Vacuum Brake Booster: Service and Repair

REPLACEMENT
1. DRAIN BRAKE FLUID

NOTICE: Wash off the brake fluid immediately if it comes into contact with a painted surface.

2. REMOVE AIR CLEANER ASSY
3. REMOVE BRAKE MASTER CYLINDER SUB-ASSY
SST 09023-00100





4. DISCONNECT VACUUM HOSE ASSY
a. Remove the bolt and separate the vacuum hose from the vacuum hose bracket.
b. Slide the clip and disconnect the vacuum hose from the brake booster.
5. REMOVE FRONT DOOR SCUFF PLATE LH
6. REMOVE COWL SIDE TRIM SUB-ASSY LH
7. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER
8. REMOVE PUSH ROD PIN
a. Remove the clip and push rod pin.
9. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Loosen the lock nut and remove the push rod clevis.





10. REMOVE FRONT BRAKE TUBE NO. 5
a. Using SST and remove the front brake tube No. 5.
SST 09023-00100





11. REMOVE BRAKE BOOSTER ASSY
a. Remove the 4 nuts.
b. Pull out: the brake booster assy.
12. REMOVE BRAKE BOOSTER GASKET
13. INSTALL BRAKE BOOSTER GASKET
a. Install a new brake booster gasket to the brake booster.





14. INSTALL BRAKE BOOSTER ASSY
a. Install the brake booster with the 4 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)





15. INSTALL FRONT BRAKE TUBE NO. 5
a. Using SST and install the front brake tube No. 5.
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
SST 09023-00100
16. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Install the push rod clevis and lock nut.
17. INSTALL PUSH ROD PIN
a. Install the push rod pin and clip.

HINT: Apply the lithium soap base glycol grease to the part indicate by arrow.

18. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER
19. INSTALL COWL SIDE TRIM SUB-ASSY LH
20. INSTALL FRONT DOOR SCUFF PLATE LH





21. INSTALL VACUUM HOSE ASSY
a. Install the vacuum hose and vacuum hose bracket to the body with a bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
b. Connect the vacuum hose to the brake booster with the clip.

22. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
SST 09737-00012, 09737-00020
23. INSTALL BRAKE MASTER CYLINDER SUB-ASSY
SST 09023-00100
24. INSTALL AIR CLEANER ASSY
25. FILL RESERVOIR WITH BRAKE FLUID
26. BLEED MASTER CYLINDER
SST 09023-00100
27. BLEED BRAKE LINE
28. CHECK FLUID LEVEL IN RESERVOIR
29. CHECK BRAKE FLUID LEAKAGE
30. CHECK AND ADJUST BRAKE PEDAL HEIGHT