BRAKE ACTUATOR INSTALLATION

PROCEDURE

1. INSTALL BRAKE ACTUATOR ASSEMBLY

   
   

   1. 

      Install the brake actuator assembly to the brake actuator bracket assembly with the bolt and 2 new nuts.

      Torque:

      Bolt

      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Nut

      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Note

      
      

      • Do not remove the hole plugs of a new brake actuator assembly before connecting the brake lines because the brake actuator assembly is filled with brake fluid.

      • Do not hold the brake actuator assembly by the connector.

      • Tighten the bolt and 2 nuts in the order shown in the illustration.

2. INSTALL BRAKE ACTUATOR WITH BRACKET

   
   

   1. 

      Install the brake actuator with bracket to the vehicle body with 3 new nuts.

      Torque:

      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      Note

      
      

      • Do not damage the brake lines, fuel lines or wire harness.

      • Tighten the 3 nuts in the order shown in the illustration.

   2. Engage each clamp to install the No. 2 fuel tube clamp and front No. 4 brake tube to the brake actuator bracket assembly.

      Note

      Do not damage the brake lines or fuel lines.

   3. 

      *a	for LHD: From 1st Chamber of Master Cylinder Sub-assembly for RHD: From 2nd Chamber of Master Cylinder Sub-assembly
      *b	for LHD: From 2nd Chamber of Master Cylinder Sub-assembly for RHD: From 1st Chamber of Master Cylinder Sub-assembly
      *c	To Front Wheel Cylinder Assembly RH
      *d	To Rear Wheel Cylinder Assembly LH
      *e	To Rear Wheel Cylinder Assembly RH
      *f	To Front Wheel Cylinder Assembly LH

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

   4. 

      *a	Torque Wrench Fulcrum Length

      Using a union nut wrench, fully tighten each brake line.

      Torque:

      Specified tightening torque (A) (w/o VSC)

      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Specified tightening torque (A) (w/ VSC)

      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

      Specified tightening torque (B)

      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Tech Tips

      
      

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        w/ VSC (A): 17.36 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.)):

        w/o VSC (A), (B): 13.38 N*m (136 kgf*cm, 10 ft.*lbf)

   5. 

      Engage the clamp to install the wire harness to the brake actuator bracket assembly.

   6. Connect the connector to the brake actuator assembly and disengage the claw (b).

   7. Pull the lever down and engage the claw (a) to engage the connector lock.

      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.

   8. Connect the connector to the ECM.

      for 1NR-FE: Click here

      for 1ZR-FE: Click here

      for 1ZR-FAE: Click here

      for 2ZR-FE: Click here

      for 8NR-FTS: Click here

3. INSTALL BRAKE ACTUATOR COVER (for 1WW, 1ND-TV with VSC)

   
   

   1. Raise the claw of a new brake actuator cover, insert the pin into the hole and engage the claw to install it to the brake actuator assembly.

      

      *a

      Claw

      *b

      Pin

4. INSTALL AIR CLEANER BRACKET (for 1WW, 1ND-TV)

   
   

   1. Install the air cleaner bracket with the 3 bolts.

      Torque:

      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

5. INSTALL FUEL FILTER SUPPORT (for 1WW, 1ND-TV)

   
   

   1. Install the fuel filter support with the 3 bolts.

      Torque:

      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }

   2. Engage the wire harness clamp to the fuel filter support.

6. INSTALL GLOW PLUG RELAY ASSEMBLY (for 1WW, 1ND-TV)

   
   

   1. Install the glow plug relay assembly to the fuel filter support with the bolt.

      Torque:

      for 1ND-TV

      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      for 1WW

      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }

   2. Connect the wire harness clamp to the fuel filter support.

7. CONNECT WIRE HARNESS (for 1ND-TV)

   
   

   1. Connect the ECM connector to the ECM.

      Click here

   2. Connect the 3 wire harness clamps to the fuel filter support.

8. CONNECT WIRE HARNESS (for 1WW)

   
   

   1. Connect the ECM connector to the ECM.

      Click here

   2. Connect the 2 wire harness clamps to the fuel filter support.

   3. Connect the connector.

9. INSTALL FUEL FILTER ASSEMBLY (for 1WW, 1ND-TV)

   for 1WW (w/ Fuel Heater Relay): Click here

   for 1WW (w/o Fuel Heater Relay): Click here

   for 1ND-TV: Click here

10. INSTALL NO. 1 FUEL FILTER PROTECTOR (for 1WW)

    for 1WW (w/ Fuel Heater Relay): Click here

    for 1WW (w/o Fuel Heater Relay): Click here

11. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1NR-FE)

    Click here

12. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1NR-FE)

    Click here

13. INSTALL NO. 1 ENGINE COVER (for 1NR-FE)

    Click here

14. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1ZR-FE)

    Click here

15. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1ZR-FE)

    Click here

16. INSTALL NO. 2 CYLINDER HEAD COVER (for 1ZR-FE)

    Click here

17. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1ZR-FAE)

    Click here

18. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1ZR-FAE)

    Click here

19. INSTALL NO. 2 CYLINDER HEAD COVER (for 1ZR-FAE)

    Click here

20. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2ZR-FE)

    Click here

21. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FE)

    Click here

22. INSTALL NO. 2 CYLINDER HEAD COVER (for 2ZR-FE)

    Click here

23. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1ND-TV)

    Click here

24. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 1ND-TV)

    Click here

25. INSTALL NO. 1 ENGINE COVER (for 1ND-TV with No. 1 Engine Cover)

    Click here

26. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 8NR-FTS)

    Click here

27. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (for 8NR-FTS)

    Click here

28. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 1WW)

    Click here

29. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY (for 1WW)

    Click here

30. INSTALL NO. 1 ENGINE COVER (for 1WW)

    Click here

31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

32. BLEED AIR FROM FUEL SYSTEM (for 1ND-TV)

    Click here

33. CHECK FUEL PUMP OPERATION AND INSPECT FOR FUEL LEAK (for 1WW)

    Click here

34. INSPECT FOR FUEL LEAK (for 1ND-TV)

    Click here

35. BLEED BRAKE SYSTEM

    Click here

36. INSPECT BRAKE ACTUATOR USING GTS

    Click here

37. PERFORM SYSTEM VARIANT LEARNING (w/ VSC)

    Click here

38. CHECK FOR AND CLEAR DTCS

    w/o VSC: Click here

    w/ VSC: Click here