Vacuum Brake Booster: Service and Repair

REMOVAL
1. REMOVE MASTER CYLINDER
2. REMOVE NO.1 UNDER COVER, NO.1 SAFETY PAD AND NO.2 HEATER TO REGISTER DUCT
3. REMOVE TILT AND TELESCOPIC ECU WITH POWER STEERING ECU
4. REMOVE CLIP AND RETURN SPRING
5. REMOVE CLEVIS PIN





6. REMOVE VACUUM HOSE
7. REMOVE BRAKE BOOSTER
a. Remove the 4 booster installation nuts and clevis.
b. Pull out the brake booster and gasket.

INSTALLATION
1. INSTALL BRAKE BOOSTER
a. Install the clevis to the operating rod.
b. Install the booster and a new gasket.
c. Install and torque the booster installation nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
d. Insert 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

NOTICE: When adjusting the length of the booster push rod, install 2 new gaskets to the master cylinder. When installing the master cylinder, remove one gasket before installing the master cylinder.

a. Install 2 new gaskets on the master cylinder.





b. Set SST on the gasket, and lower the pin until its tip slightly touches the piston.
SST 09737-00010





c. Turn the SST upside down, and set it on the booster.
SST 09737-00010
d. Measure the clearance between the booster push rod and pin head (SST).
Clearance: 0 mm (0 inch)
e. Adjust the booster push rod length until the push rod lightly touches the pin head.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
3. INSTALL THESE PARTS:
a. Tilt and telescopic ECU with power steering ECU
b. No.1 under cover, No.1 safety pad and No.2 heater to register duct
c. Vacuum hose
d. Master cylinder
4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
5. CHECK FOR FLUID LEAKAGE
6. CHECK AND ADJUST BRAKE PEDAL
7. DO OPERATIONAL CHECK