BRAKE BOOSTER PUMP(for RHD) REMOVAL

Info Added 2017-10-06

CAUTION / NOTICE / HINT

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

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link
Auxiliary battery terminal is disconnected/reconnected Memorize steering angle neutral point Lane departure alert system (w/ Steering Control)

Click here

Simple intelligent parking assist system*1
Toyota parking assist-sensor system*1
Pre-collision system
Initialize back door lock Power door lock control system

Click here

Suspension, tires, etc.*2 Initialize headlight ECU sub-assembly LH Automatic headlight beam level control system

Click here

Front wheel alignment adjustment

  1. Clear zero point calibration data.

  2. Perform yaw rate and acceleration sensor zero point calibration.

  • DTCs are stored

  • ABS warning light illuminates

  • Brake warning light/yellow (minor malfunction) illuminates

  • Slip indicator light illuminates

  • VSC disabled or malfunctions

Click here

*1: When performing learning using the GTS.

Click here

*2: The vehicle height changes because of suspension or tire replacement.

Note

While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch turns on. Therefore, when servicing the brake system components, do not operate the brake pedal or open/close the doors while the auxiliary battery is connected.

PROCEDURE


  1. PERFORM ACCUMULATOR PRESSURE ZERO DOWN

    Click here

  2. REMOVE SECURITY HORN ASSEMBLY (w/ Security Horn)

    Click here

  3. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

    Click here

  4. DRAIN BRAKE FLUID

    Note

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

  5. SEPARATE NO. 1 BRAKE ACTUATOR HOSE


    1. A005NY8

      Slide the clip and separate the No. 1 brake actuator hose from the No. 1 brake actuator tube.

  6. SEPARATE ACCUMULATOR TO BRAKE MASTER CYLINDER TUBE


    1. A005N3A

      Using a union nut wrench, disconnect the accumulator to brake master cylinder tube from the brake booster pump assembly.

    2. A005N4L

      Remove the bolt to separate the accumulator to brake master cylinder tube.

  7. REMOVE BRAKE ACTUATOR WITH BRAKE BOOSTER PUMP ASSEMBLY


    1. A005O3EC01
      B0048R7 Release the lock lever
      B0048O3 Disconnect the connector

      Release the lock lever and disconnect the connector from the brake booster pump assembly as shown in the illustration.

      Note

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

    2. A005N38C01
      B0048R7 Release the lock lever
      B0048O3 Disconnect the connector

      Release the lock lever and disconnect the connector from the brake actuator assembly as shown in the illustration.

      Note

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

    3. Disengage the clamp to separate the engine room main wire.

    4. A005NZDC01
      *a From 1st Chamber of Brake Booster with Master Cylinder Assembly
      *b From 2nd Chamber of Brake Booster with Master Cylinder 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

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

    5. A005O3U

      Using a union nut wrench, disconnect the 6 brake lines from the brake actuator assembly.

    6. A005MVV

      Disengage the 2 clamps to separate the 2 brake lines from the No. 4 brake tube clamp.

    7. Disengage the clamp to remove the No. 4 brake tube clamp from the brake actuator bracket assembly.

    8. A005NVK

      Remove the 2 bolts, 2 nuts and brake actuator with brake booster pump assembly from the vehicle body.

      Note


      • Do not apply excessive force to the brake lines.

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

      • Do not hold the brake booster pump assembly by the connector, union or wire harness.

      • Do not hold the brake actuator assembly by the connector.

      • Do not drop the brake actuator with brake booster pump assembly when carrying it.

      Tech Tips

      Remove the brake actuator with brake booster pump assembly while avoiding the brake lines.

  8. REMOVE NO. 1 BRAKE ACTUATOR HOSE


    1. A005NT8

      Slide the clip and remove the No. 1 brake actuator hose from the brake booster pump assembly.

    2. A005NR3

      Remove the No. 1 brake actuator hose from the brake actuator hose clamp.

  9. REMOVE NO. 1 BRAKE TUBE CLAMP BRACKET


    1. A005N8K

      Remove the bolt and No. 1 brake tube clamp bracket from the brake booster pump assembly.

  10. REMOVE BRAKE BOOSTER PUMP ASSEMBLY


    1. A005N5I

      Disengage the claw and 4 clamps to separate the brake booster pump assembly wire harness from the brake actuator assembly bracket.

    2. A005NFG

      Remove the nut from the brake booster pump assembly.

    3. A005OA6C02
      *1 Union
      *2 Connector
      *3 Wire Harness
      *4 Stud

      Remove the brake booster pump assembly, brake booster pump bushing and brake actuator case collar from the brake actuator bracket assembly.

      Note


      • Do not carry the brake booster pump assembly by the parts shown in the illustration.

      • Do not drop the brake booster pump assembly when carrying it.

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