BRAKE BOOSTER REMOVAL

CAUTION / NOTICE / HINT

Note

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

PROCEDURE


  1. REMOVE FRONT WHEEL

  2. REMOVE ENGINE ASSEMBLY


    1. for 1AD-FTV:

      Remove the engine assembly Click here.

    2. for 2AD-FHV:

      Remove the engine assembly Click here.

    3. for 2AD-FTV:

      Remove the engine assembly Click here.

  3. DRAIN BRAKE FLUID

    Note

    Wash off brake fluid immediately if it comes in contact with any painted surface.

  4. REMOVE BRAKE ACTUATOR ASSEMBLY (for LHD)


    1. Remove the brake actuator assembly Click here.

  5. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. Remove the brake master cylinder sub-assembly Click here.

  6. REMOVE BRAKE PEDAL RETURN SPRING

    Click here

  7. REMOVE PUSH ROD PIN

    Click here

  8. DISCONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS


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

    2. Disconnect the push rod clevis.

  9. DISCONNECT VACUUM HOSE


    1. A004SYQE04
      Text in Illustration
      *A for LHD
      *B for RHD

      Slide the clip and disconnect the vacuum hose.

  10. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY


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

  11. REMOVE CHECK VALVE GROMMET


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

  12. REMOVE FRONT BRAKE LINE


    1. for LHD:


      1. A004NY6

        Using a union nut wrench, disconnect the brake tube from the brake flexible hose LH.

      2. Remove the bolt and clamp from the body.

      3. A004SYW

        Using a union nut wrench, disconnect the brake tube from the brake flexible hose RH.

      4. A004QTR

        Remove the grommet and brake tube from the body.

      5. A004S3B

        Remove the 2 brake tube clamps from the body.

        Note

        The clamp cannot be reused after it is disconnected from the body.

      6. A004RD7

        Using a union nut wrench, disconnect the 2 brake tubes from the 2-way.

      7. Detach the 3 brake tubes from the clamp.

      8. A004T7G

        Disconnect the brake tube clamp from the brake actuator bracket.

        Note

        The clamp cannot be reused after it is disconnected from the bracket.

    2. for RHD:


      1. A004NY6

        Using a union nut wrench, disconnect the brake tube from the brake flexible hose LH.

      2. Remove the bolt and clamp from the body.

      3. A004SYW

        Using a union nut wrench, disconnect the brake tube from the brake flexible hose RH.

      4. A004QTR

        Remove the grommet and brake tube from the body.

      5. A004STY

        Remove the clamp from the body.

        Note

        The clamp cannot be reused after it is disconnected from the body.

      6. A004MQU

        Remove the clamp from the body.

        Note

        The clamp cannot be reused after it is disconnected from the body.

      7. A004SFG

        Using a union nut wrench, disconnect the 2 brake tubes from the 2-way.

      8. A004T7G

        Disconnect the brake tube clamp from the brake actuator bracket.

        Note

        The clamp cannot be reused after it is disconnected from the bracket.

  13. REMOVE BRAKE BOOSTER ASSEMBLY


    1. A004RQ9E04
      Text in Illustration
      *A for LHD
      *B for RHD

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

      Note

      Do not damage the brake lines or fuel lines.

  14. REMOVE BRAKE BOOSTER GASKET


    1. Remove the brake booster gasket from the brake booster assembly.

  15. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS


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