Brake Booster

Brake Booster - Hybrid





Removal and Installation

1. Disconnect the 2 low-voltage electrical connectors.





2. Remove the master cylinder. For additional information, refer to Hydraulic Brake Actuation Brake Master Cylinder.

3. Remove the bolt and position the ground cable aside.
- To install, tighten the bolt to 12 Nm (106 lb-in).





4. Remove the PCM. For additional information, refer to Electronic Engine Controls - Hybrid Service and Repair.

5. Detach the wiring harness and brake tube routing retainers from the PCM bracket.





6. Remove the 3 nuts and the PCM mounting bracket.
- To install, tighten the nuts to 11 Nm (97 lb-in).

7. Disconnect the vacuum hose/check valve assembly from the brake booster.

8. Disconnect the vacuum sensor, booster solenoid and the booster travel sensor electrical connectors.

9. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp switch. This switch must be removed with the brake pedal in the at-rest position. The switch plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch.

Remove the stoplamp switch. For additional information, refer to Exterior Lighting Service and Repair.

10. NOTE: The booster push rod clevis-locking pin is a one-time-use only part. Any time the booster push rod clevis-locking pin is removed, a new booster push rod clevis-locking pin must be used.

NOTE: Remove the clevis-locking pin by squeezing the locking tabs and pulling outward on the opposite end.

Remove and discard the booster push rod clevis-locking pin.

11. Remove and discard the 4 brake booster nuts and remove the brake booster.
- To install, tighten the new nuts to 23 Nm (17 lb-ft) in a clockwise pattern, starting with the lower left nut.

12. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch. This switch must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing this switch with the brake pedal in any other position will result in incorrect adjustment and may damage the switch.

To install, reverse the removal procedure.

13. Following the scan tool instructions, carry out the Multi-Calibration Routine. Principles of Operation