BRAKE BOOSTER (for RHD) REMOVAL


  1. REMOVE REAR FLOOR MAT


    1. A003TLX

      Remove the rear floor mat.

  2. REMOVE REAR DECK FLOOR BOX


    1. A003TAA

      Remove the rear deck floor box.

  3. REMOVE BATTERY BOX COVER


    1. A003UZD

      Disengage the 3 guides and remove the battery box cover.

  4. 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. A003S3N

      Disconnect the reservoir level switch connector with the parking brake applied.

    3. Disconnect the cable from the negative (-) battery terminal.

      Note

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected 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 can not be further depressed.

    6. Release the parking brake.

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


    1. A003UIU

      Remove the 2 screws <C> or <D>.

    2. A003SV9E03

      Disengage the claw and guide, and remove the No. 1 instrument panel under cover sub-assembly.

  6. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  7. REMOVE COWL BODY MOUNTING REINFORCEMENT LH


    1. A003UFL

      Remove the 3 bolts and cowl body mounting reinforcement LH.

  8. REMOVE OUTER COWL TOP PANEL


    1. A003RYXE01
      Text in Illustration
      *1 Water Guard Plate RH
      *2 No. 1 Heater Air Duct Splash Shield Seal

      Disengage each claw of the water guard plate RH and No. 1 heater air duct splash shield seal, and bend them.

    2. A003UWL

      Disengage the clamp and separate the wire harness.

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

  9. DRAIN BRAKE FLUID

    Note

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

  10. REMOVE BRAKE PEDAL RETURN SPRING


    1. A003UK4

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

  11. REMOVE PUSH ROD PIN


    1. A003TLD

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

  12. SEPARATE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. A003SP0

      Disengage the clamp.

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

  13. DISCONNECT NO. 1 RESERVOIR HOSE


    1. A003S56E01
      Text in Illustration
      *1 No. 1 Reservoir hose
      *2 No. 2 Reservoir hose
      *3 No. 2 Brake Actuator Hose

      Move the 3 clips and disconnect the No. 1 reservoir hose, No. 2 reservoir hose and No. 2 brake actuator hose.

  14. DISCONNECT NO. 2 RESERVOIR HOSE

  15. DISCONNECT NO. 2 BRAKE ACTUATOR HOSE

  16. REMOVE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET

  17. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. A003UGV

      Disengage the clamp.

    2. 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.

      Tech Tips

      Perform this step only when the connector has not been disconnected.

    3. A003RIF

      Remove the bolt and wire harness clamp bracket.

    4. A003RG5E01

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

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

      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
    6. A003SD1

      Using a union nut wrench, disconnect the brake line from the front flexible hose RH.

    7. Disengage the grommet and separate the brake line.

    8. A003SWGE01
      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.

  18. REMOVE BRAKE BOOSTER GASKET