Hydraulic Brake Booster Pump: Service and Repair
Power Brake Booster Pump Replacement
Special Tools
CH-47830 - Holding Fixture
Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (Brake Fluid Effects on Paint and Electrical Components Caution).
Removal Procedure
1. Remove the brake master cylinder with power booster and control module assembly. Refer to Brake Master Cylinder with Power Brake Booster and Chassis Control Module Replacement (LHD) (Brake Master Cylinder with Power Brake Booster and Chassis Control Module Replacement).
2. Install the CH-47830 - Holding Fixture to the master cylinder assembly.
3. Position the CH-47830 - Holding Fixture with the master cylinder assembly in a vise.
4. Clean any dirt and debris from the power brake booster pump accumulator, inlet hose, and outlet pipe mounting areas.
5. If installing a new pump, remove the hydraulic brake booster accumulator. Refer to Power Brake Booster Pump Fluid Accumulator Replacement (without RPO BRM) (Power Brake Booster Pump Fluid Accumulator Replacement (without RPO BRM))Power Brake Booster Pump Fluid Accumulator Replacement (with RPO BRM) (Power Brake Booster Pump Fluid Accumulator Replacement (with RPO BRM)).
6. Remove the power brake booster inlet hose. Refer to Power Brake Booster Inlet Hose Replacement (Power Brake Booster Inlet Hose Replacement).
7. Remove the power brake booster outlet front pipe. Refer to Power Brake Booster Outlet Front Pipe Replacement (Power Brake Booster Outlet Front Pipe Replacement).
8. Remove the plugs (1) from the pump motor connector openings.
Note: Prior to disconnecting the power brake booster pump motor wiring harness from the electronic brake control module (EBCM), note the position the black negative wire and the red positive wire. The black negative wire is toward the front of the vehicle. The red positive wire is facing the rear of the vehicle.
9. Remove the power brake booster pump motor wire terminal retaining screws (2).
10. Remove the black negative wire (3) and the red positive wire (4) from the EBCM.
11. Remove the power brake booster pump bracket bolts (1).
12. Remove the power brake booster pump (2) from the mounting studs on the master cylinder.
Note: DO NOT reuse the pump damper retainer ring. Replace with a NEW retainer ring.
13. Remove the retainer ring (3) on the mounting bracket (4) by breaking the retaining ring.
14. Remove the mounting bracket (4).
15. If damaged, replace the dampers (5) and (6).
Installation Procedure
1. Install the dampers (5) and (6), to the pump bracket if removed.
2. Install the mounting bracket (4) to the pump (2).
3. Install a NEW damper retainer ring (3).
Ensure the retaining ring is fully seated.
4. Install the pump (2) to the mounting studs on the master cylinder.
Caution: Refer to Fastener Caution (Fastener Caution).
5. Install the pump bracket bolts (1) and tighten to 8 Nm (71 lb in).
Note: Ensure the positive and negative wires from the pump are installed in the correct location to the EBCM as noted prior to removal. The black negative wire is toward the front of the vehicle. The red positive wire is toward the rear of the vehicle.
6. Install the red positive wire (4).
7. Install the black negative wire (3).
8. Install the power brake booster pump motor wire retaining screws (2) and tighten to 3 Nm (27 lb in).
9. Install the plugs (1) to the EBCM pump motor connector openings.
10. Install the power brake booster outlet front pipe. Refer to Power Brake Booster Outlet Front Pipe Replacement (Power Brake Booster Outlet Front Pipe Replacement).
11. Install the power brake booster inlet hose. Refer to Power Brake Booster Inlet Hose Replacement (Power Brake Booster Inlet Hose Replacement).
12. If removed previously, install the hydraulic brake booster accumulator (1). Refer to Power Brake Booster Pump Fluid Accumulator Replacement (without RPO BRM) (Power Brake Booster Pump Fluid Accumulator Replacement (without RPO BRM))Power Brake Booster Pump Fluid Accumulator Replacement (with RPO BRM) (Power Brake Booster Pump Fluid Accumulator Replacement (with RPO BRM)).
13. Remove the CH-47830 - Holding Fixture from the master cylinder assembly.
14. Install the brake master cylinder with power booster and control module assembly. Refer to Brake Master Cylinder with Power Brake Booster and Chassis Control Module Replacement (LHD) (Brake Master Cylinder with Power Brake Booster and Chassis Control Module Replacement).