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 1ZR-FAE:

      Remove the engine assembly Click here.

    2. for 2ZR-FAE:

      Remove the engine assembly Click here.

    3. for 1WW:

      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


    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. A002P2XE02
      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 VACUUM SENSOR ASSEMBLY (for 1WW)


    1. Remove the vacuum sensor assembly from the brake booster assembly.

  13. REMOVE VACUUM SENSOR GROMMET (for 1WW)


    1. Remove the vacuum sensor grommet from the brake booster assembly.

  14. REMOVE FRONT BRAKE LINE


    1. for LHD:


      1. A002NBJ

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

      2. Remove the bolt and clamp from the body.

      3. A002QK1

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

      4. A002QGU

        Detach the grommet from the body.

      5. A002NMW

        Detach the 2 brake tube clamps from the body.

        Note

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

      6. A002O8K

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

      7. A002LPK

        Detach the brake tube clamp from the brake actuator bracket.

        Note

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

    2. for RHD:


      1. A002NBJ

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

      2. Remove the bolt and clamp from the body.

      3. A002QK1

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

      4. A002QGU

        Detach the grommet from the body.

      5. A002MZJ

        Detach the clamp from the body.

        Note

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

      6. A002QED

        Detach the clamp from the body.

        Note

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

      7. A002OLC

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

      8. A002LPK

        Detach the brake tube clamp from the brake actuator bracket.

        Note

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

  15. REMOVE BRAKE BOOSTER ASSEMBLY


    1. A002LN6E03
      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.

  16. REMOVE BRAKE BOOSTER GASKET


    1. 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 from the brake booster assembly.