BRAKE BOOSTER(for RHD) REMOVAL

Info Added 2017-10-06

CAUTION / NOTICE / HINT

Note

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

PROCEDURE


  1. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  2. REMOVE CLUTCH MASTER CYLINDER ASSEMBLY (for Manual Transaxle)

    Click here

  3. REMOVE BRAKE PEDAL RETURN SPRING

    Click here

  4. LOOSEN CLEVIS LOCK NUT


    1. A001XH5C01
      *1 Clevis Lock Nut
      *2 Brake Master Cylinder Push Rod Clevis

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

  5. REMOVE PUSH ROD PIN

    Click here

  6. REMOVE NO. 1 ENGINE UNDER COVER

    Click here

  7. REMOVE DASH PANEL HEAT INSULATOR


    1. A001VQ5

      Remove the nut.

    2. A001UEB

      Remove the 2 nuts and dash panel heat insulator.

  8. SEPARATE VACUUM HOSE ASSEMBLY


    1. A001TGY

      Remove the 2 nuts and separate the vacuum hose assembly.

  9. SEPARATE BRAKE TUBE


    1. A001TS5

      Using a union nut wrench, disconnect the front No. 3 brake tube from the front brake flexible hose.

    2. A001U8S

      Using a union nut wrench, disconnect the front No. 1 brake tube, front No. 2 brake tube and front No. 3 brake tube from the brake actuator assembly.

    3. Disengage the 11 clamps to remove the 2 No. 1 brake tube clamps from the front No. 1 brake tube, front No. 2 brake tube, front No. 3 brake tube and front No. 5 brake tube.

    4. A001V5BC01
      *1 Brake Tube
      *2 Clutch Tube

      for Manual Transaxle:


      1. Disengage the clamp to separate the clutch tube from the 2 brake tube clamps.

    5. Disengage the 6 clamps to separate the 2 No. 2 brake tube clmaps from the front No. 1 brake tube, front No. 2 brake tube and front No. 3 brake tube.

    6. A001TC7

      Disengage the 2 clamps to remove the No. 2 brake tube clamps from the vehicle body.

    7. A001WCP

      Disengage the 3 clamps to remove the No. 1 brake tube clamp from the front No. 1 brake tube, front No. 2 brake tube and front No. 3 brake tube.

  10. DISCONNECT CHECK VALVE TO CONNECTOR TUBE HOSE


    1. A001SEP

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

  11. SEPARATE SUCTION PIPE SUB-ASSEMBLY (for TMMT Made)


    1. A001XEM

      Remove the 2 nuts and separate the suction pipe sub-assembly from the engine mounting sub-assembly and vehicle body.

  12. INSTALL SUCTION PIPE SUB-ASSEMBLY (for TMC Made)


    1. A001TOI

      Disengage the 2 clamps to separate the suction pipe sub-assembly from the piping clamp.

  13. REMOVE BRAKE BOOSTER ASSEMBLY


    1. A001W8X

      w/ Stop and Start System:

      Disconnect the connector from the vacuum sensor assembly.

    2. A001SA5

      w/ Vacuum Warning Switch:


      1. Disconnect the vacuum warning switch connector from the vacuum warning switch assembly.

    3. A001T48C01
      B004987 Protective Tape

      Apply protective tape around the vehicle body.

    4. A001SCF

      Remove the 4 nuts.

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

    6. A001TAT

      Move aside the front No. 1 brake tube, front No. 2 brake tube and front No. 3 brake tube as shown in the illustration.

      Note

      Do not apply excessive force to the brake tubes.

    7. While pushing the suction pipe sub-assembly toward the bottom of the vehicle, remove the brake booster assembly.

      Note


      • Do not apply excessive force to the brake tubes or refrigerant lines.

      • Do not apply excessive force to the suction pipe sub-assembly.

  14. REMOVE BRAKE BOOSTER GASKET


    1. Remove the brake booster gasket from the brake booster assembly.