RX400h · Service Manual BRAKE

REMOVAL

Removal / installation


1. DISCONNECT CABLE FROM BATTERY NEGATIVE TERMINAL

NOTICE:
Wait for 90 seconds after disconnecting the cable to prevent the airbag working.


2. REMOVE ABS MOTOR RELAY

  1. C108426
    In order to prohibit brake control, remove the 2 ABS motor relays with the ignition switch off.

    NOTICE:
    If the pump motor operates while air remains inside the brake actuator hose, the air will enter the actuator, resulting in difficulty in bleeding the brakes.


3. REMOVE FRONT WIPER ARM RH

  1. Remove the 2 nuts and the front wiper arm and blade assembly RH.


4. REMOVE FRONT WIPER ARM LH

  1. Remove the nut and the front wiper arm and blade assembly LH.


5. REMOVE FRONT FENDER TO COWL SIDE SEAL RH

6. REMOVE FRONT FENDER TO COWL SIDE SEAL LH

7. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

  1. E110470
    Remove the 2 clips.

  1. Disengage the 6 claws and the clamp, and remove the cowl top ventilator louver sub-assembly.


8. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

  1. E110471E01
    Disconnect the connector.

  1. Remove the 5 bolts and the windshield wiper motor and link assembly.

    HINT:
    Bolt <A> cannot be removed because it is integrated into windshield wiper link assembly.


9. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER

  1. A112528E01
    Separate the wire harness clamp and grommet (A).

  1. Remove the 4 shock absorber nuts (B).

  1. Remove the 4 bolts, 2 nuts and cowl top panel sub-assembly.

  1. Install the 4 shock absorber nuts.

    Torque:
    80 N*m{ 815 kgf*cm , 59 ft.*lbf }


10. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (RHD)

  1. Disconnect the warning switch connector.

  1. Separate the brake actuator hose from the clamp.

  1. C108792E08
    Remove the 2 clips and brake actuator hose.

  1. C108790E02
    Remove the 2 clips and 2 reservoir tubes from the brake master cylinder reservoir assembly.

  1. C108791
    Remove the 2 bolts and the brake master cylinder reservoir assembly.


11. REMOVE RESERVOIR TUBE NO.1

  1. LHD:

    1. C111405
      Remove the nut.

    2. C111406E01
      Remove the clip, and separate the reservoir tube No.1.

  1. RHD:

    1. C106858E01
      Remove the clip, and separate the reservoir tube No.1.


12. REMOVE RESERVOIR TUBE NO.2

  1. Remove the clip, and separate the reservoir tube No.2.


13. REMOVE FRONT DOOR SCUFF PLATE LH (LHD)

  1. B111782
    Disengage the 6 claws and 4 clips, and remove the front door scuff plate.

  1. Disconnect the connector. (w/ illumination scuff plate)


14. REMOVE FRONT DOOR SCUFF PLATE RH (RHD)
Remove of the front door scuff plate RH is the same as the front scuff plate LH. (Click here)

15. REMOVE COWL SIDE TRIM ASSEMBLY LH (LHD)

  1. B108509
    Remove the 2 clips and the cowl side trim sub-assembly LH.


16. REMOVE COWL SIDE TRIM ASSEMBLY RH (RHD)
Remove of the cowl side trim assembly RH is the same as the cowl side trim assembly LH. (Click here)

17. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER

  1. B108510E02
    Using a screwdriver, open the instrument panel finish panel sub-assembly lower cover.

    HINT:
    Tape the screwdriver tip before use.

  1. Remove the bolt <A> and the screw <C>.

  1. Disconnect the hood lock control cable assembly.

  1. Disengage the 5 claws and the 4 clips.

  1. Disconnect the connectors and then remove the instrument panel finish panel sub-assembly lower.


18. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY

  1. C111085
    Disconnect the connector from the driver side knee airbag assembly.

    NOTICE:
    When handling the airbag connector, take care not to damage the airbag wire harness.

  1. Remove the 4 bolts and the driver side knee airbag assembly.


19. REMOVE BRAKE PEDAL RETURN SPRING

20. SEPARATE MASTER CYLINDER PUSH ROD CLEVIS

  1. Remove the clip and clevis pin and disconnect the push rod clevis from the brake pedal.


21. REMOVE BRAKE MASTER CYLINDER W/SIMULATOR ASSEMBLY (LHD)

  1. C111407
    Using SST, disconnect the 2 brake tubes.
    SST
    09023-00101  

  1. C111408
    Disconnect the connector, and separate the wire harness clamp.

  1. C111403
    Remove the 4 nuts, the gasket and the brake master cylinder with simulator.


22. REMOVE BRAKE MASTER CYLINDER W/SIMULATOR ASSEMBLY (RHD)

  1. C106859
    Using SST, disconnect the 2 brake tubes.
    SST
    09023-00101  

  1. C116336
    Disconnect the connector, and separate the wire harness clamp.

  1. C108416
    Remove the 4 nuts, the gasket and the brake master cylinder with simulator.

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