BRAKE ACTUATOR > REMOVAL

for Preparation Click here



1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL


2. REMOVE BATTERY CLAMP SUB-ASSEMBLY (for 1ND-TV RHD)


    A198368

  1. Remove the 2 nuts and the battery clamp.



3. REMOVE BATTERY (for 1ND-TV RHD)


4. REMOVE FUEL FILTER ASSEMBLY (for 1ND-TV RHD)


    A202203

  1. Disconnect the 2 wire harness clamps.

  1. Disconnect the connector.



    A202202

  1. Disconnect the 2 connectors.



    A202864

  1. Disconnect the 2 fuel hose clamps from the fuel filter.

  1. Disconnect the 2 fuel hoses.



    A202863

  1. Loosen the fuel filter drain plug to drain fuel.

  1. Tighten the fuel filter drain plug.



    A202865

  1. Remove the 2 nuts and fuel filter.



5. DRAIN BRAKE FLUID

NOTICE:
If brake fluid leaks onto any painted surface, immediately clean it off completely.



6. REMOVE COWL PANEL SUB-ASSEMBLY

  1. Remove the cowl panel sub-assembly (Click here).



7. REMOVE HEATER ASSEMBLY (w/ Combustion Type Power Heater)

  1. Remove the heater assembly (Click here).



8. REMOVE NO. 2 HEATER BRACKET SUB-ASSEMBLY (w/ Combustion Type Power Heater)


    C197215

  1. Remove the bolt and the No. 2 heater bracket sub-assembly from the body.



9. REMOVE COWL VENTILATOR SPLASH SHIELD RH (for LHD)


    C197216

  1. Disengage the claw, guide and the cowl ventilator splash shield RH from the body.



10. REMOVE FRONT FENDER EXTENSION RH (for LHD)


    C197217

  1. Remove the 2 bolts, 3 nuts and the front fender extension RH from the body.



11. REMOVE BRAKE ACTUATOR WITH BRACKET (for LHD)


    C197218

  1. Disengage the 3 wire harness clamps from the body.



    C197219

  1. Release the lock lever and disconnect the brake actuator connector.

    NOTICE:
    Be careful not to allow brake fluid to enter the removed connector.



    C197221

  1. Using a union nut wrench (10 mm), disconnect the No. 3 brake tube from the brake tube way.



    C197222E01

  1. Using a union nut wrench (10 mm and 12 mm), disconnect the 6 brake tubes from the actuator.
    Text in Illustration 
    *1
    		Flare Nut ( 10 mm)
    *2
    		Flare Nut ( 12 mm)



    C197223E01

  1. Use tags or make a memo to identify the places to reconnect.
    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 1st of Master Cylinder
    *6
    		From 2nd of Master Cylinder



    C197220

  1. Disengage the 2 clamps and separate the brake tube assembly from the body.



    C197224

  1. Remove the 3 bolts and the brake actuator with bracket from the body.

    NOTICE:
    1. Do not damage the brake tubes or wire harness.
    2. Do not carry the brake actuator assembly by the connector.



12. REMOVE BRAKE ACTUATOR WITH BRACKET (for RHD)


    C196610

  1. Release the lock lever and disconnect the brake actuator connector.

    NOTICE:
    Be careful not to allow brake fluid to enter the removed connector.



    C196611

  1. Using a union nut wrench (10 mm), disconnect the No. 5 brake tube from the brake tube way.



    C196612E01

  1. Using a union nut wrench (10 mm and 12 mm), disconnect the 6 brake tubes from the actuator.
    Text in Illustration 
    *1
    		Flare Nut ( 10 mm)
    *2
    		Flare Nut ( 12 mm)



    C196617E01

  1. Use tags or make a memo to identify the places to reconnect.
    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 1st of Master Cylinder
    *6
    		From 2nd of Master Cylinder



    C196613

  1. Disengage the 4 clamps and separate the brake tube assembly from the body.



    C196614

  1. Remove the 3 bolts and the brake actuator with bracket from the body.

    NOTICE:
    1. Do not damage the brake tubes or wire harness.
    2. Do not carry the brake actuator assembly by the connector.



13. REMOVE BRAKE ACTUATOR BRACKET ASSEMBLY (for LHD)


    C197225

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



14. REMOVE BRAKE ACTUATOR BRACKET ASSEMBLY (for RHD)


    C196615

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