BRAKE BOOSTER REMOVAL

Note

Release the vacuum from the booster by depressing the brake pedal several times. Then remove the brake master cylinder sub-assembly from the brake booster assembly.


  1. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY

    Tech Tips

    Refer to the procedure up to Remove Driver Side Knee Airbag Assembly Click here.

  2. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Tech Tips

    Refer to the procedure up to Remove Cowl Top Ventilator Louver Sub-assembly Click here.

  3. DRAIN BRAKE FLUID

    Note

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

  4. REMOVE NO. 3 ENGINE ROOM RELAY BLOCK (for LHD)


    1. A0163BG

      Remove the bolt, nut and No. 3 engine room relay block.

      Note

      Cover the No. 3 engine room relay block with a piece of cloth to prevent brake fluid from getting on it.

  5. REMOVE NO. 3 ENGINE ROOM RELAY BLOCK (for RHD)


    1. A01613O

      Remove the bolt, nut and No. 3 engine room relay block.

      Note

      Cover the No. 3 engine room relay block with a piece of cloth to prevent brake fluid from getting on it.

  6. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for LHD)


    1. A015ZEG

      Disengage the clamp and disconnect the connector.

    2. A0160M5

      Using a union nut wrench (10 mm), disconnect the 2 brake lines from the brake master cylinder sub-assembly.

    3. A0163D6

      Remove the 2 nuts and brake master cylinder sub-assembly from the brake booster assembly.

      Note

      Do not damage the brake lines.

    4. Remove the O-ring from the brake master cylinder sub-assembly.

  7. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (for RHD)


    1. A015YUC

      Disengage the clamp and disconnect the connector.

    2. A0162T3

      Using a union nut wrench (10 mm), disconnect the 2 brake lines from the brake master cylinder sub-assembly.

    3. A015ZUX

      Remove the 2 nuts, wire harness clamp bracket and brake master cylinder sub-assembly from the brake booster assembly.

      Note

      Do not damage the brake lines.

    4. Remove the O-ring from the brake master cylinder sub-assembly.

  8. REMOVE BRAKE ACTUATOR WITH BRACKET (for LHD)


    1. A0162HOE04
      Text in Illustration
      *1 Lock Lever

      Release the lock lever and disconnect the brake actuator connector.

      Note

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

    2. A01615R

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

    3. A0163E7E04
      Text in Illustration
      *1 to Front Wheel Cylinder RH
      *2 to Front Wheel Cylinder LH
      *3 to Rear Wheel Cylinder RH
      *4 to Rear Wheel Cylinder LH
      *5 from 1st Master Cylinder Chamber
      *6 from 2nd Master Cylinder Chamber

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

    4. A01616K

      Disengage the clamp.

    5. Slide the clip and disconnect the vacuum hose from the check valve.

    6. A015ZOVE01
      Text in Illustration
      *1 Front No. 1 Brake Line
      *2 Rear No. 1 Brake Line

      Remove the front No. 1 brake line and rear No. 1 brake line from the clamp.

      Note

      Do not damage the brake lines.

    7. A0162O3

      Remove the 2 bolts and nut from the brake actuator with bracket.

    8. A01614G

      Remove the brake actuator with bracket.

      Note

      Do not damage the brake lines.

  9. REMOVE BRAKE ACTUATOR WITH BRACKET (for RHD)


    1. A0163EVE04
      Text in Illustration
      *1 Lock Lever

      Release the lock lever and disconnect the brake actuator connector.

    2. A0160LFE04

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

    3. A0160LFE05
      Text in Illustration
      *1 to Front Wheel Cylinder RH
      *2 to Front Wheel Cylinder LH
      *3 to Rear Wheel Cylinder RH
      *4 to Rear Wheel Cylinder LH
      *5 from 1st Master Cylinder Chamber
      *6 from 2nd Master Cylinder Chamber

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

    4. A016364E06
      Text in Illustration
      *1 Turn
      *2 Hold

      Using a union nut wrench, separate the front No. 2 brake line from the brake flexible hose.

    5. A0163GHE05
      Text in Illustration
      *1 Grommet
      *2 Front No. 2 Brake Line

      Remove the grommet and front No. 2 brake line.

      Note

      Do not damage the brake lines or clamp.

    6. A015YRV

      Remove the 2 bolts and nut, and separate the brake actuator assembly with bracket from the body.

    7. A0162BL

      Remove the brake actuator assembly with bracket.

      Note

      Do not damage the brake lines.

  10. DISCONNECT VACUUM HOSE (for RHD)


    1. A01636F

      Disengage the clamp.

    2. Slide the clip and disconnect the vacuum hose.

  11. REMOVE BRAKE LINE (for RHD)


    1. A0161O6

      Disengage the clamp and remove the front No. 1 brake line and rear No. 1 brake line.

      Note

      Be careful not to damage the brake lines or clamp. If any parts are damaged, replace them with new ones.

  12. REMOVE BRAKE PEDAL RETURN SPRING


    1. A01603J

      Remove the brake pedal return spring.

  13. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. A016032E04

      Remove the clip and push rod pin, then separate the push rod clevis.

  14. REMOVE BRAKE BOOSTER ASSEMBLY (for LHD)


    1. A0162B7E02
      Text in Illustration
      *a Hold
      *b Turn

      Using a union nut wrench, disconnect the front No. 3 brake line.

    2. Disengage the grommet and remove the front No. 3 brake line.

      Note

      Do not kink or damage the brake line.

    3. A0162RA

      Remove the 4 nuts and brake booster assembly.

      Note

      Do not kink or damage the brake lines.

  15. REMOVE BRAKE BOOSTER ASSEMBLY (for RHD)


    1. A0161Y4

      Remove the 4 nuts and brake booster assembly.

      Note

      Do not kink or damage the brake lines.

  16. REMOVE BRAKE BOOSTER GASKET


    1. Remove the brake booster gasket from the brake booster assembly.

  17. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY


    1. Remove the brake vacuum check valve assembly from the brake booster assembly.

  18. REMOVE CHECK VALVE GROMMET


    1. Remove the check valve grommet from the brake booster assembly.

  19. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. Remove the lock nut and brake master cylinder push rod clevis.