BRAKE BOOSTER REMOVAL


  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 notice before proceeding with work Click here.

  2. DISABLE BRAKE CONTROL


    1. Wait at least 2 minutes after turning 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. A01I65X

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

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

    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 can not be further depressed.

    6. Release the parking brake.

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  4. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A01I4GH

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

    2. A01I388

      Remove the 10 bolts and front outer cowl top panel sub-assembly.

  5. DRAIN BRAKE FLUID

    Note

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

  6. REMOVE COOL AIR INTAKE DUCT SEAL


    1. A01I34Z

      Remove the 9 clips and cool air intake duct seal.

  7. REMOVE INLET AIR CLEANER ASSEMBLY


    1. A01I41G

      Remove the 2 bolts and inlet air cleaner assembly.

  8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01I34Q

      Disconnect the mass air flow meter connector and wire harness clamp from the air cleaner cap sub-assembly.

    2. Disconnect the ventilation hose from the cylinder head cover.

    3. Disconnect the connector and wire harness clamp.

    4. A01I2EB

      Release the 2 clamps and remove the air cleaner cap sub-assembly.

    5. A01I32VE01
      Text in Illustration
      *1 Retainer
      *2 Fuel Tube Connector
      *3 Pipe
      *4 O-ring
      *a Pinch
      *b Pull

      Disconnect the 2 fuel vapor feed hoses.

      Note


      • Remove any dirt or foreign matter on the fuel tube connector before performing this work.

      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the pipe.

      • Perform this work by hand. Do not use any tools.

      • Protect the disconnected parts by covering them with plastic bags after disconnecting each fuel vapor feed hose.

    6. A01I3VF

      Loosen the hose clamp and disconnect the air cleaner hose from the throttle with motor body assembly.

  9. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  10. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01I575E03
      Text in Illustration
      *a Projection

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

  11. REMOVE PUSH ROD PIN


    1. A01I46P

      Remove the clip and push rod pin.

    2. Separate the brake master cylinder push rod clevis from the brake pedal support assembly.

  12. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A01I2MZ

      Remove the 2 bolts and brake master cylinder reservoir assembly.

  13. SEPARATE NO. 1 BRAKE ACTUATOR TUBE


    1. A01I3T4

      Remove the nut and disengage the clamp.

    2. A01I59Q

      Remove the nut and separate the No. 1 brake actuator tube from the vehicle body.

  14. DISCONNECT NO. 2 RESERVOIR HOSE


    1. A01I5OK

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

  15. DISCONNECT NO. 1 RESERVOIR HOSE


    1. A01I4F2

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

  16. REMOVE RESERVOIR BRACKET


    1. A01I2UF

      Disengage the 2 clamps to separate the wire harness from the reservoir bracket.

    2. A01I3DP

      Remove the 3 bolts and reservoir bracket.

  17. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. A01I5NKE01
      Text in Illustration
      *a Matchmark
      A01I3Q9 Cut

      Put matchmarks at the position where the wire harness clamp is installed.

    2. Cut the wire harness clamp and separate the wire harness from the brake booster with master cylinder assembly.

    3. A01I2LB

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

      Text in Illustration
      A01I3Q9 Release the lock lever
      A01I679 Disconnect the connector
    4. A01I5CHE01

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

    5. 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
    6. A01I5OAE01
      Text in Illustration
      *1 Connector Portion
      *2 Union
      *3 Push Rod Clevis
      *4 Boot
      *5 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 parts shown in bold in the illustration.

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

    7. A01I5WT

      Turn the wire harness clamp counterclockwise to remove it from the brake booster with master cylinder assembly.

  18. REMOVE BRAKE BOOSTER GASKET