BRAKE ACTUATOR (for RHD) REMOVAL

Note

While the battery is connected, even if the power 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 or open/close the doors while the battery is connected.


  1. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A01GZ6XE01

      While using both hands, lift the rear side of the V-bank cover sub-assembly upwards to detach the 4 clips labeled B. Slide the V-bank cover sub-assembly towards 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.

  2. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  3. DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTOR


    1. A01GXZU

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

  4. 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.

  5. REMOVE LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

    A01GWKI

  6. REMOVE DECK BOARD ASSEMBLY (w/o Spare Tire)

    A01GZ3P

  7. REMOVE DECK TRIM SIDE BOARD LH (w/o Spare Tire)


    1. A01GXQQ

      Detach the 2 clips and remove the deck trim side board LH.

  8. REMOVE BATTERY SERVICE HOLE COVER LH


    1. A01GZIME02
      Text in Illustration
      *A for Standard
      *B for Ottoman
      *1 Fastening Tape

      Detach the clip, fastening tape and remove the battery service hole cover LH.

  9. PRECAUTION

    Note

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

  10. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

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

  11. DISCONNECT NO. 2 INVERTER COOLING PIPE


    1. A01GYTN

      Remove the bolt.

    2. Disconnect the No. 2 inverter cooling pipe from the skid control ECU bracket.

  12. REMOVE SKID CONTROL ECU

    Click here

  13. REMOVE SKID CONTROL ECU BRACKET

    Click here

  14. DISCONNECT NO. 3 RELAY BLOCK


    1. A01H1WM

      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.

  15. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A01GZHIE02
      Text in Illustration
      *1 Reservoir
      *2 Lock
      *3 Reservoir Connector

      Disconnect the wire harness clamp from the reservoir.

    2. Detach the connector clamp from the reservoir bracket, and then disconnect the brake fluid level warning switch connector.

    3. Disconnect the No. 1 brake actuator hose from the reservoir.

    4. Release the locks of the reservoir connectors. Then disconnect the No. 2 brake actuator hose (labeled A) and No. 1 reservoir hose (labeled B) 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.

  16. REMOVE NO. 1 RESERVOIR HOSE


    1. A01GZCR

      Remove the hose clip and No. 1 reservoir hose from the master cylinder.

    2. Remove the hose clip and reservoir connector from the No. 1 reservoir hose.

  17. REMOVE RESERVOIR BRACKET


    1. A01GX2S

      Remove the 3 bolts and reservoir bracket.

  18. REMOVE FRONT WHEEL

  19. DISCONNECT BRAKE TUBE


    1. A01GZ20

      Release the lock lever and disconnect the brake actuator connector.

      Note

      Do not allow brake fluid to contact the connector face.

    2. A01GZK0

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

    3. A01GXCIE04

      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 Brake Master Cylinder

      • *6: From Brake Stroke Simulator Cylinder

    4. A01H1YC

      Using a union nut wrench, disconnect the No. 1 and No. 2 brake actuator tubes.

      Note

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

  20. REMOVE BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY


    1. A01H18N

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

    2. A01H0NF

      Disconnect the front fender liner rear side and then remove the 2 nuts.

    3. Remove the bolt, 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.

  21. REMOVE NO. 5 BRAKE ACTUATOR BRACKET


    1. A01GX3Y

      Remove the bolt and No. 5 brake actuator bracket.

  22. 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. A01H18T

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

  23. REMOVE BRAKE ACTUATOR PROTECTOR


    1. A01H0XW

      Remove the protector.

  24. 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. A01GYY0

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

    2. A01H1V2

      Remove the hose clip and reservoir connector.

  25. 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. A01GZQM

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

  26. DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTOR BOX


    1. A01GWY5E06
      Text in Illustration
      *1 Connector Box

      Disconnect the brake accumulator pump connector box.


      1. Detach the 2 wiring harness clamps.

      2. Remove the nut and connector box.

  27. REMOVE NO. 4 BRAKE ACTUATOR BRACKET


    1. A01H22H

      Remove the bolt and No. 4 brake actuator bracket.

  28. REMOVE BRAKE ACCUMULATOR PUMP


    1. A01GZ00E02
      Text in Illustration
      *1 Brake Accumulator Pump
      *2 Clamp (A)
      *3 Bush (B)

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

    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.

  29. REMOVE BRAKE ACTUATOR


    1. A01H2AD

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

    2. A01GYH2E02
      Text in Illustration
      *1 Cushion
      *2 Spacer

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

    3. A01H19Z

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