Vacuum Brake Booster: Service and Repair
REPLACEMENT
NOTICE: Wash the brake fluid off immediately if it adheres to any painted surfaces.
1. DRAIN BRAKE FLUID
NOTICE: Wash the brake fluid off immediately if it adheres to any painted surfaces.
2. REMOVE AIR CLEANER CAP SUB-ASSY
3. DISCONNECT CLUTCH RESERVOIR TUBE (M/T TRANSAXLE)
a. Slide the clip and disconnect the clutch reservoir tube.
4. REMOVE BRAKE MASTER CYLINDER
SST 09023-00100
5. REMOVE BATTERY
6. REMOVE BRAKE ACTUATOR WITH BRACKET
7. REMOVE BRAKE BOOSTER ASSY
a. Slide the clip and disconnect the vacuum hose from the brake booster assy.
b. Remove the brake pedal return spring, the clip and the clevis pin.
c. Loosen the push rod clevis lock nut.
d. Remove the 4 nuts and push rod clevis.
e. Pull out the brake booster assy and the gasket.
8. INSTALL BRAKE BOOSTER ASSY
a. Install the brake booster assy and a new gasket.
b. Install the brake booster assy with the 4 nuts and push rod clevis.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
c. Apply lithium soap base glycol grease to the clevis pin.
d. Install the clip and the clevis pin.
NOTICE: The direction for the clip installation is shown in the illustration.
e. Install the brake pedal return spring.
f. Slide the clip and connect the vacuum hose to the brake booster assy.
9. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
NOTICE: Adjust the brake booster assy w/o vacuum. (Depress the brake pedal several times with the engine stopped.)
HINT: Adjustment of the brake booster push rod is performed when the brake master cylinder sub-assy is replaced with a new one. The adjustment is not necessary when the brake master cylinder sub-assy is reinstalled and the brake booster assy is replaced with a new one.
a. Apply the chalk to the tip of the accessory tool.
HINT: The accessory tool is enclosed with a new brake master cylinder sub-assy.
b. Place the accessory tool on the brake booster assy.
c. Measure the clearance between the brake booster push rod and accessory tool.
Clearance: 0 mm (0 inch)
HINT: Adjust the clearance in the following cases:
^ If there is clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the clearance is too small.
^ If the chalk does not stick to the tip of the brake booster push rod, the clearance is too large.
d. If clearance is not within the specified range, fix the push rod using SST and adjust the length of the protruding adjusting bolt.
HINT: When adjusting the push rod, depress the brake pedal sufficiently so that the push rod sticks out.
10. INSTALL BRAKE ACTUATOR WITH BRACKET
11. INSTALL BRAKE MASTER CYLINDER
SST 09023-00100
12. INSTALL CLUTCH RESERVOIR TUBE (M/T TRANSAXLE)
a. Slide the clip and connect the clutch reservoir tube.
13. INSTALL AIR CLEANER CAP SUB-ASSY
14. INSTALL BATTERY
15. FILL RESERVOIR WITH BRAKE FLUID
16. BLEED MASTER CYLINDER
17. BLEED BRAKE LINE
18. BLEED CLUTCH PIPE LINE (M/T TRANSAXLE)
19. CHECK AND ADJUST BRAKE PEDAL HEIGHT
20. CHECK PEDAL FREE PLAY
21. CHECK PEDAL RESERVE DISTANCE
22. CHECK FLUID LEVEL IN RESERVOIR
23. CHECK BRAKE FLUID LEAKAGE
24. CHECK BRAKE ACTUATOR WITH HAND-HELD TESTER