Disassembly and Assembly

Part 1 Of 2:

Part 2 Of 2:

DISASSEMBLY





1. PLACE HYDRAULIC BRAKE BOOSTER IN VISE
Using SST, set the hydraulic brake booster in vise.
SST 09630-00014 (09631-00142), 09950-60010 (09951-00180, 09951-00190)
2. REMOVE FLUID LEVEL, WARNING SWITCH CONNECTOR CLAMP
a. Disconnect the connector.
b. Remove the bolt and clamp.
3. REMOVE RESERVOIR AND GROMMETS
a. Remove reservoir cap.
b. Remove the 3 set screws and pull out the reservoir.
Torque: 1.7 Nm (17.5 kgf-cm, 15.2 inch lbs.)
c. Remove the 3 grommets.
4. REMOVE CLEVIS AND CYLINDER BOOT
a. Loosen the lock nut, then remove the clevis and lock nut.
Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.)
b. Remove the cylinder boot.





5. REMOVE BRAKE ACTUATOR TUBE NO. 1
Using SST, remove the brake actuator tube No. 1.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
6. REMOVE BOOSTER PUMP AND ASSEMBLY
a. Remove the actuator hose.
b. Remove the 4 screws and wire harness from the booster and pump.
c. Remove the 2 bolts, accumulator bracket.
d. Remove the 2 bolts and booster pump motor assembly.
e. Remove the bolt and No.1 pump bracket.
f. Remove the 2 washers, 2 cushions, 2 collars and sleeve.
g. Remove the 2 bolts and No. 2 pump bracket.
h. Remove the cushion from No. 2 pump bracket.





7. ABS & BA & TRAC & VSC only: REMOVE MASTER CYLINDER PRESSURE SENSOR
Using 30 mm deeper socket wrench and remove the oil pressure sensor.
Torque: 81 Nm (830 kgf-cm, 60 ft. lbs.)

NOTICE: If replacing the master cylinder pressure sensor, since the sensor is non-reusable, use a sensor of the supply part No shown.

PART NO: 89637-30050





8. REMOVE PISTON
a. Pressing the piston in with a screwdriver, use a pin or an equivalent to push the snap ring from the hole in the body then remove it with another screwdriver.
b. Remove the piston, pulling straight out, not at an angle.

NOTICE:
^ If pulled out and installed at an angle, there is a possibility that the cylinder bore could be damaged.
^ At the time of reassembly, be careful not to damage the rubber lips on the pistons.





9. REMOVE ACCUMULATOR FROM BOOSTER PUMP
a. Using SST, remove the accumulator.
SST 09318-12010
Torque: 54 Nm (550 kgf-cm, 36 ft. lbs.)
b. Remove the silencer tube, spring and O-ring.

INSPECTION
INSPECT HYDRAULIC BRAKE BOOSTER PUMP MOTOR OPERATION





a. Connect the positive (+) lead from the battery to terminal 1 of pump motor, and the negative (-) lead to terminal 2.
b. Check that the pump motor operation.

DISPOSAL
DISPOSAL METHOD OF ACCUMULATOR





a. Place the accumulator in a vise, cover it with a cloth over.
b. Using a saw, then cut the accumulator body slowly.

CAUTION: Do not cut at a place except a stretch.

c. When the outer body of the accumulator is cut, gas discharges.

REASSEMBLY





Reassembly is in the reverse order of disassembly.

INSTALL ACCUMULATOR BRACKET
When installing the accumulator bracket, adjust to secure the clearance shown in the illustration on the left.
Standard clearance:
A + B: 4.1 mm (0.161 inch) or less
C: 0.3 - 3.8 mm (0.012 - 0.150 inch)

HINT: Secure more than 0.3 mm (0.012 inch) clearance for A and B each.