Operation CHARM: Car repair manuals for everyone.

II. Brake Booster Assembly Removal

CAUTION:
THE NEGATIVE BATTERY CABLE MUST BE DISCONNECTED FIRST TO PREVENT ARCING.





1. Disconnect battery cables.

2. Remove front air intake duct assembly and air cleaner assembly.

3. On vehicles equipped with an SOHC engine, remove air cleaner assembly support bracket from engine support bracket.

IMPORTANT:
Two of the battery tray support assembly bolts are located in the fenderwell.





4. Remove the battery shield, battery and battery tray support assembly.

5. Disconnect brake fluid level sensor connector.

6. If equipped with ABS, disconnect the two ABS solenoid connectors.





7. Remove two brake master cylinder nuts.

8. Remove positive battery cable clip attached to power brake booster assembly mounting stud.

NOTICE:
Do not bend/kink brake lines.

9. Move brake master cylinder away from power brake booster assembly, far enough that power brake booster assembly can be removed.

10. Disconnect vacuum hose and power brake booster check valve from power brake booster assembly. Remove power brake booster check valve from vacuum hose and discard.

11. Remove four power brake booster nuts attaching power brake booster assembly to body.

12. Remove brake pedal push rod retainer and washer from brake pedal, then remove power brake booster push rod from brake pedal pushrod pin.

NOTICE:
The power brake booster assembly and pushpin are a matched set. Power brake booster assemblies are measured during manufacture and a pushpin of the correct length is selected and fitted to the power brake booster assembly. Power brake boosters and pushpins are not interchangeable and must always be installed as a set.

13. Remove power brake booster assembly from vehicle.