BRAKE BOOSTER PUMP(for LHD) REMOVAL

PROCEDURE

1. Click here

   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. Click here

   RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

   Click here

3. Click here

   DISABLE BRAKE CONTROL

   Click here

4. Click here

   REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

   (Click here)

5. Click here

   REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY

   Click here

6. Click here

   REMOVE COOL AIR INTAKE DUCT SEAL

   Click here

7. Click here

   REMOVE INLET AIR CLEANER ASSEMBLY

   Click here

8. Click here

   REMOVE AIR CLEANER CAP SUB-ASSEMBLY

   Click here

9. Click here

   REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

10. Click here

    REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

11. Click here

    SEPARATE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY

    
    
    1. 

       Remove the bolt from the hook connector.

    2. 

       Turn the hook connector and separate the air conditioning tube and accessory assembly from the air conditioning unit.

       Note:
       

       • Do not deform the piping.

       • Do not damage the plastic clamp.

    3. Remove the O-ring from the air conditioning tube and accessory assembly.

       Note:

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

12. Click here

    SEPARATE SUCTION PIPE SUB-ASSEMBLY

    
    
    1. 

       Separate the suction pipe sub-assembly from the air conditioning unit.

       Note:
       

       • Do not deform the piping.

       • Do not damage the plastic clamp.

    2. Remove the O-ring from the suction pipe sub-assembly.

       Note:

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

13. Click here

    DRAIN BRAKE FLUID

    Note:

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

14. Click here

    SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

    Click here

15. Click here

    SEPARATE NO. 1 BRAKE ACTUATOR TUBE

    Click here

16. Click here

    DISCONNECT NO. 2 BRAKE ACTUATOR HOSE

    
    
    1. 

       Move the clip and disconnect the No. 2 brake actuator hose from the No. 1 brake actuator tube.

17. Click here

    DISCONNECT FRONT NO. 1 BRAKE TUBE

    
    
    1. 

       Using a union nut wrench, disconnect the front No. 1 brake tube from the brake booster pump assembly.

18. Click here

    REMOVE BRAKE BOOSTER PUMP ASSEMBLY WITH BRACKET

    
    
    1. 

       Disconnect the 2 connectors from the brake booster pump assembly.

    2. 

       Remove the bolt and separate the connector box of the brake booster pump assembly from the brake actuator bracket assembly.

       Table 1. Text in Illustration

       *1	Connector Box

    3. 

       Remove the 3 bolts and brake booster pump assembly with bracket from the vehicle body.

       Note:

       Do not kink or damage the brake line, suction pipe sub-assembly or air conditioning tube and accessory assembly.

19. Click here

    REMOVE NO. 2 BRAKE ACTUATOR HOSE

    
    
    1. 

       Move the clip and remove the No. 2 brake actuator hose from the brake booster pump assembly.

20. Click here

    REMOVE BRAKE BOOSTER PUMP ASSEMBLY

    
    
    1. 

       Disengage the wire harness clamp from the brake actuator bracket assembly.

    2. 

       Remove the nut, brake actuator case collar, brake booster pump bushing and brake booster pump assembly from the brake actuator bracket assembly.

       Table 2. Text in Illustration

       *1	Union
       *2	Stud
       *3	Connector Box and Wire Harness

       Note:
       

       • Do not carry the brake booster pump assembly by the parts shown in bold (*1, *2 and *3) in the illustration.

       • Do not drop the brake booster pump assembly when carrying it.

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

21. Click here

    INSTALL BRAKE BOOSTER PUMP ASSEMBLY