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Home >> Lexus >> 2019 >> RX 450h Base >> Repair and Diagnosis >> Brakes >> Traction Control >> Brake Control System (Service Information) >> Brake Actuator >> Removal [08/2019 - ] >> Procedure

Removal [08/2019 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Refer to PRECAUTION [08/2019 - ]

  2. DISCONNECT BRAKE BOOSTER PUMP CONNECTOR 
    1. With the power switch off, disconnect the 2 brake booster pump connectors.
      GTY637613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. PERFORM ACCUMULATOR PRESSURE ZERO DOWN 
    1. Drain the brake fluid in the brake master cylinder reservoir assembly to near the MIN line.
      GTY789676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Type A
      *B Type B
      *a MIN Line
    2. Connect the Techstream to the DLC3 with the power switch off.
    3. Check that the parking brake is applied, and turn the power switch on (IG).
    4. Turn the Techstream on and enter the following menus: Chassis / ABS/VSC/TRAC / Utility / ECB (Electronically Controlled Brake System) Utility / Zero Down.

      Chassis > ABS/VSC/TRAC > Utility 

      Tester Display
      ECB Utility

      HINT: 

      Using the Techstream to perform accumulator pressure zero down causes the pressurized brake fluid in the accumulator to be returned to the brake master cylinder reservoir assembly.

    5. When the buzzer sounds, turn the power switch off.
    6. Turn the Techstream off and disconnect the Techstream from the DLC3.
  4. DRAIN BRAKE FLUID 
    NOTE:

    If brake fluid leaks onto any painted surface, immediately wash it off.

  5. REMOVE DECK BOARD ASSEMBLY (w/o Rear No. 2 Seat) 

    Refer to PROCEDURE - Step 2

  6. REMOVE REAR DECK FLOOR BOX (w/o Rear No. 2 Seat) 

    Refer to PROCEDURE - Step 4

  7. REMOVE REAR NO. 4 FLOOR BOARD (w/ Rear No. 2 Seat) 

    Refer to PROCEDURE - Step 3

  8. REMOVE BATTERY SERVICE HOLE COVER (w/ Rear No. 2 Seat) 

    Refer to PROCEDURE - Step 4

  9. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    w/o Rear No. 2 Seat: Refer to PROCEDURE - Step 4 [08/2019 - ]

    w/ Rear No. 2 Seat: Refer to PROCEDURE - Step 5 [08/2019 - ]

  10. REMOVE ECM ASSEMBLY 

    Refer to REMOVAL [08/2019 - ]

  11. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [10/2015 - ]

  12. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  13. REMOVE V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 25

  14. SEPARATE NO. 1 RESERVOIR HOSE 
    1. Slide the clip and disconnect the No. 1 reservoir hose from the reservoir tube.
      GTY622686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. SEPARATE NO. 2 RESERVOIR HOSE 
    1. Slide the clip and disconnect the No. 2 reservoir hose from the reservoir tube.
      GTY622688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Disconnect the 2 connectors from the brake master cylinder reservoir assembly and air conditioner tube and accessory assembly.
      GTY677513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps to separate the wire harness from the brake master cylinder reservoir assembly.
    3. Slide the 2 clips and disconnect the brake actuator hose and No. 2 brake actuator hose from the brake master cylinder reservoir assembly.
      GTY671364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Actuator Hose
      *2 No. 2 Brake Actuator Hose
    4. Remove the 2 nuts and brake master cylinder reservoir assembly.
      GTY635278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE RESERVOIR BRACKET 
    1. Disengage the clamp to separate the wire harness from the reservoir bracket.
      GTY635281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, 2 nuts and reservoir bracket.
  18. REMOVE BRAKE ACTUATOR WITH BRACKET 
    1. Release the lock lever and disconnect the connector from the brake actuator assembly.
      GTY666139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Release the lock lever
      Disconnect the connector
      NOTE:

      Be careful not to allow any brake fluid to enter the connector.

    2. Use tags or make a memo to identify the places to reconnect the brake lines.
      GTY635133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a From Brake Stroke Simulator Cylinder Sub-assembly
      *b From Brake 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
    3. Using a union nut wrench, disconnect the 6 brake lines from the brake actuator assembly.
      GTY635266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and separate the brake tube clamp from the vehicle body.
      GTY635265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the nut and separate the connector box.
      GTY635268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a union nut wrench, separate the No. 1 brake actuator tube from the brake actuator assembly.
      GTY635267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not kink or damage the No. 1 brake actuator tube.
      • Do not allow any foreign matter such as dirt or dust to enter the No. 1 brake actuator tube from the connecting parts.
    7. Remove the bolt and No. 1 brake tube clamp to separate the No. 1 brake actuator tube from the No. 1 brake actuator bracket.
      GTY635270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the bolt, nut and No. 1 brake actuator bracket.
      GTY635269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the brake actuator bracket spacer and brake actuator bracket cushion from the No. 1 brake actuator bracket assembly.
      GTY635058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the 2 nuts and brake actuator with bracket.
      GTY635272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not kink or damage the brake lines.
      • Do not hold the brake actuator with bracket by the connector, hose or union.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

      HINT: 

      Remove the brake actuator with bracket while avoiding the brake lines.

  19. REMOVE BRAKE ACTUATOR HOSE 
    1. Slide the clip and disconnect the brake actuator hose from the brake actuator assembly to remove it.
      GTY635273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE BRAKE ACTUATOR ASSEMBLY 
    1. Remove the 3 bolts and brake actuator assembly from the brake actuator bracket assembly.
      GTY635057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 brake actuator bracket spacers and 2 brake actuator bracket cushions from the brake actuator bracket assembly.
      GTY677466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. SEPARATE SUCTION PIPE SUB-ASSEMBLY 
    1. Disengage the clamp to separate the suction pipe sub-assembly.
      GTY677514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not deform the refrigerant lines.
      • Do not damage the clamp.
  22. SEPARATE NO. 3 ECM BRACKET 
    1. Remove the 2 bolts and separate the No. 3 ECM bracket.
      GTY635283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. SEPARATE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 
    1. Remove the bolt and separate the air conditioner tube and accessory assembly.
      GTY635284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not deform the refrigerant lines.

  24. REMOVE BRAKE BOOSTER PUMP ASSEMBLY WITH BRACKET 
    1. Remove the bolt and washer inlet.
      GTY635280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the No. 2 brake actuator hose from the brake actuator hose clamp.
      GTY678476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Actuator Hose Clamp
    3. Disengage the clamp to separate the wire harness from the brake booster pump assembly with bracket.
      GTY635271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and 2 nuts and brake booster pump assembly with bracket from the vehicle body.
      GTY677512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not hold the brake booster pump assembly with bracket by the connector, hose, brake tube, union or wire harness.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.
      • Do not damage the vehicle body.
      • Do not apply excessive force to the refrigerant lines.
      • Do not kink or damage the brake lines.
  25. REMOVE NO. 1 BRAKE ACTUATOR TUBE 
    1. Using a union nut wrench, remove the No. 1 brake actuator tube from the brake booster pump assembly.
      GTY635264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not kink or damage the No. 1 brake actuator tube and brake booster pump assembly.
      • Do not allow any foreign matter such as dirt or dust to enter the No. 1 brake actuator tube from the connecting parts.
  26. REMOVE BRAKE BOOSTER PUMP ASSEMBLY 
    1. Disengage the clamp to separate the wire harness.
      GTY635060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, nut and brake actuator bracket assembly from the brake booster pump assembly with bracket.
      GTY677467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 brake actuator bracket cushions from the brake actuator bracket assembly.
      GTY635065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Break the brake actuator bracket clamp to disengage the claw, and then remove the brake booster pump bushing from the brake actuator bracket assembly.
      GTY670588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Actuator Bracket Clamp
      *2 Brake Booster Pump Bushing
    5. Remove the brake booster pump assembly from the brake actuator bracket assembly.
      GTY635055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the brake actuator bracket cushion from the brake actuator bracket assembly.
      GTY635054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 2 BRAKE ACTUATOR HOSE 
    1. Slide the clip and disconnect the No. 2 brake actuator hose from the brake booster pump assembly to remove it.
      GTY677463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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