Brake Booster Replacement

LHD Model

1. Remove the master cylinder.

1. Disconnect the vacuum hose (A) from the brake booster (B).

1. Remove the hand primer bracket (A).
   NOTE: Do not disconnect the hose with hand primer (B).

1. Remove the fuel filter bracket (A) from frame.
   NOTE: For the fuel heater equipped model, remove the fuel heater with fuel filter bracket.

1. Remove the cable (A) from the body.

1. Remove the brake lines from the hose clamp (A).

1. Remove the air cleaner.

1. Remove the intake air duct.

1. Remove the lock pin (A) and the joint pin (B), then disconnect the yoke (C) from the brake pedal.

1. Remove the brake booster mounting nuts (D).

1. Remove the yoke from brake booster rod (E).

1. Move the brake booster (A) toward front and right side.
   - Be careful not to damage the booster surfaces and threads of the brake booster rod (B) and the booster stud bolts.
   - Be careful not to bend or damage the brake lines.

1. Turn the brake booster (A) until the brake booster rod (B) comes upward.

1. Remove the brake booster (A) from the engine compartment.

1. Install the brake booster in the reverse order of removal, and note these items:
   - Tighten all mounting hardware to the specified torque valves.
   - Use a new lock pin whenever installing.
   - After installing the brake booster and master cylinder, fill the reservoir with new brake fluid, bleed the brake system, and adjust the brake pedal height and free play.

RHD Model

1. Remove the master cylinder.

1. Remove the clutch master cylinder from the body.
   NOTE: Do not disconnect the reservoir hose and the clutch pipe from the master cylinder.

1. Disconnect the vacuum hose (A) from the brake booster (B).

1. Remove the air cleaner.

1. Remove the intake air duct.

1. Remove the P/S hose mounting bracket (A).

1. Remove the brake lines from the clamp (A).

1. Remove the install pipe mounting brackets (A).

1. Remove the EVRV mounting bolts (A).

1. Open the cable clamp (A), then disconnect the heater valve cable (B) from the heater valve arm (C).

1. Remove the heater valve bracket (D).

1. Remove the throttle cable bracket (A).

1. Remove the cable (A) from the body.

1. Remove the breather hose (A).
   NOTE: While installation, connect the hose securely until it contacts the stop on the line, then align the top mark (B) and tab of the hose clamp (C).

1. Remove the hose (A) from the clamp (B).

1. Remove the engine wire harness protector (C).

1. Remove the lines mounting bolts.

1. Remove the A/C pipe stays (A).

1. Remove the hand primer bracket (A).
   NOTE: Do not disconnect the hose with hand primer (B).

1. Remove the fuel filter bracket (A) from the frame.
   NOTE: For the fuel heater equipped model, remove the fuel heater with fuel filter bracket.

1. Remove the APP sensor (A).

1. Remove the access panel (A) on the passenger's side.

1. Remove the strut bar (B) on the passenger's side.

1. Remove the lock pin (A) and the joint pin (B), then disconnect the yoke (C) from the bake pedal.

1. Remove the brake booster mounting nuts (D).

1. Remove the yoke from brake booster rod (E).

1. Move the brake booster (A) toward the front, and left side.
   - Be careful not to damage the booster surfaces and threads of the brake booster rod (B) and the booster stud bolts.
   - Be careful not to bend or damage the brake lines.

1. Turn the brake booster (A) until the brake booster rod (B) comes downward.

1. Set the cable (A) under the brake booster (B), and move the brake booster to left side of vehicle.

1. Remove the brake booster (A) from the engine compartment.

1. Install the brake booster in the reverse order of removal, and note these items:
   - Tighten all mounting hardware to the specified torque values.
   - Use a new lock pin whenever installing.
   - After installing the brake booster and master cylinder, fill the reservoir with new brake fluid, bleed the brake system, and adjust the brake pedal height and free play.