  14. INSTALL NO. 1 RESERVOIR HOSE 
    1. Connect the No. 1 reservoir hose to the reservoir tube, and slide the clip to secure it.
  15. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 87

  16. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 12 [10/2015 - 08/2016] Refer to PROCEDURE - Step 12 [08/2016 - 08/2019]

  17. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY 

    Refer to PROCEDURE - Step 2

  18. INSTALL ECM ASSEMBLY 

    Refer to PROCEDURE - Step 3

  19. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2

  20. BLEED BRAKE SYSTEM 

    Refer to BLEEDING [10/2015 - 08/2018]

  21. PERFORM INITIALIZATION AND CALIBRATION OF LINEAR SOLENOID VALVE 

    Refer to INITIALIZATION [10/2015 - 08/2018]

  22. CHECK AND CLEAR DTC 

    Refer to DTC CHECK / CLEAR [10/2015 - 08/2018]

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