Vacuum Brake Booster: Service and Repair

REMOVAL





CAUTION: If external force "F" is applied from above when brake booster is placed in this position, the resin portion as indicated by "P", may be damaged.

1. Pull up parking brake lever, and block tires.
2. Disconnect ground cable from battery.
3. Remove or disconnect the following parts at engine compartment.
1. Disconnect connector for brake fluid level indicator.
2. Remove brake pipes from master cylinder.
3. Remove master cylinder installing nuts.
4. Disconnect vacuum hose from brake booster.
4. Remove the following parts from the pedal bracket.
1. Snap pin and clevis pin
2. Four brake booster installing nuts
5. Remove brake booster while shunning brake pipes.

NOTE:
^ Be careful not to drop brake booster. Brake booster should be discarded if it has been dropped.
^ Use special care when handling operating rod. If excessive force is applied to operating rod, sufficient to cause a change in the angle in excess of ±3°, it may result in damage to the power piston cylinder.
^ Use care when placing brake booster on the floor.





^ Do not change the push rod length. If it has been changed, reset the projected length "L" to the standard length.
Standard:
Without VDC L = 10 mm (0.39 inch)
With VDC L = 1.8 mm (0.071 inch)

INSTALLATION
1. Mount brake booster in position.





2. Connect operating rod to brake pedal with clevis pin and snap pin.





3. Connect vacuum hose to brake booster.
4. Mount master cylinder onto brake booster.
5. Connect brake pipes to master cylinder.
6. Connect electric connector for brake fluid level indicator.





7. Adjust operating rod of brake booster.
Standard: L 145.3 mm (5.72 inch)
If it is not in specified value, adjust it by adjusting brake booster operating rod.





8. Measure the clearance between threaded end of stop light and stopper.
If it is not in specified value, adjust it by adjusting position of stop light switch.

CAUTION: Be careful not to rotate stop light switch.

Stop light switch clearance: A 0.3 mm (0.012 inch)
9. Apply grease to operating rod connecting pin to prevent it from wearing.
10. Bleed air from brake system.
Tightening torque (Air bleeder screw): 8 Nm (0.8 kgf.m, 5.8 ft. lbs.)
11. Conduct road tests to ensure brakes do not drag.