Vacuum Brake Booster: Service and Repair

Vacuum Brake Booster Replacement

^ Tools Required
- J 22805-B Power Brake Booster Holder

Removal Procedure

Caution: When replacing the power booster brake, make sure that the cruise control cable is not routed between the booster and the cowl. If the cable is damaged or pinched, it must be replaced. Failure to do this could result in personal injury.





1. Remove the left instrument panel insulator.
2. Disconnect the stoplamp switch electrical connector from the stoplamp switch.
3. Remove the retaining clip and disconnect the brake booster pushrod from the brake pedal.
4. Remove the cross vehicle brace.
5. Remove the fuel injector sight shield.
6. Disconnect the brake fluid level sensor electrical connector from the brake fluid level sensor.

Important: It is not necessary to disconnect the brake pipes from the master cylinder to the Brake Pressure Modulator Valve.

7. Remove the two master cylinder retaining nuts and position the master cylinder aside.
8. Disconnect the vacuum brake booster check valve from the brake booster. Position aside the vacuum hose and the check valve as an assembly.





9. Disconnect the throttle and cruise control cables from the throttle body.
10. Remove the throttle bracket, throttle cable, and the cruise control cable from the throttle body as an assembly. Position the throttle bracket and cables aside.
11. Rotate the engine forward for service access.
12. Remove the EGR valve wiring harness heat shield.
13. Remove the EGR valve.
14. Remove the transmission fluid filler tube bracket retainer and position the filler tube aside.





15. Attach the J22805-B to the booster using the master cylinder retaining nuts.
16. Unlock the booster from the front of the cowl.
Use a flat bladed tool to depress the brake booster locking tab (1) out of the cowl mounting flange, while turning the booster counterclockwise with a ratchet on the J22805-B (2).
17. Remove the vacuum brake booster.

Installation Procedure

Notice: Internal components of this booster are not serviceable. The housing must not be unstaked and separated. Separating the housing will cause permanent deformation, preventing the booster from holding proper volume.

Notice: Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged.





1. Install the vacuum brake booster.
Position the vacuum brake booster on the cowl counterclockwise from the final installation position so that the locking flanges on the vacuum brake booster and on the cowl mounting flange engage.

Important: Ensure that the locking tab and the flanges are in the fully engaged position.

2. Turn the vacuum brake booster clockwise with a ratchet on the J 22805-B (2). DO NOT use a flat bladed tool in the locking tab to install the vacuum brake booster. When the vacuum brake booster is correctly installed, the locking tab (1) slides up the flange and engages the locking notch.
3. Remove the J22805-B (2) from the installed vacuum brake booster.





4. Install the transmission fluid filler tube bracket retainer and reposition the filler tube.
5. Install the EGR valve.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the EGR valve wiring harness heat shield.
^ Tighten the EGR valve wiring harness heat shield nut and bolt to 10 Nm (89 inch lbs.).
7. Return the engine to the original rest position. Install the left and right engine mount struts.
8. Reposition the throttle bracket and cables to the throttle body. Install the throttle bracket, throttle cable, and the cruise control cable assembly to the throttle body.
9. Connect the throttle and cruise control cables to the throttle body.





10. Reposition and connect the vacuum hose and check valve assembly to the booster.
11. Reposition the master cylinder onto the booster and install the master cylinder retaining nuts.
^ Tighten the nuts to 25 Nm (18 ft. lbs.).
12. Connect the brake fluid level sensor electrical connector to the brake fluid level sensor.





13. Install the fuel injector sight shield.
14. Install the cross vehicle brace.
15. Connect the brake booster pushrod to the brake pedal and install the retaining clip.
16. Connect the stoplamp switch electrical connector to the stoplamp switch.
17. Install the left instrument panel insulator.