BRAKE BOOSTER PUMP REMOVAL

CAUTION / NOTICE / HINT

Note:

While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch turns on. Therefore, when servicing the brake system components, do not operate the brake pedal or open/close the doors while the auxiliary battery is connected.

PROCEDURE

  1. REMOVE DECK BOARD ASSEMBLY

    Click here

  2. REMOVE BATTERY SERVICE COVER

    Click here

  3. DISABLE BRAKE CONTROL

    Click here

  4. DRAIN BRAKE FLUID

    Note:

    Wash off brake fluid immediately if it comes in contact with any painted surface.

  5. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  6. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY (for LHD)

    Click here

  7. DISCONNECT HEATER ACCESSORY ASSEMBLY

    1. B374997

      Disconnect the connector.

    2. Detach the clamp.

    3. Remove the 3 bolts and nut and disconnect the heater accessory assembly.

  8. DISCONNECT NO. 1 BRAKE ACTUATOR HOSE

    1. C297106

      Slide the clip and disconnect the No. 1 brake actuator hose from the brake booster pump assembly.

  9. DISCONNECT FRONT NO. 1 BRAKE TUBE

    1. C297108

      Using a union nut wrench, disconnect the front No. 1 brake tube from the brake booster pump assembly.

    2. Remove the bolt and disconnect the front No. 1 brake tube from the No. 1 brake clamp bracket.

  10. REMOVE NO. 1 BRAKE TUBE CLAMP BRACKET

    1. C297109

      Remove the bolt and No. 1 brake tube clamp bracket from the brake booster pump assembly.

  11. REMOVE BRAKE BOOSTER PUMP ASSEMBLY WITH BRACKET

    1. C297107

      Disconnect the 2 connectors and detach the clamp from the brake booster pump assembly.

    2. Detach the brake tube clamp from the brake actuator bracket assembly.

    3. C297110

      Remove the 3 nuts and brake booster pump assembly with bracket.

  12. REMOVE BRAKE BOOSTER PUMP ASSEMBLY

    1. C297828C01

      *1

      Brake Actuator Case Collar

      Nut

      *2

      Brake Actuator Case Collar

      *3

      Brake Booster Pump Bushing

      *4

      Brake Actuator Bracket Assembly

      *5

      Brake Booster Pump Assembly

      *6

      Brake Actuator Bracket Cushion

      *a

      Union

      *b

      Connector

      *c

      Stud

      Remove the 2 brake actuator case collar nuts, 2 brake booster pump bushings, 2 brake actuator case collars and brake booster pump assembly from the brake actuator bracket assembly.

      Note:

      • When handling the brake booster pump assembly, do not hold it at the parts marked *a, *b and *c in the illustration.

      • Do not drop the brake booster pump assembly when carrying it. Do not use a brake booster pump assembly that has been dropped.

      • Do not damage the brake tubes or clamps. If damaged, replace them with new ones.

      • Do not allow brake fluid to contact the inside of the connector.

    2. Remove the 2 brake actuator bracket cushions from the brake actuator bracket assembly.