BRAKE BOOSTER(for LHD) REMOVAL

PROCEDURE


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal, Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Click here.

  2. DISABLE BRAKE CONTROL


    1. Wait at least 2 minutes after the power switch off.

      Note

      When the brake pedal is depressed or the door courtesy switch is turned on even if the power switch is off, the brake control system activates. Therefore do not depress the brake pedal or open/close the doors until the reservoir level switch connector is disconnected.

    2. B001MA5

      Disconnect the reservoir level switch connector with the parking brake applied.

    3. Disconnect the cable from the negative (-) auxiliary battery terminal.


    4. Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.

    5. Check that the brake pedal cannot be further depressed.

    6. Release the parking brake.

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  4. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL


    1. B001KER

      Disengage the 2 claws and remove the No. 1 heater air duct splash shield seal.

  5. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL


    1. B001LJ5

      Disengage the claw and guide, and remove the No. 2 heater air duct splash shield seal.

  6. REMOVE COWL BODY MOUNTING REINFORCEMENT LH


    1. B001KGA

      Remove the 2 bolts and cowl body mounting reinforcement LH.

  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. B001M70

      Disengage the clamp and separate the wire harness.

    2. B001MUO

      w/ Wiper Deicer:

      Disengage the 3 clamps, disconnect the connector and separate the wire harness.

    3. B001M12

      Remove the 9 bolts and outer cowl top panel sub-assembly.

  8. REMOVE SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper)

    Click here

  9. DRAIN BRAKE FLUID

    Note

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

  10. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

    Click here

  11. REMOVE BRAKE PEDAL RETURN SPRING

    Click here

  12. REMOVE PUSH ROD PIN

    Click here

  13. SEPARATE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. B001MHN

      Disengage the 2 clamps.

    2. Remove the 2 nuts and separate the brake master cylinder reservoir with bracket.

  14. DISCONNECT RESERVOIR HOSE


    1. B001M88E02
      Text in Illustration
      *1 No. 1 Reservoir Hose
      *2 No. 2 Reservoir Hose

      Move the 2 clips and disconnect the No. 1 reservoir hose and No. 2 reservoir hose from the brake booster with master cylinder assembly.

  15. DISCONNECT BRAKE ACTUATOR HOSE


    1. B001KAI

      Move the clip and disconnect the brake actuator hose from the brake booster pump assembly.

  16. REMOVE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET

  17. REMOVE NO. 5 BRAKE ACTUATOR BRACKET


    1. B001MRQ

      Disengage the clamp.

    2. Remove the 2 nuts and No. 5 brake actuator bracket.

  18. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. B001KVC

      Release the lock lever and disconnect the connector from the brake booster with master cylinder assembly.

      Note

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

    2. B001KRZ

      Remove the 2 bolts and No. 2 brake tube clamp bracket from the brake booster with master cylinder assembly.

    3. B001KSBE03

      Using a union nut wrench, disconnect the 5 brake lines from the brake booster with master cylinder assembly.

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

      Text in Illustration
      *a to Front Wheel Cylinder LH
      *b to Rear Wheel Cylinder RH
      *c to Brake Booster Pump Assembly
      *d to Rear Wheel Cylinder LH
      *e to Front Wheel Cylinder RH
    5. B001MFU

      Disengage the 2 clamps and separate the brake line.

    6. B001ML7E03
      Text in Illustration
      *1 Connector Portion
      *2 Union
      *3 Push Rod Clevis and Boot
      *4 Front No. 2 Brake Tube

      Remove the 4 nuts and brake booster with master cylinder assembly.

      Note


      • Do not kink or damage the brake lines.

      • Do not carry the brake booster with master cylinder assembly by the portion shown in bold in the illustration.

  19. REMOVE BRAKE BOOSTER GASKET