Vacuum Brake Booster: Service and Repair

BRAKE BOOSTER ASSEMBLY
REPLACEMENT
1. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.

2. REMOVE FRONT WIPER ARM HEAD CAP
3. REMOVE FR WIPER ARM & BLADE ASSEMBLY LH
4. REMOVE FR WIPER ARM & BLADE ASSEMBLY RH
5. REMOVE HOOD TO COWL TOP SEAL
6. REMOVE COWL TOP VENTILATOR LOUVER LH
7. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSEMBLY
8. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER
9. REMOVE COWL WATER EXTRACT HOSE NO.1
10. REMOVE COWL BODY MOUNTING BRACKET LOWER LH
11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
12. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
SST 09023-00101
13. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
14. REMOVE FRONT WHEEL LH





15. REMOVE FRONT BRAKE TUBE NO.5
a. Using SST, disconnect the front brake tube No.5 and remove it.
SST 09023-00101





16. SEPARATE BRAKE TUBE
a. Separate the 3 brake tubes from the clamps shown in the illustration.
b. Remove the clamp from the brake tubes.





17. REMOVE BRAKE BOOSTER ASSEMBLY
a. Loosen the clevis lock nut and remove the push rod clevis from the brake booster assembly.
b. Slide the clip, disconnect the vacuum hose from the brake booster assembly.
c. Remove the 4 nuts and brake booster assembly.
d. Remove the check valve assembly and grommet from the brake booster assembly.
18. REMOVE BRAKE BOOSTER GASKET
19. INSTALL BRAKE BOOSTER GASKET
a. Install a new brake booster gasket to the brake booster assembly.





20. INSTALL BRAKE BOOSTER ASSEMBLY
a. Install the grommet and check valve assembly to the brake hooter assembly.
b. Install the brake booster assembly with the 4 nuts.
Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.)
c. Connect the vacuum hose to the brake booster assembly with the clip.
d. Install the push rod clevis and clevis lock nut to the brake hooter assembly.

HINT: After adjusting the brake pedal height, torque the clevis lock nut.





21. INSTALL BRAKE TUBE
a. Install the 3 brake tubes to the clamps shown in the illustration.
b. Install the clamp to the brake tubes.





22. INSTALL FRONT BRAKE TUBE NO.5
a. Using SST, connect the front brake tube No.5.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)

NOTICE: Make sure that the grommet is installed correctly.

23. INSTALL FRONT WHEEL LH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
24. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
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25. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
26. INSTALL COWL BODY MOUNTING BRACKET LOWER LH
27. INSTALL COWL WATER EXTRACT HOSE NO.1
28. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
29. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
30. FILL RESERVOIR WITH BRAKE FLUID
31. BLEED MASTER CYLINDER
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32. BLEED BRAKE LINE
33. CHECK AND ADJUST BRAKE PEDAL HEIGHT
34. CHECK PEDAL FREE PLAY
35. CHECK PEDAL RESERVE DISTANCE
36. CHECK FLUID LEVEL IN RESERVOIR
37. CHECK FOR BRAKE FLUID LEAKAGE
38. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSEMBLY
39. INSTALL COWL TOP VENTILATOR LOUVER LH
40. INSTALL HOOD TO COWL TOP SEAL
41. INSTALL FR WIPER ARM & BLADE ASSEMBLY RH
42. INSTALL FR WIPER ARM & BLADE ASSEMBLY LH
43. INSTALL FRONT WIPER ARM HEAD CAP
44. INSPECT BRAKE BOOSTER ASSEMBLY