Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement
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).

Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM.

Removal Procedure




1. Turn the ignition switch to the OFF position.
2. Without draining the cooling system or disconnecting the hoses, remove and position aside the radiator surge tank. Refer to Radiator Surge Tank Replacement (Radiator Surge Tank Replacement).
3. Clean the brake pressure modulator valve (BPMV) pipe fitting areas of any accumulated dirt and foreign material.
4. Disconnect the electrical connector from the electronic brake control module (EBCM).
5. Place a shop towel under the BPMV to catch any brake fluid loss.
6. Disconnect the RF brake pipe fitting (1).
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination.




7. Disconnect the LR brake pipe fitting (1).
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination.




8. Disconnect the RR brake pipe fitting (1).
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination.




9. Disconnect the LF brake pipe fitting (1).
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination.




10. Deplete the vacuum reserve from the vacuum brake booster by removing the vacuum check valve (1) from the vacuum brake booster grommet.




11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
12. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (Service and Repair).
13. Remove the 3 BPMV bracket nuts (1).
14. Lower the vehicle.




15. Remove the master cylinder nuts (1).
16. Remove the master cylinder and the EBCM/BPMV and bracket as an assembly from the vehicle.




17. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (Instrument Panel Insulator Replacement - Left Side).
18. Disconnect the brake pedal position sensor electrical connector.
19. Remove the 2 brake pedal assembly nuts.




20. Remove the brake pedal pushrod retainer clip (1).
21. Remove the wave washers (2) and disconnect the brake pedal pushrod (3) from the pedal pivot pin (4).
22. Tilt the vacuum brake booster upward slightly and remove the booster from the vehicle.
Do not apply excessive side pressure on the pushrod.

Installation Procedure




1. Maneuver the vacuum brake booster into position in the vehicle.

Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the (2) brake pedal assembly nuts and tighten to 15 Nm (11 lb ft).




3. Install the wave washers (2) and connect the brake pedal pushrod (3) to the pedal pivot pin (4).
Do not apply excessive side pressure on the pushrod.
4. Install the brake pedal pushrod retainer clip (1).
5. Connect the brake pedal position sensor electrical connector.
6. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (Instrument Panel Insulator Replacement - Left Side).




7. Inspect the seal on the master cylinder for damage and replace, if necessary.
Ensure the seal is properly positioned on the body of the master cylinder.
8. Install the master cylinder and the EBCM/BPMV and bracket assembly to the vehicle.
9. Install the master cylinder nuts (1) and tighten to 25 Nm (18 lb ft).




10. Raise and support the vehicle.
11. Install the 3 BPMV bracket nuts (1) and tighten to 10 Nm (89 lb in).
12. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (Service and Repair).
13. Lower the vehicle.




14. Install the vacuum check valve (1) to the vacuum brake booster grommet.
If necessary, a small amount of denatured alcohol may be used as a lubricant for assembly. Do not use soap.




15. Connect the LF brake pipe fitting (1) and tighten to 20 Nm (15 lb ft).




16. Connect the RR brake pipe fitting (1) and tighten to 20 Nm (15 lb ft).




17. Connect the LR brake pipe fitting (1) and tighten to 20 Nm (15 lb ft).




18. Connect the RF brake pipe fitting (1) and tighten to 20 Nm (15 lb ft).

Note: Ensure the electrical connector is correctly inserted into the EBCM prior to placing the locking lever into position. Failure to make a proper connection may cause communication problems with the module.

19. Connect the EBCM electrical connector.
20. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement (Radiator Surge Tank Replacement).
21. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Hydraulic Brake System Bleeding).
22. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration ().