BRAKE BOOSTER(for RHD) REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during brake booster assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link
Battery terminal is disconnected/reconnected Memorize steering angle neutral point LKA/LDA System

Click here

Intelligent clearance sonar system
Pre-Crash Safety System

Lighting System (EXT)


  • Cornering lights
Adaptive High Beam System
Parking Assist Monitor System (w/ Parallel Parking Assist Function)

Click here

Parking Assist Monitor System (w/o Parallel Parking Assist Function)

Click here

Panoramic View Monitor System

Click here

Drive the vehicle until stop and start control is permitted (approximately 15 to 60 minutes) Stop and start system

Click here

Initialize back door lock Power door lock control system

Click here

Reset back door close position Power back door system

Click here

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. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    for HFC-134a (R134a): Click here

    for HFO-1234yf (R1234yf): Click here

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  4. REMOVE FUEL PUMP ASSEMBLY (for 2GR-FKS)

    Click here

  5. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY WITH WAY

    Click here

  6. REMOVE FRONT DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure as for the LH side.

    w/o Rear No. 2 Seat: Click here

    w/ Rear No. 2 Seat: Click here

  7. REMOVE COWL SIDE TRIM BOARD RH

    Tech Tips

    Use the same procedure as for the LH side.

    Click here

  8. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

    Click here

  9. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (for 8AR-FTS)

    Click here

  10. DISCONNECT CHECK VALVE TO BRAKE BOOSTER HOSE (for 8AR-FTS)


    1. B005LK8

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

  11. DISCONNECT UNION TO CHECK VALVE HOSE (for 2GR-FKS)


    1. w/o Rear Air Conditioning System:


      1. B005OZ8

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

    2. w/ Rear Air Conditioning System:


      1. B005PZ9

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

  12. SEPARATE ENGINE ROOM MAIN WIRE


    1. B005MOM

      for 8AR-FTS:


      1. Disconnect the connector from the vacuum sensor assembly.

    2. for 2GR-FKS:


      1. Disconnect the connector from the vacuum warning switch assembly.

    3. Disengage the 8 clamps to separate the engine room main wire.

  13. SEPARATE BRAKE LINE


    1. B005QAS

      Using a union nut wrench, disconnect the front No. 6 brake tube and front No. 7 brake tube from the brake actuator assembly.

      Note


      • Do not kink or damage the brake lines.

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

    2. B005NH0

      Disengage the 2 clamps and remove the front No. 6 brake tube and front No. 7 brake tube.

      Note


      • Do not damage the 2 clamps.

      • Do not kink or damage the brake lines.

  14. SEPARATE SUCTION PIPE SUB-ASSEMBLY (w/o Sub-cool Accelerator)


    1. for 8AR-FTS:


      1. B005M2X

        Disengage the clamp from the suction pipe sub-assembly.

      2. B005QFQ

        Disengage the clamp to separate the suction pipe sub-assembly.

        Note


        • Do not deform the refrigerant lines.

        • Do not damage the clamp.

    2. for 2GR-FKS:


      1. B005MLT

        Disengage the clamp from the suction pipe sub-assembly.

      2. B005NVH

        Disengage the clamp to separate the suction pipe sub-assembly.

        Note


        • Do not deform the refrigerant lines.

        • Do not damage the clamp.

    3. B005Q5S

      Remove the bolt and rotate the hook connector.

    4. Disconnect the suction pipe sub-assembly from the air conditioning unit assembly.

    5. 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.

  15. SEPARATE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/o Sub-cool Accelerator)


    1. for 8AR-FTS:


      1. B005M6D

        Disengage the clamp to separate the air conditioner tube and accessory assembly from the piping clamp.

        Note


        • Do not deform the refrigerant lines.

        • Do not damage the clamp.

      2. B005PVH

        Remove the bolt and separate the air conditioner tube and accessory assembly.

        Note

        Do not deform the refrigerant lines.

    2. for 2GR-FKS:


      1. B005ON9

        Disconnect the connector from the air conditioner tube and accessory assembly.

      2. Disengage the clamp.

      3. B005PCA

        Remove the bolt and separate the air conditioner tube and accessory assembly.

        Note

        Do not deform the refrigerant lines.

      4. B005L8S

        Disengage the clamp to separate the air conditioner tube and accessory assembly.

        Note


        • Do not deform the refrigerant lines.

        • Do not damage the clamp.

    3. B005MFJ

      Disconnect the air conditioner tube and accessory assembly from the air conditioning unit assembly.

    4. 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.

  16. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (w/o Sub-cool Accelerator)


    1. for 2GR-FKS with Rear Air Conditioning System:


      1. B005L80

        Remove the piping clamp.

        Click here

      2. B005OVZ

        Disconnect the suction pipe sub-assembly from the air conditioning hose and accessory.

        Note

        Do not deform the refrigerant lines.

      3. Remove the 2 O-rings 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.

  17. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/o Sub-cool Accelerator)


    1. for 2GR-FKS with Rear Air Conditioning System:


      1. B005PHG

        Remove the piping clamp.

        Click here

      2. B005N2G

        Disconnect the air conditioner tube and accessory assembly from the air conditioning hose and accessory.

        Note

        Do not deform the refrigerant lines.

      3. 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.

  18. SEPARATE SUCTION HOSE SUB-ASSEMBLY (w/ Sub-cool Accelerator)


    1. B005OCE

      Separate the suction hose sub-assembly from the No. 2 air conditioner tube and accessory assembly.

      Click here

      Note

      Do not deform the refrigerant lines.

    2. Remove the 2 O-rings and piping clamp 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.

  19. SEPARATE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/ Sub-cool Accelerator)


    1. B005MZJ

      Remove the piping clamp.

      Click here

    2. B005PVH

      Remove the bolt and separate the air conditioner tube and accessory assembly.

      Note

      Do not deform the refrigerant lines.

    3. B005PFG

      Disconnect the air conditioner tube and accessory assembly from the No. 2 air conditioner tube and accessory assembly.

    4. 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.

  20. REMOVE NO. 2 AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/ Sub-cool Accelerator)


    1. B005Q9R

      Remove the bolt and separate the No. 2 air conditioner tube and accessory assembly.

      Note

      Do not deform the refrigerant lines.

    2. B005PMM

      Remove the bolt and rotate the hook connector.

    3. Remove the No. 2 air conditioner tube and accessory assembly from the air conditioning unit assembly.

      Note

      Do not deform the refrigerant lines.

    4. Remove the 2 O-rings from the No. 2 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.

  21. REMOVE NO. 2 VENTILATION HOSE (for 2GR-FKS)


    1. B005MS5

      Slide the clip and disconnect the No. 2 ventilation hose to remove it from the cylinder head cover sub-assembly.

  22. DISCONNECT FUEL TUBE SUB-ASSEMBLY (for 2GR-FKS)

    Click here

  23. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (for 2GR-FKS)

    Click here

  24. REMOVE NO. 1 DELIVERY PIPE SPACER (for 2GR-FKS)

    Click here

  25. REMOVE INJECTOR VIBRATION INSULATOR (for 2GR-FKS)

    Click here

  26. SEPARATE ENGINE WIRE (for 2GR-FKS)


    1. Disengage the 4 clamps and disconnect the 8 connectors.

      B005MUNC01
      B005NIZ Connector B005LWS Bolt

    2. Remove the 3 bolts to separate the engine wire.

  27. REMOVE IGNITION COIL ASSEMBLY (for 2GR-FKS)


    1. B005LG6

      Remove the 3 bolts and 3 ignition coil assemblies.

  28. REMOVE VVT SENSOR (for 2GR-FKS)

    for Intake Side of Bank 1: Click here

  29. REMOVE VVT SENSOR (for 2GR-FKS)

    for Exhaust Side of Bank 1: Click here

  30. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for 2GR-FKS)

    Click here

  31. REMOVE BRAKE PEDAL RETURN SPRING

    Click here

  32. LOOSEN LOCK NUT


    1. B005PHEC02
      *1 Lock Nut
      *2 Brake Master Cylinder Push Rod Clevis

      Loosen the lock nut of the brake master cylinder push rod clevis.

  33. REMOVE PUSH ROD PIN

    Click here

  34. REMOVE BRAKE BOOSTER ASSEMBLY


    1. B005NYE

      Remove the 4 nuts and push the brake booster assembly toward the engine compartment.

      Note

      Do not apply excessive force to the refrigerant lines.

    2. Remove the brake master cylinder push rod clevis and lock nut from the brake booster assembly.

    3. Remove the brake booster assembly from the vehicle body.

      Note

      Do not apply excessive force to the refrigerant lines.

  35. REMOVE BRAKE BOOSTER GASKET