Vacuum Brake Booster: Service and Repair

REMOVAL






1. Remove the remote ground cable from the ground stud located on the left shock tower.






2. Correctly isolate remote ground cable when servicing vehicle by installing the ground cable insulator on the strut tower ground stud as shown. This will prevent accidental grounding of the remote ground cable.






3. Remove the PCV hose from the air chamber located on the front of the intake manifold. Remove bolt attaching the air chamber to the intake manifold. Then unlatch lid of air cleaner from air cleaner housing and loosen clamp attaching air inlet hose to throttle body. Remove the air cleaner lid, air inlet hose and air chamber as an assembly from the engine.






4. Remove the throttle cable and if equipped the speed control cable from the throttle body . Remove the vacuum hose from the throttle body. Remove the wiring harness connectors from AIS motor and the Throttle Position Sensor on the throttle body. Then, remove the 4 bolts attaching the throttle body to the intake manifold and remove it from intake manifold.
5. Without removing cables from bracket, remove the throttle and speed control cable mounting bracket from the intake manifold.





6. Remove the EGR tube from the intake manifold and EGR valve.






7. If equipped, remove the vehicle's wiring harness connector from the speed control servo. Remove the 2 speed control servo mounting bracket to strut tower attaching nuts. Without removing speed control cable from servo, move speed control servo out of the way.






8. Remove the wiring harness connector from the brake fluid level sensor in the master cylinder fluid reservoir.










9. Remove the primary and secondary brake tubes from the master cylinder.







10. Remove the 2 nuts attaching the master cylinder assembly to the power brake vacuum booster.

CAUTION: When removing the routing clip and brake tubes from the mounting stud do not bend or kink the chassis brake line tubes.

11. Remove the routing clip and chassis brake tubes (as an assembly) from the mounting stud for the master cylinder.
12. Remove the master cylinder from the vacuum booster.






13. Remove the vacuum harness connector and electrical connector from the purge solenoid. Remove bracket and purge solenoid as an assembly from the vehicle.






14. Remove dipstick tube attaching bolt. Then remove the dipstick tube and dipstick as an assembly from the transaxle.
15. Remove the vacuum hoses from the check valve located on the power brake vacuum booster.






16. Locate the power brake vacuum booster input rod to brake pedal attachment under instrument panel. Position a small screwdriver between the center tang on the power brake booster input rod to brake pedal pin retaining clip. Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin. Then pull retaining clip off brake pedal pin. Discard retaining clip. Replace only with a new retaining clip when assembled.







17. Remove the 4 nuts attaching the vacuum booster to the dash panel. Nuts are accessible from under dash panel in area of the steering column and pedal bracket assembly.






18. Slide the vacuum booster straight forward until mounting studs clear dash panel. Then lift the vacuum booster strait up to remove it from the vehicle.

CAUTION: Do not attempt to disassemble the power brake vacuum booster it is to be serviced ONLY as a complete assembly.

INSTALLATION
1. Position power brake booster onto dash panel.
2. Install and torque the 4 power brake vacuum booster mounting nuts to 37 Nm (27 ft. lbs.) torque.
3. Using lubriplate, or an equivalent, coat the surfaces of the brake pedal pin that contact the power brake vacuum booster input rod.
4. Connect power brake vacuum booster input rod to brake pedal pin and install a NEW retaining clip. Use only a new retainer clip DO NOT USE the old clip.
5. Install the dipstick tube in transaxle. Install dipstick tube attaching bolt and securely tighten.
6. Install the vacuum hoses on the check valve in the power brake vacuum booster.
7. Position purge control solenoid on left front strut tower and install and securely tighten attaching bolt. Then correctly route and install the vacuum harness connector and electrical connector on the purge control solenoid.
8. Position master cylinder on vacuum booster, aligning push rod on vacuum booster with the piston of the master cylinder.

CAUTION: When installing the routing clip and brake tubes on the mounting stud, do not bend or kink the chassis brake line tubes. Be sure the chassis broke tubes are routed correctly. The chassis brake tubes can not touch each other or other components or the body of the vehicle.

9. Install the routing clip and chassis brake tubes on the inboard mounting stud for the master cylinder.
10. Install the 2 master cylinder to power brake unit mounting nuts. Tighten the 2 mounting nuts to a torque of 28 Nm (250 inch lbs.).
11. Install the primary and secondary brake tubes in the outlet ports of the master cylinder. Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.).
12. Install the vehicle's wiring harness connector on the master cylinder brake fluid level senso.
13. If equipped, install speed control servo on the mounting studs in the left strut tower. Install the 2 speed control servo bracket mounting nuts. Tighten the 2 mounting nuts to a torque of 6 Nm (55 inch lbs.). Install electrical connector on speed control servo.
14. Install the EGR tube with NEW gaskets on the intake manifold and EGR valve. Install the 4 mounting bolts and tighten to a torque of 11 Nm (95 inch lbs.).
15. Install the throttle body and a NEW gasket on the intake manifold. Install the 4 throttle body attaching bolts and tighten to a torque of 22 Nm (200 inch lbs.).
16. Install the vacuum hose on the throttle body. Install the wiring harness connectors on the AIS motor and the Throttle Position Sensor located on the throttle body.
17. Install the mounting bracket for the throttle cable and speed control cable onto the intake manifold and securely tighten the mounting bolts.
18. Install the throttle cable, and if equipped, the speed control cable on the cam of the throttle body assembly.
19. Install the air cleaner lid, air inlet hose and air chamber as an assembly on the engine. Latch lid of air cleaner to air cleaner housing. Securely tighten the clamp attaching the air inlet hose to the throttle body. Install and securely tighten the bolt attaching the air chamber to the intake manifold.
20. Install the remote ground cable on the ground stud located on the left strut tower. Install and securely tighten the ground cable attaching nut.
21. Check brake light switch for correct adjustment. If required, adjust stop lamp switch as necessary. See Lighting and Horns, Brake Lamp Switch, Adjustments.
22. Road test vehicle to ensure proper operation of the vehicles brake system.