Installation

BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: BRAKE ACTUATOR: INSTALLATION

1. INSTALL BRAKE ACTUATOR (for 2AZ-FE)

(a) Install the brake actuator to the brake actuator bracket assembly with the 3 bolts.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

NOTICE:
* If installing a new brake actuator, do not remove the hole plugs before connecting the 6 brake lines because the brake actuator is filled with brake fluid.
* Do not carry the brake actuator by the connector.
* Tighten the 3 bolts in the order shown in the illustration.

2. INSTALL BRAKE ACTUATOR (for 2ZR-FE)

(a) Install the brake actuator to the brake actuator bracket assembly with the 3 bolts.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

NOTICE:
* If installing a new brake actuator, do not remove the hole plugs before connecting the 6 brake lines because the brake actuator is filled with brake fluid.
* Do not carry the brake actuator by the connector.
* Tighten the 3 bolts in the order shown in the illustration.

3. INSTALL BRAKE ACTUATOR WITH BRACKET (for 2AZ-FE)

(a) Install the brake actuator with bracket to the body with the 2 bolts and nut.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

NOTICE:
* Do not damage the brake lines or wire harness.
* Tighten the 2 bolts and nut in the order shown in the illustration.

(b) Temporarily tighten each brake line to the correct position of the brake actuator with bracket as shown in the illustration.

HINT
* *1: To front wheel cylinder RH
* *2: To front wheel cylinder LH
* *3: To rear wheel cylinder RH
* *4: To rear wheel cylinder LH
* *5: From 1st master cylinder chamber
* *6: From 2nd master cylinder chamber

(c) Using a union nut wrench (10 mm), fully tighten each brake line.

without a union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

with a union nut wrench - Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
* This torque value is effective when the union nut wrench is parallel to the torque wrench.

(d) Install the brake line clamp with the bolt.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

(e) Connect the actuator connector and lock the lock lever.

NOTICE:
Make sure that the connector is locked securely.

4. INSTALL BRAKE ACTUATOR WITH BRACKET (for 2ZR-FE)

(a) Install the brake actuator with bracket to the body with the 2 bolts and nut.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

NOTICE:
* Do not damage the brake lines or wire harness.
* Tighten the 2 bolts and nut in the order shown in the illustration.

(b) Temporarily tighten each brake line to the correct positions of the brake actuator with bracket as shown in the illustration.

without a union nut wrench (10 mm) - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

with a union nut wrench (10 mm) - Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)

without a union nut wrench (12 mm) - Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)

with a union nut wrench (12 mm) - Torque : 18 Nm (178 kgf-cm, 13 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
* This torque value is effective when the union nut wrench is parallel to the torque wrench.

(d) Install the brake line clamp with the bolt.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

(e) Connect the actuator connector.

NOTICE:
Make sure that the connector is locked securely.

5. INSTALL WINDSHIELD WASHER JAR ASSEMBLY

(a) Install the windshield washer jar assembly and clamp to the body with the 2 bolts.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

(b) Install the bolt and clamp, and connect the washer hoses and motor connectors.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

6. INSTALL RADIATOR RESERVE TANK SUB-ASSEMBLY

(a) Install the radiator reserve tank sub-assembly with the 3 bolts.

Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

7. INSTALL FRONT BUMPER ASSEMBLY

HINT
Refer to the instructions for Installation of the front bumper assembly Installation.

8. INSTALL GENERATOR ASSEMBLY (for 2ZR-FE)

HINT
Refer to the instructions for Installation of the generator assembly Installation.

9. INSTALL GENERATOR ASSEMBLY (for 2AZ-FE)

HINT
Refer to the instructions for Installation of the generator assembly Installation.

10. INSTALL FRONT WHEEL RH

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

12. REMOVE CENTER COWL TOP VENTILATOR LOUVER Service and Repair

13. FILL RESERVOIR WITH BRAKE FLUID Service and Repair

14. BLEED BRAKE MASTER CYLINDER Service and Repair

15. BLEED BRAKE LINE Service and Repair

16. BLEED BRAKE ACTUATOR Service and Repair

17. INSPECT BRAKE FLUID LEVEL Testing and Inspection

18. INSPECT FOR BRAKE FLUID LEAK

19. INSTALL CENTER COWL TOP VENTILATOR LOUVER Service and Repair

20. INSPECT ACTUATOR USING TECHSTREAM

Testing and Inspection

21. PERFORM YAW RATE AND ACCELERATION SENSOR ZERO POINT CALIBRATION

* for 2ZR-FE: Programming and Relearning

* for 2AZ-FE: Programming and Relearning

22. CHECK FOR SENSOR SIGNAL

* for 2ZR-FE: Test Mode Procedure

* for 2AZ-FE: Test Mode Procedure