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BRAKE ACTUATOR 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 any door courtesy switch is turned on. Therefore, when servicing the brake system components, do not depress the brake pedal or open/close the doors while the battery is connected.

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  1. Click here

    DISCONNECT BRAKE BOOSTER PUMP CONNECTOR


    1. A01NJCZ

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

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    PERFORM ACCUMULATOR PRESSURE ZERO DOWN


    1. A01NMFPE01

      Drain the brake fluid in the reservoir tank near the MIN line.

      Table 1. Text in Illustration
      *1 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.

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    REMOVE ECM

    Tip:

    Refer to the instructions for Removal of the ECM (Click here).

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    REMOVE FRONT WHEEL

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    REMOVE BRAKE ACTUATOR AND BRAKE BOOSTER PUMP


    1. Release the lock lever and disconnect the connector.

      A01NMK5
      Note:

      Do not allow brake fluid to contact the connector face.

    2. A01NNBC

      Disconnect the 4 clamps.

    3. A01NL0CE01

      Separate the brake actuator hose and No. 2 brake actuator hose.

      Table 2. Text in Illustration
      *1 Brake Actuator Hose
      *2 No. 2 Brake Actuator Hose
    4. A01NML3

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

    5. A01NJWWE01

      Use tags or make a note to identify the reconnection locations.

      Table 3. Text in Illustration
      *1 To front wheel cylinder RH
      *2 To front wheel cylinder LH
      *3 To rear wheel cylinder RH
      *4 To rear wheel cylinder LH
      *5 From stroke simulator
      *6 From master cylinder
    6. A01NMK9

      Remove the 3 nuts and the brake actuator and brake booster pump.

      Note:

      • Do not damage the brake lines.

      • When removing the brake actuator and brake booster pump from the vehicle, do not hold it by the connectors, harnesses, hoses or lines.

      • Do not drop the brake actuator and brake booster pump. Do not use parts that have been dropped.

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    REMOVE BRAKE ACTUATOR HOSE

    Note:

    When disconnecting the brake actuator hose, be careful that there is no excessive weight applied to the union of the brake actuator (especially in the vertical direction).


    1. A01NKI2

      Remove the hose clip and the brake actuator hose.

  7. Click here

    REMOVE CONNECTOR BOX


    1. A01NI2X

      Remove the connector box.


      1. Detach the wiring harness clamp.

      2. Remove the nut and connector box.

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    REMOVE NO. 3 BRAKE ACTUATOR TUBE

    Note:

    • Do not damage the No. 3 brake actuator tube or brake actuator and brake booster pump.

    • When removing the No. 3 brake actuator tube, hold the tube and brake actuator and brake booster pump securely.


    1. A01NM8Y

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

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    REMOVE BRAKE ACTUATOR


    1. A01NLSH

      Remove the 3 nuts and brake actuator with brackets.

    2. A01NK80E01

      Remove the 3 bolts and No. 1 brake actuator bracket from the brake actuator.

    3. A01NL2DE03

      Remove the 2 cushions and 2 spacers from the No. 1 brake actuator bracket.

      Table 4. Text in Illustration
      *1 Spacer
      *2 Cushion
  10. Click here

    REMOVE NO. 2 BRAKE ACTUATOR BRACKET


    1. A01NI4EE01

      Remove the bolt and No. 2 brake actuator bracket.

    2. A01NNFJE03

      Remove the cushion and spacer from the No. 2 brake actuator bracket.

      Table 5. Text in Illustration
      *1 Spacer
      *2 Cushion
  11. Click here

    REMOVE BRAKE BOOSTER PUMP


    1. A01NLEBE03

      Break and remove the brake actuator bracket clamp and then remove the brake booster pump bushing from the brake actuator bracket.

      Table 6. Text in Illustration
      *1 Brake Actuator Bracket Clamp
      *2 Brake Booster Pump Bushing
    2. A01NMCRE02

      Remove the brake booster pump from the brake actuator bracket.

      Table 7. Text in Illustration
      *1 Brake Actuator Bracket Clamp
      *2 Brake Booster Pump Bushing
      *3 Brake Actuator Bracket
      *4 Brake Booster Pump
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    REMOVE NO. 2 BRAKE ACTUATOR HOSE

    Note:

    When disconnecting the No. 2 brake actuator hose, be careful that there is no excessive weight applied to the union of the brake accumulator (especially in the vertical direction).


    1. A01NIPI

      Remove the clip and No. 2 brake actuator hose from the brake booster pump.