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Power Vacuum Brake Booster Replacement — RHD 3.0L

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 master cylinder. Refer to Master Cylinder Replacement : RHD  → LHD .
  2. Carefully position aside the brake pipes and secure with heavy mechanics wire or equivalent.
  3. Remove the power brake booster vacuum check valve and hose from the power 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 throttle body assembly. Refer to Throttle Body Assembly Replacement : LF1 or LFW .
  5. Remove the evaporative emission canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement : LF1 or LFW .

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  6. Remove the driver knee bolster. Refer to Driver Knee Bolster Replacement : Long Body  → Short Body .
  7. Disconnect the brake pedal position sensor electrical connector.
  8. Remove the power vacuum brake booster pushrod nut (1) and disconnect the power vacuum brake booster pushrod from the brake pedal.

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  9. Remove the power vacuum brake booster nuts (1).
  10. Lower the the frame with the powertrain assembly sufficiently to allow removal of the power vacuum brake booster. Refer to Frame Replacement .

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

  11. Carefully pull the power vacuum brake booster (1) forward until the mounting studs clear the dash panel.
  12. Remove the power vacuum brake booster.
  13. Inspect the power vacuum brake booster gasket for damage and replace, if necessary.

Installation Procedure
  1. Position the power vacuum brake booster gasket to the dash panel, if removed.
  2. Install the power vacuum brake booster.

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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.

  3. While guiding the power vacuum brake booster pushrod and mounting studs through the dash panel, install the power vacuum brake booster (1).
  4. Raise and install the the frame with the powertrain assembly. Refer to Frame Replacement .

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


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

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  7. Install the power vacuum brake booster pushrod nut (1) and tighten to 9 N·m (80 lb ft).
  8. Connect the brake pedal position sensor electrical connector.
  9. Install the driver knee bolster. Refer to Driver Knee Bolster Replacement : Long Body  → Short Body .
  10. Install the evaporative emission canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement : LF1 or LFW .
  11. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement : LF1 or LFW .
  12. Install the power brake booster vacuum check valve and hose to the power 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 .
  13. Install the master cylinder . Refer to Master Cylinder Replacement : RHD  → LHD .
   


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