Vacuum Brake Booster: Service and Repair

Brake Booster

Service Repair No - 70.50.01

Removal

All vehicles





1. Remove the driver side closing trim panel.
^ Release the clip.
^ Remove the 2 screws.
^ Disconnect the electrical connector.





2. Remove the instrument panel access panel.
^ Release the 2 screws.





3. Remove the brake pedal buffer.
^ Remove the 4 Torx screws.
^ Release the wiring harness clip.
4. Remove the brake booster push rod clevis pin.
^ Remove the retaining clip.
5. Remove the inner plenum base.

6. CAUTION: Brake fluid will damage paint finished surfaces. If spilled, immediately remove the fluid and clean the area with water.

Position an absorbent cloth to collect fluid spillage.





7. CAUTION: Before the disconnection or removal of any components, ensure the area around joint faces and connections are clean. Plug any open connections to prevent contamination.





Disconnect 2 brake tubes from the ABS module.

Vehicles with manual transmission





1. Disconnect the clutch master cylinder supply line.

All vehicles





1. Remove the 2 brake tubes from the master cylinder.
2. Disconnect the low brake fluid warning indicator switch electrical connector.
3. Disconnect the brake booster vacuum hose from the brake booster.
4. Remove the brake master cylinder.
^ Remove the 2 nuts.





5. Remove the brake booster.
^ Remove the 4 nuts.

Installation
All vehicles

1. Install the brake booster.
^ Tighten the nuts to 23 Nm (17 ft. lbs.).
2. Install the brake master cylinder.
^ Tighten the nuts to 26 Nm (19 ft. lbs.).
3. Connect the brake booster vacuum hose.

Vehicles with manual transmission
1. Connect the clutch master cylinder supply line.

All vehicles
1. Connect the low brake fluid warning indicator switch electrical connector.
2. Install the brake tubes.
^ Tighten the M12 brake pipe unions to 16 Nm (12 ft. lbs.).
^ Tighten the M14 brake pipe unions to 18 Nm (13 ft. lbs.).
3. Install the inner plenum base.
4. Install the brake booster push rod clevis pin.
^ Install a new retaining clip.
5. Install the brake pedal buffer.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
^ Secure the wiring harness clip.
6. Install the instrument panel access panel.
^ Secure the 2 screws.
7. Bleed the brake system using T4.
8. Install the closing trim panel.
^ Connect the electrical connector.
^ Secure the clip.
^ Tighten the screws.

Vehicles with manual transmission
1. Bleed the clutch system.