Vacuum Brake Booster: Service and Repair

Brake Booster


















Removal and Installation

All vehicles

1. Remove the 4 strut upper mount nuts and remove the strut tower brace.
- To install, tighten the nuts to 30 Nm (22 lb-ft).


Vehicles not equipped with Gasoline Turbocharged Direct Injection (GTDI)

2. Remove the Air Cleaner (ACL) outlet pipe.

3. Remove the Hydraulic Control Unit (HCU).

Vehicles equipped with GTDI (Gasoline Turbocharged Direct Injection)

4. Remove the RH turbocharger intake tube.

5. Disconnect the ABS module electrical connector.

All vehicles

6. Remove the brake master cylinder.

7. Disconnect the brake booster vacuum fitting and position aside.

8. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp switch. This switch must be removed with the brake pedal in the at-rest position. The switch plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch.

Remove the stoplamp switch.

9. NOTE: The booster push rod clevis-locking pin is a one-time use only part. Any time the booster push rod clevis-locking pin is removed, a new booster push rod clevis-locking pin should be used.

NOTE: Remove the clevis-locking pin by squeezing the locking tabs and pulling outward on the opposite end.
Remove and discard booster push rod clevis-locking pin.


10. Remove the 4 nuts and remove the brake booster.
- Discard the nuts.

- To install, tighten the new nuts to 25 Nm (18 lb-ft).


11. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch. This switch must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing this switch with the brake pedal in any other position will result in incorrect adjustment and may damage the switch.

To install, reverse the removal procedure.