Vacuum Brake Booster: Service and Repair

REPLACEMENT

HINT: COMPONENTS: See Diagrams; Exploded Views and Instrument Panel, Gauges and Warning Indicators.

1. REMOVE AIR CLEANER ASSEMBLY
2. DRAIN BRAKE FLUID

NOTICE: Wash off the brake fluted immediately if it comes into contact with a painted surface.

3. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
SST 09023-00100





4. SEPARATE CHARCOAL CANISTER ASSEMBLY
a. Remove the 2 bolts and separate the charcoal canister from the body.





5. REMOVE VACUUM HOSE ASSEMBLY
a. Remove the bolt and separate the vacuum line from the body.
b. Slide the clip and disconnect the vacuum hose from the brake booster.
6. REMOVE FRONT DOOR SCUFF PLATE LH
7. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER
8. REMOVE INSTRUMENT PANEL INSERT SUB-ASSEMBLY LOWER LH
9. REMOVE BRAKE PEDAL RETURN SPRING
10. REMOVE PUSH ROD PIN
a. Remove the clip and push rod pin.
11. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Loosen the lock nut and remove the push rod clevis.





12. REMOVE FRONT BRAKE TUBE NO. 5
a. Using SST and remove the front brake tube No. 5.
SST 09023-00100





13. REMOVE BRAKE BOOSTER ASSEMBLY
a. Remove the 4 nuts.
b. Pull out the brake booster assembly.
14. REMOVE BRAKE BOOSTER GASKET
15. INSTALL BRAKE BOOSTER GASKET
a. Install a new brake booster casket to the brake booster.





16. INSTALL BRAKE BOOSTER ASSEMBLY
a. Install the brake booster with the 4 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)





17. INSTALL FRONT BRAKE TUBE NO. 5
a. Using SST and install the front brake tube No. 5.
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
SST 09023-00100
18. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Install the push rod clevis and lock nut.
19. INSTALL PUSH ROD PIN
a. Install the push rod pin and clip.

HINT: Apply the lithium soap base glycol grease to the part indicate by arrow.

20. INSTALL BRAKE PEDAL RETURN SPRING
21. INSTALL INSTRUMENT PANEL INSERT SUB-ASSEMBLY LOWER LH
22. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY UPPER
23. INSTALL FRONT DOOR SCUFF PLATE LH





24. INSTALL VACUUM HOSE ASSEMBLY
a. Install the vacuum line to the body with a bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
b. Connect the vacuum hose to the brake booster with the clip.





25. CONNECT CHARCOAL CANISTER ASSEMBLY
a. Install the charcoal canister with the 2 bolts.
Torque: 43 Nm (440 kgf-cm, 32 inch lbs.)
26. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
SST 09023-01000
27. FILL RESERVOIR WITH BRAKE FLUID
28. BLEED MASTER CYLINDER
SST 09023-00100
29. BLEED BRAKE LINE
30. INSTALL AIR CLEANER ASSEMBLY
31. CHECK FLUID LEVEL IN RESERVOIR
32. CHECK BRAKE FLUID LEAKAGE
33. CHECK AND ADJUST BRAKE PEDAL HEIGHT