Vacuum Brake Booster: Service and Repair

BRAKE BOOSTER

COMPONENTS:

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. DRAIN BRAKE FLUID

NOTICE: Wash off brake fluid immediately if it comes in contact with any painted surface.

3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
4. DISCONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle)
a) Slide the clip and disconnect the clutch reservoir tube.
5. REMOVE BRAKE MASTER CYLINDER SUBASSEMBLY
a) Remove the brake master cylinder.
6. REMOVE BATTERY
7. REMOVE BRAKE ACTUATOR ASSEMBLY WITH BRACKET
a) Remove the brake actuator with bracket.

8. REMOVE BRAKE BOOSTER ASSEMBLY
a) Slide the clip and disconnect the vacuum hose from the brake booster.

b) Remove the brake pedal return spring, clip and 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 and gasket.

INSTALLATION

1. INSTALL BRAKE BOOSTER ASSEMBLY
a) Install the brake booster and a new gasket.
b) Install the booster and a new gasket with the 4 nuts.
Torque: 13 Nm (127 kgf-cm, 9 ft. lbs.)
c) Install the push rod clevis to the booster.

d) Apply lithium soap base glycol grease to the clevis pin.
e) Install the clip and clevis pin.

NOTICE: The clip must be installed as shown in the illustration.

f) Install the brake pedal return spring.

g) Connect the vacuum hose to the brake booster and slide the clip.
2. CHECK AND ADJUST BRAKE BOOSTER PUSH ROD
3. INSTALL BRAKE ACTUATOR ASSEMBLY WITH BRACKET
4. INSTALL BRAKE MASTER CYLINDER SUBASSEMBLY
5. CONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle)
a) Slide the clip and connect the clutch reservoir tube.
6. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
7. INSTALL BATTERY
8. FILL RESERVOIR WITH BRAKE FLUID
9. BLEED AIR FROM BRAKE MASTER CYLINDER
10. BLEED AIR FROM BRAKE LINE
11. BLEED AIR FROM CLUTCH LINE (for Manual Transaxle)
12. CHECK AND ADJUST BRAKE PEDAL HEIGHT
13. CHECK BRAKE PEDAL FREE PLAY
14. CHECK BRAKE PEDAL RESERVE DISTANCE
15. CHECK BRAKE FLUID LEVEL IN RESERVOIR
16. CHECK FOR BRAKE FLUID LEAKAGE
17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
18. CHECK BRAKE ACTUATOR WITH INTELLIGENT TESTER
a) Check the brake actuator with the intelligent tester.
19. PERFORM INITIALIZATION
a) Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.