Vacuum Brake Booster: Service and Repair
BRAKE BOOSTERCOMPONENTS:
REMOVAL
1. DRAIN BRAKE FLUID
NOTICE: Wash off brake fluid immediately if it comes in contact with any painted surface.
2. REMOVE FRONT WIPER ARM HEAD CAP
3. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH
4. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH
5. REMOVE HOOD TO COWL TOP SEAL
6. REMOVE COWL TOP VENTILATOR LOUVER LH
7. REMOVE WINDSHIELD WIPER MOTOR AND LINK
8. REMOVE OUTER COW TOP PANEL SUB-ASSEMBLY
9. REMOVE NO. 1 COWL WATER EXTRACT HOSE
10. REMOVE LOWER COWL BODY MOUNTING BRACKET LH
11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
12. REMOVE BRAKE MASTER CYLINDER SUBASSEMBLY
13. DISCONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS
14. REMOVE FRONT WHEEL LH
15. REMOVE NO. 5 FRONT BRAKE TUBE
a) Using SST, disconnect the No. 5 front brake tube and remove it.
SST 09023-00101
16. REMOVE BRAKE TUBE
a) Remove the 3 brake tubes from the clamps as 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 clevis from the brake booster.
b) Slide the clip and disconnect the vacuum hose from the brake booster.
c) Remove the 4 nuts and brake booster.
d) Remove the check valve and grommet from the brake booster.
18. REMOVE BRAKE BOOSTER GASKET
INSTALLATION
1. INSTALL BRAKE BOOSTER GASKET
a) Install a new gasket to the brake booster.
2. INSTALL BRAKE BOOSTER ASSEMBLY
a) Install the grommet and check valve to the brake booster.
b) Install the brake booster with the 4 nuts.
Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.)
c) Connect the vacuum hose to the brake booster with the clamp.
d) Install the push rod clevis and lock nut to the brake booster.
HINT: After adjusting the brake pedal height, torque the clevis lock nut.
3. INSTALL BRAKE TUBE
a) Install the 3 brake tubes to the clamps as shown in the illustration.
b) Install the clamp to the brake tubes.
4. CONNECT NO. 5 FRONT BRAKE TUBE
a) Using SST, connect the No. 5 front brake tube.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) without SST
14 Nm (143 kgf-cm, 10 ft. lbs.) with SST
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 inch).
NOTICE: Make sure that the grommet is installed correctly.
5. INSTALL FRONT WHEEL LH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
6. INSTALL BRAKE MASTER CYLINDER SUBASSEMBLY
7. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
8. INSTALL LOWER COWL BODY MOUNTING BRACKET LH
9. INSTALL NO. 1 COWL WATER EXTRACT HOSE
10. INSTALL OUTER COWL TOP PANEL SUBASSEMBLY
11. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS
12. FILL RESERVOIR WITH BRAKE FLUID
13. BLEED AIR FROM BRAKE MASTER CYLINDER
14. BLEED AIR FROM BRAKE LINE
15. CHECK AND ADJUST BRAKE PEDAL HEIGHT
16. CHECK BRAKE PEDAL FREE PLAY
17. CHECK BRAKE PEDAL RESERVE DISTANCE
18. CHECK BRAKE FLUID LEVEL IN RESERVOIR
19. CHECK FOR BRAKE FLUID LEAKAGE
20. INSTALL WINDSHIELD WIPER MOTOR AND LINK
21. INSTALL COWL TOP VENTILATOR LOUVER LH
22. INSTALL HOOD TO COWL TOP SEAL
23. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH
24. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH
25. INSTALL FRONT WIPER ARM HEAD CAP
26. CHECK BRAKE BOOSTER ASSEMBLY