BRAKE BOOSTER(for LHD) REMOVAL

PROCEDURE


  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 notice before proceeding with work Click here.

  2. DISABLE BRAKE CONTROL


    1. Wait at least 2 minutes after turning 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. A0059XE

      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 can not be further depressed.

    6. Release the parking brake.

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

    Click here

  4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  5. REMOVE COWL BODY MOUNTING REINFORCEMENT LH


    1. A005DBO

      Remove the 3 bolts and cowl body mounting reinforcement LH.

  6. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A005ASF

      Disengage the clamp of the wire harness.

    2. A005B00

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

    3. A005DHJ

      Disengage the claw and bend the water guard plate RH.

    4. A005DZ3

      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

    Click here

  9. REMOVE PUSH ROD PIN

    Click here

  10. SEPARATE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. A005A3A

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

  11. DISCONNECT NO. 1 RESERVOIR HOSE


    1. A005F3KE03
      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. A005AEK

      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. A005AM7

      Disengage the clamp.

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

  16. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. A005AJ8

      Release the lock lever and disconnect the connector.

      Note

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

    2. A005AC2

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

    3. A005D8HE05

      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
      *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
    5. A0059OT

      Disengage the 2 clamps to separate the brake line from the vehicle body.

    6. A005EZPE01
      Text in Illustration
      *1 Connector Portion
      *2 Union
      *3 Push Rod Clevis
      *4 Boot
      *5 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.

  17. REMOVE BRAKE BOOSTER GASKET