BRAKE ACTUATOR(for LHD) REMOVAL

CAUTION / NOTICE / HINT

PROCEDURE

1. PRECAUTION

   Note

   After turning the engine 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. REMOVE FRONT WHEEL LH

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4. DRAIN BRAKE FLUID

   Note

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

5. REMOVE FRONT UPPER SUSPENSION TO COWL BRACE LH

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6. SEPARATE NO. 3 ENGINE ROOM RELAY BLOCK ASSEMBLY

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7. REMOVE WIRING HARNESS CLAMP BRACKET

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8. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

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9. REMOVE BRAKE MASTER CYLINDER O-RING

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10. DISCONNECT UNION TO CHECK VALVE HOSE

    
    

    1. 

       Slide the clip and disconnect the union to check valve hose from the brake booster assembly.

11. TEMPORARILY INSTALL BRAKE ACTUATOR WITH BRACKET

    
    

    1. Temporarily install the brake actuator with bracket with the 2 bolts and nut.

       Note

       
       

       • Do not damage the brake lines.

       • Do not hold the brake actuator with bracket by the connector.

12. REMOVE FRONT NO. 1 BRAKE TUBE

    
    

    1. 

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

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

    2. 

       Using a union nut wrench, disconnect the front No. 1 brake tube from the brake actuator assembly.

       Note

       
       

       • Do not kink or damage the front No. 1 brake tube.

       • Do not allow any foreign matter such as dirt or dust to enter the front No. 1 brake tube from the connecting parts.

    3. Disengage the clamp to remove the front No. 1 brake tube.

13. REMOVE REAR NO. 1 BRAKE TUBE

    
    

    1. 

       Using a union nut wrench, disconnect the rear No. 1 brake tube from the brake actuator assembly.

       Note

       
       

       • Do not kink or damage the rear No. 1 brake tube.

       • Do not allow any foreign matter such as dirt or dust to enter the rear No. 1 brake tube from the connecting parts.

    2. Disengage the clamp to remove the rear No. 1 brake tube.

14. REMOVE BRAKE ACTUATOR WITH BRACKET

    
    

    1. 

       	Release the lock lever
       	Disconnect the connector

       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. 

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

    3. 

       Remove the 2 bolts, nut and brake actuator with bracket.

       Note

       
       

       • Do not damage the brake lines.

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

       Tech Tips

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

15. REMOVE NO. 5 BRAKE ACTUATOR BRACKET

    
    

    1. 

       Remove the bolt and No. 5 brake actuator bracket.

16. REMOVE BRAKE ACTUATOR ASSEMBLY

    
    

    1. 

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

17. REMOVE BRAKE ACTUATOR BOLT CUSHION

    
    
    1. 

       *1	Brake Actuator Case Collar
       *2	Brake Actuator Bolt Cushion

       Remove the 3 brake actuator case collars from the brake actuator bolt cushions.

    2. Remove the 3 brake actuator bolt cushions from the brake actuator bracket assembly.