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Home >> Toyota >> 2015 >> Avalon Hybrid Limited >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System (Hydraulic) - Service Information - (Hybrid) >> Brake Booster >> 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 notice before proceeding with work (Refer to PRECAUTION [10/2014 - ] ).

  2. DISABLE BRAKE CONTROL 
    1. Wait at least 2 minutes after turning the power switch off.
      NOTE:

      When the brake pedal is depressed or any 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.
      GTY559692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the cable from the negative (-) auxiliary battery terminal (Refer to REMOVAL [10/2014 - ] ).
    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 can not be further depressed.
    6. Release the parking brake.
  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    (Refer to REMOVAL [10/2014 - ] )

  4. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY 
    1. Disengage the 2 clamps to separate the wire harness from the front outer cowl top panel sub-assembly.
      GTY380834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 10 bolts and front outer cowl top panel sub-assembly.
      GTY316543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. DRAIN BRAKE FLUID 
    NOTE:

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

  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. REMOVE PUSH ROD PIN 

    See step  6

  12. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Remove the 2 bolts and separate the brake master cylinder reservoir assembly from the reservoir bracket.
      GTY318798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. SEPARATE NO. 1 BRAKE ACTUATOR TUBE 
    1. Remove the nut and disengage the clamp.
      GTY318800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut and separate the No. 1 brake actuator tube from the vehicle body.
      GTY318797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. DISCONNECT NO. 2 RESERVOIR HOSE 
    1. Slide the hose clamp and disconnect the No. 2 reservoir hose from the brake booster with master cylinder assembly.
      GTY318802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT NO. 1 RESERVOIR HOSE 
    1. Slide the hose clamp and disconnect the No. 1 reservoir hose from the brake booster with master cylinder assembly.
      GTY318801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE RESERVOIR BRACKET 
    1. Disengage the 2 clamps to separate the wire harness from the reservoir bracket.
      GTY318799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and reservoir bracket.
      GTY318807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY 
    1. Put matchmarks at the position where the wire harness clamp is installed.
      GTY608461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Matchmark
      Cut
    2. Cut the wire harness clamp and separate the wire harness from the brake booster with master cylinder assembly.
    3. Release the lock lever and disconnect the connector from the brake booster with master cylinder assembly.
      GTY322776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Release
      Disconnect
    4. Using a union nut wrench, disconnect the 5 brake lines from the brake booster with master cylinder assembly.
      GTY574284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. 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
    6. Remove the 4 nuts and brake booster with master cylinder assembly.
      GTY564639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    7. Turn the wire harness clamp counterclockwise to remove it from the brake booster with master cylinder assembly.
      GTY322777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE BRAKE BOOSTER GASKET 
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