Vacuum Brake Booster: Service and Repair
REPLACEMENT
NOTICE: Wash the brake fluid off immediately if it adheres to any painted surface
1. DRAIN BRAKE FLUID
2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
3. DISCONNECT CLUTCH RESERVOIR TUBE (M/T TRANSAXLE)
a. Slide the clip and disconnect the clutch reservoir tube.
4. REMOVE BRAKE MASTER CYLINDER
SST 09023-00101
5. REMOVE BATTERY
6. REMOVE BRAKE ACTUATOR WITH BRACKET
7. REMOVE BRAKE BOOSTER ASSEMBLY
a. Slide the clip and disconnect the vacuum hose from the brake booster assembly.
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 assembly and the gasket.
8. INSTALL BRAKE BOOSTER ASSEMBLY
a. Install the brake booster assembly and a new gasket.
b. Install the brake booster assembly 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 as follows.
e. Install the brake pedal return spring.
f. Connect the vacuum hose to the brake booster assembly and slide the clip.
9. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
NOTICE: Make an adjustment with the brake booster assembly having no 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-assembly is replaced with a new one. The adjustment is not necessary when the brake master cylinder sub-assembly is reinstalled and the brake booster assembly is replaced with a new one.
a. Apply the chalk to the tip of an accessory tool.
HINT: Then accessory tool is enclosed with a new brake master cylinder sub-assembly.
b. Place the accessory tool in the brake booster assembly.
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 a 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 on the tip of the brake booster push rod, the clearance is large.
d. If clearance is outside of the specified range, fix the push rod using SST and adjust the length of the protruding adjusting bolt.
SST 09737-00020
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 09023-00101
12. INSTALL CLUTCH RESERVOIR TUBE (M/T TRANSAXLE)
a. Slide the clip and connect the clutch reservoir tube.
13. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
14. INSTALL BATTERY
15. FILL RESERVOIR WITH BRAKE FLUID
16. BLEED MASTER CYLINDER
17. BLEED BRAKE LINE
18. BLEED CLUTCH 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 FOR BRAKE FLUID LEAKAGE
24. CHECK BRAKE ACTUATOR WITH HAND-HELD TESTER