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Brake Actuator ASSY: Replacement

  1. DRAIN BRAKE FLUID 
    NOTE: Wash brake fluid off immediately if it adheres to any painted surface.
  2. REMOVE FRONT WHEEL RH 
  3. REMOVE FRONT FENDER LINER RH 
  4. REMOVE RADIATOR GRILLE SUB-ASSY (see  REPLACEMENT  ) 
  5. REMOVE FRONT BUMPER COVER (see  REPLACEMENT  ) 
  6. REMOVE LH HEADLAMP ASSY (see  REPLACEMENT  ) 
  7. REMOVE WINDSHIELD WASHER JAR ASSY 
    Fig 1: Disconnecting Brake Tubes From Actuator With Bracket
    G02614265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE BRAKE ACTUATOR WITH BRACKET 
    1. Disconnect the actuator connector.
    2. Using SST, disconnect the 6 brake tubes from the actuator with bracket.

      SST 09023-00101

      Fig 2: Identifying Memo Position
      G02614266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Use tags or make a memo to identify the places to reconnect.
    4. Remove the 2 bolts, nut and the actuator with bracket.
    NOTE: Be careful not to damage the brake tubes and wire harness.
    Fig 3: Removing Nuts And Brake Actuator From Bracket
    G02614267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE BRAKE ACTUATOR ASSY 
    1. Remove the 2 nuts and brake actuator from the bracket.
  10. INSTALL BRAKE ACTUATOR ASSY 
    1. Install the brake actuator with the 2 nuts to the bracket.

      Torque: 6.0 N.m (61 kaf cm. 53 in..lbf) 

  11. INSTALL BRAKE ACTUATOR WITH BRACKET 
    1. Install the actuator with bracket, the 2 bolts and nut.

      Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 

      NOTE:
      • Be careful not to damage the brake tubes and wire harness.
      • Tighten the bolts in order from 1 to 3.
    2. Connect the actuator connector.
      NOTE: Make sure that the lever is locked securely.
      Fig 4: Installing Actuator With Bracket, Bolts And Nut
      G02614268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, connect each brake tube to correct positions of the actuator with bracket, as shown in the illustration.

      SST 09023-00101

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

    Fig 5: Connecting Brake Tube To Correct Positions Of Actuator With Bracket
    G02614269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL WINDSHIELD WASHER JAR ASSY 
  13. INSTALL LH HEADLAMP ASSY 
  14. INSTALL FRONT BUMPER COVER 
  15. INSTALL RADIATOR GRILLE SUB-ASSY 
  16. INSTALL FRONT FENDER LINER RH 
  17. INSTALL FRONT WHEEL RH 

    Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf) 

  18. FILL RESERVOIR WITH BRAKE FLUID (see  BRAKE FLUID  ) 
  19. BLEED MASTER CYLINDER (see  BRAKE FLUID  ) 

    SST 09023-00101

  20. BLEED BRAKE LINE (see  BRAKE FLUID  ) 
  21. CHECK FLUID LEVEL IN RESERVOIR (see  BRAKE FLUID  ) 
  22. CHECK FOR BRAKE FLUID LEAKAGE 
  23. CHECK ACTUATOR WITH HAND-HELD TESTER (see  BRAKE ACTUATOR ASSY  ) 
  24. VEHICLE PREPARATION FOR FOG LAMP AIM ADJUSTMENT (see  ADJUSTMENT  ) 
  25. PREPARATION FOR FOG LAMP AIMING (see  ADJUSTMENT  ) 
  26. FOG LAMP AIMING INSPECTION (see  ADJUSTMENT  ) 
  27. FOG LAMP AIMING ADJUSTMENT (see  ADJUSTMENT  ) 
  28. VEHICLE PREPARATION FOR HEADLAMP AIM ADJUSTMENT (see  ADJUSTMENT  ) 
  29. PREPARATION FOR HEADLAMP AIMING (Using a tester) (see  ADJUSTMENT  ) 
  30. PREPARATION FOR HEADLAMP AIMING (Using a screen) (see  ADJUSTMENT  ) 
  31. HEADLAMP AIMING INSPECTION (see  ADJUSTMENT  ) 
  32. HEADLAMP AIMING ADJUSTMENT (SEE ADJUSTMENT )
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