BRAKE BOOSTER(for RHD) 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 notices before proceeding with work Click here.

  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  3. DISABLE BRAKE CONTROL

    Click here

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

    Click here

  5. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  6. REMOVE COWL BODY MOUNTING REINFORCEMENT RH


    1. A005C8N

      Remove the 3 bolts and cowl body mounting reinforcement RH.

  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A005BIK

      Disengage the clamp and separate the wire harness.

    2. A005DR5

      Disengage the 2 clamps and separate the wire harness from the outer cowl top panel sub-assembly.

    3. A0059V6

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

    4. A005ALZ

      Disengage the claw and bend the water guard plate RH.

    5. A005APR

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

  8. DRAIN BRAKE FLUID

    Note

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

  9. REMOVE BRAKE PEDAL RETURN SPRING

    Click here

  10. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  11. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  12. REMOVE PUSH ROD PIN

    Click here

  13. SEPARATE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET


    1. A005DHN

      Disengage the clamp.

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

  14. DISCONNECT NO. 1 RESERVOIR HOSE


    1. A005AQTE02
      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 from the brake booster with master cylinder assembly and No. 1 brake actuator tube.

  15. DISCONNECT NO. 2 RESERVOIR HOSE

  16. DISCONNECT NO. 2 BRAKE ACTUATOR HOSE

  17. REMOVE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET

  18. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. A005A8W

      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. A005CM3

      Remove the bolt and wire harness clamp bracket.

    4. A005AQRE03

      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. A005EFO

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

    7. A005B1M

      Disengage the grommet and separate the brake line.

    8. A005EXFE01
      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.

  19. REMOVE BRAKE BOOSTER GASKET