Toyota Yaris: Brake Actuator / Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the brake actuator assembly removal/installation are shown below.

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal.

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2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

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3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

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4. DRAIN BRAKE FLUID

NOTICE:

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

5. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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6. REMOVE FRONT NO. 1 VENTILATOR SEAL

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7. REMOVE WATER GUARD PLATE RH

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8. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

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9. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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10. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

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11. REMOVE DASH PANEL HEAT INSULATOR

(a) Remove the nut.

(b) Remove the nut, clamp and dash panel heat insulator.

12. SEPARATE RESERVE SEALED TANK

(a) Remove the 2 bolts to separate the reserve sealed tank.

13. REMOVE AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY

(a) Remove the bolt.

(b) Rotate the hook connector and disconnect the air conditioning tube and accessory assembly as shown in the illustration.

(c) Remove the 2 O-rings from the air conditioning tube and accessory assembly.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

(d) Disengage the 2 clamps to separate the air conditioning tube and accessory assembly.

14. REMOVE BRAKE ACTUATOR WITH BRACKET

(a) Move aside the air conditioning tube and accessory assembly as shown in the illustration.

Move in this Direction

NOTICE:

Do not apply excessive force to the air conditioning tube and accessory assembly.

(b) Release the lock lever and disconnect the connector from the brake actuator assembly.

	Release the lock lever
	Disconnect the connector

NOTICE:

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

(c) Use tags or make a memo to identify the places to reconnect the brake lines.

*a From 1st Chamber of Brake Master Cylinder Sub-assembly *b From 2nd Chamber of Brake 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

(d) Using a union nut wrench, disconnect the 6 brake lines from the brake actuator assembly. NOTICE: Do not kink or damage the brake lines. Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

(e) Disengage the 5 clamps to remove the No. 1 brake tube clamp from the brake lines. NOTICE: Do not kink or damage the brake lines.

(f) Disengage the 5 clamps to remove the No. 2 brake tube clamp from the brake lines.

(g) Disengage the clamp and remove the No. 2 brake tube clamp from the vehicle body.

(h) Remove the 2 nuts.

(i) Remove the bolt and brake actuator with bracket. NOTICE: Do not kink or damage the brake lines. Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts. Be careful not to allow any brake fluid to enter the connector. Do not hold the brake actuator assembly by the connector. Do not drop the brake actuator with bracket when carrying it. HINT: Remove the brake actuator with bracket while avoiding the brake lines.

15. REMOVE NO. 1 BRAKE ACTUATOR BRACKET

(a) Remove the 3 nuts and No. 1 brake actuator bracket from the brake actuator bracket assembly. NOTICE: Do not hold the brake actuator assembly by the connector. Be careful not to allow any brake fluid to enter the connector. Do not drop the brake actuator assembly when carrying it.

16. REMOVE BRAKE ACTUATOR ASSEMBLY

(a) Remove the 3 bolts and brake actuator assembly from the brake actuator bracket assembly. NOTICE: Do not hold the brake actuator assembly by the connector. Be careful not to allow any brake fluid to enter the connector. Do not drop the brake actuator assembly when carrying it.

17. REMOVE NO. 1 BRAKE ACTUATOR CASE COLLAR

(a) Remove the 3 No. 1 brake actuator case collars from the brake actuator bracket cushion.

18. REMOVE BRAKE ACTUATOR BRACKET CUSHION

(a) Remove the 3 brake actuator bracket cushions from the brake actuator bracket assembly.