Vacuum Brake Booster: Service and Repair

REMOVAL

CAUTION:
- Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately.
- Be careful not to deform or bend brake pipes, during removal of booster.

INSPECTION

Output Rod Length Check

Testing For Vacuum At Booster:

1. Apply vacuum of -66.7 kPa (-500 mm Hg, -19.69 in Hg) to brake booster with a hand vacuum pump.
2. Check output rod length.
Specified length: 10.275 - 10.525 mm (0.4045 - 0.4144 inch)

INSTALLATION

CAUTION:
- Be careful not to deform or bend brake pipes during installation of booster.
- Replace clevis pin if damaged.
- Refill with new brake fluid "DOT 3".
- Never reuse drained brake fluid.
- Take care not to damage brake booster mounting bolt thread when installing. Due to the narrow angle of installation, the threads can be damaged by the dash panel.





1. Before fitting booster, temporarily adjust clevis to dimension shown.





2. Fit booster, then secure mounting nuts (brake pedal bracket to brake booster) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts to 16 - 22 Nm (12 - 16 ft. lbs..
5. Install master cylinder.
6. Adjust brake pedal height and free play.
7. Secure lock nut for clevis to 16 - 22 Nm (12 - 16 ft. lbs..
8. Bleed air. Refer to Brake Fluid / Service and Repair / Bleeding Brake Fluid.