Vacuum Brake Booster: Service and Repair

REMOVAL
1. REMOVE AIR CLEANER COVER WITH AIR CLEANER HOSE
2. REMOVE MASTER CYLINDER
3. w/ VSC: REMOVE PRECHARGE PUMP ASSEMBLY
4. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER
5. REMOVE LOWER NO. 1 INSTRUMENT PANEL, LOWER LH INSTRUMENT PANEL INSERT AND NO. 2 HEATER TO REGISTER DUCT





6. REMOVE BRAKE BOOSTER ASSEMBLY
a. Remove the pedal return spring.
b. Remove the clip and clevis pin.
c. Remove the 4 nuts and clevis.
d. 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 (130 kgf-cm, 9 ft. lbs.)
d. Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin.
e. Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD





a. Set the SST on the master cylinder, and lower the pin until its tip slightly touches the piston.
SST 09737-00011





b. Turn the SST upside down, and set it on the booster.
SST 09737-00011
c. Measure the clearance between the booster push rod and pin head (SST).
Clearance: 0 mm (0 inch)





d. Using SST, adjust the booster push rod length until the push rod lightly touches the pin head.
SST 09737-00020
3. w/ VSC: INSTALL PRECHARGE PUMP ASSEMBLY
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 LEAKS
8. CHECK AND ADJUST BRAKE PEDAL
9. INSTALL NO.2 HEATER TO REGISTER DUCT, LOWER LH INSTRUMENT PANEL INSERT AND LOWER NO. 1 INSTRUMENT PANEL
10. DO OPERATIONAL CHECK