BRAKE ACTUATOR (for RHD) REMOVAL

Note

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


  1. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A01GMKRE01

      Using both hands, lift the rear side of the cover upwards to detach the 4 clips labeled B. Then slide the cover toward the front of the vehicle to detach the 2 clips labeled A and remove the V-bank cover sub-assembly.

      Note


      • The V-bank cover sub-assembly may be damaged if its front and rear are lifted at the same time.

      • When detaching the clips labeled A, be sure to slide the cover toward the front of the vehicle.

  2. REMOVE COWL TOP VENTILATOR LOUVER LH


    1. A01GM4S

      for LHD:

      Remove the 6 clips and cowl top ventilator louver RH.

    2. A01GI9P

      for RHD:

      Remove the 6 clips and cowl top ventilator louver LH.

  3. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  4. DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTOR


    1. A01GN5S

      With the power switch off, disconnect the 2 brake accumulator pump connectors.

  5. PERFORM ACCUMULATOR ZERO DOWN


    1. Drain the brake fluid in the reservoir tank near the MIN line.

    2. Connect the intelligent tester to the DLC3 with the power switch off.

    3. Turn the power switch on (IG).

    4. Turn the intelligent tester on and enter the following menus: Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Utility / Zero Down.

      Tech Tips

      Using the intelligent tester to perform accumulator zero down causes the pressurized fluid in the accumulator to be returned to the brake fluid reservoir.

    5. When the buzzer sounds, turn the power switch off.

    6. Turn the intelligent tester off.

  6. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the battery terminal, Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  8. REMOVE SKID CONTROL ECU

    Click here

  9. REMOVE SKID CONTROL ECU BRACKET

    Click here

  10. DISCONNECT NO. 3 RELAY BLOCK


    1. A01GIQR

      While pushing the claw of the No. 3 relay block, pull out the No. 3 relay block and disconnect it from the reservoir bracket.

      Note

      Do not allow brake fluid to contact the No. 3 relay block.

  11. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A01GLXTE01

      Disconnect the wire harness clamp (labeled A) from the reservoir.

    2. Detach the connector clamp (labeled B) from the reservoir bracket, and then disconnect the brake fluid level warning switch connector (labeled C).

    3. Disconnect the No. 1 brake actuator hose (labeled D) from the reservoir.

    4. A01GKWQE02
      Text in Illustration
      *1 Reservoir
      *2 Lock
      *3 Reservoir Connector

      Release the locks of the reservoir connectors. Then disconnect the No. 2 brake actuator hose (labeled E) and No. 1 reservoir hose (labeled F) from the reservoir.

      Note


      • Check for any dirt and foreign matter contamination in the reservoir and around the reservoir connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the reservoir and reservoir connector.

      • Do not use any tools to separate the reservoir and reservoir connector.

      • If the reservoir and reservoir connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.

      • Put the reservoir and reservoir connector ends in plastic bags to prevent damage and dirt contamination.

    5. Remove the 2 bolts and brake fluid reservoir.

  12. REMOVE NO. 1 RESERVOIR HOSE


    1. A01GJI6E01

      Remove the hose clip (labeled A) and No. 1 reservoir hose (labeled B) from the master cylinder.

    2. Remove the hose clip (labeled C) and reservoir connector (labeled D) from the No. 1 reservoir hose (labeled B).

  13. REMOVE RESERVOIR BRACKET


    1. A01GK8N

      Remove the 3 bolts and reservoir bracket.

  14. REMOVE FRONT WHEEL

  15. DISCONNECT BRAKE TUBE


    1. A01GNOP

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

    2. A01GJ4QE04

      Use tags or make a note to identify the reconnection locations.


      • *1: To FR RH

      • *2: To FR LH

      • *3: To: RR RH

      • *4: To RR LH

      • *5: From Master Cylinder

      • *6: From Stroke Simulator

    3. A01GN1XE01

      Using a union nut wrench, disconnect the No. 1 (labeled A) and No. 2 (labeled B) brake actuator tubes.

      Note

      Do not damage the No. 1 and No. 2 brake actuator tubes.

  16. REMOVE BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY


    1. A01GHY8

      Release the lock lever and disconnect the brake actuator connector.

      Note

      Do not allow brake fluid to contact the connector face.

    2. A01GJPL

      Disconnect the No. 1 brake actuator hose from the clamp and then remove the clamp.

    3. A01GN9EE01

      Disconnect the front fender liner rear side and then remove the 2 nuts (labeled A).

    4. Remove the bolt (labeled B) and brake actuator and brake accumulator pump.

      Note


      • Do not damage the brake tubes.

      • When removing the brake actuator and brake accumulator pump from the vehicle, do not hold the connector, harness, hose or tube parts.

      • Do not drop the brake actuator and brake accumulator pump. Do not use parts that have been dropped.

  17. REMOVE NO. 5 BRAKE ACTUATOR BRACKET


    1. A01GJ8F

      Remove the bolt and No. 5 brake actuator bracket.

  18. REMOVE NO. 1 BRAKE ACTUATOR HOSE

    Note

    When disconnecting the hose, be careful that there is no excessive weight applied to the union of the brake actuator (especially in the union rotation direction).


    1. A01GJY0

      Remove the hose clip and the No. 1 brake actuator hose.

  19. REMOVE BRAKE ACTUATOR PROTECTOR


    1. A01GINX

      Remove the protector.

  20. REMOVE NO. 2 BRAKE ACTUATOR HOSE

    Note

    When disconnecting the hose, be careful that there is no excessive weight applied to the union of the brake accumulator pump (especially in the union rotation direction).


    1. A01GMR7

      Remove the hose clip and No. 2 brake actuator hose.

    2. A01GK24

      Remove the hose clip and reservoir connector.

  21. REMOVE NO. 3 BRAKE ACTUATOR TUBE

    Note


    • Do not damage the No. 3 brake actuator tube, brake actuator and brake accumulator pump.

    • When removing the No. 3 brake actuator tube, hold the tube, brake actuator and brake accumulator pump securely.


    1. A01GK8O

      Using a union nut wrench, disconnect the No. 3 brake actuator tube.

  22. DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTOR BOX


    1. A01GIW0E04
      Text in Illustration
      *1 Connector Box

      Disconnect the brake accumulator pump connector box as follows:


      1. Detach the 2 wiring harness clamps (labeled A).

      2. Remove the nut (labeled B) and connector box.

  23. REMOVE NO. 4 BRAKE ACTUATOR BRACKET


    1. A01GLI0

      Remove the bolt and No. 4 brake actuator bracket.

  24. REMOVE BRAKE ACCUMULATOR PUMP


    1. A01GN05E01
      A01GJE5E04

      Break and remove the brake actuator bracket clamp (labeled A), and then remove the brake accumulator pump.

      Text in Illustration
      *1 Brake Accumulator Pump
      *2 Clamp (A)
      *3 Bush (B)

    2. Remove the brake booster pump bush (labeled B) from the brake actuator bracket.

    3. Remove the brake booster pump bushes (labeled C) and brake booster pump collars (labeled D) from the brake accumulator pump.

  25. REMOVE BRAKE ACTUATOR


    1. A01GI48

      Remove the 3 bolts, brake actuator bracket and brake actuator.

    2. A01GI3OE02
      Text in Illustration
      *1 Cushion
      *2 Spacer

      Remove the 3 cushions and 3 spacers from the brake actuator bracket.

    3. A01GLCK

      Remove the 3 bolts and No. 3 brake actuator bracket from the brake actuator.