BRAKE ACTUATOR(for RHD) REMOVAL

CAUTION / NOTICE / HINT

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.

PROCEDURE


  1. REMOVE V-BANK COVER SUB-ASSEMBLY

    Click here

  2. REMOVE COWL TOP VENTILATOR LOUVER LH

    Click here

  3. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  4. DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTOR

    Click here

  5. PERFORM ACCUMULATOR ZERO DOWN

    Click here

  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. A001DJ9

      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

    Click here

  12. REMOVE NO. 1 RESERVOIR HOSE

    Click here

  13. REMOVE RESERVOIR BRACKET

    Click here

  14. REMOVE FRONT WHEEL

  15. DISCONNECT BRAKE TUBE


    1. A001E8Y

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

    2. A001F5RE01

      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. A0019ZME02

      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. A001AXH

      Release the lock lever and disconnect the brake actuator connector.

      Note

      Do not allow brake fluid to contact the connector face.

    2. A001B40

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

    3. A001DIVE01

      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. A001AB3

      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. A001AN9

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

  19. REMOVE BRAKE ACTUATOR PROTECTOR


    1. A0019NS

      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. A001DOA

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

    2. A001A0C

      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. A001BSY

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

  22. DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTOR BOX


    1. A001E9ZE07
      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. A0019I5

      Remove the bolt and No. 4 brake actuator bracket.

  24. REMOVE BRAKE ACCUMULATOR PUMP


    1. A001AETE01
      A001EFEE04

      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. A001CCV

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

    2. A001DE9E01
      Text in Illustration
      *1 Cushion
      *2 Spacer

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

    3. A001AEK

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