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 for 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. A01KT26

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

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

      for Wagon: Click here

      for Hatchback: 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 cannot be further depressed.

    6. Release the parking brake.

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  4. REMOVE WATER GUARD PLATE LH


    1. A01KTL9

      Disengage the clamp and remove the water guard plate LH.

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


    1. A01KTGB

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

  6. REMOVE OUTER COWL TOP PANEL


    1. A01KTOMC01
      A01KRLR Bolt
      A01KR22 Nut

      Remove the 11 bolts, nut and outer cowl top panel.

  7. DRAIN BRAKE FLUID

    Note

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

  8. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (w/ Instrument Panel Under Cover)

    Click here

  9. REMOVE BRAKE PEDAL RETURN SPRING

    Click here

  10. REMOVE PUSH ROD PIN

    Click here

  11. SEPARATE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. A01KT2J

      Disengage the 2 clamps to separate the wire harness.

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

  12. DISCONNECT NO. 2 RESERVOIR HOSE


    1. A01KSSL

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

  13. DISCONNECT NO. 1 RESERVOIR HOSE


    1. A01KSU0

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

  14. DISCONNECT BRAKE ACTUATOR HOSE


    1. A01KS33

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

  15. REMOVE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET

  16. REMOVE NO. 5 BRAKE ACTUATOR BRACKET


    1. A01KSGT

      Disengage the clamp.

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

  17. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. A01KTJ1C01
      A01KRLR Release the lock lever
      A01KR22 Disconnect the connector

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

      Note

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

    2. A01KSRD

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

    3. A01KSPAC01
      *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

      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.

    5. A01KT82C01
      *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 portion shown in the illustration.

  18. REMOVE BRAKE BOOSTER GASKET