BRAKE ACTUATOR REMOVAL

PROCEDURE

1. PRECAUTION

   Note

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

   Click here

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

   Note

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

   Click here

3. DRAIN BRAKE FLUID

   Note

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

4. REMOVE NO. 1 ENGINE COVER (for 1NR-FE)

   Click here

5. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 1NR-FE)

   Click here

6. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 1NR-FE)

   Click here

7. REMOVE NO. 2 CYLINDER HEAD COVER (for 1ZR-FAE)

   Click here

8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 1ZR-FAE)

   Click here

9. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 1ZR-FAE)

   Click here

10. REMOVE NO. 1 ENGINE COVER (for 1AD-FTV)

    Click here

11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 1AD-FTV)

    Click here

12. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 1AD-FTV)

    Click here

13. REMOVE NO. 1 ENGINE COVER (for 1ND-TV with No. 1 Engine Cover)

    Click here

14. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 1ND-TV)

    Click here

15. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 1ND-TV)

    Click here

16. REMOVE FUEL FILTER ASSEMBLY (for 1AD-FTV, 1ND-TV)

    for 1AD-FTV: Click here

    for 1ND-TV: Click here

17. DISCONNECT WIRE HARNESS (for 1AD-FTV, 1ND-TV)

    
    

    1. 

       Disconnect the 3 wire harness clamps from the fuel filter support.

    2. Disconnect the ECM connector from the ECM.

       for 1AD-FTV: Click here

       for 1ND-TV: Click here

18. REMOVE GLOW PLUG RELAY ASSEMBLY (for 1AD-FTV, 1ND-TV)

    
    

    1. 

       Remove the bolt and separate the glow plug relay assembly from the fuel filter support.

    2. Disengage the wire harness clamp from the fuel filter support.

19. REMOVE FUEL FILTER SUPPORT (for 1AD-FTV, 1ND-TV)

    
    

    1. 

       Disengage the wire harness clamp from the fuel filter support.

    2. Remove the 3 bolts and fuel filter support.

20. REMOVE AIR CLEANER BRACKET (for 1AD-FTV, 1ND-TV)

    
    

    1. 

       Remove the 3 bolts and air cleaner bracket.

21. REMOVE BRAKE ACTUATOR WITH BRACKET

    
    

    1. Disconnect the connector from the ECM.

       for 1NR-FE: Click here

       for 1ZR-FAE: Click here

    2. 

       Disengage the claw (a) and raise the lock lever.

    3. Engage the claw (b) and disconnect the connector from the brake actuator assembly.

       Note

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

    4. Disengage the clamp and separate the wire harness from the brake actuator bracket assembly.

    5. 

       *a	for LHD: From 1st Chamber of Master Cylinder Sub-assembly for RHD: From 2nd Chamber of Master Cylinder Sub-assembly
       *b	for LHD: From 2nd Chamber of Master Cylinder Sub-assembly for RHD: From 1st Chamber of Master Cylinder Sub-assembly
       *c	To Front Wheel Cylinder Assembly RH
       *d	To Rear Wheel Cylinder Assembly LH
       *e	To Rear Wheel Cylinder Assembly RH
       *f	To Front Wheel Cylinder Assembly LH

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

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

    7. 

       Disengage each clamp to separate the No. 2 fuel tube clamp and front No. 4 brake tube from the brake actuator bracket assembly.

       Note

       Do not damage the brake lines or fuel lines.

    8. Remove the 3 nuts and brake actuator with bracket from the vehicle body.

       Note

       Do not damage the brake lines, fuel lines or wire harness.

22. REMOVE BRAKE ACTUATOR ASSEMBLY

    
    

    1. 

       Remove the bolt, 2 nuts and brake actuator assembly from the brake actuator bracket assembly.