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Brake Actuator: Removal

NOTE: While the battery is connected, even if the engine switch is off, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal and open/close the doors while the battery is connected.
  1. REMOVE V-BANK COVER SUB-ASSEMBLY  (See REMOVAL )
  2. REMOVE COWL TOP VENTILATOR LOUVER RH  (See REMOVAL )
  3. REMOVE FRONT WIPER ARM LH  (See REMOVAL )
  4. REMOVE FRONT WIPER ARM RH  (See REMOVAL )
  5. REMOVE ENGINE ROOM SIDE COVER LH  (See REMOVAL )
  6. REMOVE ENGINE ROOM SIDE COVER RH  (See REMOVAL )
  7. REMOVE FRONT FENDER PROTECTOR UPPER LH  (See REMOVAL )
  8. REMOVE FRONT FENDER PROTECTOR UPPER RH  (See REMOVAL )
  9. REMOVE HOOD TO COWL TOP SEAL  (See REMOVAL )
  10. REMOVE FRONT FENDER TO COWL SIDE SEAL LH  (See REMOVAL )
  11. REMOVE FRONT FENDER TO COWL SIDE SEAL RH  (See REMOVAL )
  12. REMOVE COWL TOP VENTILATOR LOUVER PROTECTOR LH  (See REMOVAL )
  13. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  14. DRAIN BRAKE FLUID 
    NOTE: If brake fluid leaks onto any painted surface, wash or remove it completely.
  15. PERFORM ACCUMULATOR PRESSURE ZERO DOWN 
    CAUTION: Be sure to perform this procedure before removing the brake actuator and brake accumulator pump.
    1. Connect the Techstream to the DLC3 with the engine switch off.
    2. Turn the engine switch on (IG).
    3. Turn the Techstream ON and perform accumulator zero down by following the prompts displayed on the Techstream.

      HINT:

      Select: Chassis / ABS/VSC/TRC / Utility / Electronically Controlled Brake system Utility / Zero Down.

    4. When the buzzer sounds, turn the engine switch off.
      NOTE: Do not push the engine switch on (IG). If the engine switch is pushed on (IG), the brake accumulator pump operates so that the brake accumulator is accumulated with brake fluid.
  16. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
    NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
  17. REMOVE SKID CONTROL ECU  (See REMOVAL  )
  18. REMOVE SKID CONTROL ECU BRACKET  (See REMOVAL  )
  19. DISCONNECT NO. 3 RELAY BLOCK 
    1. While pushing the claw of the No. 3 relay block, pull out the No. 3 relay block and disconnect it from the reservoir bracket.
      Fig 1: Locating No. 3 Relay Block
      G04949699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not allow brake fluid to contact the No. 3 relay block.
  20. REMOVE BRAKE FLUID RESERVOIR  (See REMOVAL )
  21. REMOVE NO. 1 RESERVOIR HOSE  (See REMOVAL )
  22. REMOVE RESERVOIR BRACKET  (See REMOVAL )
  23. REMOVE FRONT WHEEL 
  24. DISCONNECT BRAKE TUBE 
    1. Using a union nut wrench, disconnect the 6 brake tubes from the actuator.
      Fig 2: Locating Brake Tubes
      G05848314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Use tags or make a note to identify the reconnection locations.
      Fig 3: Identifying Stroke Simulator And Master Cylinder Tubes
      G04949701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a union nut wrench, disconnect the No. 1 (labeled A) and No. 2 (labeled B) brake actuator tubes.
      NOTE: Do not damage the No. 1 and No. 2 brake actuator tubes.
      Fig 4: Locating Brake Actuator Tubes Union Nuts
      G05848316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE BRAKE ACTUATOR AND BRAKE ACCUMULATOR PUMP ASSEMBLY 
    1. Release the lock lever and disconnect the brake actuator connector.
      NOTE: Do not allow brake fluid to contact the connector face.
      Fig 5: Releasing Lock Lever
      G04949703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 brake accumulator pump connectors.
      NOTE: Do not allow brake fluid to contact the connector faces.
      Fig 6: Locating Brake Accumulator Pump Connectors
      G04949820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the No. 1 brake actuator hose from the clamp and then remove the clamp.
      Fig 7: Identifying No. 1 Brake Actuator Hose From Clamp
      G04949705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the front fender liner rear side and then remove the 2 nuts (labeled A).
    5. Remove the bolt (labeled B) and brake actuator and brake accumulator pump.
      NOTE:
      • Do not damage the brake tubes.
      • When removing the brake actuator and brake accumulator pump from the vehicle, do not hold the connector, harness, hose or tube parts.
      • Do not drop the brake actuator and brake accumulator pump. Do not use parts that have been dropped.
        Fig 8: Locating Brake Actuator And Brake Accumulator Pump Nuts And Bolt
        G04949706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 5 BRAKE ACTUATOR BRACKET 
    1. Remove the bolt and No. 5 brake actuator bracket.
  27. REMOVE NO. 1 BRAKE ACTUATOR HOSE 
    NOTE: When disconnecting the hose, be careful that there is no excessive weight applied to the union of the brake actuator (especially in the union rotation direction).
    Fig 9: Identifying No. 5 Brake Actuator Bracket Bolt
    G04949707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the hose clip and the No. 1 brake actuator hose.
      Fig 10: Identifying No. 1 Brake Actuator Hose And Clip
      G04949708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE BRAKE ACTUATOR PROTECTOR 
    1. Remove the protector.
  29. REMOVE NO. 2 BRAKE ACTUATOR HOSE 
    NOTE: When disconnecting the hose, be careful that there is no excessive weight applied to the union of the brake accumulator pump (especially in the union rotation direction).
    Fig 11: Locating Brake Actuator Protector
    G04949709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the No. 2 brake actuator hose from the No. 3 brake actuator bracket and then remove the clamp.
    2. Remove the hose clip and No. 2 brake actuator hose.
      Fig 12: Identifying No. 2 Brake Actuator Hose Clip
      G04949710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the hose clip and reservoir connector.
  30. REMOVE NO. 3 BRAKE ACTUATOR TUBE 
    NOTE:
    • Do not damage the No. 3 brake actuator tube, brake actuator and brake accumulator pump.
    • When removing the No. 3 brake actuator tube, hold the tube, brake actuator and brake accumulator pump securely.
      Fig 13: Identifying Hose Clip And Reservoir Connector
      G04949711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a union nut wrench, disconnect the No. 3 brake actuator tube.
      Fig 14: Locating No. 3 Brake Actuator Tube Nuts
      G05848326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. DISCONNECT BRAKE ACCUMULATOR PUMP CONNECTOR BOX 
    1. Disconnect the brake accumulator pump connector box as follows:
      1. Detach the wiring harness clamp (labeled A).
      2. Remove the nut (labeled B) and connector box.
        Fig 15: Identifying Brake Accumulator Pump Connector Box With Clamp And Nut
        G04949713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 4 BRAKE ACTUATOR BRACKET 
    1. Remove the bolt and No. 4 brake actuator bracket.
      Fig 16: Identifying No. 4 Brake Actuator Bracket Bolt
      G04949714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE BRAKE ACCUMULATOR PUMP 
    1. Break and remove the brake actuator bracket clamp (labeled A), and then remove the brake accumulator pump.
      Fig 17: Locating Brake Accumulator Pump Clamp
      G04949715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the brake booster pump bush (labeled B) from the brake actuator bracket.
    3. Remove the brake booster pump bush (labeled C) and brake booster pump collar (labeled D) from the brake accumulator pump.
      Fig 18: Identifying Brake Booster Pump Bush And Clamp
      G04949716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE BRAKE ACTUATOR 
    1. Remove the 3 bolts, brake actuator bracket and brake actuator.
      Fig 19: Identifying Brake Actuator Bracket And Brake Actuator With Bolts
      G04949717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 cushions and 3 spacers from the brake actuator bracket.
      Fig 20: Identifying Brake Actuator Bracket Cushions And Spacers
      G04949718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 bolts and No. 3 brake actuator bracket from the brake actuator.
      Fig 21: Identifying No. 3 Brake Actuator Bracket With Bolts
      G04949719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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