BRAKE BOOSTER(for LHD) REMOVAL

Info Added 2017-08-02

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 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. A0003KD

      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 cannot 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. A0006H6E03

      w/ Wiper Deicer System:

      Disengage the clamp (A).

    2. Disengage the 2 clamps (B).

    3. Disconnect the connector and separate the wire harness from the front outer cowl top panel sub-assembly.

    4. A00075O

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

    5. A0005QB

      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

    Click here

  7. REMOVE INLET AIR CLEANER ASSEMBLY

    Click here

  8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  9. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  10. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  11. REMOVE PUSH ROD PIN

    Click here

  12. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A0005Q2

      Remove the 2 bolts and brake master cylinder reservoir assembly.

  13. SEPARATE NO. 1 BRAKE ACTUATOR TUBE


    1. A0005WW

      Remove the nut and disengage the clamp.

    2. A00091N

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

  14. DISCONNECT NO. 2 RESERVOIR HOSE


    1. A0003UH

      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. A00080E

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

  16. REMOVE RESERVOIR BRACKET


    1. A0004WT

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

    2. A0003X9

      Remove the 3 bolts and reservoir bracket.

  17. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. A0007ZIE04
      Text in Illustration
      *a Matchmark
      A0005GR 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. A0005KC

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

      Text in Illustration
      A0005GR Release the lock lever
      A0009JS Disconnect the connector
    4. A0008OOE06

      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. A0005C4E06
      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. A0006T9

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

  18. REMOVE BRAKE BOOSTER GASKET