BRAKE ACTUATOR(for LHD) REMOVAL

Info Added 2017-10-06

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during brake actuator assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link
Auxiliary battery terminal is disconnected/reconnected Memorize steering angle neutral point Lane departure alert system (w/ Steering Control)

Click here

Simple intelligent parking assist system*1
Toyota parking assist-sensor system*1
Pre-collision system
Initialize back door lock Power door lock control system

Click here

Replacement of brake actuator assembly

  1. Bleed air

  2. Clear the data stored during previous linear solenoid valve offset learning, ABS holding solenoid valve learning, brake pedal stroke sensor assembly zero point calibration and system information memorization.

  3. Perform linear solenoid valve offset learning, ABS holding solenoid valve learning, brake pedal stroke sensor assembly zero point calibration and system information memorization.

  • DTCs are stored

  • ABS warning light illuminates

  • Brake warning light/yellow (minor malfunction) illuminates

  • Slip indicator light illuminates

  • VSC disabled or malfunctions

for Initialization: Click here

for Calibration: Click here

*1: When performing learning using the GTS.

Click here

CAUTION / NOTICE / HINT

Note

While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch turns on. Therefore, when servicing the brake system components, do not operate the brake pedal or open/close the doors while the auxiliary battery is connected.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Click here

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  4. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

    Click here

  5. REMOVE WATER GUARD PLATE LH

    Click here

  6. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  7. REMOVE COWL BODY MOUNTING REINFORCEMENT RH

    Click here

  8. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  9. PERFORM ACCUMULATOR PRESSURE ZERO DOWN

    Click here

  10. DRAIN BRAKE FLUID

    Note

    If brake fluid leaks onto any painted surface, immediately wash it off.

  11. SEPARATE SUCTION PIPE SUB-ASSEMBLY


    1. A001OSB

      Disengage the 2 clamps to separate the suction pipe sub-assembly.

    2. A001ORM

      Remove the bolt and rotate the hook connector.

    3. Disconnect the suction pipe sub-assembly from the air conditioning unit assembly.

    4. Remove the O-ring from the suction pipe sub-assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  12. SEPARATE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. A001OFI

      Disengage the 2 clamps to separate the air conditioner tube and accessory assembly.

    2. A001O8G

      Disconnect the air conditioner tube and accessory assembly from the air conditioning unit assembly.

    3. Remove the O-ring from the air conditioner tube and accessory assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  13. DISCONNECT ENGINE ROOM MAIN WIRE


    1. A001RA9C01
      B0048R7 Release the lock lever
      B0048O3 Disconnect the connector

      Release the lock lever and disconnect the connector from the brake booster pump assembly as shown in the illustration.

      Note

      Be careful not to allow any brake fluid to enter the connector.

    2. A001QP4C01
      B0048R7 Release the lock lever
      B0048O3 Disconnect the connector

      Release the lock lever and disconnect the connector from the brake actuator assembly as shown in the illustration.

      Note

      Be careful not to allow any brake fluid to enter the connector.

    3. Disengage the clamp and separate the engine room main wire.

  14. SEPARATE NO. 1 BRAKE ACTUATOR HOSE


    1. A001RZA

      Slide the clip and disconnect the No. 1 brake actuator hose from the No. 1 brake actuator tube.

    2. A001PDH

      Separate the No. 1 brake actuator hose from the brake actuator hose clamp.

  15. SEPARATE BRAKE LINE


    1. A001RRNC01
      *a From 1st Chamber of Brake Booster with Master Cylinder Assembly
      *b From 2nd Chamber of Brake Booster with Master Cylinder Assembly
      *c To Front Wheel Cylinder Assembly LH
      *d To Rear Wheel Cylinder Assembly RH
      *e To Rear Wheel Cylinder Assembly LH
      *f To Front Wheel Cylinder Assembly RH

      Use tags or make a memo to identify the places to reconnect the brake lines.

    2. A001PF0

      Using a union nut wrench, disconnect the 6 brake lines from the brake actuator assembly.

  16. SEPARATE ACCUMULATOR TO BRAKE MASTER CYLINDER TUBE


    1. A001QDS

      Using a union nut wrench, disconnect the accumulator to brake master cylinder tube from the brake booster pump assembly.

    2. Remove the bolt to separate the accumulator to brake master cylinder tube.

  17. SEPARATE BRAKE BOOSTER PUMP ASSEMBLY


    1. A001R5G

      Disengage the claw and clamp to separate the brake booster pump assembly wire harness from the brake actuator bracket assembly.

    2. A001OGAC01
      B0048R7 Move in this Direction

      Remove the nut to separate the brake booster pump assembly from the brake actuator bracket assembly.

      Tech Tips

      Move the brake booster pump assembly to the position where the lower bolt of the brake actuator assembly can be removed.

  18. REMOVE BRAKE ACTUATOR ASSEMBLY


    1. A001Q01

      Remove the 3 bolts and brake actuator assembly from the brake actuator bracket assembly.

      Note


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

      • Do not apply excessive force to the brake lines or refrigerant lines.

      • Be careful not to allow any brake fluid to enter the connector.

      • Do not drop the brake actuator assembly when carrying it.