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HYDRAULIC BRAKE BOOSTER (for RHD) REMOVAL

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Note:

  • When installing, coat the parts indicated by arrows with lithium soap base glycol grease (Click here).

  • Be sure not to allow the pump to contact the floor; support it with the booster body. If the pump contacts the floor, the red brake tube between the pump and booster body may be deformed, the operating sound of the pump may become loud enough to hear within the cabin, and fluid may leak.

  • As high pressure is applied to the brake actuator tube No. 1, never deform it.

  • Do not turn the ignition switch to ON until the procedures are completed.

  • Before starting the work, make sure that the ignition switch is off and depress the brake pedal more than 20 times.

Tip:

When pressure in the power supply system is released, the reaction force decreases and the stroke becomes longer.

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  1. Click here

    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    Note:

    • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (Click here).

    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

  2. Click here

    DRAIN BRAKE FLUID

    Note:

    Wash off brake fluid immediately if it comes into contact with a painted surface.

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    REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY


    1. Remove the lower No. 1 instrument panel airbag assembly (Click here).

  4. Click here

    REMOVE PUSH ROD PIN


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

  5. Click here

    REMOVE CLUTCH MASTER CYLINDER ASSEMBLY


    1. Remove the clutch master cylinder assembly (Click here).

  6. Click here

    DISCONNECT WATER HOSE JOINT


    1. A01DM5L

      w/ Rear Heater:

      Disconnect the water hose joint.

  7. Click here

    REMOVE HYDRAULIC BRAKE BOOSTER ASSEMBLY


    1. A01DUU7

      Disconnect the 3 connectors from the hydraulic brake booster assembly.

    2. A01DQM1E04

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

      Tip:

      • *1: To front wheel cylinder RH

      • *2: To front wheel cylinder LH

      • *3: To rear wheel cylinder RH

      • *4: To rear wheel cylinder LH

    3. A01DTVJ

      Remove the brake tube from the 2 brake tube clamps.

    4. Disconnect the 2 brake tube clamps from the body.

    5. A01DOB7E01

      Using a union nut wrench, disconnect the 4 brake lines from the hydraulic brake booster assembly.

    6. Remove the bolt and disconnect the clamp from the hydraulic brake booster assembly.

    7. A01DNUP

      Remove the 4 nuts and pull out the hydraulic brake booster assembly.

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    REMOVE BRAKE BOOSTER GASKET


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