Removal [08/2013 - ]

WARNING: This page is about a different car, the 2014 Lexus ES 300h. However, it is still accessible from the selected car via links, so may be relevant.

PRECAUTION
NOTE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal, Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION [08/2013 - ] .
DISABLE BRAKE CONTROL
1. Wait at least 2 minutes after turning the power switch off.
  NOTE:
  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.
2. Disconnect the reservoir level switch connector with the parking brake applied.
  
  Fig 1: Identifying Reservoir Level Switch Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the cable from the negative (-) auxiliary battery terminal. Refer to REMOVAL [08/2013 - ] .
4. Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.
5. Check that the brake pedal cannot be further depressed.
6. Release the parking brake.
REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
Refer to REMOVAL [08/2013 - ]
REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY
1. w/ Wiper Deicer System:
  Disengage the clamp (A).
  
  Fig 2: Identifying Wiper Deicer System
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disengage the 2 clamps (B).
3. Disconnect the connector and separate the wire harness from the front outer cowl top panel subassembly.
4. Disengage the 2 clamps and separate the wire harness from the front outer cowl top panel sub-assembly.
  
  Fig 3: Removing Front Outer Cowl Top Panel Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 10 bolts and front outer cowl top panel sub-assembly.
  
  Fig 4: Identifying Front Outer Cowl Top Panel Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DRAIN BRAKE FLUID
NOTE:
If brake fluid leaks onto any painted surface, immediately clean it off.
REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL [08/2013 - ] - Step 1
REMOVE INLET AIR CLEANER ASSEMBLY . Refer to REMOVAL [08/2013 - ] - Step 26
REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to REMOVAL [08/2013 - ] - Step 3
REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
REMOVE AIR CLEANER CASE SUB-ASSEMBLY . Refer to REMOVAL [08/2013 - ] - Step 29
REMOVE PUSH ROD PIN See step 6
SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY
1. Remove the 2 bolts and brake master cylinder reservoir assembly.
  
  Fig 5: Identifying Brake Master Cylinder Reservoir Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE NO. 1 BRAKE ACTUATOR TUBE
1. Remove the nut and disengage the clamp.
  
  Fig 6: Identifying No. 1 Brake Actuator Tube Nut & Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the nut and separate the No. 1 brake actuator tube from the vehicle body.
  
  Fig 7: Identifying Nut & No. 1 Brake Actuator Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT NO. 2 RESERVOIR HOSE
1. Move the clip and disconnect the No. 2 reservoir hose from the brake booster with master cylinder assembly.
  
  Fig 8: Identifying No. 2 Reservoir Hose Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT NO. 1 RESERVOIR HOSE
1. Move the clip and disconnect the No. 1 reservoir hose from the brake booster with master cylinder assembly.
  
  Fig 9: Identifying No. 1 Reservoir Hose Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RESERVOIR BRACKET
1. Disengage the 2 clamps to separate the wire harness from the reservoir bracket.
  
  Fig 10: Identifying Wire Harness Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 bolts and reservoir bracket.
  
  Fig 11: Identifying Reservoir Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

Put matchmarks at the position where the wire harness clamp is installed.

Fig 12: Identifying Wire Harness Clamp Matchmarks

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	Matchmark
	Cut

Cut the wire harness clamp and separate the wire harness from the brake booster with master cylinder assembly.

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

Fig 13: Releasing Lock Lever

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

	Release the lock lever
	Disconnect the connector

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

Fig 14: Identifying Brake Lines At Brake Booster
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

TEXT IN ILLUSTRATION

*a	to Front Wheel Cylinder LH
*b	to Rear Wheel Cylinder RH
*c	to Brake Booster Pump Assembly
*d	to Rear Wheel Cylinder LH
*e	to Front Wheel Cylinder RH

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

Fig 15: Identifying Brake Booster With Master Cylinder Assembly Components

TEXT IN ILLUSTRATION

*1	Connector Portion
*2	Union
*3	Push Rod Clevis
*4	Boot
*5	Front No. 2 Brake Tube

NOTE:

Do not kink or damage the brake lines.
Do not carry the brake booster with master cylinder assembly by the parts shown in bold in the illustration.
Be careful not to allow any brake fluid to enter the connector.

Turn the wire harness clamp counterclockwise to remove it from the brake booster with master cylinder assembly.

Fig 16: Identifying Wire Harness Clamp
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE BRAKE BOOSTER GASKET