Vacuum Brake Booster: Service and Repair

Vacuum Brake Booster Replacement

Removal Procedure

Caution: Refer to Brake Fluid Irritant Caution.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice.

1. Relieve fuel line pressure.
2. Drain the cooling system.
3. Remove the coolant recovery reservoir.
4. Remove the left front cross brace.
5. Remove the engine control module (ECM) cover from the air cleaner housing.
6. Remove the ECM and set aside. It is not necessary to disconnect the electrical connector.
7. Remove the air cleaner assembly.
8. Remove the fuel lines from the pipes and vapor line.
9. Remove the heater hose from the coolant cross over pipe and reposition out of the way.
10. Release the fuel lines from the shock tower for easier access to the brake pipes.
11. Disconnect the fluid level sensor switch from the brake master cylinder.
12. Disconnect the brake lines from the master cylinder and remove the master cylinder.
13. Remove the brake pressure modulator valve (BPMV) assembly and bracket.




14. Remove the brake booster vacuum hose from the vacuum brake booster check valve and position aside.
15. Remove the knee bolster.




16. Remove the booster push pin retaining clip and washer from the brake pedal assembly.
17. Remove the brake booster push rod (2) from the brake pedal (1).




18. Remove the brake booster mounting nuts.
19. Rotate the engine forward to gain access to the brake booster.
20. Remove the brake booster.

Installation 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. Position the brake booster to the cowl and the mounting plate.

Notice: Refer to Fastener Notice.

2. Install the brake booster mounting nuts.

Tighten the brake booster mounting nuts to 25 N.m (18 lb ft).

3. Install the master cylinder.




4. Install the brake booster push rod (2) to the brake pedal (1).
5. Install the washer and the brake booster pushrod retaining clip.

Notice: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear.

6. Calibrate the brake pedal position sensor.
7. Install the knee bolster.
8. Rotate the engine back and install the engine mounts, bolts, and nuts.




9. Install the brake booster vacuum hose to the vacuum brake booster check valve.
10. Install the BPMV and bracket assembly.
11. Install the brake master cylinder and connect the brake lines.
12. Connect the fluid level sensor switch on the master cylinder.
13. Install the fuel pipes to the pipes shock tower.
14. Install the heater hose to the coolant cross over pipe.
15. Install the air cleaner assembly.
16. Install the ECM.
17. Install the ECM cover.
18. Install the left front cross brace.
19. Install the coolant recovery reservoir.
20. Fill and bleed the cooling system.
21. Bleed the hydraulic brake system.