Brake Booster (For Sedan) Removal

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

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

Remove the nut and front wiper arm.

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

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

Remove the cowl top ventilator louver sub-assembly.

Disconnect the washer hoses.

Disengage the 5 hooks.

Remove the 2 bolts.

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

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

Disengage the wire harness clamp.

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

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

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

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

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

Disconnect the cable from the battery terminal.

Loosen the nut and remove the battery clamp.

Remove the battery.

Separate the wire harness clamp from the battery carrier.

Remove the 5 bolts and remove the battery carrier.

Release the lock lever and disconnect the brake actuator connector.

NOTICE:

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

Using a union nut wrench 10 mm and a union nut wrench 12 mm, separate the 6 brake tubes from the brake actuator.

Text in Illustration

	Flare Nut 10 mm
	Flare Nut 12 mm

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

Remove the 3 bolts and brake actuator with bracket.

NOTICE:

Do not damage the brake tubes or wire harness.

Release the lock lever and disconnect the brake actuator connector.

NOTICE:

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

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

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

Remove the 3 bolts and brake actuator with bracket.

NOTICE:

Do not damage the brake tubes or wire harness.

Slide the clip and disconnect the reservoir tube.

Disconnect the brake fluid level warning switch connector.

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

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

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

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 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.
   

Disconnect the brake fluid level warning switch connector.

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

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

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

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 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.
   

Disconnect the brake fluid level warning switch connector.

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

Remove the 2 nuts and brake tube way and remove the brake master cylinder sub-assembly.

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

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 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.
   

Remove the brake pedal return spring.

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

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

Using a union nut wrench, remove the brake tube assembly from the proportioning valve.

Slide the clip and disconnect the vacuum hose from the check valve.

Remove the 4 nuts and remove the brake booster.

Remove the gasket from the brake booster.

Loosen the push rod lock nut and remove the push rod clevis.

Remove the vacuum check valve from the brake booster.

Remove the grommet from the brake booster.