BRAKE BOOSTER (for LHD) REMOVAL

Note

Release the vacuum from the booster by depressing the brake pedal several times. Then remove the brake master cylinder from the brake booster.


  1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. Remove the windshield wiper motor and link assembly Click here.

  2. DRAIN BRAKE FLUID

    Note

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

  3. REMOVE KNEE AIRBAG ASSEMBLY


    1. Remove the knee airbag assembly Click here.

  4. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. A0117SR

      Loosen the push rod lock nut.

    2. Remove the clip and the push rod pin and separate the push rod clevis from the brake pedal.

    3. Remove the push rod clevis from the brake booster.

  5. REMOVE BATTERY CLAMP SUB-ASSEMBLY (for 1ND-TV)


    1. A011ADE

      Remove the 2 nuts and the battery clamp.

  6. REMOVE BATTERY (for 1ND-TV)

  7. REMOVE FUEL FILTER ASSEMBLY (for 1ND-TV)


    1. A011B6X

      Disconnect the 2 wire harness clamps.

    2. Disconnect the connector.

    3. A011A0C

      Disconnect the 2 connectors.

    4. A0119HL

      Disconnect the 2 fuel hose clamps from the fuel filter.

    5. Disconnect the 2 fuel hoses.

    6. A011BBN

      Loosen the fuel filter drain plug to drain fuel.

    7. Tighten the fuel filter drain plug.

    8. A0118XZ

      Remove the 2 nuts and fuel filter.

  8. DISCONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle)


    1. A011BEP

      Move the clip and disconnect the clutch reservoir tube.

  9. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (w/o Stop and Start System)


    1. A0118HX

      Disconnect the brake fluid level warning switch connector and disengage the clamp.

    2. A0118IJ

      Using a union nut wrench (12 mm), disconnect the 2 brake tubes from the brake master cylinder sub-assembly.

    3. A011ARK

      Remove the 2 nuts.

    4. Remove the brake master cylinder sub-assembly from the brake booster.

      Note


      • The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.

      • Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.

      • Release the vacuum from the booster by depressing the brake pedal several times. Then remove the brake master cylinder from brake booster.

      • When installing the master cylinder to the brake booster, or when removing the master cylinder from the brake booster, make sure that the master cylinder is kept horizontal or its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling off.

      • Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a piece of cloth and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the piston.

      • Do not use any other type of grease or fluid.

    5. Remove the O-ring from the brake master cylinder sub-assembly.

  10. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (w/ Stop and Start System)


    1. A0118EB

      Disconnect the brake fluid level warning switch connector and the vacuum sensor wire connector, and disengage the clamp.

    2. A0119LR

      Using a union nut wrench (12 mm), disconnect the 2 brake tubes from the brake master cylinder sub-assembly.

    3. A0117EQ

      Disengage the clamp and separate the vacuum sensor wire harness from the brake master cylinder sub-assembly.

    4. Disconnect the vacuum hose.

    5. A0118W6

      Remove the 2 nuts and vacuum sensor assembly.

    6. Remove the brake master cylinder sub-assembly from the brake booster.

      Note


      • The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.

      • Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.

      • Release the vacuum from the booster by depressing the brake pedal several times. Then remove the brake master cylinder from brake booster.

      • When installing the master cylinder to the brake booster, or when removing the master cylinder from the brake booster, make sure that the master cylinder is kept horizontal or its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling off.

      • Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a piece of cloth and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the piston.

      • Do not use any other type of grease or fluid.

    7. Remove the O-ring from the brake master cylinder sub-assembly.

  11. REMOVE NO. 1 HOSE TO HOSE TUBE


    1. A011924E01

      Slide the 2 clips and disconnect the vacuum hose from the check valve and hose tube.

    2. Remove the 2 bolts from the body.

  12. REMOVE HEATER PUMP ASSEMBLY (w/ Combustion Type Power Heater)

    A011AC2

    1. Disconnect the connector.

    2. Disconnect the 2 fuel hoses.

    3. Remove the nut and heater pump.

  13. REMOVE BRAKE BOOSTER ASSEMBLY


    1. A011AL2

      Using a union nut wrench (10 mm), disconnect the brake tube from the brake tube way.

    2. A0119FP

      Disengage the 2 clamps and separate the brake tube assembly from the body.

    3. A0117FR

      Disengage the 3 clamps and separate the wire harness from the body.

    4. A011772

      Remove the wire harness clamp and 4 nuts and brake booster assembly from the body.

      Note

      Do not damage the brake lines or fuel lines.

  14. REMOVE BRAKE BOOSTER GASKET


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

  15. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY


    1. Remove the vacuum check valve assembly from the brake booster assembly.

  16. REMOVE CHECK VALVE GROMMET


    1. Remove the check valve grommet from the brake booster assembly.