BRAKE BOOSTER(for RHD) REMOVAL

CAUTION / NOTICE / HINT

Note

Make sure to release vacuum from the brake booster assembly before removing the brake master cylinder sub-assembly from the brake booster assembly.

PROCEDURE


  1. PRECAUTION

    Note

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

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  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

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  3. REMOVE FRONT WHEEL RH

  4. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY WITH WAY

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  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  6. DRAIN ENGINE COOLANT

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  7. REMOVE V-BANK COVER SUB-ASSEMBLY

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  8. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

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  9. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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  10. SEPARATE ENGINE ROOM MAIN WIRE


    1. B003ZCLC01
      *a Wire Harness Protector

      Remove the bolt and disengage the clamp to separate the wire harness protector.

    2. Disengage the 5 clamps to separate the engine room main wire.

  11. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. B00409SC01
      *1 Brake Master Cylinder Reservoir Assembly
      *2 Reservoir Bracket

      Disconnect the reservoir level switch connector and remove the bolt from the brake master cylinder reservoir assembly.

    2. Move the brake master cylinder reservoir assembly as shown in the illustration to disengage the 2 claws, and remove it.

  12. REMOVE RESERVOIR BRACKET


    1. A002AY2

      Disengage the clamp to separate the engine room main wire.

    2. Remove the 2 nuts and reservoir bracket.

  13. DISCONNECT UNION TO CHECK VALVE HOSE


    1. A018J4F

      Slide the clip and disconnect the union to check valve hose from the brake booster assembly.

  14. REMOVE NO. 2 ENGINE MOUNTING STAY RH

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  15. REMOVE ENGINE MOVING CONTROL ROD BRACKET

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  16. SEPARATE SUCTION HOSE SUB-ASSEMBLY


    1. A0027S9

      Disengage the clamp to separate the suction hose sub-assembly.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    2. A018HWG

      Disengage the clamp to separate the suction hose sub-assembly from the brake actuator assembly.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    3. A002BC5

      Disengage the claw to separate the suction hose sub-assembly.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    4. A0029KN

      Disengage the claw to release the piping clamp.

      Note

      Do not damage the clamp.

    5. A00276H

      Remove the bolt and rotate the hook connector.

    6. Disconnect the suction hose sub-assembly from the air conditioning unit assembly.

    7. Remove the O-ring from the suction hose sub-assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

    8. Separate the suction hose sub-assembly from the vehicle body.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

  17. SEPARATE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. A00282P

      Disengage the clamp to separate the air conditioner tube and accessory assembly from the piping clamp.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    2. A018J2A

      Disengage the clamp to separate the air conditioner tube and accessory assembly from the brake actuator assembly.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    3. A002COU

      Remove the bolt and separate the air conditioner tube and accessory assembly.

      Note

      Do not deform the refrigerant lines.

    4. A0029LE

      Disconnect the air conditioner tube and accessory assembly from the air conditioning unit assembly.

    5. Remove the O-ring from the air conditioner tube and accessory assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

    6. A002CNY

      Remove the nut and separate the air conditioner tube and accessory assembly from the vehicle body.

      Note

      Do not deform the refrigerant lines.

  18. DISCONNECT SUCTION HOSE SUB-ASSEMBLY


    1. A002BFJ

      Remove the piping clamp.

      Click here

    2. A002BNV

      Disconnect the suction hose sub-assembly from the No. 1 air conditioning accessory assembly.

      Note

      Do not deform the refrigerant lines.

    3. Remove the 2 O-rings from the suction hose sub-assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  19. SEPARATE BRAKE LINE


    1. A01GEJG

      Using a union nut wrench, disconnect the 3 brake lines from the brake actuator assembly.

      Note


      • Do not kink or damage the brake lines.

      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the connecting parts.

    2. Disengage the clamp to separate the 3 brake lines.

      Note


      • Do not damage the clamp.

      • Do not kink or damage the brake lines.

    3. B003Z9ZC01
      *1 Front No. 6 Brake Tube
      *2 Front No. 7 Brake Tube
      *3 Front No. 8 Brake Tube

      Disengage the 3 clamps and remove the front No. 6 brake tube and front No. 7 brake tube.

      Note


      • Do not damage the 3 clamps.

      • Do not kink or damage the brake lines.

      Tech Tips

      Remove the front No. 6 brake tube and front No. 7 brake tube while avoiding the front No. 8 brake tube.

  20. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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  21. REMOVE THROTTLE BODY GASKET

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  22. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

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  23. REMOVE THROTTLE BODY BRACKET

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  24. REMOVE NO. 1 SURGE TANK STAY

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  25. REMOVE NO. 2 VENTILATION HOSE


    1. A018KWS

      Slide the clip and disconnect the No. 2 ventilation hose to remove it from the cylinder head cover sub-assembly.

  26. REMOVE HOSE BRACKET


    1. A018MF6

      Disengage the clamp to separate the engine wire.

    2. Remove the bolt and hose bracket.

  27. SEPARATE ENGINE WIRE


    1. B00409RC01
      B003ZIE Bolt
      B003Z8F Connector

      Remove the bolt, disengage the 4 clamps and disconnect the 10 connectors.

    2. A018K6G

      Remove the bolt and separate the engine wire from the cylinder head cover sub-assembly.

  28. REMOVE IGNITION COIL ASSEMBLY


    1. A018LV8

      Remove the 3 bolts and 3 ignition coil assemblies.

  29. REMOVE FUEL HOSE PROTECTOR

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  30. REMOVE NO. 2 TIMING GEAR COVER

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  31. REMOVE OIL PIPE

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  32. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  33. REMOVE BRAKE PEDAL RETURN SPRING

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  34. LOOSEN LOCK NUT


    1. B003Z6QC01
      *1 Lock Nut
      *2 Brake Master Cylinder Push Rod Clevis

      Loosen the lock nut of the brake master cylinder push rod clevis.

  35. REMOVE PUSH ROD PIN

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  36. REMOVE BRAKE BOOSTER ASSEMBLY


    1. A00280P

      Remove the 4 nuts and push the brake booster assembly toward the engine compartment.

    2. Remove the brake master cylinder push rod clevis and lock nut from the brake booster assembly.

    3. Remove the brake booster assembly from the vehicle body.

  37. REMOVE BRAKE BOOSTER GASKET