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 ignition 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

    Click here

  3. REMOVE FUEL PUMP ASSEMBLY

    Click here

  4. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY WITH WAY

    Click here

  5. SEPARATE ENGINE ROOM MAIN WIRE


    1. B003Z7CC01
      *a Wire Harness Protector

      Disconnect the connector from the vacuum warning switch assembly.

    2. Remove the bolt and disengage the clamp to separate the wire harness protector.

    3. Disengage the 5 clamps to separate the engine room main wire.

  6. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. B00409SC01
      *1 Brake Master Cylinder Reservoir Assembly
      *2 Reservoir Bracket

      Disconnect the reservoir level switch connector and remove the bolt from the brake master cylinder reservoir assembly.

    2. Move the brake master cylinder reservoir assembly as shown in the illustration to disengage the 2 claws, and remove it.

  7. REMOVE RESERVOIR BRACKET


    1. A002AY2

      Disengage the clamp to separate the engine room main wire.

    2. Remove the 2 nuts and reservoir bracket.

  8. DISCONNECT UNION TO CHECK VALVE HOSE


    1. A002B8D

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

  9. REMOVE NO. 2 ENGINE MOUNTING STAY RH

    Click here

  10. REMOVE ENGINE MOVING CONTROL ROD BRACKET

    Click here

  11. SEPARATE SUCTION HOSE SUB-ASSEMBLY


    1. A0027S9

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

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    2. A0027CH

      Disengage the clamp to separate the suction hose sub-assembly from the brake actuator assembly.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    3. A002BC5

      Disengage the claw to separate the suction hose sub-assembly.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    4. A0029KN

      Disengage the claw to release the piping clamp.

      Note

      Do not damage the clamp.

    5. A00276H

      Remove the bolt and rotate the hook connector.

    6. Disconnect the suction hose sub-assembly from the air conditioning unit assembly.

    7. Remove the O-ring 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.

    8. Separate the suction hose sub-assembly from the vehicle body.

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

  12. SEPARATE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. A00282P

      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. A0029LH

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

      Note


      • Do not deform the refrigerant lines.

      • Do not damage the clamp.

    3. A002COU

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

      Note

      Do not deform the refrigerant lines.

    4. A0029LE

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

    5. 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.

    6. A002CNY

      Remove the nut and separate the air conditioner tube and accessory assembly from the vehicle body.

      Note

      Do not deform the refrigerant lines.

  13. DISCONNECT SUCTION HOSE SUB-ASSEMBLY


    1. A002BFJ

      Remove the piping clamp.

      Click here

    2. A002BNV

      Disconnect the suction hose sub-assembly from the No. 1 air conditioning accessory assembly.

      Note

      Do not deform the refrigerant lines.

    3. Remove the 2 O-rings 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.

  14. SEPARATE BRAKE LINE


    1. A002CHA

      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. A0029J5

      Disengage the 3 clamps and remove the front No. 6 brake tube and front No. 7 brake tube.

      Note


      • Do not damage the 3 clamps.

      • Do not kink or damage the brake lines.

  15. REMOVE NO. 2 VENTILATION HOSE


    1. A002AQ5

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

  16. SEPARATE ENGINE WIRE


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

      B003ZXMC01
      B003ZIE Connector B003Z8F Bolt

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

  17. REMOVE IGNITION COIL ASSEMBLY


    1. A002966

      Remove the 3 bolts and 3 ignition coil assemblies.

  18. REMOVE VVT SENSOR

    for Intake Side of Bank 1: Click here

  19. REMOVE VVT SENSOR

    for Exhaust Side of Bank 1: Click here

  20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  21. REMOVE BRAKE PEDAL RETURN SPRING

    Click here

  22. LOOSEN LOCK NUT


    1. B003Z6QC01
      *1 Lock Nut
      *2 Brake Master Cylinder Push Rod Clevis

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

  23. REMOVE PUSH ROD PIN

    Click here

  24. REMOVE BRAKE BOOSTER ASSEMBLY


    1. A00280P

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

    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.

  25. REMOVE BRAKE BOOSTER GASKET