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Brake Booster: Removal

NOTE: Make sure to release the vacuum from the brake booster before removing the master cylinder from the brake booster.
Fig 1: Depressing And Holding Down Pedal
G04978361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. REMOVE NO. 2 CYLINDER HEAD COVER (for 2ZR-FE)  (See REMOVAL )
  2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FE)  (See REMOVAL )
  3. REMOVE AIR CLEANER CASE (for 2ZR-FE)  (See REMOVAL )
  4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (for 2AZ-FE)  (See REMOVAL )
  5. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (for 2AZ-FE)  (See ON-VEHICLE INSPECTION )
  6. REMOVE AIR CLEANER CASE (for 2AZ-FE)  (See REMOVAL )
  7. REMOVE FRONT WIPER ARM HEAD CAP  (See ON-VEHICLE INSPECTION )
  8. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See ON-VEHICLE INSPECTION )
  9. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  10. REMOVE HOOD TO COWL TOP SEAL  (See REMOVAL )
  11. REMOVE CENTER NO. 1 COWL TOP VENTILATOR LOUVER  (See REMOVAL )
  12. REMOVE COWL TOP VENTILATOR LOUVER LH  (See REMOVAL )
  13. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See REMOVAL )
  14. REMOVE OUTER COWL TOP PANEL (for TMC Made)  (See REMOVAL )
  15. REMOVE OUTER COWL TOP PANEL (except TMC Made)  (See REMOVAL )
  16. REMOVE SUSPENSION TOWER DAMPER ASSEMBLY (w/ Front Strut Bar)  (See REMOVAL )
  17. DRAIN BRAKE FLUID 
  18. DISCONNECT CLUTCH TUBE (for Manual Transaxle)  (See REMOVAL )
  19. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY  (See REMOVAL )
  20. REMOVE BRAKE PEDAL RETURN SPRING  (See REMOVAL )
  21. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS  (See REMOVAL )
  22. DISCONNECT VACUUM HOSE 
    1. Slide the clip and disconnect the vacuum hose.
  23. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY 
    1. Remove the vacuum check valve assembly from the brake booster assembly.
  24. REMOVE CHECK VALVE GROMMET 
    1. Remove the check valve grommet from the brake booster assembly.
      Fig 2: Locating Vacuum Hose Clip
      G05389628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE NO. 5 FRONT BRAKE TUBE 
    1. Using a union nut wrench (10 mm), disconnect the No. 5 front brake tube from the front brake flexible hose LH.
      Fig 3: Disconnecting No. 5 Front Brake Tube
      G06010030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the grommet and No. 5 front brake tube from the body.
      Fig 4: Identifying No. 5 Front Brake Tube Grommet
      G06010031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE BRAKE BOOSTER ASSEMBLY 
    1. Disengage the 2 clamps and separate the brake lines from the body.
      Fig 5: Locating Brake Lines Clamps
      G06010032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts and brake booster assembly from the body.
    NOTE: Do not damage the brake lines or fuel lines.
  27. REMOVE BRAKE BOOSTER GASKET 
    1. Remove the brake booster gasket from the brake booster assembly.
  28. 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.
      Fig 6: Locating Brake Pedal Support Sub-Assembly Nuts
      G06009980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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