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Home >> Toyota >> 2022 >> Avalon XLE >> Repair and Diagnosis >> Brakes >> Traction Control >> Brake Control System (Service Information) >> BRAKE ACTUATOR (for Gasoline Model) >> Installation [04/2018 - 08/2020] >> Procedure

Installation [04/2018 - 08/2020]: Procedure

  1. INSTALL BRAKE ACTUATOR BOLT CUSHION 
    1. Install the brake actuator bolt cushion to the brake actuator bracket assembly.
  2. INSTALL NO. 1 BRAKE ACTUATOR CASE COLLAR 
    1. Install the No. 1 brake actuator case collar to the brake actuator bracket cushion.
      NOTE:

      Make sure that the No. 1 brake actuator case collar is in full contact with the brake actuator bracket cushion.

  3. INSTALL BRAKE ACTUATOR ASSEMBLY 
    1. Install the brake actuator assembly to the brake actuator bracket assembly.
    2. Tighten the 2 nuts and install the bolt.

      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 bolt and 2 nuts in the order shown in the illustration.
      Fig 1: Identifying Brake Actuator Assembly Bolt And Nuts With Tightening Sequence
      GTY762387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL BRAKE ACTUATOR WITH BRACKET 
    1. Temporarily install the brake actuator with bracket to the vehicle body.
      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.
      GTY859980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stud Bolt

      HINT: 

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

    2. Install the 2 bolts and nut in the order shown in the illustration.
      Fig 2: Identifying Brake Actuator With Bracket Bolts And Nut With Tightening Sequence
      GTY853643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      Install the 2 bolts from the bottom of the vehicle.

    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 [04/2018 -]

      • 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. GTY820958Courtesy 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) 

      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 [04/2018 -]

      • 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 [04/2018 -]

      • 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. 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 [04/2018 -]

      • 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)

    15. 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. 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 

    Refer to PROCEDURE - Step 2

    NOTE:

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

    Refer to INITIALIZATION [04/2018 - 08/2020]

  9. BLEED BRAKE SYSTEM 

    Refer to BLEEDING [04/2018 -]

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

    Refer to CALIBRATION [04/2018 - 08/2021]

  11. PERFORM TEST MODE INSPECTION 

    Refer to TEST MODE PROCEDURE [04/2018 - 08/2020]

  12. INSPECT BRAKE ACTUATOR USING TECHSTREAM 

    Refer to ON-VEHICLE INSPECTION [04/2018 - 08/2021] 

  13. CHECK FOR AND CLEAR DTCS 

    Refer to DTC CHECK / CLEAR [04/2018 - 08/2021]

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