BRAKE BOOSTER(for LHD) REMOVAL

PROCEDURE


  1. PRECAUTION

    Note

    After turning the ignition 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 ignition switch off.

      Note

      When the brake pedal is depressed or the door courtesy switch is turned on even if the ignition 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. A01V0E9

      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 LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (w/ Knee Airbag)

    Click here

  4. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

    Click here

  5. REMOVE LOWER NO. 2 INSTRUMENT PANEL FINISH PANEL (w/o Knee Airbag)

    Click here

  6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Knee Airbag)

    Click here

  7. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY

    Click here

  8. REMOVE FRONT NO. 1 VENTILATOR SEAL


    1. A01V1I7

      Disengage the clamp and remove the front No. 1 ventilator seal.

  9. REMOVE FRONT AIR SHUTTER SEAL RH

    Tech Tips

    Use the same procedure as for the front No. 1 ventilator seal.

  10. REMOVE INNER COWL TOP TO COWL BRACE


    1. A01UXRE

      Remove the 2 bolts and the inner cowl top to cowl brace.

  11. REMOVE OUTER COWL TOP PANEL


    1. A01UZ4Q

      Disengage the 2 clamps and separate the wire harness from the outer cowl top panel.

    2. A01V0H7

      Remove the nut and separate the No. 2 reservoir bracket from the outer cowl top panel.

    3. Remove the 8 bolts and the outer cowl top panel.

      A01V036

  12. DRAIN BRAKE FLUID

    Note

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

  13. REMOVE BRAKE PEDAL RETURN SPRING

    Click here

  14. REMOVE PUSH ROD PIN

    Click here

  15. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A01UZVY

      Remove the 2 nuts and the No. 2 reservoir bracket and separate the brake master cylinder reservoir assembly from the reservoir bracket.

  16. DISCONNECT NO. 2 RESERVOIR HOSE


    1. A01V1TI

      Move the clip and disconnect the No. 2 reservoir hose from the brake booster with master cylinder assembly.

  17. DISCONNECT NO. 1 RESERVOIR HOSE


    1. A01UXP2

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

  18. REMOVE RESERVOIR BRACKET


    1. A01UXPG

      Remove the 2 bolts and the reservoir bracket.

  19. DISCONNECT BRAKE ACTUATOR HOSE


    1. A01UYE8

      Move the clip and disconnect the brake actuator hose from the brake master cylinder reservoir assembly.

  20. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. Remove the brake master cylinder reservoir assembly.

  21. REMOVE TUBE CLAMP BRACKET


    1. A01UZ37

      Remove the 2 bolts and the tube clamp bracket from the brake booster with master cylinder assembly and the front No. 1 brake tube clamp.

  22. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. A01V0EN

      Release the lock lever and disconnect the connector.

      Text in Illustration
      A01V0R7 Release the lock lever
      A01UY2W Disconnect the connector

      Note

      Be careful not to allow the brake fluid to enter the removed connector.

    2. Using a union nut wrench 10 mm, disconnect the 5 brake lines from the brake booster with master cylinder assembly.

    3. A01V1M7E03
      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

      Use tags or make a memo to identify the places to reconnect the brake lines.

    4. A01UYL0E02
      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 the 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 portion shown in bold in the illustration.

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

  23. REMOVE BRAKE BOOSTER GASKET


    1. Remove the brake booster gasket from the brake booster with master cylinder assembly.