BRAKE BOOSTER (for RHD) 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. A003Y4O

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

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


    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 WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  4. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL


    1. A003Z14

      Disengage the 2 claws and remove the No. 1 heater air duct splash shield seal.

  5. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL


    1. A003WN3

      Disengage the claw and guide, and remove the No. 2 heater air duct splash shield seal.

  6. REMOVE COWL BODY MOUNTING REINFORCEMENT RH


    1. A003YWK

      Remove the 2 bolts and cowl body mounting reinforcement RH.

  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A003X05

      Disengage the clamp and separate the wire harness.

    2. A003X62

      w/ Wiper Deicer:

      Disengage the 3 clamps, disconnect the connector and separate the wire harness.

    3. A003ZGV

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

  8. REMOVE SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper)


    1. A003VPIE01
      Text in Illustration
      *a LH Side
      *b RH Side

      Remove the 2 nuts and the suspension tower damper from the vehicle.

  9. DRAIN BRAKE FLUID

    Note

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

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


    1. A003ZMA

      Remove the screw <E>.

    2. Disengage the 2 clips.

    3. Disengage the clamp.

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

  11. REMOVE BRAKE PEDAL RETURN SPRING


    1. A003VLV

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

  12. REMOVE PUSH ROD PIN


    1. A003VFK

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

  13. SEPARATE RESERVOIR TUBE ASSEMBLY


    1. A003VUB

      Remove the 2 bolts, nut and separate the reservoir tube assembly.

    2. A003WMJE01
      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.

  14. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. A003ZNZ

      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.

    3. A003XXC

      Remove the bolt and wire harness clamp bracket.

    4. A003YECE01

      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. A003VNC

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

    7. A003V8Q

      Disengage the grommet and separate the brake line.

    8. A003Y59E01
      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 bold in the illustration.

  15. REMOVE BRAKE BOOSTER GASKET