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Brake Actuator ASSY: Replacement

NOTE: Be sure to replace the actuator and the resistor together. If they are not replaced together, motor noise may be increased. 
  1. REMOVE FR WIPER ARM LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  2. REMOVE FR WIPER ARM RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  3. REMOVE HOOD TO COWL TOP SEAL (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  4. REMOVE COWL TOP VENTILATOR LOUVER LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  5. REMOVE COWL TOP VENTILATOR LOUVER RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  6. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (See WINDSHIELD WIPER MOTOR ASSY )
  7. PERFORM ACCUMULATOR PRESSURE DOWN 
    NOTE: Carry out accumulator zero down and lower the internal pressure before removing the brake actuator. 
    1. Move the shift lever to the P position. Apply the parking brake and connect the hand-held tester to the DLC3.
    2. Turn the power switch on (IG).
    3. Turn on the hand-held tester. Select "ZERO DOWN".
      NOTE: Keep the fluid inside the reservoir above the "LOW" level by replenishing. 

      HINT:

      • Accumulator pressure is released and accumulated repeatedly, which circulates the fluid inside the accumulator when performing this procedure.
      • The pump motor rotates and the accumulator is pressurized every time turning the power switch from off to on (IG).
    4. Turn the power switch off.
  8. BRAKE CONTROL (ECB) OFF 
    NOTE:
    • Prohibit the brake control (ECB) certainly before air bleeding  .
    • Be sure to remove the motor relays No.1 and No.2 first, then the brake actuator  .
    1. With the power switch off to prohibit brake control, remove the motor relays No.1 and No.2.
    Fig 1: Removing Motor Relays No.1 And No.2
    G02592354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: If the pump motor operates while there is air remaining inside the brake actuator hose, the air will enter the actuator, resulting in difficulty in air bleeding. 
  9. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (See  REPLACEMENT   ) 
  10. REMOVE W/CONVERTER INVERTER ASSY (See  REPLACEMENT  ) 

    HINT:

    Refer to the procedures from the removal of the engine under cover LH up until the removal of the inverter assy with converter.

  11. DRAIN BRAKE FLUID 
    NOTE: Wash brake fluid off immediately if it adheres to any painted surface. 
  12. SEPARATE WATER W/MOTOR & BRACKET PUMP ASSY 
    1. Remove the 2 bolts and connector, separate the heater water pump assy from the gusset assy.
      Fig 2: Removing Connector
      G02592355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 clamps and bolt, and remove the heater hose bracket from the gusset assy.
      Fig 3: Removing Heater Hose Bracket From Gusset Assy
      G02592356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE BRAKE ACTUATOR WITH BRACKET 
    1. Release the lock and separate the connector from the brake actuator assy.
    2. Remove the clip and separate the brake actuator hose No.2 from the brake actuator assy.
      Fig 4: Removing Brake Actuator With Bracket
      G02592357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, separate the front brake tube No.5 from the brake actuator assy and front brake flexible hose.

      SST 09023-00101

    4. Remove the bolt and front brake tube No.5 from the bracket of the brake actuator assy.
      Fig 5: Removing Front Brake Tube No.5 From Bracket Of Brake Actuator Assy
      G02592358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, separate the front brake tube No.1.

      SST 09023-00101

    6. Remove the bolt and the front brake tube No.1 from the bracket of the brake actuator assy.
      Fig 6: Removing Bolt And Front Brake Tube No.1 From Bracket
      G02592359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 3 nuts and the brake actuator tubes assy from the brake stroke simulator and brake actuator assy.
      Fig 7: Removing 3 Nuts And Brake Actuator Tubes Assy
      G02592360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using SST, remove the bolt and the 4 brake tubes from the brake stroke simulator and brake actuator assy.

      SST 09023-00101

      Fig 8: Removing Brake Stroke Simulator And Brake Actuator Assy
      G02592361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the bolt, 2 nuts and the brake actuator assy with gusset assy.
      Fig 9: Removing Brake Actuator Assy With Gusset Assy
      G02592362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE BRAKE ACTUATOR ASSY 
    1. Remove the 2 bolts and brake actuator damper.
      Fig 10: Removing Brake Actuator Assy
      G02592363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, nut, and the bracket from the brake actuator assy.
      Fig 11: Removing Bracket From Brake Actuator Assy
      G02592364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts, bolt, and the brake actuator assy from the gusset assy.
      Fig 12: Removing Brake Actuator Assy From Gusset Assy
      G02592365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and brake actuator bracket No.2 from the brake actuator assy.
      Fig 13: Removing Brake Actuator Bracket No.2 From Brake Actuator Assy
      G02592366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISPOSE OF BRAKE ACTUATOR ASSY 
    1. Using a drill, slowly make a hole at the radius indicated at the middle of A in the illustration and bleed the charged gas.
    NOTE: Be sure to wear protective glasses as fragments may fly out due to pressure. 

    HINT:

    • The hole may be drilled up to approximately 5mm to 10mm away from the point indicated by A without problem.
    • The gas is nitrogen, which is colorless, odorless, and harmless.
    Fig 14: Disposing Brake Actuator Assy
    G02592367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL BRAKE ACTUATOR ASSY 
    1. Aligning the positioning pin, install the brake actuator bracket No.2 to the brake actuator assy with the bolt.

      Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

      Fig 15: Installing Brake Actuator Assy
      G02592368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Aligning the positioning pin, install the brake actuator assy to gusset assy with the 2 nuts and bolt.

      Torque: 7.5 N.m (76 kgf.cm, 66 in..lbf) 

      NOTE: Tighten the nuts and bolt in the order shown in the illustration.
      Fig 16: Installing Brake Actuator Assy To Gusset Assy With 2 Nuts And Bolt
      G02592369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bracket to the brake actuator assy with the bolt and nut.

      Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

      NOTE: Tighten the nuts and bolt in the order shown in the illustration. 
      Fig 17: Installing Bracket To Brake Actuator Assy
      G02592370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the brake actuator damper to the brake actuator assy with the 2 bolts.

      Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

      NOTE: Tighten the bolts in the order shown in the illustration. 
      Fig 18: Installing Brake Actuator Damper To Brake Actuator Assy
      G02592371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL BRAKE ACTUATOR WITH BRACKET 
    1. Install the brake actuator assy and the gusset assy with the bolt and 2 nuts.

      Torque: 20 N.m (200 kgf.cm, 15 ft.lbf) 

      Fig 19: Installing Brake Actuator With Bracket
      G02592372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the 4 brake tube to the brake stroke simulator and brake actuator assy.

      SST 09023-00101

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

    3. Set the brake tube with the clamp bracket bolt.

      Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf) 

      Fig 20: Installing Brake Tube To Brake Stroke Simulator And Brake Actuator Assy
      G02592373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the brake actuator tube assy with the 2 nuts.

      Torque: 8.5 N.m (87 kgf.cm, 75 in..lbf) 

      Fig 21: Installing Brake Actuator Tube Assy With Nuts
      G02592374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Set the brake actuator tube assy with the nut.

      Torque: 8.5 N.m (87 kgf.cm, 75 in..lbf) 

      NOTE: Press the brake actuator tube assy so that there is no clearance between the bracket and the actuator tube assy as shown in the illustration, and tighten the nut. 
      Fig 22: Pressing Brake Actuator Tube Assy
      G02592375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using SST, install the front brake tube No.1 to the brake actuator and 2 way.

      SST 09023-00101

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

    7. Install the bolt and the front brake tube No.1 to the bracket of the brake actuator assy.

      Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf) 

      Fig 23: Installing Bolt And Front Brake Tube No.1 To Bracket Of Brake Actuator Assy
      G02592376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using SST, install the front brake tube No.5.

      SST 09023-00101

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

    9. Install the bracket of front brake tube No.5 with the bolt.

      Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf) 

      Fig 24: Installing Bracket Of Front Brake Tube No.5 With Bolt
      G02592377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Install the connector to the brake actuator assy, and fix it with the lock.
    11. Install the brake actuator hose No.2 to the brake actuator assy with the clip.
      Fig 25: Installing Connector To Brake Actuator Assy
      G02592378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. CONNECT WATER W/MOTOR & BRACKET PUMP ASSY 
    1. Install the heater hose bracket to the gusset assy with the 2 clamps and bolt.
      Fig 26: Installing Heater Hose Bracket To Gusset Assy
      G02592379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the heater water pump assy with 2 bolts.
      NOTE: Tighten bolt A and then bolt B.
    3. Connect the connector to the heater water pump assy.
      Fig 27: Connecting Connector To Heater Water Pump Assy
      G02592380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL W/CONVERTER INVERTER ASSY (See  REPLACEMENT  ) 

    HINT:

    Refer to the procedures from the installation of the inverter assy with converter up until the installation of the engine under cover LH.

  20. REMOVE INSTRUMENT PANEL REGISTER ASSY NO.1 (See  INSTRUMENT PANEL SUB-ASSY  ) 
  21. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER (See  INSTRUMENT PANEL SUB-ASSY  ) 
  22. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY UPPER (See  INSTRUMENT PANEL SUB-ASSY  ) 
  23. REMOVE INSTRUMENT PANEL REGISTER ASSY NO.3 (See  INSTRUMENT PANEL SUB-ASSY  ) 
  24. REMOVE INSTRUMENT PANEL REGISTER ASSY NO.4 (See  INSTRUMENT PANEL SUB-ASSY  ) 
  25. REMOVE INSTRUMENT PANEL REGISTER ASSY NO.2 (See  INSTRUMENT PANEL SUB-ASSY  ) 
  26. REMOVE MULTI-DISPLAY ASSY (See  INSTRUMENT PANEL SUB-ASSY  ) 
  27. REMOVE GLOVE COMPARTMENT DOOR STOPPER SUB-ASSY (See  INSTRUMENT PANEL SUB-ASSY  ) 
  28. REMOVE GLOVE COMPARTMENT DOOR ASSY (See  INSTRUMENT PANEL SUB-ASSY  ) 
  29. REMOVE GLOVE COMPARTMENT DOOR (See  INSTRUMENT PANEL SUB-ASSY  ) 
  30. REMOVE INSTRUMENT PANEL SPEAKER PANEL SUB-ASSY NO.1 W/CTR SPEAKER (W PREMIUM SOUND SYSTEM) (See  INSTRUMENT PANEL SUB-ASSY  ) 
  31. REMOVE FRONT PILLAR GARNISH CORNER PIECE LH (See  INSTRUMENT PANEL SUB-ASSY  ) 
  32. REMOVE FRONT PILLAR GARNISH CORNER PIECE RH (See  INSTRUMENT PANEL SUB-ASSY  ) 
  33. REMOVE FRONT PILLAR GARNISH LH (See  INSTRUMENT PANEL SUB-ASSY  ) 
  34. REMOVE FRONT PILLAR GARNISH RH (See  INSTRUMENT PANEL SUB-ASSY  ) 
  35. DISCONNECT PASSENGER AIRBAG CONNECTOR (See  INSTRUMENT PANEL SUB-ASSY  ) 
  36. REMOVE INSTRUMENT PANEL SUB-ASSY W/PASSENGER AIRBAG ASSY (See  INSTRUMENT PANEL SUB-ASSY  ) 
  37. REPLACE BRAKE ACTUATOR RESISTOR 
    1. Remove the nut.
    2. Disconnect the connector and remove the resistor.
    3. Connect the connector and install the resistor.
    4. Install the nut.

      Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf) 

      Fig 28: Installing Resistor
      G02592381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL INSTRUMENT PANEL SUB-ASSY W/PASSENGER AIRBAG ASSY (See  INSTRUMENT PANEL SUB-ASSY  ) 
  39. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT (See  REPLACEMENT   ) 
  40. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  41. INSTALL FR WIPER ARM LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  42. INSTALL FR WIPER ARM RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  43. FILL RESERVOIR WITH BRAKE FLUID (See  BRAKE FLUID   ) 
  44. BLEED BRAKE ACTUATOR (See  BRAKE FLUID   ) 
  45. CHECK BRAKE FLUID LEAKAGE 
  46. CHECK FLUID LEVEL IN RESERVOIR 
  47. CHECK AND CLEAR DTC (See  DIAGNOSTIC TROUBLE CODES CHECK/CLEAR  ) 
  48. SYSTEM INITIALIZATION (See  INITIALIZATION  ) 
  49. ACTIVE TEST (See  DATA LIST/ACTIVE TEST  ) 
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