Removal

BRAKE SYSTEM (OTHER): BRAKE BOOSTER: REMOVAL

1. REMOVE REAR NO. 2 FLOOR BOARD (for Separate Type) Removal

2. REMOVE REAR DECK FLOOR BOX Removal

3. REMOVE REAR NO. 3 FLOOR BOARD Removal

4. DISABLE BRAKE CONTROL

(a) Wait at least 2 minutes after the power switch off.

NOTICE:
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.

(b) Disconnect the reservoir level switch connector with the parking brake applied.





(c) Disconnect the cable from the auxiliary battery negative (-) terminal.

(d) Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.

(e) Check that the brake pedal can not be further depressed.

(f) Release the parking brake.

5. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Removal

6. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Removal

7. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

(a) Remove the 3 bolts and cowl body mounting reinforcement LH.





8. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

(a) Disengage the 2 clamps and guide of the wire harness.





Text in Illustration





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





(c) Disengage the claw and bend the water guard plate RH.





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





9. DRAIN BRAKE FLUID

NOTICE:
If brake fluid leaks onto any painted surface, immediately wash it off.

10. REMOVE BRAKE PEDAL RETURN SPRING Removal

11. REMOVE PUSH ROD PIN Removal

12. SEPARATE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET

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





13. DISCONNECT NO. 1 RESERVOIR HOSE

(a) Move the 2 clips and disconnect the No. 1 reservoir hose and No. 2 reservoir hose from the brake booster with master cylinder assembly.





Text in Illustration





14. DISCONNECT NO. 2 RESERVOIR HOSE

15. DISCONNECT BRAKE ACTUATOR HOSE

(a) Move the clip and disconnect the brake actuator hose from the brake booster pump assembly.





16. REMOVE BRAKE MASTER CYLINDER RESERVOIR WITH BRACKET

17. REMOVE NO. 5 BRAKE ACTUATOR BRACKET

(a) Disengage the clamp.





(b) Remove the 2 nuts and No. 5 brake actuator bracket.

18. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

(a) Release the lock lever and disconnect the connector from the brake booster with master cylinder assembly.





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

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





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





(d) Use tags or make a memo to identify the places to reconnect.

Text in Illustration





(e) Disengage the 2 clamps and separate the brake line.





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





Text in Illustration





NOTICE:
* Do not kink or damage the brake lines.
* Do not carry the brake booster with master cylinder assembly by the portion shown in the illustration.

19. REMOVE BRAKE BOOSTER GASKET