BRAKE BOOSTER > REMOVAL

for Preparation Click here

NOTICE:

After turning the ignition 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).

1. Wait at least 2 minutes after turning the ignition switch off.
   

   NOTICE:

   When the brake pedal is depressed or the door courtesy switch is turned on even if the ignition 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. 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.
   

1. Remove the 3 bolts and inner cowl top to cowl brace.
   

1. Disengage the clamp to remove the front air shutter seal.
   

1. Disengage the clamp to remove the front No. 1 ventilator seal.
   

1. Disengage the clamp to separate the wire harness from the outer cowl top panel sub-assembly.
   

2. Remove the 8 bolts, nut and outer cowl top panel sub-assembly.
   

NOTICE:

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

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

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

1. Remove the 2 nuts and separate the brake master cylinder reservoir assembly from the reservoir bracket.
   

1. Move the clip and disconnect the No. 2 reservoir hose from the brake booster with master cylinder assembly.
   

1. Move the clip and disconnect the No. 1 reservoir hose from the brake booster with master cylinder assembly.
   

1. Remove the 2 bolts and reservoir bracket.
   

1. Move the clip and disconnect the brake actuator hose from the brake master cylinder reservoir assembly.
   

1. Remove the 2 bolts and tube clamp bracket from the brake booster with master cylinder assembly and front No. 1 brake tube.
   

1. Release the lock lever and disconnect the connector.
   

   Text in Illustration 

   	Release the lock lever
   	Disconnect the connector

   NOTICE:

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

2. Using a union nut wrench, disconnect the 5 brake lines from the brake booster with master cylinder assembly.
   

3. Use tags or make a memo to identify the places to reconnect the lines.
   

   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

4. Remove the 4 nuts and brake booster with master cylinder assembly.
   

   Text in Illustration 

   *1	Connector Portion
   *2	Union
   *3	Push Rod Clevis
   *4	Boot
   *5	Front No. 2 Brake Tube

   NOTICE:

   1. Do not kink or damage the brake lines.
      
   2. Do not carry the brake booster with master cylinder assembly by the portion shown in bold in the illustration.
      
   3. Be careful not to allow any brake fluid to enter the connector.