Vacuum Brake Booster: Service and Repair

REMOVAL
1. Remove air cleaner cover with air cleaner hose.
2. Remove master cylinder.
3. Remove charcoal canister.
4. Disconnect vacuum hose from brake booster.
5. Remove pedal return spring.
6. Remove clip and clevis pin.

Removal Of Gasket And Clevis:

7. Remove brake booster, gasket and clevis.
Remove the 4 nuts and clevis. Pull out the brake booster and gasket.

INSTALLATION
1. Install brake booster.
a. Install the booster and a new gasket.
b. Install the clevis to the operating rod.
c. Install and torque the booster installation nuts.
Torque: 13 Nm (9 ft. lbs.)
d. Install the clevis, and torque the lock nut.
Torque: 25 Nm (19 ft. lbs.)
e. Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin.
f. Install the pedal return spring.

Length Of Booster Push Rod Adjustment:

2. Adjust length of booster push rod.
a. Install a new gasket on the master cylinder.
b. Set the Special Service Tool (SST) 09737-00010 or equivalent, on the gasket, and lower the pin until its tip slightly touches the piston.





c. Turn the SST 09737-00010 upside down, and set it on the booster.
d. Measure the clearance between the booster push rod and pin head (SST).
Clearance: 0 mm (0 inch)
e. Adjust the booster push rod length until the push rod lightly touches the pin head.
3. Install charcoal canister and bracket.
4. Install master cylinder.
5. Connect vacuum hose to brake booster.
6. Fill brake reservoir with brake fluid and bleed brake system.
7. Check for fluid leakage.
8. Check and adjust brake pedal.
9. Do operational check.