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BRAKE ACTUATOR (for RHD) REMOVAL

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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.

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  1. Click here

    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. Click here

    REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    (Click here)

  3. Click here

    DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTOR


    1. A01GXZU

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

  4. Click here

    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.

      Tip:

      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. Click here

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

  6. Click here

    REMOVE DECK BOARD ASSEMBLY (w/o Spare Tire)

  7. Click here

    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. Click here

    REMOVE BATTERY SERVICE HOLE COVER LH


    1. A01GZIME02

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

      Table 1. Text in Illustration
      *A for Standard
      *B for Ottoman
      *1 Fastening Tape
  9. Click here

    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. Click here

    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. Click here

    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. Click here

    REMOVE SKID CONTROL ECU

    (Click here)

  13. Click here

    REMOVE SKID CONTROL ECU BRACKET

    (Click here)

  14. Click here

    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. Click here

    REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A01GZHIE02

      Disconnect the wire harness clamp from the reservoir.

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

    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. Click here

    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. Click here

    REMOVE RESERVOIR BRACKET


    1. A01GX2S

      Remove the 3 bolts and reservoir bracket.

  18. Click here

    REMOVE FRONT WHEEL

  19. Click here

    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. Click here

    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. Click here

    REMOVE NO. 5 BRAKE ACTUATOR BRACKET


    1. A01GX3Y

      Remove the bolt and No. 5 brake actuator bracket.

  22. Click here

    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. Click here

    REMOVE BRAKE ACTUATOR PROTECTOR


    1. A01H0XW

      Remove the protector.

  24. Click here

    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. Click here

    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. Click here

    DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTOR BOX


    1. A01GWY5E06

      Disconnect the brake accumulator pump connector box.

      Table 3. Text in Illustration
      *1 Connector Box

      1. Detach the 2 wiring harness clamps.

      2. Remove the nut and connector box.

  27. Click here

    REMOVE NO. 4 BRAKE ACTUATOR BRACKET


    1. A01H22H

      Remove the bolt and No. 4 brake actuator bracket.

  28. Click here

    REMOVE BRAKE ACCUMULATOR PUMP


    1. A01GZ00E02

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

      Table 4. 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.

  29. Click here

    REMOVE BRAKE ACTUATOR


    1. A01H2AD

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

    2. A01GYH2E02

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

      Table 5. Text in Illustration
      *1 Cushion
      *2 Spacer
    3. A01H19Z

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