Vacuum Brake Booster: Service and Repair

REMOVAL

1. Remove Air Cleaner cover with Air Cleaner hose.
2. Remove Master Cylinder. Refer to Master Cylinder, Brakes - Service and Repair. Service and Repair
3. Remove Charcoal Canister.
4. Disconnect vacuum hose from Brake Booster.
5. Remove pedal return spring.
6. Remove clip and clevis pin.

Removal Of Gasket And Clevis:

7. Remove Brake Booster, gasket and clevis.
(a) Remove 4 nuts and clevis.
(b) Pull out the Brake Booster and gasket.

INSTALLATION

1. Install Brake Booster.
(a) Install the Booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the Booster installation nuts.
Torque: 13 Nm (130 kg.cm, 9 ft. lbs.)
(d) Install the clevis, and torque the lock nut.
Torque: 25 Nm (260 kg.cm, 19 ft. lbs.)
(e) Install the clevis pin into the clevis and Brake Pedal, and install the clip to the clevis pin.
(f) Install the pedal return spring.

Length Of Booster Push Rod Adjustment:

2. Adjust length of Booster Push Rod.
(a) Install a new gasket on the Master Cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip slightly touches the piston. SST 09737-00010
(c) Turn the SST upside down, and set it on the Booster. SST 09737-00010
(d) Measure the clearance between the Booster Push Rod and pin head (SST). Clearance: 0 mm (0 inch)





(e) Adjust the Booster Push Rod length until the push rod lightly touches the pin head.
3. Install Charcoal Canister to original position.
4. Install Master Cylinder.
5. Install Air Cleaner cover with Air Cleaner hose.
6. Connect vacuum hose to Brake Booster.
7. Fill brake reservoir with brake fluid and bleed brake system. Brake Bleeding
8. Check for fluid leakage.
9. Check and adjust brake pedal. Refer to Brake Pedal Assy - Testing and Inspection.
10. Do operational check. Refer to Brake Booster - Testing and Inspection.