BRAKE BOOSTER(for RHD) 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

    Click here

  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 INSTRUMENT PANEL FINISH PANEL (w/o Knee Airbag)

    Click here

  6. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY

    Click here

  7. REMOVE FRONT NO. 1 VENTILATOR SEAL


    1. A004E43

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

  8. REMOVE FRONT AIR SHUTTER SEAL RH

    Tech Tips

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

  9. REMOVE INNER COWL TOP TO COWL BRACE


    1. A004EC1

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

  10. REMOVE OUTER COWL TOP PANEL


    1. A004F9Z

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

    2. A004FIS

      Remove the nut and separate the reservoir bracket from the outer cowl top panel.

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

      A004EUP

  11. DRAIN BRAKE FLUID

    Note

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

  12. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A004GHY

      Remove the 2 nuts and separate the brake master cylinder reservoir assembly from the reservoir bracket.

  13. DISCONNECT NO. 2 RESERVOIR HOSE


    1. A004FGW

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

  14. DISCONNECT NO. 1 RESERVOIR HOSE


    1. A004ESZ

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

  15. DISCONNECT NO. 2 BRAKE ACTUATOR HOSE


    1. A004GH8

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

  16. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. Remove the brake master cylinder reservoir assembly.

  17. REMOVE RESERVOIR BRACKET


    1. A004EB2

      Remove the bolt, nut and the reservoir bracket.

  18. REMOVE BRAKE PEDAL RETURN SPRING

    Click here

  19. REMOVE PUSH ROD PIN

    Click here

  20. DISCONNECT BRAKE LINE


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

    2. A004FJAE04
      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.

    3. A004FXF

      Disengage the brake tube clamp from the clamp bracket of the brake booster with master cylinder assembly.

  21. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. A004F8C

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

      Text in Illustration
      A004F2L Release the lock lever
      A004F32 Disconnect the connector
    2. A004FZM

      Disengage the wire harness clamp from the stud bolt of the brake booster with master cylinder assembly.

    3. A004FZVE04
      Text in Illustration
      *1 Connector Portion
      *2 Union
      *3 Brake Master Cylinder 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.

  22. REMOVE BRAKE BOOSTER GASKET


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