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-FE)

   Click here

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

   Click here

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

   Click here

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

    Click here

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

    Click here

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

    Click here

13. REMOVE NO. 2 CYLINDER HEAD COVER (for 2ZR-FE)

    Click here

14. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FE)

    Click here

15. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 2ZR-FE)

    Click here

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

    Click here

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

    Click here

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

    Click here

19. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (for 8NR-FTS)

    Click here

20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 8NR-FTS)

    Click here

21. REMOVE NO. 1 ENGINE COVER (for 1WW)

    Click here

22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY (for 1WW)

    Click here

23. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 1WW)

    Click here

24. REMOVE NO. 1 FUEL FILTER PROTECTOR (for 1WW)

    w/ Fuel Heater Relay:Click here

    w/o Fuel Heater Relay:Click here

25. REMOVE FUEL FILTER ASSEMBLY (for 1WW, 1ND-TV)

    for 1WW (w/ Fuel Heater Relay):Click here

    for 1WW (w/o Fuel Heater Relay):Click here

    for 1ND-TV:Click here

26. DISCONNECT WIRE HARNESS (for 1ND-TV)

    1. 

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

    2. Disconnect the ECM connector from the ECM.

       Click here

27. DISCONNECT WIRE HARNESS (for 1WW)

    1. 

       Disconnect the connector.

    2. Disengage the 2 clamps to disconnect the engine wire.

    3. Disconnect the ECM connector from the ECM.

       Click here

28. REMOVE GLOW PLUG RELAY ASSEMBLY (for 1WW, 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.

29. REMOVE FUEL FILTER SUPPORT (for 1ND-TV)

    1. 

       Disengage the wire harness clamp from the fuel filter support.

    2. Remove the 3 bolts and fuel filter support.

30. REMOVE FUEL FILTER SUPPORT (for 1WW)

    1. 

       Disengage the wire harness clamp from the fuel filter support.

    2. Remove the 3 bolts and fuel filter support.

31. REMOVE AIR CLEANER BRACKET (for 1WW, 1ND-TV)

    1. 

       Remove the 3 bolts and air cleaner bracket.

32. REMOVE BRAKE ACTUATOR COVER (for 1WW, 1ND-TV with VSC)

    1. 

       Raise the claw and remove the brake actuator cover from the brake actuator assembly.

33. REMOVE BRAKE ACTUATOR WITH BRACKET

    1. Disconnect the connector from the ECM.

       for 1NR-FE:Click here

       for 1ZR-FE:Click here

       for 1ZR-FAE:Click here

       for 2ZR-FE:Click here

       for 8NR-FTS: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.

34. REMOVE BRAKE ACTUATOR ASSEMBLY

    1. 

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