Vacuum Brake Booster: Service and Repair

BRAKE BOOSTER

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

REMOVAL





1. REMOVE BRAKE PEDAL RETURN SPRING
(a) Remove the brake pedal return spring.
2. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS





3. DISCONNECT NO. 2 VACUUM HOSE
(a) Move the clip and disconnect the No. 2 vacuum hose.
4. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

HINT: Refer to the procedures up to "REMOVE MASTER CYLINDER".





5. REMOVE BRAKE BOOSTER ASSEMBLY
(a) Remove the 4 nuts and the brake booster assembly.

NOTICE: Do not damage the brake lines.





6. REMOVE BRAKE BOOSTER GASKET
(a) Remove the brake booster gasket.
7. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Loosen the lock nut and remove the brake master cylinder push rod clevis.

INSTALLATION
1. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Temporarily install the lock nut and the brake master cylinder push rod clevis to the brake booster assembly.

NOTICE: Fully tighten the lock nut after adjusting the pedal height.

Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)





2. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket.





3. INSTALL BRAKE BOOSTER ASSEMBLY
(a) Install the brake booster assembly and the gasket with the 4 nuts.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)

NOTICE: Do not damage the brake lines.





4. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Apply lithium soap base glycol grease to the push rod pin.
(b) Connect the brake master cylinder push rod clevis to the brake pedal with the push rod pin and a new clip as shown in the illustration.





5. INSTALL BRAKE PEDAL RETURN SPRING
(a) Install the brake pedal return spring.
6. INSPECT AND ADJUST BRAKE PEDAL HEIGHT
7. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

HINT: Refer to the procedures up to "INSTALL BRAKE MASTER CYLINDER".





8. CONNECT NO. 2 VACUUM HOSE
(a) Connect the No. 2 vacuum hose and move the clip.