Vacuum Brake Booster: Service and Repair

BRAKE BOOSTER

Components:

REMOVAL
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE COOL AIR INTAKE DUCT SEAL
3. REMOVE ENGINE ROOM SIDE COVER LH
4. REMOVE ENGINE ROOM COVER SIDE
5. REMOVE FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY LH
6. REMOVE FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY RH
7. REMOVE FRONT WIPER ARMAND BLADE ASSEMBLY LH
8. REMOVE FRONT WIPER ARMAND BLADE ASSEMBLY RH
9. REMOVE FRONT FENDER TO COWL SIDE SEAL LH
10. REMOVE FRONT FENDER TO COWL SIDE SEAL RH
11. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY
12. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.

13. REMOVE ENGINE ROOM RELAY NO.3 BLOCK
14. REMOVE BRAKE MASTER WITH PLATE CYLINDER SUB-ASSEMBLY
15. REMOVE ABS AND TRACTION ACTUATOR ASSEMBLY
16. REMOVE CONSOLE UPPER PANEL GARNISH FRONT
17. REMOVE CONSOLE UPPER PANEL SUB-ASSEMBLY
18. REMOVE INSTRUMENT PANEL FINISH PANEL END LH
19. REMOVE FRONT DOOR SCUFF PLATE LH
20. REMOVE FRONT DOOR OPENING TRIM COVER LH
21. REMOVE INSTRUMENT SIDE PANEL LH
22. REMOVE INSTRUMENT PANEL UNDER COVER NO.1 SUB-ASSEMBLY
23. REMOVE INSTRUMENT PANEL SAFETY PAD NO.1 SUB-ASSEMBLY
24. REMOVE INSTRUMENT PANEL AIR BAG ASSEMBLY NO.1 LOWER
25. REMOVE BRAKE PEDAL RETURN SPRING
a. Remove the brake pedal return spring.

26. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Remove the clip and the push rod pin, then separate the push rod clevis.

27. REMOVE BRAKE BOOSTER ASSEMBLY
a. Remove the clip and disconnect the vacuum hose.

b. Remove the 4 nuts and brake booster assembly.

NOTICE: Do not damage the brake tubes.

28. REMOVE BRAKE BOOSTER GASKET
29. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY
a. Remove the check valve assembly and grommet.

30. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Loosen the lock nut and remove the push rod clevis.

INSTALLATION
1. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Temporarily install the push rod clevis with the lock nut.
b. Adjust and tighten the push rod clevis with the lock nut.

2. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY
a. Install the grommet and check valve assembly.

3. INSTALL BRAKE BOOSTER GASKET
a. Install anew brake booster gasket to the brake booster assembly.

4. INSTALL BRAKE BOOSTER ASSEMBLY
a. Install the brake booster assembly with the 4 nuts.
Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.)

NOTICE: Do not damage the brake tubes.

b. Connect the vacuum hose with the clip.

5. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Apply lithium soap base glycol grease to the clevis pin.
b. Install the push rod clevis to the brake pedal support assembly with the clevis pin and a new clip.

6. INSTALL BRAKE PEDAL RETURN SPRING
a. Install the brake pedal return spring.

7. INSTALL ABS AND TRACTION ACTUATOR ASSEMBLY
8. INSTALL BRAKE MASTER WITH PLATE CYLINDER SUB-ASSEMBLY
9. INSTALL ENGINE ROOM RELAY BLOCK NO.3
10. ADD BRAKE FLUID
11. CONNECT BATTERY NEGATIVE TERMINAL
12. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY
13. INSTALL FRONT FENDER TO COWL SIDE SEAL LH
14. INSTALL FRONT FENDER TO COWL SIDE SEAL RH
15. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
16. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
17. INSTALL FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY LH
18. INSTALL FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY RH
19. ADD RESERVOIR WITH BRAKE FLUID
20. BLEED MASTER CYLINDER
21. BLEED BRAKE LINE
22. BLEED ABS AND TRACTION ACTUATOR ASSEMBLY
23. INSPECT FLUID LEVEL IN THE RESERVOIR
24. INSPECT BRAKE FLUID LEAKAGE
25. INSPECT ABS AND TRACTION ACTUATOR ASSEMBLY
26. INSTALL COOL AIR INTAKE DUCT SEAL
27. INSPECT BRAKE PEDAL HEIGHT
28. INSPECT PEDAL FREE PLAY
29. INSPECT PEDAL RESERVE DISTANCE
30. INSTALL INSTRUMENT PANEL AIR BAG ASSEMBLY NO.1 LOWER
31. INSTALL INSTRUMENT PANEL SAFETY PAD NO.1 SUB-ASSEMBLY
32. INSTALL INSTRUMENT PANEL UNDER COVER NO.1 SUB-ASSEMBLY
33. INSTALL INSTRUMENT SIDE PANEL LH
34. INSTALL FRONT DOOR OPENING TRIM COVER LH
35. INSTALL FRONT DOOR SCUFF PLATE LH
36. INSTALL INSTRUMENT PANEL FINISH PANEL END LH
37. INSTALL CONSOLE UPPER PANEL SUB-ASSEMBLY
38. INSTALL CONSOLE UPPER PANEL GARNISH FRONT
39. INSTALL ENGINE ROOM COVER SIDE
40. INSTALL ENGINE ROOM SIDE COVER LH
41. INSPECT VSC SENSOR SIGNAL
42. INSPECT SRS WARNING LIGHT
43. PERFORM INITIALIZATION
Some systems need initialization after reconnecting the cable to the negative battery terminal.