Vacuum Brake Booster: Service and Repair

Vacuum Brake Booster Replacement
Removal Procedure

Caution: Refer to Brake Fluid Irritant Caution in Service Precautions.

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

1. Relieve fuel line pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac-N-Fill).
3. Remove the coolant reservoir.
4. Remove the left front cross brace.
5. Remove the powertrain control module (PCM) cover from the air cleaner housing.
6. Remove the PCM and set aside. It is not necessary to disconnect the electrical connector.
7. Remove the air cleaner and the duct.
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. Unclip 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 ABS module and bracket.





14. Remove the brake booster vacuum hose from the vacuum brake booster check valve. Reposition the vacuum hose.
15. Remove the knee bolster.





16. Remove the booster push pin retaining clip and washer (2) 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. Remove the 2 front engine mounts, nuts, and bolts.
20. Rotate the engine forward to gain access to the brake booster removal.
21. 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.

2. Notice: Refer to Fastener Notice in Service Precautions.

Install the brake booster mounting nuts.
Tighten the brake booster mounting nuts to 25 Nm (18 ft. lbs.).
3. Install the master cylinder.





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

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

Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration.
6. Install the knee bolster.
7. Rotate the engine back and install the engine mounts, bolts, and nuts. Refer to Rotating the Engine for Service Access.





8. Install the brake booster vacuum hose to the vacuum brake booster check valve.
9. Install the ABS module bracket and module.
10. Install the brake master cylinder and connect the brake lines.
11. Connect the fluid level sensor switch on the master cylinder.
12. Install the fuel pipes to the pipes shock tower.
13. Install the heater hose to the coolant cross over pipe.
14. Install the air cleaner and duct.
15. Install the PCM.
16. Install the PCM cover.
17. Install the left front cross brace.
18. Install the coolant reservoir.
19. Fill and bleed the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac-N-Fill).
20. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure).