Disassembly and Assembly

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 RESERVOIR AND GROMMETS
a. Remove the 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.
3. REMOVE CYLINDER BOOT





4. REMOVE OIL PRESSURE SENSOR
Using 30 mm deep socket wrench and remove the oil pressure sensor, spacer and O-ring.

Torque: 81 Nm (830 kgf.cm, 60 ft. lbs.)





5. REMOVE PISTONS
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 No. 1 and No. 2 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.

6. DISCONNECT ACTUATOR HOSE
7. REMOVE 3 BOLTS, 2 HANGERS AND CLAMP





8. REMOVE BRAKE ACTUATOR TUBE NO. 1
Using SST, remove the brake actuator tube No. 1.
SST 09023-00100

Torque: 15 Nm (155 kgf.cm, 11 ft. lbs.)

9. REMOVE BOOSTER PUMP AND ACCUMULATOR
a. Remove the 2 screws and disconnect the accumulator coil lead wire from the booster assembly.
b. Using 5 mm socket hexagon wrench, remove the 3 bolts, No. 1 accumulator bracket, No. 2 accumulator bracket, booster pump and accumulator with the No. 1 pump bracket.
c. Remove the bolt and No. 1 pump bracket, and remove the 2 washers, 3 cushions, 2 collars and sleeve.
d. Remove the 2 bolts and No. 2 pump bracket.





10. PLACE BOOSTER PUMP IN VISE
Place the booster pump with a cloth shown in the illustration on the left.





11. 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 0-ring.

NOTICE: Ensure no foreign matter enters the pump.

DISPOSAL
DISPOSAL METHOD OF ACCUMULATOR





a. Follow the procedures described below and drain the high pressure gas from the accumulator.
b. Place the accumulator in a vise, cover it with a cloth over a saw then cut the accumulator body slowly.

CAUTION: Never cut at a stretch.

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

REASSEMBLY
Reassembly is in the reverse order of disassembly.

Accumulator Bracket Clearance:

INSTALL ACCUMULATOR BRACKET
When installing the accumulator bracket, adjust to ensure that clearance (A, B, D and E) shown in the illustration corresponds to each value in the graphs and are within the C range, using a thickness gauge.

C Range: 0.1 - 0.4 mm (0.004 - 0.016 inch)