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Home >> Toyota >> 2015 >> Avalon Hybrid Limited >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) - Service Information - (Hybrid) >> Brake Booster Pump >> Removal [10/2014 - ] >> Procedure

Removal [10/2014 - ]: Procedure

  1. 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 notices before proceeding with work (Refer to PRECAUTION [10/2014 - ] ).

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  3. DISABLE BRAKE CONTROL 

    See step  2

  4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    (Refer to REMOVAL [10/2014 - ] )

  5. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY 

    See step  4

  6. REMOVE COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 1 and PROCEDURE - Step 1

  7. REMOVE INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 23

  8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  9. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 25

  10. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 26

  11. SEPARATE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 
    1. Remove the bolt from the hook connector.
      GTY317437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn the hook connector and separate the air conditioner tube and accessory assembly from the air conditioning unit.
      GTY322470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not deform the piping.
      • Do not damage the clamp.
    3. Remove the O-ring from the air conditioner tube and accessory assembly.
      NOTE:

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  12. SEPARATE SUCTION HOSE SUB-ASSEMBLY 
    1. Separate the suction hose sub-assembly from the air conditioning unit.
      GTY322474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not deform the piping.
      • Do not damage the clamp.
    2. Remove the O-ring from the suction hose sub-assembly.
      NOTE:

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  13. DRAIN BRAKE FLUID 
    NOTE:

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

  14. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    See step  12

  15. SEPARATE NO. 1 BRAKE ACTUATOR TUBE 

    See step  13

  16. DISCONNECT NO. 2 BRAKE ACTUATOR HOSE 
    1. Slide the hose clamp and disconnect the No. 2 brake actuator hose from the No. 1 brake actuator tube.
      GTY318812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT FRONT NO. 1 BRAKE TUBE 
    1. Using a union nut wrench, disconnect the front No. 1 brake tube from the brake booster pump assembly.
      GTY318811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE BRAKE BOOSTER PUMP ASSEMBLY WITH BRACKET 
    1. Disconnect the 2 connectors from the brake booster pump assembly.
      GTY318813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and separate the connector box of the brake booster pump assembly from the brake actuator bracket assembly.
      GTY320879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Connector Box
    3. Remove the 3 bolts and brake booster pump assembly with bracket from the vehicle body.
      GTY322779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not kink or damage the brake line, suction hose sub-assembly or air conditioner tube and accessory assembly.

  19. REMOVE NO. 2 BRAKE ACTUATOR HOSE 
    1. Slide the hose clamp and remove the No. 2 brake actuator hose from the brake booster pump assembly.
      GTY318824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE BRAKE BOOSTER PUMP ASSEMBLY 
    1. Disengage the wire harness clamp from the brake actuator bracket assembly.
      GTY318820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut, brake actuator case collar, brake booster pump bushing and brake booster pump assembly from the brake actuator bracket assembly.
      GTY541794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Union
      *2 Stud
      *3 Connector Box and Wire Harness
      NOTE:
      • Do not carry the brake booster pump assembly by the parts shown in bold (*1, *2 and *3) in the illustration.
      • Do not drop the brake booster pump assembly when carrying it.
      • Be careful not to allow any brake fluid to enter the connector.
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