Removal and Installation

BRAKE BOOSTER


Removal and Installation


COMPONENTS






CAUTION:
- Be careful not to deform or bend brake tube while removing and installing brake booster.
- Replace clevis pin if it is damaged.
- Be careful not to damage brake booster stud bolt threads. If brake booster is tilted during installation, the dash panel may damage the threads.

INSPECTION BEFORE REMOVAL

Air Tight

CAUTION:
Check the air tight condition when the master cylinder and the brake booster is installed.
1. With a handy vacuum pump, apply vacuum pressure of �66.7 kPa (�500 mmHg, �19.70 in Hg) to the brake booster.
2. If the air tight condition cannot be maintained, perform the following operation.
a. Check the no dirt and dust are present on the brake booster and brake master cylinder mating faces.
Clean it if necessary.
b. Check O-ring on the master cylinder. If anything is found, replace the O-ring.
c. Check the air tight condition again. If the condition still cannot be maintained, replace the brake booster.

REMOVAL
1. Remove cowl top. Refer to Locations.





2. Remove brake master cylinder. Refer to Removal and Replacement.
3. Disconnect front left brake tube from ABS actuator and electric unit (control unit). Refer to Diagrams.
4. Remove vacuum hose from brake booster. Refer to Component.
5. Remove snap pin and clevis pin from inside vehicle.
6. Remove nuts on brake booster and brake pedal assembly.
7. Remove brake booster from dash panel in engine room side.

INSTALLATION
1. Loosen lock nut to adjust input rod length so that length "B" (in the figure) satisfies the specified value.






Length "B" : 125 mm (4.92 in)

2. After adjusting "B", temporarily tighten lock nut to install booster assembly to vehicle. At this time, make sure that a gasket between booster assembly and dash panel is installed.

CAUTION:
Always install gasket between brake booster and dash panel.
3. Connect brake pedal with clevis of input rod.
4. Install brake pedal bracket mounting nuts and bolt, and tighten them to the specified torque. Refer to Removal and Replacement.
5. Install vacuum hose into brake booster. Refer to Removal and Installation.
6. Install master cylinder to brake booster. Refer to Removal and Replacement.
7. Adjust the brake pedal height and the play of the brake pedal. Refer to Procedures.
8. Tighten lock nut of input rod to the specified torque. Refer to "COMPONENTS".
9. Connect front left brake tube to ABS actuator and electric unit (control unit). Refer to Diagrams.
10. Install cowl top. Refer to Locations.
11. Refill new brake fluid and bleed air. Refer to Service and Repair.