BRAKE BOOSTER (for LHD) > REMOVAL

for Preparation Click here

NOTICE:

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

1. Remove the windshield wiper motor and link assembly (Click here).
   

NOTICE:

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

1. Remove the knee airbag assembly (Click here).
   

1. Loosen the push rod lock nut.
   

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

3. Remove the push rod clevis from the brake booster.
   

1. Remove the 2 nuts and the battery clamp.
   

1. Disconnect the 2 wire harness clamps.
   

2. Disconnect the connector.
   

3. Disconnect the 2 connectors.
   

4. Disconnect the 2 fuel hose clamps from the fuel filter.
   

5. Disconnect the 2 fuel hoses.
   

6. Loosen the fuel filter drain plug to drain fuel.
   

7. Tighten the fuel filter drain plug.
   

8. Remove the 2 nuts and fuel filter.
   

1. Move the clip and disconnect the clutch reservoir tube.
   

1. Disconnect the brake fluid level warning switch connector and disengage the clamp.
   

2. Using a union nut wrench (12 mm), disconnect the 2 brake tubes from the brake master cylinder sub-assembly.
   

3. Remove the 2 nuts.
   

4. Remove the brake master cylinder sub-assembly from the brake booster.
   

   NOTICE:

   1. The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder 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 from brake booster.
      
   4. When installing the master cylinder to the brake booster, or when removing the master cylinder from the brake booster, make sure that the master cylinder 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 base glycol grease around the circumference (sliding part) of the piston.
      
   6. Do not use any other type of grease or fluid.
      

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

1. Disconnect the brake fluid level warning switch connector and the vacuum sensor wire connector, and disengage the clamp.
   

2. Using a union nut wrench (12 mm), disconnect the 2 brake tubes from the brake master cylinder sub-assembly.
   

3. Disengage the clamp and separate the vacuum sensor wire harness from the brake master cylinder sub-assembly.
   

4. Disconnect the vacuum hose.
   

5. Remove the 2 nuts and vacuum sensor assembly.
   

6. Remove the brake master cylinder sub-assembly from the brake booster.
   

   NOTICE:

   1. The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder 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 from brake booster.
      
   4. When installing the master cylinder to the brake booster, or when removing the master cylinder from the brake booster, make sure that the master cylinder 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 base glycol grease around the circumference (sliding part) of the piston.
      
   6. Do not use any other type of grease or fluid.
      

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

1. Slide the 2 clips and disconnect the vacuum hose from the check valve and hose tube.
   

2. Remove the 2 bolts from the body.
   

1. Disconnect the connector.
   

2. Disconnect the 2 fuel hoses.
   

3. Remove the nut and heater pump.
   

1. Using a union nut wrench (10 mm), disconnect the brake tube from the brake tube way.
   

2. Disengage the 2 clamps and separate the brake tube assembly from the body.
   

3. Disengage the 3 clamps and separate the wire harness from the body.
   

4. Remove the wire harness clamp and 4 nuts and brake booster assembly from the body.
   

   NOTICE:

   Do not damage the brake lines or fuel lines.

1. Remove the brake booster gasket from the brake booster assembly.
   

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

1. Remove the check valve grommet from the brake booster assembly.