Vacuum Brake Booster: Service and Repair

REMOVAL
1. REMOVE FRONT LH WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
2. REMOVE MASTER CYLINDER
3. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER
4. DISCONNECT FRONT LH BRAKE LINE





a. Using SST and spanner, disconnect the brake line from the flexible hose of front LH brake.
SST 09023-00100
b. Separate the grommet from body through the brake line.





c. Disconnect the front LH brake line from the clamp.
5. REMOVE BRAKE BOOSTER





a. Remove the 3 bolts and disconnect the 3 clamps.
b. Remove the lower finish panel.
c. Remove the return spring, clip and clevis pin.





d. Remove the clevis and 4 nuts.





e. Move the brake line as illustrated and ensure sufficient space.
f. Pull out the booster and gasket.

INSTALLATION
1. INSTALL BRAKE BOOSTER
a. Install a new gasket to the booster.
b. Install the booster.
c. Install and torque the booster installation nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
d. Install the clevis to the operating rod.
e. Insert the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin.
f. Install the pedal return spring.
g. Install the vacuum hose.





h. Install the 3 clamps with 3 bolts.
Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)





2. CONNECT FRONT LH BRAKE LINE
a. Connect the front LH brake line to the clamp.
b. Using SST and spanner, connect the brake line to the flexible hose of front LH brake.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
c. Attach the grommet to body through the brake line.
3. ADJUST LENGTH OF BOOSTER PUSH ROD
a. Install 2 new gaskets on the master cylinder.





b. Set the SST on the gasket, and lower the pin until its tip slightly touches the piston.
SST 09737-00011
c. Turn the 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. Adjust the booster push rod length until the push rod slightly touches the pin head.

HINT: When adjusting the push rod, depress the brake pedal enough so that the push rod sticks out.

4. INSTALL BRAKE MASTER CYLINDER
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
6. CHECK FOR FLUID LEAKAGE
7. CHECK AND ADJUST BRAKE PEDAL
8. INSTALL LOWER FINISH PANEL
9. DO OPERATIONAL CHECK