Vacuum Brake Booster: Service and Repair

Vacuum Brake Booster Replacement

Removal Procedure
1. Remove the fuel injector sight shield.
2. Remove the accelerator control cable and position the cable out of the way.
3. Remove the accelerator control cable bracket and position the cables out of the way.





4. Remove the cruise control module (1) and position out of the way.





5. Disconnect the electrical connector from the EGR valve (1).
6. Disconnect the engine harness clips (3)
7. Position the wiring harness (2) out of the way.





8. Disconnect the brake fluid level sensor wire connector (1).
9. Remove the master cylinder attaching nuts.
10. Remove the master cylinder from the booster. Carefully set the master cylinder aside.





11. Remove the vacuum booster check valve from the vacuum booster.
12. Remove the left insulator panel.
13. Remove the left knee bolster bracket.
14. Remove the steering column support mounting nuts.
15. Lower the steering column and support.
16. Disconnect the stoplamp/ABS/shift lock switch from the brake pedal assembly.
17. Disconnect the TCC/cruise control release switch from the brake pedal assembly.





18. Remove the vacuum brake booster pushrod retainer clip (3).
19. Remove the brake booster foam spacer (2)
20. Remove the booster pushrod (1) from the brake pedal.





21. Remove the booster attaching nuts (1) from the brake pedal assembly.





22. Remove the booster from the vehicle.
23. Remove the gasket.

Installation Procedure





1. Install the gasket to booster.
2. Install the booster to the vehicle.





3. Install the booster pushrod (1) to the brake pedal.
4. Install the booster pushrod spacer (2).
5. Install the booster pushrod retainer clip (3).

Notice: Refer to Fastener Notice in Service Precautions.





6. Install the booster attaching nuts (1) onto the booster studs.
^ Tighten the brake pedal to booster stud nuts to 23 Nm (17 ft. lbs.).
7. Connect the TCC/cruise control release switch to the brake pedal assembly.
8. Connect the stoplamp/ABS/shift lock switch to the brake pedal assembly.





9. Install the master cylinder onto the booster
10. Install the master cylinder attaching nuts.
^ Tighten the nuts to 25 Nm (18 ft. lbs.).
11. Install the steering column.
12. Install the left knee bolster bracket.
13. Install the left insulator panel.
14. Install the vacuum booster check valve to the vacuum booster.





15. Connect the brake fluid level sensor wire connector (1).





16. Connect the cruise control module (1).
17. Install the accelerator control cable bracket.
18. Install the accelerator control cable.





19. Connect the electrical connector to the EGR valve (1).
20. Connect the engine harness clips (3).
21. Install the fuel injector sight shield.