BRAKE BOOSTER (for RHD) REMOVAL

Note

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


  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. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (for 2GR-FE)

    Click here

  3. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (for 2AR-FE)


    1. Start the engine.

    2. Operate the cooler compressor under the conditions shown below:

      Item Condition Indicator
      Operating Time 3 minutes or more -
      Temperature setting Max cool -
      Blower speed High A01G9SU
      Engine Idling -
      A/C switch On A01G57E

      This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

      Tech Tips

      It is not necessary to operate the cooler compressor if the A/C does not operate because of compressor lock, etc.

    3. Stop the engine.

    4. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

      Tech Tips

      Use the refrigerant recovery unit in accordance with the manufacturer's instruction manual.

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (for 2AR-FE)

    Note

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

  5. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  6. REMOVE FRONT BUMPER COVER

    Click here

  7. REMOVE RADIATOR SIDE DEFLECTOR RH


    1. A01G4EL

      Disengage the 3 claws and guide to remove the radiator side deflector RH.

  8. SEPARATE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. A01G8YCE01
      Text in Illustration
      *A for 2AR-FE
      *B for 2GR-FE

      Disconnect the pressure sensor connector and disengage the clamp.

    2. A01G8UM

      Remove the bolt from the hook connector.

    3. A01G4GN

      Turn the hook connector and separate the air conditioner tube and accessory assembly from the air conditioning unit.

      Note


      • Do not deform the piping.

      • Do not damage the clamp.

    4. A01G4VQ

      Remove the bolt and separate the air conditioner tube and accessory assembly from the cooler condenser assembly.

      Note


      • Do not deform the piping.

      • Do not damage the clamp.

    5. 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.

  9. SEPARATE SUCTION PIPE SUB-ASSEMBLY


    1. A01G4GG

      Disengage the clamp from the brake actuator bracket assembly.

    2. A01G5KI

      Separate the clamp with suction pipe sub-assembly and air conditioner tube and accessory assembly from the No. 1 brake tube clamp.

    3. A01G48A

      Separate the suction pipe sub-assembly from the air conditioning unit.

      Note


      • Do not deform the piping.

      • Do not damage the clamp.

    4. 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.

  10. REMOVE NO. 1 BRAKE TUBE CLAMP


    1. A01G5R0

      Disengage the clamp to separate the brake lines.

      Note

      Do not kink or damage the brake lines.

    2. Remove the bolt and No. 1 brake tube clamp from the vehicle body.

  11. REMOVE BRAKE LINE


    1. A01G5NH

      Using a union nut wrench, disconnect the 2 brake lines from the brake actuator assembly.

    2. A01G9RL

      Remove the 2 clamps to make the 2 brake lines free.

      Note


      • Do not kink or damage the brake lines.

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

  12. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for 2AR-FE)


    1. A01G9RQ

      Disconnect the union to check valve hose and wire harness clamp.

    2. Disconnect the 2 vacuum hoses and connector.

    3. Remove the bolt and vacuum switching valve assembly.

  13. DISCONNECT UNION TO CHECK VALVE HOSE (for 2AR-FE)


    1. A01G4E0

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

  14. REMOVE PUSH ROD PIN


    1. A01G6DY

      Remove the clip and push rod pin.

  15. REMOVE BRAKE BOOSTER ASSEMBLY


    1. A01G6EC

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

      Note

      Do not kink or damage the brake lines, air conditioner tube and accessory assembly or suction pipe sub-assembly.

  16. REMOVE BRAKE BOOSTER GASKET


    1. A01G9F4

      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.

  18. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY


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

  19. REMOVE CHECK VALVE GROMMET


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