Brake Booster: Removal

NOTE: Release the vacuum from the booster by depressing the brake pedal several times. Then remove the brake master cylinder sub-assembly from the brake booster assembly.

REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (for 1AR-FE) (See REMOVAL )
REMOVE V-BANK COVER SUB-ASSEMBLY (for 2GR-FE) (See REMOVAL )
SEPARATE EJECTOR TUBE (for 1AR-FE) (See REMOVAL )
REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See REMOVAL )
REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See REMOVAL )
REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (See REMOVAL )
REMOVE WINDSHIELD WIPER MOTOR AND LINK (See REMOVAL )
REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (See REMOVAL )
REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 1AR-FE) (See REMOVAL )
REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for 1AR-FE) (See REMOVAL )
REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2GR-FE) (See REMOVAL )
REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for 2GR-FE) (See REMOVAL )
DRAIN BRAKE FLUID
DISCONNECT NO. 1 RESERVOIR TUBE (See REMOVAL )
DISCONNECT BRAKE LINE (See REMOVAL )
REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY (See REMOVAL )
SEPARATE VACUUM HOSE ASSEMBLY (for 1AR-FE)
1. Slide the 2 clips and disconnect the 2 vacuum hoses.
  
  Fig 1: Locating Vacuum Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 nuts and separate the vacuum hose assembly.
  
  Fig 2: Locating Vacuum Hoses Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT VACUUM HOSE (for 2GR-FE)
1. Slide the clip and disconnect the vacuum hose.
REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY
1. for 1AR-FE:
  1. Remove the 2 vacuum check valve assemblies from the brake booster assembly.
2. for 2GR-FE:
  1. Remove the vacuum check valve assembly from the brake booster assembly.
    
    Fig 3: Locating Vacuum Hose Clip
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHECK VALVE GROMMET
1. for 1AR-FE:
  1. Remove the 2 check valve grommets from the brake booster assembly.
2. for 2GR-FE:
  1. Remove the check valve grommet from the brake booster assembly.
REMOVE BRAKE PEDAL RETURN SPRING (See REMOVAL )
SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS (See REMOVAL )
REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
1. Remove the 4 nuts and push out the brake booster assembly.
  NOTE: Do not damage the brake lines.
  
  Fig 4: Locating Brake Booster Assembly Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Loosen the lock nut, and remove the brake master cylinder push rod clevis and lock nut from the brake booster assembly.
  
  Fig 5: Identifying Push Rod Clevis And Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE ENGINE WIRE
1. Disengage the 9 clamps.
2. Remove the bolt and separate the engine wire from the body.
  
  Fig 6: Identifying Engine Wire Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE ENGINE WIRE (w/Security Horn)
1. Disengage the 9 clamps, and disconnect the alarm horn connector.
2. Remove the bolt and separate the engine wire from the body.
  
  Fig 7: Identifying Engine Wire Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER ASSEMBLY
1. Disengage the 2 clamps and separate the 2 brake lines from the body.
  NOTE: Be careful not to damage the brake lines or clamps. If any parts are damaged, replace them with new ones.
2. Remove the brake booster assembly from the body.
  NOTE: Do not damage the brake lines.
  
  Fig 8: Locating Brake Lines Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER GASKET
1. Remove the brake booster gasket from the brake booster assembly.