Vacuum Brake Booster: Service and Repair

BRAKE BOOSTER

COMPONENTS:

REMOVAL
1. DISCONNECT BATTERY NEGATIVE TERMINAL

CAUTION: Wait for 90 seconds after disconnecting the terminal to prevent airbag deployment.

2. REMOVE COOL AIR INTAKE DUCT SEAL
3. REMOVE ENGINE ROOM SIDE COVER LH
4. REMOVE ENGINE ROOM SIDE COVER RH
5. REMOVE FRONT UPPER FENDER PROTECTOR LH
6. REMOVE FRONT UPPER FENDER PROTECTOR RH
7. REMOVE ROOF DRIP SIDE FINISH MOULDING LH
8. REMOVE ROOF DRIP SIDE FINISH MOULDING RH
9. REMOVE FRONT WIPER ARM HEAD CAP
10. REMOVE WINDSHIELD WIPER ARMAND BLADE ASSEMBLY LH
11. REMOVE WINDSHIELD WIPER ARMAND BLADE ASSEMBLY RH
12. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY
13. REMOVE FRONT WHEEL
14. DRAIN BRAKE FLUID

NOTICE: If brake fluid leaks onto any painted surface, wash off or remove the brake fluid completely.

15. REMOVE NO. 3 ENGINE ROOM RELAY BLOCK
16. REMOVE BRAKE ACTUATOR ASSEMBLY WITH BRACKET
17. SEPARATE CLUTCH RESERVOIR HOSE
18. REMOVE BRAKE MASTER CYLINDER SUBASSEMBLY
19. REMOVE FRONT DOOR SCUFF PLATE LH (w/Illumination)
20. REMOVE FRONT DOOR SCUFF PLATE LH (w/o/Illumination)
21. REMOVE FRONT DOOR OPENING TRIM COVER LH
22. REMOVE INSTRUMENT SIDE PANEL LH
23. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
24. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY
25. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY
26. REMOVE BRAKE PEDAL RETURN SPRING
a. Remove the brake pedal return spring.

27. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Remove the clip and the push rod pin, then separate the push rod clevis.
28. REMOVE BRAKE BOOSTER ASSEMBLY

a. Move the clip and disconnect the vacuum hose.

b. Remove the 4 nuts and brake booster assembly.

NOTICE: Do not damage the brake lines.

29. REMOVE BRAKE BOOSTER GASKET
a. Remove the brake booster gasket from the brake booster assembly.
30. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY
a. Remove the check valve assembly and grommet.
31. 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 fully 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 a new 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 lines.

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 BRAKE MASTER CYLINDER SUB-ASSEMBLY
8. CONNECT CLUTCH RESERVOIR HOSE (for Manual Transmission)
9. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET
10. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK
11. CONNECT BATTERY NEGATIVE TERMINAL
12. FILL RESERVOIR WITH BRAKE FLUID
13. BLEED MASTER CYLINDER
14. BLEED BRAKE LINE
15. BLEED BRAKE ACTUATOR ASSEMBLY
16. BLEED AIR FROM CLUTCH LINE (for Manual Transmission)
17. INSPECT FLUID LEVEL IN THE RESERVOIR
18. INSPECT BRAKE FLUID LEAKAGE
19. INSPECT BRAKE PEDAL HEIGHT
20. INSPECT PEDAL FREEPLAY
21. INSPECT PEDAL RESERVE DISTANCE
22. DISCONNECT BATTERY NEGATIVE TERMINAL

CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working.

23. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY
24. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY
25. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
26. INSTALL INSTRUMENT SIDE PANEL LH
27. INSTALL FRONT DOOR OPENING TRIM COVER LH
28. INSTALL FRONT DOOR SCUFF PLATE LH (w/o/Illumination)
29. INSTALL FRONT DOOR SCUFF PLATE LH (w/Illumination)
30. INSPECT BRAKE ACTUATOR ASSEMBLY
31. INSTALL FRONT WHEEL
32. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY
33. INSTALL WINDSHIELD WIPER ARMAND BLADE ASSEMBLY RH
34. INSTALL WINDSHIELD WIPER ARMAND BLADE ASSEMBLY LH
35. INSTALL FRONT WIPER ARM HEAD CAP
36. INSTALL ROOF DRIP SIDE FINISH MOULDING RH
37. INSTALL ROOF DRIP SIDE FINISH MOULDING LH
38. INSTALL FRONT UPPER FENDER PROTECTOR RH
39. INSTALL FRONT UPPER FENDER PROTECTOR LH
40. INSTALL ENGINE ROOM SIDE COVER RH
41. INSTALL ENGINE ROOM SIDE COVER LH
42. INSTALL COOL AIR INTAKE DUCT SEAL
43. CONNECT BATTERY NEGATIVE TERMINAL
44. INSPECT VSC SENSOR SIGNAL

a. Inspect the VSC sensor signal.
45. INSPECT SRS WARNING LIGHT
46. PERFORM INITIALIZATION
Some systems need initialization after reconnecting the negative battery terminal.