Removal and Replacement

HYDRAULIC BRAKE BOOSTER

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

REMOVAL

NOTICE: Before starting the procedures, make sure that the ignition switch is OFF and depress the brake pedal more than 40 times.

HINT: When the power supply system's pressure is released, the brake pedal resistance decreases.

NOTICE:
^ As high pressure is applied to the No. 1 brake actuator tube, make sure that it does not deform.
^ Do not turn the ignition switch ON until the procedures are completed.

1. FOLLOW PRECAUTION
(a) Follow the Restraint System; Service Precautions.

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. DRAIN BRAKE FLUID

NOTICE: Wash off brake fluid immediately if it comes in contact with any painted surface.

4. REMOVE V-BANK COVER
5. REMOVE BRAKE MASTER CYLINDER COVER ASSEMBLY
6. REMOVE DOOR SCUFF PLATE ASSEMBLY LH
7. REMOVE FRONT DOOR OPENING TRIM COVER LH
8. REMOVE NO. 1 INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY
9. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY
10. DISCONNECT MASTER CYLINDER PUSH ROD CLEVIS
11. REMOVE FRONT WHEEL LH
12. REMOVE BRAKE MASTER CYLINDER SUBASSEMBLY

(a) Using SST, disconnect the 4 brake lines from the master cylinder.
SST 09023-00101

(b) Attach identification tags to the lines or write down line connection locations so that the lines can be reconnected correctly.

(d) Disconnect the 5 connectors and harness clamp from the master cylinder.

(e) Remove the 2 nuts and disconnect the brake lines from the vehicle body.
(f) Remove the 4 nuts and pull out the master cylinder.

INSTALLATION

NOTICE: As high pressure will be applied to the No. 1 brake actuator tube, make sure that it does not deform.

1. INSTALL BRAKE MASTER CYLINDER SUBASSEMBLY
(a) Install the master cylinder with the 4 nuts.
Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf)

(b) Install the brake lines to the vehicle body with the 2 nuts.
Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf)

(c) Using SST and a wrench, connect the front brake line LH to the flexible hose.
SST 09023-00101
Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) without SST 14 N*m (143 kgf*cm, 10 ft.*lbf) with SST

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

(d) Using SST, connect each brake line to the correct position of the master cylinder, as shown in the illustration.
SST 09023-00101
Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) without SST 14 N*m (143 kgf*cm, 10 ft.*lbf) with SST

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

(e) Connect the 5 connectors and harness clamp to the master cylinder.

2. CONNECT MASTER CYLINDER PUSH ROD CLEVIS
3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY
4. INSTALL NO. 1 INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY
5. INSTALL FRONT DOOR OPENING TRIM COVER LH
6. INSTALL DOOR SCUFF PLATE ASSEMBLY LH
7. INSTALL BRAKE MASTER CYLINDER COVER ASSEMBLY
8. INSTALL V-BANK COVER
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. FILL RESERVOIR WITH BRAKE FLUID
11. BLEED AIR FROM HYDRAULIC BRAKE MASTER CYLINDER (When using intelligent tester)
12. BLEED AIR FROM HYDRAULIC BRAKE MASTER CYLINDER (When using ABS actuator checker (SST))
13. BLEED AIR FROM BRAKE LINE
14. CHECK AND ADJUST BRAKE PEDAL HEIGHT
15. CHECK BRAKE PEDAL FREE PLAY
16. CHECK BRAKE PEDAL RESERVE DISTANCE
17. CHECK BRAKE FLUID LEVEL IN RESERVOIR
18. CHECK FOR BRAKE FLUID LEAKAGE
19. INSTALL FRONT WHEEL LH
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)

20. CHECK HYDRAULIC BRAKE MASTER CYLINDER FLUID PRESSURE CHANGE
21. INSPECT BRAKE MASTER CYLINDER OPERATION (When using intelligent tester)
22. INSPECT BRAKE MASTER CYLINDER OPERATION (When using ABS actuator checker)
23. PERFORM INITIALIZATION
(a) Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

24. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light.