Vacuum Brake Booster: Service and Repair

Brake Booster

Removal
All vehicles





1. Remove the brake booster push rod retaining clip.
^ Release the brake booster push rod retaining clip.
^ Remove the brake booster push rod retaining clip.





2. Disconnect the brake fluid low level warning indicator electrical connector.





3. Detach the brake fluid low level warning indicator wiring harness from the coolant expansion tank.





4. NOTE: Install blanking plugs to the cooling system vent hoses and the coolant expansion tank.

Detach the cooling system vent hoses from the coolant expansion tank.





5. Remove the coolant expansion tank retaining bolt.





6. Reposition the coolant expansion tank.
^ Detach the coolant expansion tank.
^ Reposition the coolant expansion tank.

Vehicles with 2.0L engine





1. Detach the cruise control cable.





2. Detach the throttle cable.
^ Reposition the throttle lever to the fully open position.
^ Detach the throttle cable.





3. Detach the Idle Air Control (IAC) valve wiring harness.





4. Detach the throttle cable retaining bracket.





5. Disconnect the speed control module electrical connector.





6. Remove the speed control module retaining bolt.





7. Reposition the speed control module.

Vehicles with manual transmission





1. CAUTION: If brake fluid is split on the paintwork, the affected area must be immediately washed down with cold water. Failure to follow this instruction may result in damage to the vehicle.

NOTE: Install blanking plugs to the clutch master cylinder feed hose and the brake fluid reservoir.

Detach the clutch master cylinder feed hose.

All vehicles





1. Detach the brake fluid supply tubes from the retaining clip.





2. Detach the brake master cylinder assembly from the brake booster.
^ Remove and discard the O-ring seal at the rear of the brake master cylinder.





3. Using a suitable cord, reposition the brake master cylinder assembly.





4. Detach the brake booster vacuum hose.





5. Detach the brake booster.
^ Remove the brake booster retaining nuts.





6. Remove the brake booster support bracket.





7. Remove the brake booster.

Installation
All vehicles





1. NOTE: Make sure the brake booster push rod is correctly aligned to the brake pedal.

NOTE: Do not install the brake booster retaining nuts at this stage.

Install the brake booster.





2. Install the brake booster support bracket.
^ Loosely install the brake booster support bracket retaining bolt.





3. Attach the brake booster.
^ Tighten to 25 Nm.





4. Tighten the brake booster support bracket retaining bolt.





5. Attach the brake booster vacuum hose.





6. NOTE: Install a new brake master cylinder to brake booster O-ring seal.

NOTE: Make sure the brake booster push rod is correctly aligned to the brake master cylinder assembly.

Attach the brake master cylinder assembly to the brake booster.
^ Tighten to 25 Nm.





7. Attach the brake fluid supply tubes to the retaining clip.

Vehicles with manual transmission





1. CAUTION: If brake fluid is split on the paintwork, the affected area must be immediately washed down with cold water. Failure to follow this instruction may result in damage to the vehicle.

NOTE: Remove the blanking plugs from the clutch master cylinder feed hose and the brake fluid reservoir.

Attach the clutch master cylinder feed hose.

Vehicles with 2.0L engine





1. Reposition the speed control module.





2. Install the speed control module retaining bolt.
^ Tighten to 4 Nm.





3. Connect the speed control module electrical connector.





4. Attach the throttle cable retaining bracket.





5. Attach the IAC valve wiring harness.





6. Attach the throttle cable.
^ Reposition the throttle lever to the fully open position.
^ Attach the throttle cable.





7. Attach the cruise control cable.

All vehicles





1. Attach the coolant expansion tank.
^ Reposition the coolant expansion tank.
^ Attach the coolant expansion tank.





2. Install the coolant expansion tank retaining bolt.
^ Tighten to 3 Nm.





3. NOTE: Remove the blanking plugs from the cooling system vent hoses and the coolant expansion tank.

Attach the cooling system vent hoses to the coolant expansion tank.





4. Attach the brake fluid low level warning indicator wiring harness to the coolant expansion tank.





5. Connect the brake fluid low level warning indicator electrical connector.





6. Install the brake booster push rod retaining clip.
7. Check and top up the cooling system as required.

Vehicles with manual transmission
1. Bleed the clutch system.