BRAKE BOOSTER (for RHD) REMOVAL


  1. PRECAUTION

    Note

    After the engine switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait for the time specified in the following table before disconnecting the cable from the negative (-) battery terminal.

    Waiting Time before Disconnecting Cable from Negative (-) Battery Terminal
    Specification Waiting Time
    w/o Telematics transceiver 60 sec.
    w/ Telematics transceiver 120 sec.

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

    4. Stop the engine.

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

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  4. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

    Click here

  5. REMOVE FRONT BUMPER COVER

    for Standard: Click here

    for Sport Package: Click here

  6. REMOVE FRONT WHEEL RH

  7. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (for 1AR-FE)


    1. A019KNK

      Lift the rear of the No. 1 engine cover sub-assembly to detach the cover from the 2 pins, and then lift the front of the No. 1 engine cover sub-assembly to detach the cover from the pin and remove the No. 1 engine cover sub-assembly.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover sub-assembly to break.

  8. DISCONNECT VACUUM HOSE (for 1AR-FE)


    1. A019NAZ

      Slide the clip and disconnect the vacuum hose from the brake booster assembly.

  9. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for 1AR-FE)


    1. A019NQI

      Disconnect the union to connector tube hose and wire harness clamp.

    2. Disconnect the 2 vacuum hoses and connector.

    3. Remove the bolt and vacuum switching valve assembly.

  10. DISCONNECT VACUUM HOSE (for 2GR-FE)


    1. A019M2J

      Slide the clip and disconnect the vacuum hose.

  11. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY


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

  12. REMOVE CHECK VALVE GROMMET


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

  13. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY


    1. A019PJ7

      Disconnect the connector.

    2. Remove the bolt and brake master cylinder reservoir assembly.

  14. REMOVE RESERVOIR BRACKET


    1. A019P7X

      Disengage the clamp.

    2. Remove the 2 nuts to remove the reservoir bracket.

  15. DRAIN ENGINE COOLANT (for 2GR-FE)


    1. Loosen the radiator drain cock plug and drain the coolant.

      Note

      Do not remove the radiator cap, cylinder block drain cock plugs and radiator drain cock plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. Remove the radiator cap from the radiator assembly.

    3. Loosen the 2 cylinder block drain cock plugs.

      A019LCUE01
      Text in Illustration
      *1 Air Drain Cock Plug *2 Radiator Cap
      *3 Cylinder Block Drain Cock Plug *4 Radiator Drain Cock Plug

  16. REMOVE V-BANK COVER SUB-ASSEMBLY (for 2GR-FE)


    1. A019LVN

      Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the 2 retainers on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly.

      Note

      Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.

  17. REMOVE NO. 2 AIR CLEANER INLET (for 2GR-FE)


    1. A019O60

      Disconnect the 2 vacuum hose clamps from the No. 2 air cleaner inlet.

    2. Remove the 2 bolts and No. 2 air cleaner inlet.

  18. REMOVE NO. 1 AIR CLEANER INLET (for 2GR-FE)


    1. A019ND6

      Disconnect the vacuum hose clamp from the No. 1 air cleaner inlet.

    2. Remove the bolt and No. 1 air cleaner inlet.

  19. REMOVE BATTERY (for 2GR-FE)


    1. Disconnect the positive (+) cable from the positive (+) battery terminal.

    2. A019LTJ

      Loosen the nut, and remove the bolt from the battery clamp.

    3. Remove the battery and battery tray.

  20. REMOVE AIR CLEANER ASSEMBLY (for 2GR-FE)


    1. A019K7G

      Separate the mass air flow meter connector and wire harness clamp.

    2. A019LPG

      Separate the vacuum hose from the intake air surge tank assembly.

    3. Separate the vacuum hose from the hose clamp.

    4. A019KSB

      Separate the vacuum switching valve connector and 2 wire harness clamps.

    5. A019LU3

      Separate the 2 vacuum hoses.

    6. A019L8LE01
      Text in Illustration
      *1 Ventilation Hose
      *2 Fuel Vapor Feed Hose

      Separate the ventilation hose and the fuel vapor feed hose.

    7. Loosen the hose clamp and separate the air cleaner hose from the throttle body.

    8. A019JQO

      Remove the 2 bolts and remove the air cleaner assembly.

  21. REMOVE INTAKE AIR SURGE TANK ASSEMBLY (for 2GR-FE)


    1. A019KAPE01
      Text in Illustration
      *1 for RHD:
      *2 for LHD:

      Disconnect the union to check valve hose.

    2. A019JMB

      Disconnect the throttle body assembly connector and wire harness clamp.

    3. A019N1A

      Disconnect the vacuum hose clamp and fuel vapor feed hose.

    4. A019MBG

      Disconnect the 2 water by-pass hoses.

    5. A019M0E

      Disconnect the ventilation hose and vacuum hose.

    6. A019KEL

      Disconnect the connector from the intake air control valve assembly.

    7. A019NBS

      Remove the bolt and separate the No. 1 surge tank stay from the intake air surge tank assembly.

    8. Remove the bolt and separate the throttle body bracket from the intake air surge tank assembly.

    9. A019MTQ

      Remove the 2 nuts from the intake air surge tank assembly.

    10. Using a 5 mm socket hexagon wrench, remove the 4 bolts.

    11. Remove the intake air surge tank assembly and 3 air surge tank to intake manifold gaskets.

  22. REMOVE NO. 1 SURGE TANK STAY (for 2GR-FE)


    1. A019NO0

      Remove the bolt and No. 1 surge tank stay.

  23. REMOVE THROTTLE BODY BRACKET (for 2GR-FE)


    1. A019OY3

      Remove the bolt and throttle body bracket.

  24. REMOVE IGNITION COIL ASSEMBLY (for 2GR-FE)


    1. A019KGI

      Disengage the 3 clamps.

    2. A019LHV

      Disconnect the 3 connectors.

    3. A019NR3

      Remove the 3 bolts and 3 ignition coil assemblies (for Bank 1).

  25. REMOVE NO. 2 TIMING GEAR COVER (for 2GR-FE)


    1. A019O7B

      Remove the 2 bolts and No. 2 timing gear cover.

  26. REMOVE OIL PIPE (for 2GR-FE)


    1. A019O2ME04
      Text in Illustration
      *1 Oil Pipe Union
      *2 Bolt

      Remove the bolt.

    2. Remove the 2 oil pipe unions and oil pipe.

    3. Remove the oil control valve filter RH and gaskets.

  27. SEPARATE ENGINE WIRE (for 2GR-FE)


    1. A019O86

      Remove the bolt and separate the ground cable.

    2. A019LIG

      Disconnect the 4 connectors and ventilation hose, and disengage the 2 clamps from the cylinder head cover sub-assembly.

    3. A019P0Z

      Remove the bolt and separate the wire harness protector.

  28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for 2GR-FE)


    1. A019N8Q

      Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.

    2. A019N77

      Remove the 3 gaskets.

  29. SEPARATE WIRE HARNESS (for 1AR-FE)


    1. A019LK3

      Disengage the 4 clamps and separate the wire harness.

  30. SEPARATE SUCTION HOSE SUB-ASSEMBLY


    1. A019L08

      Remove the nut and separate the suction hose sub-assembly from the suction pipe sub-assembly.

    2. 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.

      • Do not deform the piping.

  31. REMOVE SUCTION PIPE SUB-ASSEMBLY


    1. A019NVF

      Remove the bolt and separate the suction pipe bracket from the brake actuator bracket.

    2. A019PKX

      Remove the bolt and slide the hook connector.

    3. A019KBP

      Disengage the clamp.

    4. Remove the suction pipe sub-assembly from the air conditioning unit.

    5. 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.

      • Do not deform the piping.

      • Do not damage the plastic clamp.

  32. REMOVE AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. A019OEJ

      Separate the air conditioning tube and accessory assembly from the air conditioning unit.

    2. A019KQN

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

    3. A019JZ0

      Disengage the 2 clamps, disconnect the connector and remove the air conditioning tube and accessory assembly.

    4. Remove the 2 O-rings from the air conditioning tube and accessory assembly and air conditioning unit.

      Note


      • Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

      • Do not deform the piping.

      • Do not damage the plastic clamp.

    5. A019LIK

      Remove the tube clamp.

  33. REMOVE BRAKE LINE


    1. A019KYU

      Using a union nut wrench, disconnect the No. 8 front brake tube from the front flexible hose RH.

    2. A019NCNE01
      Text in Illustration
      *1 Front Brake Tube
      *2 No. 8 Front Brake Tube

      Using a union nut wrench, disconnect the front brake tube*1 and No. 8 front brake tube*2 from the brake actuator assembly.

    3. Disengage the 5 clamps and separate the brake lines.

      Note


      • Do not kink or damage the brake lines.

      • Do not allow any foreign matter such as dirt and dust to enter the brake lines.

  34. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY


    1. A019N9N

      Remove the 2 screws <D>.

    2. A019L8S

      Disengage the claw and 2 guides as shown in the illustration.

    3. Disconnect each connector.

    4. Disengage each clamp and remove the No. 1 instrument panel under cover sub-assembly.

  35. REMOVE BRAKE PEDAL RETURN SPRING


    1. A019OXA

      Remove the brake pedal return spring from the push rod pin and instrument panel reinforcement.

  36. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. A019JQT

      Remove the clip and push rod pin, and separate the brake master cylinder push rod clevis from the brake pedal sub-assembly.

  37. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. A019N8M

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

      Note

      Do not kink or damage the brake lines.

    2. Loosen the lock nut and remove the brake master cylinder push rod clevis and lock nut.

  38. REMOVE BRAKE BOOSTER ASSEMBLY


    1. Remove the brake booster assembly from the body.

      Note

      Do not kink or damage the brake lines.

  39. REMOVE BRAKE BOOSTER GASKET


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