Overhaul

HYDRAULIC BRAKE BOOSTER

COMPONENTS:

DISASSEMBLY

1. SET HYDRAULIC BRAKE BOOSTER ASSEMBLY
a. Using SST, set the hydraulic brake booster in a vise.
SST 09630-00014 (09631-00142), 09950-60010 (09951-00180, 09951-00190)
2. REMOVE FLUID LEVEL WARNING SWITCH CONNECTOR CLAMP
a. Disconnect the connector.
b. Remove the bolt and clamp.
3. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
a. Remove the reservoir cap.
b. Remove the 3 screws and pull out the reservoir.
c. Remove the 3 grommets.
4. REMOVE MASTER CYLINDER PUSH ROD CLEVIS
a. Loosen the lock nut, then remove the clevis and lock nut.
5. REMOVE CYLINDER BOOT
a. Remove the cylinder boot.

6. REMOVE NO. 1 BRAKE ACTUATOR TUBE
a. Using SST, remove the actuator tube.
SST 09023-00101
7. REMOVE BRAKE BOOSTER PUMP ASSEMBLY
a. Remove the actuator hose.
b. Remove the 4 screws and wire harness from the booster pump.
c. Remove the 2 bolts and accumulator bracket.
d. Remove the 2 bolts and booster pump.
e. Remove the bolt and No. 1 pump bracket.
f. Remove the 2 washers, 2 cushions, 2 collars and sleeve.
g. Remove the 2 bolts and No. 2 pump bracket.
h. Remove the cushion from the No. 2 pump bracket.

8. REMOVE OIL PRESSURE SENSOR
a. Using a 30 mm deep socket, remove the oil pressure sensor.

9. REMOVE PISTON
a. Pressing the piston in with a screwdriver, use a pin or an equivalent to push the snap ring from the hole in the body then remove it with another screwdriver.
b. Remove the piston by pulling it straight out, not at an angle.

NOTICE: If pulling it out at an angle, there is a possibility that the cylinder bore could be damaged.

10. REMOVE BRAKE BOOSTER ACCUMULATOR ASSEMBLY
a. Using SST, remove the accumulator.
SST 09318-12010
b. Remove the silencer tube, spring and O-ring.

INSPECTION

1. CHECK HYDRAULIC BRAKE BOOSTER PUMP OPERATION
a. Connect the positive (+) lead from the battery to terminal 1 of the pump, and the negative (-) lead to terminal 2.
b. Check that the pump operates normally.

REASSEMBLY

1. INSTALL BRAKE BOOSTER ACCUMULATOR ASSEMBLY
a. Install the silencer, spring and a new O-ring.
b. Using SST, install the accumulator.
SST 09318-12010
Torque: 54 Nm (550 kgf-cm, 36 ft. lbs.)
2. INSTALL PISTON

NOTICE:
^ If the piston is installed at an angle, there is possibility that the cylinder bore could be damaged.
^ Be careful not to damage the rubber lips on the pistons.

3. INSTALL OIL PRESSURE SENSOR
a. Using a 30 mm deep socket, install the oil pressure sensor.
Torque: 81 Nm (830 kgf-cm, 60 ft. lbs.)

NOTICE: If replacing the pressure sensor, since the sensor is non-reusable, use a sensor of the supply part No. shown.
Part No.: 89637-30050

4. INSTALL BRAKE BOOSTER PUMP ASSEMBLY
a. Install the cushion to the No. 2 pump bracket.
b. Install the No. 2 pump bracket with the 2 bolts.
c. Install the 2 washers, 2 cushions, 2 collars and sleeve.
d. Install the No. 1 pump bracket with the bolt.
e. Install the booster pump with the 2 bolts.
f. Install the accumulator bracket with the 2 bolts.
1 When installing the accumulator bracket, adjust to secure the clearance as shown in the illustration.
A + B: 0.1 mm (0.161 inch) or less
C: 0.3 to 3.8 mm (0.012 to 0.150 inch)

HINT: Secure more than 0.3 mm (0.012 inch) clearance for A and B each.

g. Install the wire harness to the booster pump with the 4 screws.
h. Install the actuator hose.

5. INSTALL NO. 1 BRAKE ACTUATOR TUBE
a. Using SST, install the actuator tube.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) without SST
14 Nm (143 kgf-cm, 10 ft. lbs.) with SST

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 inch).

6. INSTALL CYLINDER BOOT
a. Install the cylinder boot.
7. INSTALL MASTER CYLINDER PUSH ROD CLEVIS
a. Install the clevis and lock nut.
b. Tighten the lock nut.
Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.)
8. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
a. Install the 3 grommets.
b. Install the reservoir with the 3 screws.
Torque: 1.7 Nm (17.5 kgf-cm, 15.2 inch lbs.)
c. Install the reservoir cap.
9. INSTALL FLUID LEVEL WARNING SWITCH CONNECTOR CLAMP
a. Install the clamp with the bolt.
b. Connect the connector.