Vacuum Brake Booster: Service and Repair

BRAKE BOOSTER

COMPONENTS:

REMOVAL
1. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.

2. REMOVE AIR CLEANER ASSEMBLY
3. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY





4. DISCONNECT VACUUM HOSE ASSEMBLY
(a) Slide the clip and disconnect the vacuum hose from the brake booster assembly.





5. REMOVE NO. 5 FRONT BRAKE LINE
(a) Using SST, remove the No. 5 front brake line.
SST 09023-00101
6. REMOVE FRONT DOOR SCUFF PLATE LH (for Coupe)
7. REMOVE FRONT DOOR SCUFF PLATE LH (for Convertible)
8. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (for Coupe)
9. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH (for Convertible)
10. REMOVE INSTRUMENT PANEL FINISH LOWER PANEL LH
11. REMOVE BRAKE PEDAL RETURN SPRING
12. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
13. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Loosen the push rod lock nut and remove the push rod clevis.





14. REMOVE BRAKE BOOSTER ASSEMBLY
(a) Remove the 4 nuts.
(b) Pull out the brake booster assembly.

NOTICE: Be careful not to damage the brake lines and the wire harness.

15. REMOVE BRAKE BOOSTER GASKET

INSTALLATION
1. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster.





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

NOTICE: Be careful not to damage the brake lines and the wire harness.

3. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Install the push rod clevis and the push rod lock nut.

HINT: After adjusting the brake pedal height, torque the lock nut.

4. INSTALL PUSH ROD PIN
5. INSTALL BRAKE PEDAL RETURN SPRING
6. INSTALL INSTRUMENT PANEL FINISH LOWER PANEL LH
(a) Install instrument panel finish lower panel LH.
7. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (for Coupe)
(a) Install cowl side trim sub-assembly LH.
8. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH (for Convertible)
(a) Install cowl side trim sub-assembly LH.
9. INSTALL FRONT DOOR SCUFF PLATE LH (for Coupe)
10. INSTALL FRONT DOOR SCUFF PLATE LH (for Convertible)





11. INSTALL NO. 5 FRONT BRAKE LINE
(a) Using SST, install the No. 5 front brake line.
SST 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





12. CONNECT VACUUM HOSE ASSEMBLY
(a) Connect the vacuum hose to the brake booster assembly and slide the clip.
13. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
14. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
15. FILL RESERVOIR WITH BRAKE FLUID
16. BLEED BRAKE MASTER CYLINDER
17. BLEED BRAKE LINE
18. INSTALL AIR CLEANER ASSEMBLY
19. CHECK FLUID LEVEL IN RESERVOIR
20. CHECK FOR FLUID LEAK
21. CHECK AND ADJUST BRAKE PEDAL HEIGHT