Vacuum Brake Booster: Service and Repair

REMOVAL
1. REMOVE ENGINE ROOM SIDE COVER
2. MOVE ASIDE ENGINE ROOM NO. 3 R/B
Remove the 2 bolts and bracket, move aside the engine room No. 3 R/B.
3. REMOVE MASTER CYLINDER
4. REMOVE NO. 1 UNDER COVER AND NO. 1 SAFETY PAD
5. REMOVE CLIP AND RETURN SPRING
6. REMOVE CLEVIS PIN
7. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER





8. REMOVE BRAKE BOOSTER
a) Remove the 4 installation nuts and clevis.
b) Pull out the brake booster and gasket.

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 kgf-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





a) Set 2 feeler gauges (0.5 mm) to the cylinder body symmetrically.
b) Set SST on the 2 feeler gauges, and lower the pin until its tip slightly touches the piston.
SST 09737-00011

NOTICE: Adjust the clearance with no negative pressure applied inside the booster. (With the engine stopped, press the brake pedal several times to set the pressure inside the booster to the atmospheric pressure.)





c) Turn SST upside down, and set it on the booster.
SST 09737-00011
d) Measure the clearance between the booster push rod and pin head (SST).
Clearance: 0 mm (0 inch)





e) Using SST, adjust the booster push rod length until the push rod lightly touches the pin head.
SST 09737-00020
3. INSTALL MASTER CYLINDER
4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
5. CHECK FOR FLUID LEAKAGE
6. CHECK AND ADJUST BRAKE PEDAL
7. INSTALL NO. 1 SAFETY PAD AND NO. 1 UNDER COVER
8. DO OPERATIONAL CHECK