Vacuum Brake Booster: Service and Repair

Brake Booster





Removal and Installation

All vehicles
1. Remove the hydraulic control unit (HCU).
2. Disconnect the speed control actuator electrical connector.
3. Remove the speed control actuator bolts and position the actuator aside.
^ To install, tighten to 9 Nm (80 inch lbs.).

PZEV vehicles
4. Remove the evaporative emission canister purge valve.

All vehicles
5. Disconnect the heater hose bracket pin-type retainer from the cowl.





6. Remove the brake master cylinder.
7. Disconnect the electrical connectors and twist to remove the switches.
1 Speed control deactivation switch (if equipped).
2 Stop lamp switch.
3 Clutch pedal position (CPP) switch (manual transmission vehicles).





8. Disconnect the brake booster actuating rod from the brake pedal.
1 Apply the brake pedal.
2 Disengage the tab.
3 Remove and discard the brake booster actuating rod pin.





9. Remove the brake booster retaining nuts.
^ To install, tighten to 23 Nm (17 ft. lbs.).

10. CAUTION: Install a new brake booster actuating rod pin.

Remove the brake booster.

11. CAUTION: Make sure that the brake booster actuator rod is correctly positioned through the bulkhead rubber boot.

CAUTION: Make sure the brake booster gasket is correctly positioned on the brake booster before installation.

To install, reverse the removal procedure.
12. Bleed the brake system.