BRAKE BOOSTER (for Sedan) > REMOVAL


NOTICE:
Release the vacuum from the booster by depressing the brake pedal several times.
Then remove the brake master cylinder from brake booster.


1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL


2. DRAIN BRAKE FLUID

NOTICE:
Immediately wash off any brake fluid that comes into contact with any painted surfaces.


3. REMOVE FRONT WIPER ARM HEAD CAP


    E127832E01
  1. Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the 2 front wiper arm head caps.



4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH


    E127833
  1. Operate the wiper, then stop the windshield wiper motor in the automatic stop position.

  1. Remove the nut and front wiper arm.



5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

HINT:
Use the same procedure as for the LH side.


6. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY LH


    E127834E01
  1. Using a screwdriver with its tip wrapped in protective tape, disengage the 3 claws and remove the cowl side ventilator sub-assembly LH.



7. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH

HINT:
Use the same procedure as for the LH side.


8. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    E127838
  1. Disengage the 3 clips, the 4 claws and the 8 hooks.

  1. Remove the cowl top ventilator louver sub-assembly.



    E127839
  1. Disconnect the washer hoses.

  1. Disengage the 5 hooks.



9. REMOVE FRONT WIPER MOTOR AND LINK


    E127837
  1. Remove the 2 bolts.

  1. Slide the wiper link. Disengage the meshing of the rubber pin, then disconnect the connector and remove the front wiper motor and link.



10. REMOVE FRONT AIR SHUTTER SEAL


A133324
  1. Disengage the 3 claws and remove the front air shutter seal RH.



11. REMOVE OUTER COWL TOP PANEL


    A128446
  1. Disengage the wire harness clamp.



    A128447
  1. Remove the 2 bolts and remove the cowl top to cowl inner brace.



    A128448
  1. Remove the 8 bolts and remove the cowl top panel outer.



12. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY


    B130349
  1. Disengage the 4 claws and remove the instrument panel under cover.



13. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY


B132381
  1. Disengage the 7 claws and open the instrument panel lower finish panel.



    B132382
  1. Remove the 2 <A> screws and remove the instrument panel lower finish panel.



14. REMOVE BATTERY
  1. Disconnect the cable from the battery terminal.

  1. Loosen the nut and remove the battery clamp.

  1. Remove the battery.



15. REMOVE BATTERY TRAY


16. REMOVE BATTERY CARRIER


A117309
  1. Separate the wire harness clamp from the battery carrier.

  1. Remove the 5 bolts and remove the battery carrier.



17. REMOVE BRAKE ACTUATOR ASSEMBLY (w/ ABS)


    C228099E02
  1. Release the lock lever and disconnect the brake actuator connector.

    Text in Illustration 
    *1
    Lock Lever

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


    C241445
  1. Using a 10 mm union nut wrench, separate the 6 brake tubes from the brake actuator assembly.



    C241446E01
  1. Use tags or labels to identify the place to reconnect each brake tube.

    Text in Illustration 
    *a
    to Front Wheel Cylinder RH
    *b
    to Front Wheel Cylinder LH
    *c
    to Rear Wheel Cylinder RH
    *d
    to Rear Wheel Cylinder LH
    *e
    from 1st Master Cylinder
    *f
    from 2nd Master Cylinder


    C168356
  1. Remove the 3 bolts and the brake actuator assembly with brake actuator bracket assembly.

    NOTICE:
    Do not damage the brake tubes or wire harness.


18. DISCONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle)


C215148
  1. Slide the clip and disconnect the clutch reservoir tube.



19. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (w/ ABS)
  1. Disconnect the brake fluid level warning switch connector.



    C274940
  1. Using a 10 mm union nut wrench , separate the 2 brake tubes from the brake master cylinder sub-assembly.



    C116934
  1. Remove the 2 nuts and the brake master cylinder sub-assembly.

  1. Remove the O-ring from the brake master cylinder sub-assembly.

    NOTICE:
    1. The master cylinder requires careful handling. Do not allow the brake master cylinder sub-assembly to receive any impact, such as from being dropped. Do not reuse a brake master cylinder sub-assembly that has been dropped.
    2. Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.
    3. Release the vacuum from the booster by depressing the brake pedal several times. Then remove the brake master cylinder sub-assembly from brake booster.
    4. When installing the brake master cylinder sub-assembly onto the brake booster, or when removing the brake master cylinder sub-assembly from the brake booster, make sure that the brake master cylinder sub-assembly is kept horizontal or its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling off.
    5. Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a piece of cloth and then apply an even layer of lithium soap based glycol grease around the circumference (sliding part) of the piston.
    6. Do not use any other type of grease or fluid.


20. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (w/o ABS)
  1. Disconnect the brake fluid level warning switch connector.



    C274941
  1. Using a 10 mm union nut wrench, separate the 5 brake tubes from the brake tube way and the brake master cylinder sub-assembly.



    C121833
  1. Remove the 2 nuts, brake tube way and the brake master cylinder sub-assembly.

  1. Remove the O-ring from the brake master cylinder sub-assembly.

    NOTICE:
    1. The master cylinder requires careful handling. Do not allow the brake master cylinder sub-assembly to receive any impact, such as from being dropped. Do not reuse a brake master cylinder sub-assembly that has been dropped.
    2. Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.
    3. Release the vacuum from the booster by depressing the brake pedal several times. Then remove the brake master cylinder sub-assembly from brake booster.
    4. When installing the brake master cylinder sub-assembly onto the brake booster, or when removing the brake master cylinder sub-assembly from the brake booster, make sure that the brake master cylinder sub-assembly is kept horizontal or its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling off.
    5. Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a piece of cloth and then apply an even layer of lithium soap based glycol grease around the circumference (sliding part) of the piston.
    6. Do not use any other type of grease or fluid.


21. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS


C116880
  1. Remove the brake pedal return spring.

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



22. REMOVE BRAKE TUBE (w/o ABS)


    C274942
  1. Using a 10 mm union nut wrench, separate the 2 brake tubes from the No. 1 brake tube way.



    C274943
  1. Using a 10 mm union nut wrench, remove the brake tubes from the proportioning valve.



23. REMOVE BRAKE BOOSTER


    C116936
  1. Slide the clip and disconnect the vacuum hose from the brake vacuum check valve assembly.



    C116943
  1. Remove the 4 nuts and the brake booster.

  1. Remove the gasket from the brake booster.

  1. Loosen the push rod lock nut and remove the brake master cylinder push rod clevis.



24. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY


C116937
  1. Remove the brake vacuum check valve assembly from the brake booster.

  1. Remove the grommet from the brake booster.