Lexus RX400h, Hybrid 3 2006

Actuator

Print

Removal & Installation




NOTE
This procedure requires specialized tools. Please read through the entire procedure and make sure you have access to the proper equipment before proceeding.


WARNING
If brake fluid spills on any painted surface, wash or otherwise remove it completely or it will eat through the vehicle-s paint.

  1. Perform the accumulator zero down, as outlined under the Bleeding Procedure at the beginning of this section.
  2.  
  3. Remove the ABS motor relay. When removing the ABS motor relay remove the 2 ABS motor relays with the ignition switch OFF in order to disable brake control.
    WARNING
    If the pump motor operates while air remains inside the brake reservoir tube no.1 hose, air will enter the actuator, and this will make bleeding the brakes more difficult.


    NOTE
    After the brake actuator assembly has been replaced, remove the ABS motor relay before bleeding the brakes.



    Click image to see an enlarged view

    Fig. Location of the 2 ABS motor relays

  4.  
  5. Drain brake fluid
  6.  
  7. Remove brake master cylinder reservoir as follows:
    1. Disconnect the warning switch connector.
    2.  
    3. Separate the brake actuator hose from the clamp.
    4.  
    5. Remove the 2 clips and brake actuator hose.
    6.  
    7. Remove the 2 clips and 2 reservoir tubes from the brake master cylinder reservoir assembly.
    8.  
    9. Remove the 2 bolts and the brake master cylinder reservoir assembly.

      Click image to see an enlarged view

      Fig. Removing the master cylinder reservoir

    10.  

  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the right front tire and wheel assembly.
  12.  
  13. Remove the brake actuator assembly with bracket, as follows:
    1. Remove the bolt and the brake actuator bracket no.7 with clamp.

      Click image to see an enlarged view

      Fig. Remove the bolt and the brake actuator bracket no.7 with clamp

    2.  
    3. Using special tool 09023-00101 or equivalent, disconnect the 6 brake tubes from the actuator assembly with brake actuator bracket assembly.

      Click image to see an enlarged view

      Fig. Using special tool 09023-00101 or equivalent, disconnect the 6 brake tubes from the actuator assembly with brake actuator bracket assembly

    4.  
    5. Tag or note the installed positions of the brake lines when disconnecting them.

      Click image to see an enlarged view

      Fig. Tag or note the installed positions of the brake lines when disconnecting them

    6.  
    7. Using special tool 09023-00101, disconnect the front brake no.8 tube.

      Click image to see an enlarged view

      Fig. Using special tool 09023-00101, disconnect the front brake no.8 tube

    8.  
    9. Release the lock lever and disconnect the actuator connector.
    10.  
    11. Remove the bolt from the brake tube bracket.

      Click image to see an enlarged view

      Fig. Release the lock lever and disconnect the actuator connector. Remove the bolt from the brake tube bracket

    12.  
    13. Remove the 3 nuts and brake actuator assembly with brake actuator bracket assembly.
      WARNING
      Do not damage the brake tubes when removing them.

    14.  

  14.  
  15. To disassemble and remove brake actuator assembly:
    1. Remove the 2 nuts and brake actuator assembly from the actuator bracket.
    2.  
    3. Remove the 2 brake actuator bolt holders.
    4.  

  16.  

To install:

  1. To assemble and install brake actuator assembly:
    1. Install the 2 brake actuator bolt holders.
    2.  
    3. Install the brake actuator assembly to the actuator bracket with the 2 nuts and tighten to 71 inch lbs. (8.0 Nm).
      NOTE
      Do not remove the hole plug before connecting the brake tube because a new brake actuator assembly is filled with brake fluid.

    4.  

  2.  
  3. Install the brake actuator assembly, as follows:
    1. Install the brake actuator assembly with bracket to the body with the 3 nuts. Tighten to 14 ft. lbs. (19 Nm).
      WARNING
      Do not damage the brake tubes when connecting them.



      Click image to see an enlarged view

      Fig. Install the brake actuator assembly with bracket to the body with the 3 nuts. Tighten to 14 ft. lbs. (19 Nm)

    2.  
    3. Connect the brake actuator connector.
      NOTE
      Make sure that the connector is locked securely.

    4.  
    5. Install the brake tube bracket with the bolt and tighten to 44 inch lbs. (5 Nm).
    6.  
    7. Using the special tool, connect the front brake no.8 tube to the front flexible hose. Tighten to 11 ft. lbs. (15 Nm).
    8.  
    9. Using the special tool, connect each brake tube to the correct positions on top of the actuator assembly with bracket as shown in the illustration and as tagged during removal. Tighten to 11 ft. lbs. (15 Nm).
    10.  
    11. Install the brake actuator bracket no.7 with clamp with the bolt and tighten to 14 ft. lbs. (19 Nm).
    12.  

  4.  
  5. Install the front wheel, then lower the vehicle. Tighten the lug nuts to 76 ft. lbs. (103 Nm).
  6.  
  7. Install the brake master cylinder reservoir, as follows:
    1. Install the brake master cylinder reservoir assembly with the 2 bolts and tighten to 80 inch lbs. (9 Nm).
    2.  
    3. Install the 2 reservoir tubes with the 2 clips.
    4.  
    5. Install the brake actuator hose with the 2 clips.
    6.  
    7. Install the brake actuator hose to the clamp.
      NOTE
      Install the brake actuator hose with the edges of the protector and clamp aligned.

    8.  
    9. Connect the warning switch connector.
    10.  

  8.  
  9. Fill the master cylinder reservoir with brake fluid.
  10.  
  11. Bleed brake actuator hose, master cylinder and front brake system, as outlined at the beginning of this section.
  12.  
  13. Install the 2 ABS motor relays.
  14.  
  15. Bleed the rear brake system, as outlined at the beginning of this section.
  16.  
  17. Perform the accumulator zero down, as outlined under the Bleeding Procedure at the beginning of this section.
  18.  
  19. Check the brake fluid level and add fluid as necessary.
  20.  
  21. Use a scan tools to DTC(s) if necessary.
  22.  
  23. When the brake actuator assembly is replaced, perform linear valve offset learning after bleeding is completed, as outlined later in this section.
  24.  
  25. Check for brake fluid leakage
  26.  
  27. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  28.  
  29. Dispose of brake actuator assembly, as follows:
    1. Using a drill, slowly make a hole at the circumference made by the center points of a and discharge the gas.
      CAUTION
      Be sure to wear protective glasses to protect from fragments that may become airborne due to high pressure.


      NOTE
      The hole may be drilled without problem approximately 5 mm to 10 mm ( 0.20 to 0.39 in.) away from the point indicated by -A- in the accompanying illustration. The gas is nitrogen, which is colorless, odorless, and harmless.



      Click image to see an enlarged view

      Fig. The hole may be drilled without problem approximately 5 mm to 10 mm ( 0.20 to 0.39 in.) away from the point indicated by -A- in the accompanying illustration

    2.  

  30.  

 
label.common.footer.alt.autozoneLogo