Vacuum Brake Booster: Service and Repair

REMOVAL
1. REMOVE MASTER CYLINDER
2. REMOVE TOOL BOX
3. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER





4. REMOVE 2 BRAKE LINES
Using SST, remove the 2 brake lines from the ABS actuator.
SST 09023-00100





5. REMOVE BRAKE BOOSTER
a. Using needle-nose pliers, remove the return spring and clip.
b. Remove the clevis pin and wave washer.
c. Remove the 4 nuts and clevis.
d. Pull out the brake booster and gasket.

INSTALLATION





1. INSTALL BRAKE BOOSTER
a. Install a new gasket and the brake booster with the 4 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install the clevis to the brake pedal with the wave washer, clevis pin and clip.
c. Using needle-nose pliers, 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. CONNECT VACUUM HOSE TO BRAKE BOOSTER





4. INSTALL BRAKE LINES
Using SST, install the 2 brake lines to the ABS actuator.
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
14 Nm (143 kgf-cm, 10 ft. lbs.) for use with SST

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 inch).

5. INSTALL MASTER CYLINDER
6. FILL RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
7. CHECK FOR FLUID LEAKAGE
8. CHECK AND ADJUST BRAKE PEDAL
9. DO OPERATIONAL CHECK
10. INSTALL TOOL BOX
11. INSTALL LUGGAGE COMPARTMENT TRIM BOX COVER