BRAKE BOOSTER(for RHD) REMOVAL

CAUTION / NOTICE / HINT

Note

Make sure to release vacuum from the brake booster assembly before removing the brake master cylinder sub-assembly from the brake booster assembly.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal, Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work Click here.

  2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (for 2GR-FE)

    Click here

  3. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (for 2AR-FE)

    Click here

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for 2AR-FE)

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  5. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  6. REMOVE FRONT BUMPER COVER

    Click here

  7. REMOVE RADIATOR SIDE DEFLECTOR RH

    Click here

  8. SEPARATE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. B001OJFE02
      Text in Illustration
      *A for 2AR-FE
      *B for 2GR-FE

      Disconnect the pressure sensor connector and disengage the clamp.

    2. B001NZ5

      Remove the bolt from the hook connector.

    3. B001NRL

      Turn the hook connector and separate the air conditioner tube and accessory assembly from the air conditioning unit.

      Note


      • Do not deform the piping.

      • Do not damage the clamp.

    4. B001OGI

      Remove the bolt and separate the air conditioner tube and accessory assembly from the cooler condenser assembly.

      Note


      • Do not deform the piping.

      • Do not damage the clamp.

    5. Remove the 2 O-rings 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.

  9. SEPARATE SUCTION PIPE SUB-ASSEMBLY


    1. B001O6T

      Disengage the clamp from the brake actuator bracket assembly.

    2. B001O11

      Separate the clamp with suction pipe sub-assembly and air conditioner tube and accessory assembly from the No. 1 brake tube clamp.

    3. B001OAE

      Separate the suction pipe sub-assembly from the air conditioning unit.

      Note


      • Do not deform the piping.

      • Do not damage the clamp.

    4. Remove the O-ring from the suction pipe sub-assembly.

      Note

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

  10. REMOVE NO. 1 BRAKE TUBE CLAMP


    1. B001O2H

      Disengage the clamp to separate the brake lines.

      Note

      Do not kink or damage the brake lines.

    2. Remove the bolt and No. 1 brake tube clamp from the vehicle body.

  11. REMOVE BRAKE LINE


    1. B001NMJ

      Using a union nut wrench, disconnect the 2 brake lines from the brake actuator assembly.

    2. B001O4I

      Remove the 2 clamps to make the 2 brake lines free.

      Note


      • Do not kink or damage the brake lines.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

  12. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for 2AR-FE)


    1. B001NXN

      Disconnect the union to check valve hose and wire harness clamp.

    2. Disconnect the 2 vacuum hoses and connector.

    3. Remove the bolt and vacuum switching valve assembly.

  13. DISCONNECT UNION TO CHECK VALVE HOSE (for 2AR-FE)


    1. B001O7B

      Slide the clip and disconnect the union to check valve hose from the brake booster assembly.

  14. REMOVE PUSH ROD PIN

    Click here

  15. REMOVE BRAKE BOOSTER ASSEMBLY


    1. B001O9H

      Remove the 4 nuts and brake booster assembly from the vehicle body.

      Note

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

  16. REMOVE BRAKE BOOSTER GASKET


    1. B001OGW

      Remove the brake booster gasket from the brake booster assembly.

  17. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. Loosen the lock nut and remove the brake master cylinder push rod clevis and lock nut.

  18. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY


    1. Remove the brake vacuum check valve assembly from the brake booster assembly.

  19. REMOVE CHECK VALVE GROMMET


    1. Remove the check valve grommet from the brake booster assembly.