Vacuum Brake Booster: Service and Repair
BRAKE BOOSTER ASSEMBLY
REPLACEMENT
1. REMOVE ENGINE ROOM SIDE COVER
2. SEPARATE ENGINE ROOM NO.3 R/B
a. Remove the bolt and separate the engine room No.3 R/B.
3. DRAIN BRAKE FLUID
a. Draw out fluid with syringe.
NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.
4. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
a. Remove the clamp from the 2 brake tubes.
b. Using SST, remove the 2 brake tubes from the master cylinder and ABS & TRACTION actuator assembly.
SST 09751-36011
c. Disconnect the brake fluid level warning switch connector from the brake master cylinder reservoir.
d. Remove the 2 nuts, vacuum check valve bracket and brake master cylinder sub-assembly.
5. REMOVE INSTRUMENT CLUSTER FINISH PANEL END
6. REMOVE INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER
7. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.1
8. REMOVE COIN BOX ASSEMBLY
9. REMOVE OUTER MIRROR SWITCH ASSEMBLY
10. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY NO.1
11. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.2
a. Remove the 2 bolts and hood lock release lever.
b. Remove the instrument panel under cover sub-assembly No.2.
12. REMOVE BRAKE PEDAL RETURN SPRING
a. Remove the brake pedal return spring.
13. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Remove the clip and the push rod pin.
b. Loosen the clevis lock nut and remove the brake master cylinder push rod clevis.
c. Remove the clevis lock nut.
14. REMOVE BRAKE BOOSTER ASSEMBLY
a. Slide the clip upward and disconnect the vacuum hose assembly from the vacuum check valve assembly.
b. Remove the 4 nuts and pull out the brake booster assembly.
NOTICE: Be careful not to damage the brake tubes.
c. Remove the brake booster gasket.
15. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY
a. Remove the vacuum check valve assembly and the grommet from the brake booster assembly.
16. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY
a. Install the grommet and the vacuum check valve assembly to the brake booster assembly.
17. INSTALL BRAKE BOOSTER ASSEMBLY
a. Install a new brake booster gasket.
b. Install the brake booster assembly with the 4 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
c. Connect the vacuum hose assembly to the vacuum check valve assembly and set the clip.
18. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Install the clevis lock nut and the brake master cylinder push rod clevis.
HINT: After adjusting the brake pedal height, torque the clevis lock nut.
b. Apply lithium soap base glycol grease to the push rod pin.
c. Install the push rod pin and clip.
19. INSTALL BRAKE PEDAL RETURN SPRING
a. Install the brake pedal return spring.
20. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
SST 09737-00013
21. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
a. Install the brake master cylinder sub-assembly and vacuum check valve bracket with 2 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Connect the brake fluid level warning switch connector to the master cylinder reservoir.
c. Using SST, install the brake tubes to the brake master cylinder sub-assembly and ABS & TRACTION actuator assembly.
SST 09751-36011
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
d. Install the clamp.
22. FILL RESERVOIR WITH BRAKE FLUID
23. BLEED MASTER CYLINDER
24. BLEED BRAKE LINE
25. CHECK FLUID LEVEL IN RESERVOIR
26. CHECK FOR BRAKE FLUID LEAKAGE
27. CHECK AND ADJUST BRAKE PEDAL HEIGHT
28. CHECK PEDAL FREE PLAY
29. CHECK PEDAL RESERVE DISTANCE
30. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.2
31. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY NO.1
a. Install the instrument panel under cover sub-assembly No. 1.
b. Install the 2 bolts and hood lock release lever.
32. INSTALL OUTER MIRROR SWITCH ASSEMBLY
33. INSTALL COIN BOX ASSEMBLY
34. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.1
35. INSTALL INSTRUMENT CLUSTER FINISH PANEL END
36. INSTALL INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER
37. INSTALL ENGINE ROOM NO.3 R/B
a. Install the engine room No.3 R/B with the bolt and bracket.
38. INSTALL ENGINE ROOM SIDE COVER