Vacuum Brake Booster: Service and Repair

BRAKE BOOSTER

COMPONENTS:

REMOVAL
1. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH
2. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH
3. REMOVE COWL TOP VENTILATOR LOUVER
4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
5. REMOVE COWL TOP PANEL OUTER
(a) Remove the 4 bolts, 2 nuts and cowl top panel outer from the body.

6. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.

7. REMOVE AIR CLEANER ASSEMBLY
8. REMOVE BRAKE MASTER WITH PLATE CYLINDER SUB-ASSEMBLY
SST 09023-00101





9. DISCONNECT VACUUM HOSE ASSEMBLY
(a) Slide the clip and disconnect the vacuum hose from the brake booster assembly.





10. REMOVE FRONT BRAKE TUBE NO.5
(a) Using SST, remove front brake tube No.5.
SST 09023-00101

11. REMOVE FRONT DOOR SCUFF PLATE
12. REMOVE COWL SIDE TRIM SUB-ASSEMBLY
13. REMOVE INSTRUMENT SIDE PANEL
14. REMOVE INSTRUMENT PANEL FINISH LOWER PANEL
15. REMOVE INSTRUMENT PANEL AIR BAG ASSEMBLY LOWER NO.1





16. REMOVE BRAKE PEDAL RETURN SPRING
(a) Remove the brake pedal return spring.





17. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.





18. REMOVE BRAKE BOOSTER ASSEMBLY
(a) Remove the 4 nuts.
(b) Pull out the brake booster assembly.

NOTICE: Do not damage the brake tubes and the wire harness.

19. REMOVE BRAKE BOOSTER GASKET

INSTALLATION
1. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster.





2. INSTALL BRAKE BOOSTER ASSEMBLY
(a) Install the brake booster with the 4 nuts.
Torque: 13 N*m (130 kgf/cm, 9 ft. lbs.)

NOTICE: Do not damage the brake tubes and the wire harness.

3. INSTALL MASTER CYLINDER PUSH ROD CLEVIS
(a) Install the push rod clevis and the push rod lock nut.

HINT: After adjusting the brake pedal height, tighten the lock nut.

4. INSTALL PUSH ROD PIN
(a) Apply lithium soap base glycol grease to the parts indicated by arrows.
(b) Install the push rod pin and clip.

5. INSTALL BRAKE PEDAL RETURN SPRING
6. INSTALL INSTRUMENT PANEL AIR BAG ASSEMBLY LOWER NO.1
7. INSTALL INSTRUMENT PANEL FINISH LOWER PANEL
8. INSTALL INSTRUMENT SIDE PANEL
9. INSTALL COWL SIDE TRIM SUB-ASSEMBLY
10. INSTALL FRONT DOOR SCUFF PLATE





11. INSTALL FRONT BRAKE TUBE NO.5
(a) Using SST, install front brake tube No.5.
SST 09023-00101
Torque: 15 N*m (155 kgf/cm, 11 ft. lbs.)





12. CONNECT VACUUM HOSE ASSEMBLY
(a) Connect the vacuum hose to the brake booster assembly and install the clip.

13. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
SST 09737-00020
14. INSTALL BRAKE MASTER WITH PLATE CYLINDER SUB-ASSEMBLY
SST 09023-00101
15. FILL RESERVOIR WITH BRAKE FLUID
16. BLEED MASTER CYLINDER
17. BLEED BRAKE LINE
18. INSTALL AIR CLEANER ASSEMBLY
19. CHECK FLUID LEVEL IN RESERVOIR
20. INSPECT FOR FLUID LEAK
21. INSTALL COWL TOP PANEL OUTER
(a) Install the cowl top panel outer with the 4 bolts and nut.
Torque:
Nut 80 N*m (816 kgf/cm, 59 ft. lbs.)

22. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
23. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH
24. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH
25. CHECK AND ADJUST BRAKE PEDAL HEIGHT