PROCEDURE
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.
DISABLE BRAKE CONTROL
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.
Disconnect the reservoir level switch connector with the parking brake applied.
Disconnect the cable from the negative (-) auxiliary battery terminal.
for 2ZR-FXE: Click here
for 5ZR-FXE: Click here
Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.
Check that the brake pedal cannot be further depressed.
Release the parking brake.
REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL
Disengage the 2 claws and remove the No. 1 heater air duct splash shield seal.
REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL
Disengage the claw and guide, and remove the No. 2 heater air duct splash shield seal.
REMOVE COWL BODY MOUNTING REINFORCEMENT LH
Remove the 2 bolts and cowl body mounting reinforcement LH.
REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY
Disengage the clamp and separate the wire harness.
w/ Wiper Deicer:
Disengage the 3 clamps, disconnect the connector and separate the wire harness.
Remove the 9 bolts and outer cowl top panel sub-assembly.
REMOVE SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper)
DRAIN BRAKE FLUID
Note
If brake fluid leaks onto any painted surface, immediately clean it off.
REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
REMOVE BRAKE PEDAL RETURN SPRING
REMOVE PUSH ROD PIN
SEPARATE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET
Disengage the 2 clamps.
Remove the 2 nuts and separate the brake master cylinder reservoir with bracket.
DISCONNECT RESERVOIR HOSE
*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.
DISCONNECT BRAKE ACTUATOR HOSE
Move the clip and disconnect the brake actuator hose from the brake booster pump assembly.
REMOVE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET
REMOVE NO. 5 BRAKE ACTUATOR BRACKET
Disengage the clamp.
Remove the 2 nuts and No. 5 brake actuator bracket.
REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY
Release the lock lever and disconnect the connector from the brake booster with master cylinder assembly.
Note
Be careful not to allow any brake fluid to enter the removed connector.
Remove the 2 bolts and No. 2 brake tube clamp bracket from the brake booster with master cylinder assembly.
Using a union nut wrench, disconnect the 5 brake lines from the brake booster with master cylinder assembly.
Use tags or make a memo to identify the places to reconnect.
*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 |
Disengage the 2 clamps and separate the brake line.
*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.
REMOVE BRAKE BOOSTER GASKET