Brake Booster Removal and Installation

Brake Booster Removal and Installation

Master Cylinder and Brake Booster Components

NOTE:

Brake booster lose their original performance if it is disassembled and reassembled.

If the brake booster is found faulty, replace it rather than trying to disassemble and repair it.

Removal

1) Remove battery referring to Service and Repair Battery Removal and Installation.
2) Remove air cleaner assembly referring to Air Cleaner Assembly Removal and Installation Air Cleaner Assembly Removal and Installation.
3) Remove intake manifold referring to Intake Manifold Removal and Installation Intake Manifold Removal and Installation.
4) Remove master cylinder assembly from booster referring to Master Cylinder Removal and Installation Master Cylinder Removal and Installation.
5) Disconnect vacuum hose from booster referring to Master Cylinder and Brake Booster Components Master Cylinder and Brake Booster Components.
6) Remove the following brake pipes. Front Brake Hose and Pipe Removal and Installation
- Master cylinder primary to ABS (ESP(R)) hydraulic unit pipe
- Master cylinder secondary to ABS (ESP(R)) hydraulic unit pipe
- ABS (ESP(R)) hydraulic unit to left front brake pipe
7) Remove steering joint cover.
8) Remove clip (1) and then remove push rod clevis pin (2).
9) Loosen booster mounting nuts (3) and then remove booster.






Installation

Brake Booster Inspection
1) Install booster to dash panel. Then connect push rod clevis pin (2) and clip (1).
2) Tighten booster mounting nuts (3) to specified torque, and then install steering joint cover.

Tightening torque
Booster mounting nut (a): 13 Nm (1.3 kgf-m, 9.5 lbf-ft)





3) Connect vacuum hose to booster referring to Master Cylinder and Brake Booster Components Master Cylinder and Brake Booster Components.
4) Install the following brake pipes. Front Brake Hose and Pipe Removal and Installation
- Master cylinder primary to ABS (ESP(R)) hydraulic unit pipe
- Master cylinder secondary to ABS (ESP(R)) hydraulic unit pipe
- ABS (ESP(R)) hydraulic unit to left front brake pipe
5) Install master cylinder assembly to booster referring to Master Cylinder Removal and Installation Master Cylinder Removal and Installation.
6) Install intake manifold referring to Intake Manifold Removal and Installation Intake Manifold Removal and Installation.
7) Install air cleaner assembly referring to Air Cleaner Assembly Removal and Installation Air Cleaner Assembly Removal and Installation.
8) Install battery referring to Service and Repair Battery Removal and Installation.
9) Fill reservoir with specified fluid.
10) Bleed air from brake system referring to Service and Repair Air Bleeding of Brake System
and bleed air from clutch system referring to Service and Repair Air Bleeding of Clutch System
(M/T model).
11) Check pedal height and play referring to Brake Pedal Free Height Inspection Brake Pedal Free Height Inspection
and Brake Pedal Play Inspection Brake Pedal Play Inspection.
12) Check each installed part for fluid leakage and perform brake test.