Vacuum Brake Booster: Service and Repair

REPLACEMENT
1. REMOVE AIR CLEANER ASSEMBLY
2. DRAIN BRAKE FLUID

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

3. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
SST 09023-00101





4. REMOVE VACUUM HOSE ASSEMBLY
a. Remove the bolt and separate the vacuum hose from the vacuum hose bracket.
b. Slide the clip and disconnect the vacuum hose from the brake booster.
5. REMOVE FRONT DOOR SCUFF PLATE LH
6. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER
7. REMOVE INSTRUMENT PANEL INSERT SUB-ASSEMBLY LOWER LH
8. REMOVE BRAKE PEDAL RETURN SPRING
9. REMOVE PUSH ROD PIN
a. Remove the clip and push rod pin.
10. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Loosen the lock nut and remove the push rod clevis.
11. REMOVE FRONT BRAKE TUBE NO. 5





a. Using SST and remove the front brake tube No. 5.
SST 09023-00101





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





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





16. 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 09023-00101
17. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Install the push rod clevis and lock nut.
18. 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.

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





23. INSTALL VACUUM HOSE ASSEMBLY
a. Install the vacuum hose and vacuum hose bracket 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.

24. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
SST 09737-00012, 09737-00020
25. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
SST 09023-00101
26. FILL RESERVOIR WITH BRAKE FLUID
27. BLEED MASTER CYLINDER
SST 09023-00101
28. BLEED BRAKE LINE
29. INSTALL AIR CLEANER ASSEMBLY
30. CHECK FLUID LEVEL IN RESERVOIR
31. CHECK BRAKE FLUID LEAKAGE
32. CHECK AND ADJUST BRAKE PEDAL HEIGHT