Vacuum Brake Booster: Service and Repair

Brake Booster Components:

BRAKE BOOSTER REMOVAL
1. Remove these parts:
^ Master cylinder. Service and Repair
^ No.1 under cover, No.1 safety pad and No.2 heater to register duct.
^ Tilt and telescopic Electronic Control Unit (ECU) with power steering ECU.
^ Clip and return spring.
^ Clevis pin.
^ Vacuum hose.
2. Remove Brake Booster.

Brake Booster Installation Nuts:

(a) Remove the 4 Booster installation nuts and clevis.
(b) Remove the Booster and gasket.

BRAKE BOOSTER INSTALLATION
1. Install Brake Booster.
(a) Install the clevis to the operating rod.
(b) Install the Booster and a new gasket.
(c) Install and torque the Booster installation nuts.
Torque: 13 Nm (130 kg.cm. 9 ft. lbs.)
(d) Insert the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin.
(e) Install the pedal return spring.
2. Adjust length of Booster push rod.

CAUTION: When adjusting the length of the Booster Push Rod, install 2 new gaskets to the Master Cylinder. When installing the Master Cylinder, remove one gasket before installing the Master Cylinder.

(a) Install 2 new gasket on the Master Cylinder.

Brake Booster Push Rod Length Adjustment:

(b) Set the Special Service Tool (SST) # 09737-00010 on the gasket, and lower the pin until its tip slightly touches the piston.
(c) Turn the SST upside down, and set it on the Booster.
(d) Measure the clearance between the booster push rod and pin head (SST).
Clearance: 0mm (0 inch)

Brake Booster Push Rod Length Adjustment:

(e) Adjust the Booster Push Rod length until the push rod lightly touches the pin head.
Torque: 7.4 Nm (75 kg.cm, 65 inch lbs.)
3. Install these parts:
^ Tilt and telescopic ECU with power steering ECU.
^ No.1 under cover, No.1 safety pad and No.2 heater to register duct.
^ Vacuum hose.
^ Master Cylinder.
4. Fill brake reservoir with brake fluid and bleed brake system. Service and Repair
5. Check for fluid leakage.
6. Check and adjust brake pedal. Adjustments
7. Do operational check. Testing and Inspection