Repair Procedures

Removal

1. Remove the master cylinder.
2. Disconnect the vacuum hose (A) from the brake booster (B).




3. Remove the snap pin (A), pin (B) and washer (C).




4. Remove the four booster mounting nuts (D).
5. Remove the brake booster (A) from the engine compartment.






INSTALLATION

1. Adjust push rod length of the booster, and then install the seal on the booster assembly.

Standard length : 115 ± 0.5 mm (4.528 ± 0.019 in.)





2. Insert the booster and tighten the nut (D).




3. Connect the booster push rod and brake pedal with a pin (B) and install a snap pin (A) to the pin (B).

CAUTION:
When installing the snap pin, it mount be used new one.

4. Adjust push rod length.
(1) Insert the gasket onto the master cylinder.
(2) Put the SST onto the gasket and tighten the adjusting bolt until the bolt touches the bottom of the push rod hole.




(3) Apply 500 mmHg vacuums with a vacuum pump.
(4) Invert the SST used in step 2 and place it on the booster.




(5) Check whether the clearance between the edge of the adjusting bolt and the push rod of the booster is 0 - 0.1 mm (0 - 0.004 in.).
If it is not standard clearance, loosen the lock nut of the push rod, and turn the push rod to make the adjustment.

Standard clearance : 0 - 0.1 mm (0 - 0.004 in.)





5. Install the master cylinder.
6. Connect the vacuum hose to the brake booster.
7. After filling the brake reservoir with brake fluid, bleed the system.
8. Check for fluid leakage.
9. Check and adjust the brake pedal for proper operation.
10. After installing, apply grease to the contact parts of the joint pin and brake pedal.