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Power Vacuum Brake Booster Replacement — LHD

Removal Procedure

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface section.

  1. Remove the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement .
  2. Remove and position aside the surge tank. Refer to Radiator Surge Tank Replacement : Diesel  → Petrol Engines .
  3. Disconnect the vacuum brake booster vacuum check valve and hose from the vacuum brake booster and position aside. Refer to Power Brake Booster Vacuum Check Valve and Hose Replacement : RHD 2.0L, 2.2L Diesel  → LHD 2.0L, 2.2L Diesel  → RHD 3.0L  → RHD 2.4L  → LHD 3.0L  → LHD 2.4L .
  4. Remove the master cylinder. Refer to Master Cylinder Replacement : RHD  → LHD .
  5. Remove the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement .

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  6. Remove the driver knee bolster. Refer to Driver Knee Bolster Replacement : Long Body  → Short Body .
  7. Remove the power vacuum brake booster pushrod retainer (1).
  8. Disconnect the power vacuum brake booster pushrod from the brake pedal.

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  9. Remove the power vacuum brake booster nuts (1).

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  10. Carefully pull the power vacuum brake booster forward until the mounting studs clear the dash panel.

    11. Note: Ensure the foam insulator on the mounting surface of the power vacuum brake booster withdraws with the booster.

  11. Remove the vacuum brake booster (1).

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  12. Inspect the power vacuum brake booster gasket (1) for damage and replace if necessary.

Installation Procedure

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  1. Install the power vacuum brake booster gasket (1).

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    Note: Ensure the foam insulator on the mounting surface of the power vacuum brake booster is properly installed on the booster.

  2. While guiding the power vacuum brake booster pushrod and mounting studs through the dash panel, install the power vacuum brake booster (1).

    3. Caution: Refer to Fastener Caution in the Preface section.


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  3. Install the power vacuum brake booster nuts (1) and tighten to 22 N·m (16 lb ft).

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  4. Connect the power vacuum brake booster pushrod to the brake pedal.
  5. Install the power vacuum brake booster pushrod retainer (1).
  6. Rotate the power vacuum brake booster pushrod retainer 360 degrees to ensure it is properly installed.
  7. Install the driver knee bolster. Refer to Driver Knee Bolster Replacement : Long Body  → Short Body .
  8. Install the BPMV. Refer to Brake Pressure Modulator Valve Replacement .
  9. Install the master cylinder . Refer to Master Cylinder Replacement : RHD  → LHD .

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  10. Connect the power vacuum brake booster vacuum check valve and hose to the vacuum brake booster. Refer to Power Brake Booster Vacuum Check Valve and Hose Replacement : RHD 2.0L, 2.2L Diesel  → LHD 2.0L, 2.2L Diesel  → RHD 3.0L  → RHD 2.4L  → LHD 3.0L  → LHD 2.4L .
  11. Install the surge tank. Refer to Radiator Surge Tank Replacement : Diesel  → Petrol Engines .
  12. Install the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement .
   


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