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.

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2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

   Note

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

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3. DRAIN BRAKE FLUID

   Note

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

4. SEPARATE NO. 6 BRAKE TUBE CLAMP

   
   

   1. 

      Remove the bolt and separate the No. 6 brake tube clamp.

5. SEPARATE SUCTION HOSE SUB-ASSEMBLY

   
   

   1. 

      Disengage the clamp to separate the suction hose sub-assembly from the piping clamp.

      Note

      
      

      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

   2. for 1AR-FE:

      
      

      1. 

         Remove the bolt and separate the suction hose sub-assembly from the brake actuator bracket assembly.

         Note

         
         

         • Do not deform the refrigerant lines.

         • Do not damage the clamp.

   3. for 2GR-FKS:

      
      

      1. 

         Disengage the claw to separate the suction hose sub-assembly from the suction hose clamp.

         Note

         
         

         • Do not deform the refrigerant lines.

         • Do not damage the clamp.

6. SEPARATE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY

   
   

   1. 

      Disengage the clamp to separate the air conditioner tube and accessory assembly from the piping clamp.

      Note

      
      

      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

   2. 

      Remove the bolt and separate the air conditioner tube and accessory assembly.

      Note

      
      

      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

7. REMOVE BRAKE ACTUATOR WITH BRACKET

   
   

   1. 

      Release the lock lever

      Release the lock lever and disconnect the connector from the brake actuator assembly.

      Note

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

   2. Disengage the clamp from the brake actuator bracket assembly.

   3. 

      *a	for LHD: From 1st Chamber of Brake Master Cylinder Sub-assembly for RHD: From 2nd Chamber of Brake Master Cylinder Sub-assembly
      *b	for LHD: From 2nd Chamber of Brake Master Cylinder Sub-assembly for RHD: From 1st Chamber of Brake 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

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

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

      Note

      
      

      • Do not kink or damage the brake lines.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

   5. 

      Remove the 3 bolts.

   6. Disengage the claw to remove the brake actuator with bracket.

      Note

      
      

      • Do not damage the brake lines.

      • Do not deform the refrigerant lines.

      • Do not hold the brake actuator assembly by the connector.

      Tech Tips

      Remove the brake actuator with bracket while avoiding the brake lines and refrigerant lines.

8. REMOVE BRAKE ACTUATOR ASSEMBLY

   
   

   1. 

      Disengage the 2 claws to remove the piping clamp.

   2. 

      Remove the 3 bolts and brake actuator assembly from the brake actuator bracket assembly.