BRAKE ACTUATOR REMOVAL

CAUTION / NOTICE / HINT

Tip:

Refer to the illustration to confirm the type of brake actuator assembly.

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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)

    w/o Glow Plug Controller:Click here

    w/ Glow Plug Controller:Click here

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

    w/o Glow Plug Controller:Click here

    w/ Glow Plug Controller:Click here

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

    w/o Glow Plug Controller:Click here

    w/ Glow Plug Controller: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)

    Click here

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

    for 1WW:Click here

    for 1ND-TV:Click here

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

    1. C268171

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

    2. Disconnect the ECM connector from the ECM.

      w/o Glow Plug Controller:Click here

      w/ Glow Plug Controller:Click here

  27. DISCONNECT WIRE HARNESS (for 1WW)

    1. A318490

      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. A293219

      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. A293220

      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. A358353

      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. A293221

      Remove the 3 bolts and air cleaner bracket.

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

    1. C287024

      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. for Type A Brake Actuator Assembly:

      1. C269613N02

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

      2. 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.

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

      4. C269612C01

        *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.

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

      6. C269615

        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.

      7. 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.

    3. for Type B Brake Actuator Assembly:

      1. C287018C01
        V100135

        Release
        V100136

        Disconnect

        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. C287020C01

        *a

        From 1st Chamber of Master Cylinder Sub-assembly

        *b

        From 2nd Chamber of Master Cylinder Sub-assembly

        *c

        To Front Wheel Cylinder Assembly LH

        *d

        To Rear Wheel Cylinder Assembly RH

        *e

        To Rear Wheel Cylinder Assembly LH

        *f

        To Front Wheel Cylinder Assembly RH

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

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

      4. C287021

        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.

      5. 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. for Type A Brake Actuator Assembly:

      1. C269616

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

    2. C287022

      for Type B Brake Actuator Assembly:

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