Vacuum Brake Booster: Service and Repair

BRAKE BOOSTER

COMPONENTS (Part 1):

COMPONENTS (Part 2):

REMOVAL
1. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.

2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
3. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
(a) Remove the air cleaner element, then remove the 3 bolts and air cleaner case sub-assembly.
4. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
5. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
6. REMOVE FRONT WHEEL LH

7. REMOVE BRAKE BOOSTER ASSEMBLY
(a) Using SST, disconnect the front brake tube No. 5 and remove it.
SST 09023-00101
(b) Slide the clip and disconnect the vacuum hose from the brake booster assembly.

(d) Remove the 4 nuts and push rod clevis.
(e) Pull out the brake booster assembly.
(f) Remove the brake booster gasket from the brake booster assembly.
(g) Remove the check valve assembly and grommet from the brake booster assembly.

INSTALLATION
1. INSTALL BRAKE BOOSTER ASSEMBLY
(a) Install the grommet and check the valve assembly.
(b) Install a new brake booster gasket to the brake booster assembly.
(c) Install the push rod clevis and lock nut to the brake booster assembly.

HINT: After adjusting the brake pedal height, torque the lock nut.

(d) Install the brake booster assembly with the 4 nuts.
Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf)

(e) Install the 2 or 3 brake tubes to the clamp.
(f) Connect the vacuum hose to the brake booster assembly.

(g) Using SST, connect the front brake tube No. 5.
SST 09023-00101
Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf)

NOTICE: Make sure that the grommet is installed correctly.

2. INSTALL FRONT WHEEL LH
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
3. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS
4. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
5. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
(a) Install the air cleaner case with 3 bolts, then install the air cleaner element to the air cleaner case sub-assembly.
6. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
7. FILL RESERVOIR WITH BRAKE FLUID
(a) Fill the reservoir with brake fluid.
8. BLEED MASTER CYLINDER
(a) Bleed the master cylinder.
SST 09023-00101
9. BLEED BRAKE LINE
(a) Bleed the brake line.
10. CHECK AND ADJUST BRAKE PEDAL HEIGHT
(a) Check and adjust the brake pedal height.
11. CHECK PEDAL FREE PLAY
(a) Check the pedal free play.
12. CHECK PEDAL RESERVE DISTANCE
(a) Check the pedal reserve distance.
13. CHECK FLUID LEVEL IN RESERVOIR
(a) Check the fluid level in reservoir.
14. INSPECT FOR BRAKE FLUID LEAK
15. INSPECT BRAKE BOOSTER ASSEMBLY
(a) Inspect the brake booster assembly.