Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - BRAKE SYSTEM OTHER

HYDRAULIC BRAKE BOOSTER (for LHD) - REMOVAL

  • NOTICE:
Be sure not to allow the pump to contact the floor; support it with the booster body. If the pump contacts the floor, the red brake tube between the pump and booster body may be deformed, the operating sound of the pump may become loud enough to hear within the cabin, and fluid may leak.
When installing, coat the parts indicated by arrows with lithium soap base glycol grease ().
As high pressure is applied to the brake actuator tube No. 1, never deform it.
Until the work is over, do not turn the ignition switch on.
Before starting the work, make sure that the ignition switch is off and depress the brake pedal more than 20 times.
  • HINT:
  • When pressure in the power supply system is released, the reaction force becomes light and the stroke becomes longer.
1. DRAIN BRAKE FLUID
  • NOTICE:
  • Wash off brake fluid immediately if it comes into contact with a painted surface.
2. PRECAUTION
  • NOTICE:
  • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work ().
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
  • NOTICE:
  • When disconnecting the cable, some systems need to be initialized after the cable is reconnected ().
4. REMOVE FRONT DOOR SCUFF PLATE LH
Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Detach the 7 claws and 4 clips, and remove the scuff plate.

5. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Remove the 2 screws.

Detach the 3 claws.

Disconnect the connectors and remove the No. 1 instrument panel under cover.

6. REMOVE COWL SIDE TRIM BOARD LH
Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Remove the cap nut.

Detach the 2 clips and remove the cowl side trim board.

7. REMOVE LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL
Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Using a screwdriver, detach the 2 claws and open the hole cover.

  • HINT:
  • Tape the screwdriver tip before use.
Text in Illustration
*1Protective Tape

w/ Driver Side Knee Airbag:

Remove the 2 bolts.

Detach the 16 claws.

Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

w/o Driver Side Knee Airbag:

Remove the 2 bolts.

Detach the 9 claws.

Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

for Automatic Air Conditioning System:

Detach the 2 claws and remove the room temperature sensor.

Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Detach the 2 claws and disconnect the 2 control cables.

Disconnect the connectors and remove the lower No. 1 instrument panel finish panel.

8. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY
Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Remove the 5 bolts and driver side knee airbag.

Disconnect the connector.

  • NOTICE:
  • When handling the airbag connector, take care not to damage the airbag wire harness.
9. REMOVE PUSH ROD PIN
Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Remove the clip and push rod pin from the brake pedal lever.

10. REMOVE HYDRAULIC BRAKE BOOSTER ASSEMBLY
Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Disconnect the 3 connectors from the hydraulic brake booster assembly.

Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Use tags or make a memo to identify the place to reconnect.

Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Using a union nut wrench, disconnect the 4 brake lines from the hydraulic brake booster assembly.

Hydraulic Brake Booster (For Lhd) - Removal. BRAKE SYSTEM OTHER. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Remove the 4 nuts and pull out the hydraulic brake booster assembly.

11. REMOVE BRAKE BOOSTER GASKET

Remove the brake booster gasket from the hydraulic brake booster assembly.

BRAKE SYSTEM OTHER
Land Cruiser URJ200 URJ202 GRJ200 VDJ200
HYDRAULIC BRAKE BOOSTER for LHD