Vacuum Brake Booster: Service and Repair
Part 1 Of 2:
Part 2 Of 2:
REMOVAL
1. REMOVE FRONT LH WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
2. REMOVE MASTER CYLINDER
3. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER
4. w/ ABS: REMOVE ABS ACTUATOR ASSEMBLY
5. REMOVE FRONT LH BRAKE LINE
a. Using SST and spanner, disconnect the brake line from the flexible hose of front LH brake.
SST 09751-36011
b. Pull out the brake line with the grommet from the body.
6. REMOVE BRAKE BOOSTER
a. Remove the lower No. 1 panel and finish panel.
b. Remove the return spring, clip and clevis pin.
c. Remove the clevis and 4 nuts.
d. Pull out the brake booster and gasket.
INSTALLATION
1. INSTALL BRAKE BOOSTER
a. Install a new gasket and brake booster with 4 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install the clevis, and torque the lock nut.
Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.)
c. Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin.
d. Install the pedal return spring.
2. INSTALL FRONT LH BRAKE LINE
a. Insert the brake line with the grommet into the body, and install the grommet to the body.
b. Using SST and spanner, connect the brake line to the flexible hose of front LH brake.
SST 09751-36011
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
3. w/ ABS: INSTALL ABS ACTUATOR ASSEMBLY
4. When replacing the brake master cylinder only: ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD
a. Apply chalk to the tip of an accessory tool.
b. Place the accessory tool to the brake booster.
c. Measure the clearance between the brake booster push rod and accessory tool.
Clearance: 0 mm (0 inch)
HINT: Adjust the clearance in following cases:
^ If there is a clearance between the accessory tool and the shell of the booster pleating accessory tool), the clearance is small.
^ If the chalk does not stick on the tip of the push rod, the clearance is large.
d. If the clearance is outside of the specified range, depress the brake pedal and adjust the length of the protruding push rod of the brake booster.
NOTICE: Make an adjustment with the booster having no vacuum. (Depress the brake pedal several times with the engine stopped.)
5. CONNECT VACUUM HOSE TO BRAKE BOOSTER
6. INSTALL MASTER CYLINDER
7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
8. CHECK FOR FLUID LEAKAGE
9. CHECK AND ADJUST BRAKE PEDAL
a. Check and adjust the brake pedal.
b. Install the finish panel and lower No. 1 panel.
10. DO OPERATIONAL CHECK