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Installation [10/2020 - ]: Procedure

  1. INSTALL BRAKE ACTUATOR BRACKET CUSHION 

    HINT: 

    Perform this procedure only when replacement of the brake actuator bracket cushions is necessary.

    1. Install the 3 brake actuator bracket cushions to the brake actuator bracket assembly.
  2. INSTALL NO. 2 BRAKE ACTUATOR CASE COLLAR 

    HINT: 

    Perform this procedure only when replacement of the No. 2 brake actuator case collars is necessary.

    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. Temporarily install the brake actuator assembly to the brake actuator bracket assembly with the 3 bolts.
      Fig 1: Brake Actuator Assembly Bolts Tightening Sequence
      GTY978979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the 3 bolts in the order shown in the illustration.

      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.
  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 Bolts And Nut Tightening Sequence
      GTY979312Courtesy 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. Fully 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.
    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.
      GTY766256Courtesy 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.
      GTY979692Courtesy 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) 

      GTY979352Courtesy 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 [03/2020 - ]

      • 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. GTY980003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a To Rear Wheel Cylinder Assembly RH

      Temporarily tighten the brake line to the correct position on the brake actuator assembly as shown in the illustration.

      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) 

      GTY980032Courtesy 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 [03/2020 - ]

      • 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.
      GTY979495Courtesy 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) 

      GTY980107Courtesy 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 [03/2020 - ]

      • 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. 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 [03/2020 - ]

      • 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)

    15. Connect the connector to the brake actuator assembly and lock the lock lever.
      GTY979474Courtesy 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.
      GTY742125Courtesy 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. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to INSTALLATION [03/2017 - ]

  7. INSTALL FRONT WHEEL RH 

    Refer to PROCEDURE - Step 1

  8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    For A25A-FKS: Refer to PROCEDURE - Step 2

    For 2GR-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 [10/2020 - 08/2022] , or refer to INITIALIZATION [08/2022 - ]

  9. BLEED BRAKE SYSTEM 

    Refer to BLEEDING [03/2017 - ]

  10. PERFORM SYSTEM VARIANT LEARNING AND ACCELERATION SENSOR ZERO POINT CALIBRATION 

    w/o Electric Parking Brake System: Refer to CALIBRATION [10/2020 - 08/2021] , or refer to CALIBRATION [08/2021 - ]

    w/ Electric Parking Brake System: Refer to CALIBRATION [10/2020 - 08/2021] , or refer to CALIBRATION [08/2021 - ]

  11. PERFORM TEST MODE INSPECTION 

    w/o Electric Parking Brake System: Refer to TEST MODE PROCEDURE [10/2020 - 08/2021] , or refer to TEST MODE PROCEDURE [08/2021 - ]

    w/ Electric Parking Brake System: Refer to TEST MODE PROCEDURE [10/2020 - 08/2021] , or refer to TEST MODE PROCEDURE [08/2021 - ]

  12. INSPECT BRAKE ACTUATOR USING TECHSTREAM 

    Refer to ON-VEHICLE INSPECTION [10/2020 - ] 

  13. CHECK FOR AND CLEAR DTCS 

    w/o Electric Parking Brake System: Refer to DTC CHECK / CLEAR [10/2020 - ]

    w/ Electric Parking Brake System: Refer to DTC CHECK / CLEAR [10/2020 - ]

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