Toyota Yaris: Brake Actuator / Installation

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

After performing the update ECU security key procedure, make sure to perform the initialization procedure for when the cable has been disconnected and reconnected to the negative (-) auxiliary battery terminal.

PROCEDURE

1. INSTALL BRAKE ACTUATOR BRACKET CUSHION

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

2. INSTALL NO. 1 BRAKE ACTUATOR CASE COLLAR

(a) Install the 3 No. 1 brake actuator case collars to the brake actuator bracket cushion.

NOTICE:

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

(a) Temporarily install the brake actuator assembly with the 3 bolts.

(b) Fully tighten the 3 bolts in the order shown in the illustration. Torque: 5.4 N·m {55 kgf·cm, 48 in·lbf} NOTICE: 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 NO. 1 BRAKE ACTUATOR BRACKET

(a) Temporarily install the No. 1 brake actuator bracket with the 3 bolts.

(b) Fully tighten the 3 bolts in the order shown in the illustration. Torque: 5.4 N·m {55 kgf·cm, 48 in·lbf} NOTICE: 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.

5. INSTALL BRAKE ACTUATOR WITH BRACKET

(a) Temporarily install the brake actuator with bracket to the vehicle body with the bolt and 2 nuts. NOTICE: 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.

(b) Fully tighten the bolt and 2 nuts in the order shown in the illustration.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

(c) Engage the clamp and install a new No. 2 brake tube clamp to the vehicle body.

(d) Engage the 5 clamps to install the No. 2 brake tube clamp to the brake lines.

(e) Engage the 5 clamps to install a new No. 1 brake tube clamp to the brake lines.

(f) Temporarily tighten each brake line to the correct position on the brake actuator assembly as shown in the illustration. NOTICE: 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.

*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 *e To Rear Wheel Cylinder Assembly RH *f To Front Wheel Cylinder Assembly LH

(g) Using a union nut wrench, connect the 6 brake lines to the brake actuator assembly. Torque: Specified tightening torque (A) : 15.2 N·m {155 kgf·cm, 11 ft·lbf} Specified tightening torque (B) : 19.5 N·m {199 kgf·cm, 14 ft·lbf} NOTICE: Do not kink or damage the brake lines. Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening. Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts. HINT: 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 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): (A): 13.4 N*m (137 kgf*cm, 10 ft.*lbf) When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): (B): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

*a Torque Wrench Fulcrum Length

(h) Connect the connector to the brake actuator assembly and lock the lock lever.

	Connect the connector
	Lock the lock lever

(i) Return the air conditioning tube and accessory assembly to its original position.

NOTICE:

Do not apply excessive force to the return the air conditioning tube and accessory assembly to its original position..

6. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY

(a) Remove the vinyl tape from the air conditioning tube and accessory assembly.

(b) Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning tube and accessory assembly.

Compressor Oil:

HFC-134a (R134a)

ND-OIL 8 or equivalent

(c) Install the 2 O-rings to the air conditioning tube and accessory assembly.

NOTICE:

Keep the O-ring and O-ring fitting surfaces free of foreign matter.

(d) Connect the air conditioning tube and accessory assembly to the air conditioning unit assembly.

(e) Rotate the hook connector as shown in the illustration.

(f) Insert the hose joint into the fitting hole securely and install the bolt.

Torque:

9.5 N·m {97 kgf·cm, 84 in·lbf}

(g) Engage the 2 clamps to install the air conditioning tube and accessory assembly.

7. INSTALL RESERVE SEALED TANK

(a) Install the reserve sealed tank with the 2 bolts.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

8. INSTALL DASH PANEL HEAT INSULATOR

(a) Temporarily install the dash panel heat insulator to the vehicle body with the nut (A) and clamp.

(1) Install the nut (B). Torque: 5.0 N·m {51 kgf·cm, 44 in·lbf}

(2) Tighten the nut (A).

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

9. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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10. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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11. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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12. INSTALL WATER GUARD PLATE RH

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13. INSTALL FRONT NO. 1 VENTILATOR SEAL

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14. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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15. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

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16. UPDATE ECU SECURITY KEY

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17. BLEED BRAKE SYSTEM

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18. PERFORM INITIALIZATION AND CALIBRATION

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19. PERFORM TEST MODE INSPECTION

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20. INSPECT BRAKE ACTUATOR USING GTS

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21. CHECK FOR CLEAR DTCS

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22. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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23. WARM UP ENGINE

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24. INSPECT FOR REFRIGERANT LEAK

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25. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

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