BRAKE BOOSTER (for LHD) REMOVAL


  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 notices before proceeding with work Click here.

  2. DISABLE BRAKE CONTROL


    1. Wait at least 2 minutes after 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. A00449B

      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 NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY


    1. A00420O

      Remove the 2 screws <D>.

    2. Disengage the claw and guide.

    3. Disconnect each connector and remove the No. 1 instrument panel under cover sub-assembly.

  4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  5. REMOVE COWL BODY MOUNTING REINFORCEMENT LH


    1. A00436K

      Remove the 3 bolts and cowl body mounting reinforcement LH.

  6. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A0040EX

      Disengage the clamp and separate the wire harness.

    2. A0041QO

      Disengage the claw and bend the No. 1 heater air duct splash shield seal.

    3. A004113

      Disengage the claw and bend the water guard plate RH.

    4. A0043EB

      Remove the 9 bolts and outer cowl top panel sub-assembly.

  7. DRAIN BRAKE FLUID

    Note

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

  8. REMOVE BRAKE PEDAL RETURN SPRING


    1. A00437N

      Remove the brake pedal return spring from the brake pedal support assembly and push rod pin.

  9. REMOVE PUSH ROD PIN


    1. A00427O

      Remove the clip and push rod pin to separate the brake pedal support assembly from the push rod clevis.

  10. SEPARATE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. A00448M

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

  11. DISCONNECT NO. 1 RESERVOIR HOSE


    1. A00432AE01
      Text in Illustration
      *1 No. 1 Reservoir Hose
      *2 No. 2 Reservoir Hose

      Move the 2 clips and disconnect the No. 1 reservoir hose and No. 2 reservoir hose from the brake booster with master cylinder assembly.

  12. DISCONNECT NO. 2 RESERVOIR HOSE

  13. DISCONNECT BRAKE ACTUATOR HOSE


    1. A00425I

      Move the clip and disconnect the brake actuator hose from the brake booster pump assembly.

  14. REMOVE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET

  15. REMOVE NO. 5 BRAKE ACTUATOR BRACKET


    1. A00400Y

      Disengage the clamp.

    2. Remove the 2 nuts and No. 5 brake actuator bracket.

  16. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. A0042Q1

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

      Note

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

    2. A00441K

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

    3. A0041XRE01

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

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

      Text in Illustration
      *1 to Front Wheel Cylinder LH
      *2 to Rear Wheel Cylinder RH
      *3 to Brake Booster Pump Assembly
      *4 to Rear Wheel Cylinder LH
      *5 to Front Wheel Cylinder RH
    5. A004286

      Disengage the 2 clamps and separate the brake line.

    6. A004430E01
      Text in Illustration
      *1 Connector Portion
      *2 Union
      *3 Push Rod Clevis and Boot
      *4 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 portion shown in the illustration.

  17. REMOVE BRAKE BOOSTER GASKET