BRAKE BOOSTER (for RHD) REMOVAL

Note


  • Do not adjust the brake booster push rod.

  • Completely bleed the vacuum from inside the brake booster by depressing the brake pedal several times because the piston of the master cylinder is forced out of the master cylinder due to the pressure inside.


  1. REMOVE BATTERY (for 2WZ-TV)


    1. A01382G

      Disconnect the negative battery cable.

    2. Disconnect the positive battery cable.

    3. Remove the bolt, clamp and battery.

  2. REMOVE ENGINE COVER NO.1 (for 2WZ-TV)


    1. Remove the engine cover No.1.

  3. REMOVE FRONT WIPER ARM HEAD CAP

    A0136ST

    1. Using a screwdriver with its tip wrapped in protective tape, remove the front wiper arm head cap.

  4. REMOVE FRONT WIPER ARM LH


    1. Operate the wiper, then stop the windshield wiper motor assembly in the automatic stop position.

    2. A013933

      Remove the nut and front wiper main arm.

    3. A0135UZ

      Disengage the meshing of the secondary arm from the front wiper motor and link assembly.

      Note

      Do not bend the secondary arm when removing it.

  5. REMOVE HOOD TO COWL TOP SEAL

    A01379NE01

    1. Disengage the 8 clips and remove the hood to cowl top seal.

  6. REMOVE COWL TOP VENTILATOR LOUVER LH

    A0136Y2E01

    1. Remove the clip.

    2. Disengage the 9 claws and remove the cowl top ventilator louver LH.

    3. Disconnect the washer hose.

  7. REMOVE COWL TOP VENTILATOR LOUVER RH

    A0136GYE01

    1. Remove the clip.

    2. Disengage the 8 claws and remove the cowl top ventilator louver RH.

    3. Disconnect the washer hose.

  8. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

    A0136OQ

    1. Remove the 2 bolts.

    2. Disconnect the connector and remove the front wiper motor and link assembly.

  9. REMOVE COWL TOP PANEL OUTER

    A01390L

    1. Remove the clamp of the wire harness.

    2. Remove the grommet of the wire harness.

    3. A01377P

      Remove the 10 bolts and cowl top panel.

  10. REMOVE ENGINE ROOM RELAY BLOCK (for 2WZ-TV)


    1. A0137HG

      Disconnect the engine wire harness connectors from the engine room relay block.

    2. Remove the 2 bolts and engine room relay block.

  11. DISCONNECT ENGINE WIRE (for 2WZ-TV)


    1. A0138AP

      Turn the retainers of the ECM connectors as shown in the illustration.

    2. A0138BY

      Disconnect the ECM connectors from the ECM.

    3. A0136XI

      Pull the retainer of the glow relay connector as shown in the illustration.

    4. A0137DD

      Disconnect the glow relay connector from the glow relay.

    5. A01392G

      Remove the 2 bolts, then disconnect the 2 ground terminals.

    6. A0138WG

      Remove the nut, then disconnect the battery terminal B.

  12. REMOVE BATTERY CLAMP SUB-ASSEMBLY (for 2WZ-TV)


    1. Disengage the 2 wire harness clamps.

    2. A0135TU

      Remove the 3 bolts and battery clamp.

  13. REMOVE ENGINE UNDER COVER AIR GUIDE (for 2WZ-TV)


    1. A013649

      Remove the 9 bolts.

    2. Remove the 5 screws and engine under cover.

  14. DRAIN ENGINE COOLANT (for 2WZ-TV)

    Note

    To avoid the danger of being burned, do not remove the reservoir tank cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.


    1. A01375N

      Remove the drain plug and clip, then drain the engine coolant.

    2. Disconnect the radiator by uncoupling the radiator hose No.2.

    3. A01379O

      Remove the hose clamp, disconnect the water by-pass hose.

    4. Remove the reservoir tank cap sub-assembly.

      A01389E

  15. REMOVE AIR CLEANER INLET NO.1 (for 2WZ-TV)


    1. A0137J3

      Remove the inlet air cleaner.

  16. REMOVE AIR CLEANER INLET NO.2 (for 2WZ-TV)


    1. A01390A

      Disconnect the mass air flow meter connector.

    2. A0136IS

      Using a "torx" socket wrench, remove the screw.

    3. Remove the inlet air cleaner No.2.

  17. REMOVE RADIATOR RESERVOIR TANK ASSEMBLY (for 2WZ-TV)


    1. A01367O

      Remove the 2 clips and disconnect the 2 water by-pass hoses from the reserve tank.

    2. A0135ZD

      Remove the clip and disconnect the water by-pass hose No.5.

    3. A0136BI

      Remove the bolt and radiator reserve tank.

  18. REMOVE WATER BY-PASS HOSE (for 2WZ-TV)


    1. A0136XU

      Remove the clip and water by-pass hose.

  19. REMOVE WATER BY-PASS HOSE NO.2 (for 2WZ-TV)


    1. A0135US

      Remove the clip and water by-pass hose No.2.

  20. REMOVE EXHAUST PIPE ASSEMBLY FRONT (for 2WZ-TV)


    1. Remove the bolt and clamp.

    2. Remove the exhaust front pipe stay nut and exhaust pipe support No.4.

    3. Remove the nut, clamp and the exhaust front pipe assembly.

      A0137Z8E02

  21. REMOVE FRONT BUMPER COVER (for 2WZ-TV)

    A0138CFE01

    1. Apply protective tape to the outer circumference of the front bumper cover, as shown in the illustration.

    2. Using a clip remover, remove the clip.

    3. Remove the 3 bolts, 5 screws and 2 clips.

    4. A01360O

      Disengage the 13 claws and remove the front bumper cover.

    5. A0136YZ

      Remove the 2 clips.

  22. REMOVE RADIATOR SIDE AIR SEAL NO.1 (for 2WZ-TV)

  23. DISCONNECT COOLING FAN MOTOR CONNECTOR (for 2WZ-TV)


    1. A0137JZ

      Disconnect the cooling fan motor connector.

  24. REMOVE COOLING FAN RESISTOR CONNECTOR (for 2WZ-TV with Air Conditioning System)


    1. A0137ZT

      Disconnect the 2 resistor connectors.

  25. REMOVE RADIATOR HOSE INLET (for 2WZ-TV)


    1. A0137E8

      Disconnect the radiator hose and clamp from the radiator assembly.

  26. REMOVE RADIATOR HOSE OUTLET (for 2WZ-TV)


    1. A0135SS

      Disconnect the radiator hose No.2 and clamp from the radiator assembly.

  27. SEPARATE CONDENSER ASSEMBLY (for 2WZ-TV with Air Conditioning System)


    1. A0136TM

      Remove the 2 bolts, and disconnect the condenser assembly from the radiator assembly.

  28. REMOVE FRONT CROSS MEMBER SUB-ASSEMBLY (for 2WZ-TV)


    1. A0138MG

      Remove the 6 bolts and front cross member sub-assembly.

  29. REMOVE RADIATOR ASSEMBLY (for 2WZ-TV)


    1. Remove the radiator assembly.

      Note

      Do not allow the cooler condenser assembly and radiator assembly to come into contact with each other.

    2. A01369K

      Remove the claws, bolt, and the fan assembly from the radiator assembly.

    3. A0137Q1

      Remove the 2 radiator support cushions and 2 grommets from the radiator assembly.

  30. DISCONNECT VACUUM HOSE ASSEMBLY (for 2WZ-TV)


    1. A0137N5

      Pinch the retainer as illustrated, then pull out the vacuum hose connector from the pipe.

  31. DISCONNECT HEATER WATER HOSE INLET A (for 2WZ-TV)


    1. A0136WU

      Using pliers, slide the clip to disconnect the heater water inlet hose A.

  32. DISCONNECT HEATER WATER OUTLET HOSE A (for 2WZ-TV)


    1. A0138TX

      Remove the clip, then pull out the heater water outlet hose A (from heater unit) from the heater pipe.

  33. DISCONNECT FUEL RETURN TUBE (for 2WZ-TV)


    1. A01360E

      Pinch the retainer as illustrated, then pull out the fuel tube connector from the fuel return tube.

  34. REMOVE FUEL FILTER PROTECTOR NO.1 (for 2WZ-TV)


    1. A0136I9

      Using a "torx" socket wrench, remove the 2 screws, then remove the fuel filter protector.

  35. DISCONNECT FUEL MAIN TUBE (for 2WZ-TV)


    1. A01385D

      Pinch the retainer as illustrated, then pull out the fuel tube connector from the fuel tube.

  36. REMOVE CLUTCH RELEASE FORK RETURN TENSION SPRING (for 2WZ-TV)

    A0138ACE01

    1. Remove the clutch release fork return tension spring from the spring hanger.

      Note


      • If there is any rust or deformation in the tension spring, replace it.

      • If there is any damage in the tension spring damper, replace it.

  37. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for 2WZ-TV)

    A0135UNE01

    1. Remove clips A and B, then separate the transmission shift cable from the manual transaxle.

    2. A0136KNE01

      Remove clips A and B, then separate the transmission select cable from the manual transaxle.

  38. SEPARATE CLUTCH RELEASE CABLE ASSEMBLY (for 2WZ-TV)

    A01391E

    1. Turn and loosen the clutch release cable adjusting nut.

    2. A01391Y

      Separate the clutch release cable from the manual transaxle.

  39. PLACE FRONT FACING STRAIGHT AHEAD (for 2WZ-TV)

  40. REMOVE STEERING COLUMN HOLE COVER PLATE (for 2WZ-TV)

    A0136Y5

    1. Turn back the floor carpet and disengage the 2 claws from the steering hole cover plate.

  41. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY NO.2 (for 2WZ-TV)

    A01369HE02

    1. Hold the steering wheel assembly with the seat belt in order to prevent rotation and damage to the spiral cable.

    2. A0137IGE05

      Place matchmarks on the sliding yoke sub-assembly and the intermediate shaft.

    3. Loosen bolt A and remove bolt B to separate the sliding yoke sub-assembly.

  42. SEPARATE STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO.1 (for 2WZ-TV)

    A0137CHE01

    1. Remove clip A and separate the steering column hole cover from the body.

      Note

      Do not damage clip B.

  43. REMOVE FRONT WHEEL

  44. REMOVE FAN & GENERATOR V BELT (for 2WZ-TV)


    1. A0135ZX

      While releasing the belt tension by turning the belt tensioner clockwise, remove the V-ribbed belt from the belt tensioner.

    2. A01366Y

      While turning the belt tensioner, align with its holes, and then insert the 3 mm (0.1181 in.) hexagon wrench into the holes to fix the V-ribbed belt tensioner.

  45. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (for 2WZ-TV with Air Conditioning System)

    A0137NU

    1. Disconnect the connector.

    2. Remove the 4 bolts and separate the cooler compressor and magnetic clutch.

  46. REMOVE FRONT AXLE SHAFT LH NUT (for 2WZ-TV)

    A0135U4E01

    1. Using SST and a hammer, release the staked part of the front axle hub nut.

      SST
      09930-00010

      Note

      Release the staked part of the lock nut completely. Otherwise, the screw of the drive shaft may be damaged.

    2. While applying the brake, remove the front axle hub nut.

  47. REMOVE FRONT AXLE SHAFT RH NUT (for 2WZ-TV)

    Tech Tips

    The removal procedure for the RH side is the same as that for the LH side.

  48. SEPARATE TIE ROD END SUB-ASSEMBLY LH (for 2WZ-TV)


    1. Remove the cotter pin and castle nut.

    2. A0136K6E01

      Install SST (spacer B) to the threaded section of the tie rod end.

      SST
      09960-20010   ( 09961-02060 )

      Tech Tips

      Make sure the upper ends of the threaded section of the tie rod end and SST (spacer B) are aligned.

    3. Using SST, separate the tie rod end from the front axle assembly.

      A0137FRE01
      SST
      09960-20010   ( 09961-02010 )

      Note


      • Make sure to tie the string of SST to the vehicle to prevent SST from dropping.

      • Install SST so that A and B are parallel.

      • Be sure to place the wrench on the part indicated in the illustration.

      • Do not damage the ball joint dust cover.

      • Do not damage the front disc brake dust cover.

  49. SEPARATE TIE ROD END SUB-ASSEMBLY RH (for 2WZ-TV)

    Tech Tips

    The removal procedure for the RH side is the same as that for the LH side.

  50. SEPARATE STABILIZER BAR FRONT (for 2WZ-TV)

    A013602E02

    1. Hold the bolt with a spanner (10 mm) and remove the nut.

    2. Remove the 2 cushion retainers and 2 cushions, and separate the front stabilizer bar.

  51. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH (for 2WZ-TV)


    1. Remove the clip and castle nut.

    2. A0135XUE01

      Install SST (spacer B) to the threaded section of the lower ball joint.

      SST
      09960-20010   ( 09961-02060 )

      Tech Tips

      Make sure the upper ends of the threaded section of the lower ball joint and SST (spacer B) are aligned.

    3. Using SST, separate the lower arm.

      A0136IYE01
      SST
      09960-20010   ( 09961-02010 )

      Note


      • Make sure to tie the string of SST to the vehicle to prevent SST from dropping.

      • Install SST so that A and B are parallel.

      • Be sure to place the wrench on the part indicated in the illustration.

      • Do not damage the lower ball joint dust cover.

      • Do not damage the drive shaft outboard joint boots.

      • Do not damage the front disc brake dust cover.

  52. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH (for 2WZ-TV)

    Tech Tips

    The removal procedure for the RH side is the same as that for the LH side.

  53. SEPARATE FRONT AXLE ASSEMBLY LH (for 2WZ-TV)


    1. Using a plastic hammer, tap the end of the front drive shaft assembly and disengage the fitting between the front drive shaft assembly and front axle assembly.

      Tech Tips

      If it is difficult to disengage the fitting, tap the end of the front drive shaft assembly with a brass bar and hammer.

    2. Push the front axle assembly out of the vehicle to remove the front drive shaft assembly from the front axle assembly.

      Note


      • Do not push the front axle assembly further out of the vehicle than is necessary.

      • Do not damage the front axle outboard joint boot.

      • Do not damage the speed sensor rotor.

      • Hang the front drive shaft assembly down with a piece of string or equivalent.

      • When removing the drive shaft, do not hit the sensor with it.

  54. SEPARATE FRONT AXLE ASSEMBLY RH (for 2WZ-TV)

    Tech Tips

    The removal procedure for the RH side is the same as that for the LH side.

  55. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (for 2WZ-TV)


    1. Set the engine lifter.

    2. A0136JO

      Remove the 2 bolts from the engine mounting insulator RH.

    3. A01393O

      Remove the nut from the engine mounting insulator RH.

    4. A0136QC

      Remove the 3 bolts from the engine mounting insulator LH.

    5. A01388M

      Remove the 6 bolts.

    6. A0138HH

      Remove the engine assembly with transaxle.

  56. DRAIN BRAKE FLUID

    Note

    Immediately wash off any brake fluid that comes into contact with any painted surfaces.

  57. REMOVE BRAKE MASTER CYLINDER

    A0138S6

    1. Push in the clip and disconnect the brake fluid level warning switch connector.

    2. A0137M3

      Using a 10 mm union nut wrench, separate the 2 brake tubes from the master cylinder (w/o VSC).

    3. Using a 12 mm union nut wrench, separate the 2 brake tubes from the master cylinder (w/ VSC).

    4. A0136X4

      Using a 10 mm union nut wrench, separate the brake tube No. 3 and remove it.

    5. A0135ZL

      Release the brake tube clamp from the body.

    6. A0138DC

      Remove the 2 nuts, then pull the brake master cylinder out of the brake booster.

    7. Remove the O-ring from the master cylinder.

  58. SEPARATE MASTER CYLINDER PUSH ROD CLEVIS

    A0135YT

    1. Remove the clip and push rod pin, and separate the push rod clevis.

  59. REMOVE BRAKE BOOSTER ASSEMBLY

    A0138ZX

    1. Disconnect the vacuum hose from the brake booster.

    2. A0138KW

      Remove the 4 nuts and pull out the brake booster.

    3. Remove the gasket from the brake booster.

  60. REMOVE GROMMET

    A0137M9

    1. Remove the grommet from the brake booster.

  61. REMOVE MASTER CYLINDER PUSH ROD CLEVIS