BRAKE ACTUATOR (w/ ABS) INSTALLATION


  1. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET


    1. A01DZ7XE01

      for LHD:

      Install the actuator with bracket with the 3 bolts.

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

      Note


      • Tighten the 3 bolts uniformly in alphabetical order.

      • Be careful not to damage the brake tubes.

    2. A01DYU8E02

      for RHD:

      Install the actuator with bracket with the 3 nuts.

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

      Note


      • Tighten the 3 nuts uniformly in alphabetical order.

      • Be careful not to damage the brake tubes.

    3. Using a union nut wrench, connect the 5 brake lines to the correct locations on the actuator, as shown in the illustration.

      A01DXA4E01
      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    4. Connect the actuator connector.

  2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  3. FILL RESERVOIR WITH BRAKE FLUID (for TMT Made)

    Fluid
    SAE J1703 or FMVSS No. 116 DOT 3

  4. FILL RESERVOIR WITH BRAKE FLUID (for TSAM Made)

    Fluid
    SAE J1704 or FMVSS No. 116 DOT 4

  5. BLEED AIR FROM BRAKE MASTER CYLINDER (for TMT Made)

    Tech Tips

    If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.


    1. Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.

    2. Slowly depress and hold the brake pedal.

      A01E20LE02

    3. Cover the outer holes with your finger, and release the pedal.

      A01DVKUE02

    4. Repeat the 2 previous steps 3 or 4 times.

    5. Using a union nut wrench, connect the 2 brake lines to the master cylinder.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  6. BLEED AIR FROM BRAKE MASTER CYLINDER (for TSAM Made)

    Tech Tips

    If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air from the master cylinder.


    1. Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.

    2. Slowly depress and hold the brake pedal.

      A01E20LE02

    3. Cover the outer holes with your finger, and release the pedal.

      A01DVKUE02

    4. Repeat the 2 previous steps 3 or 4 times.

    5. Using a union nut wrench, connect the 2 brake lines to the master cylinder.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  7. BLEED AIR FROM BRAKE LINE (for TMT Made)


    1. Remove the bleeder plug cap.

    2. Connect the vinyl tube to the bleeder plugs.

    3. Depress the pedal several times, and then loosen the bleeder plug with the pedal depressed.

    4. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

    5. Repeat the 2 previous steps until all the air in the brake fluid is gone.

    6. Tighten the bleeder plug.

      Torque:
      for front brake
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }
      for rear brake (2WD)
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      for rear brake (4WD and Pre-Runner)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    7. Install the cap.

    8. Bleed air from the brake line for each wheel by repeating the above procedures.

  8. BLEED AIR FROM BRAKE LINE (for TSAM Made)


    1. Remove the bleeder plug cap.

    2. Connect the vinyl tube to the bleeder plugs.

    3. Depress the pedal several times, and then loosen the bleeder plug with the pedal depressed.

    4. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.

    5. Repeat the 2 previous steps until all the air in the brake fluid is gone.

    6. Tighten the bleeder plug.

      Torque:
      for front brake (2WD)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for front brake (4WD and Pre-Runner)
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }
      for rear brake (2WD)
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      for rear brake (4WD and Pre-Runner)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    7. Install the cap.

    8. Bleed air from the brake line for each wheel by repeating the above procedures.

  9. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)

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    1. Remove the bleeder plug cap.

    2. Connect the vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.

    4. At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled out.

    6. Tighten the bleeder plug.

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

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled out of the clutch line.

  10. CHECK BRAKE FLUID LEVEL IN RESERVOIR (for TMT Made)


    1. A01DVQK

      Check the fluid level.

      If the brake fluid level is lower that the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  11. CHECK BRAKE FLUID LEVEL IN RESERVOIR (for TSAM Made)


    1. A01DVQK

      Check the fluid level.

      If the brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Fluid
      SAE J1704 or FMVSS No. 116 DOT 4

  12. CHECK FOR BRAKE FLUID LEAKAGE

  13. CHECK BRAKE ACTUATOR WITH INTELLIGENT TESTER


    1. Check brake actuator with intelligent tester Click here.