BRAKE BOOSTER REMOVAL

Note

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


  1. REMOVE FRONT WIPER ARM HEAD CAP

  2. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. A01EMRZ

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

  3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. A01EK79

      Remove the nut and the front wiper arm and blade assembly RH.

  4. REMOVE FRONT FENDER TO COWL SIDE SEAL LH


    1. A01EKVY

      Disengage the claw and 2 guides and remove the front fender to cowl side seal LH.

  5. REMOVE FRONT FENDER TO COWL SIDE SEAL RH

    Tech Tips

    Use the same procedure for the RH side and LH side.

  6. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. A01ELGA

      Using a clip remover, remove the 2 clips.

    2. A01ELW9

      Disengage the 13 claws and pull out the cowl top ventilator louver sub-assembly as shown in the illustration.

  7. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A01EIMEE01

      Disconnect the connector.

    2. A01ELYY

      Remove the 3 bolts and the windshield wiper motor and link assembly as shown in the illustration.

  8. REMOVE OUTER COWL TOP PANEL


    1. A01EIQY

      Disengage the 2 clamps and separate the wiper wire harness from the outer cowl top panel sub-assembly.

    2. A01EKSW

      Disengage the 2 clamps and connector, and separate the wire harness from the outer cowl top panel sub-assembly (w/ Windshield Deicer).

    3. A01EL1AE01
      Text in Illustration
      *1 Bolt
      *2 Nut

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

  9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01EKFY

      Disconnect the mass air flow meter connector and separate the wire harness clamp from the air cleaner cap.

    2. Separate the hose from the hose clamp.

    3. A01EKWW

      Disconnect the ventilation hose from the cylinder head cover.

    4. A01EKRC

      Unlock the hose band and separate the air cleaner cap sub-assembly from the throttle body assembly.

    5. A01EJ98

      Remove the 2 bolts and air cleaner cap sub-assembly.

  10. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  11. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01EK1G

      Disconnect the wire harness clamp.

    2. Remove the 3 bolts and air cleaner case sub-assembly.

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


    1. A01EJHF

      Remove the bolt and disconnect the security horn assembly.

    2. A01EL4H

      Disconnect the connector and remove the security horn assembly.

  13. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. A01EJV4

      Disconnect the connector and disengage the clamp.

    2. A01EL8X

      Using a union nut wrench, disconnect the 2 brake lines from the front brake tube way.

      Note


      • Do not damage or deform the brake lines during removal procedure.

      • Do not allow any foreign matter into the brake lines.

    3. A01EJEV

      Using a union nut wrench, disconnect the 2 brake lines and remove the No. 1 front brake tube from the brake master cylinder sub-assembly.

      Note


      • Do not damage or deform the brake lines during removal procedure.

      • Do not allow any foreign matter into the brake lines.

    4. A01ELMX

      Remove the 2 nuts, front brake tube way and brake master cylinder sub-assembly from the brake booster assembly.

      Note


      • Do not hold the master cylinder by the piston. (Hold the master cylinder by its body or its reservoir when carrying it.)

      • Do not pull out the master cylinder piston.

      • Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.

      • When installing the master cylinder to the brake booster, or when removing the master cylinder from the brake booster, make sure that the master cylinder is kept horizontal or its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling out.

      • Do not allow any foreign matter to contaminate the master cylinder piston. If any foreign matter gets on the piston, remove it by using a piece of cloth and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the piston.

      • Do not use any other types of grease.

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

  14. SEPARATE NO. 1 VACUUM HOSE CONNECTOR


    1. A01EL87

      Slide the clip and disconnect the vacuum hose from the brake booster assembly.

    2. Remove the 2 nuts and separate the No. 1 vacuum hose connector.

  15. REMOVE PUSH ROD PIN


    1. A01ELOC

      Remove the clip and push rod pin.

  16. REMOVE BRAKE BOOSTER ASSEMBLY


    1. A01ELWW

      Remove the 4 nuts and brake booster assembly from the body.

      Note

      Do not damage the brake lines.

  17. REMOVE BRAKE BOOSTER GASKET


    1. A01EJPD

      Remove the brake booster gasket from the brake booster assembly.

  18. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. Loosen the lock nut, and remove the brake master cylinder push rod clevis and lock nut.

  19. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY


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

  20. REMOVE CHECK VALVE GROMMET


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