Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement

Removal Procedure

1. With the engine OFF, apply and release the brake pedal several times until the pedal becomes firm to deplete the power vacuum brake booster vacuum reserve.

2. Without draining the coolant and without disconnecting the hoses, remove and position aside the radiator surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.

3. Disconnect the brake pedal position sensor electrical connector. Refer to Brake Pedal Position Sensor Replacement .





4. Release the brake pedal (1) from the power vacuum brake booster pushrod by lifting the pedal upward.

Note:
Do not reuse the brake pedal retainer.

5. Remove and discard the brake pedal retainer.





6. Disconnect the power vacuum brake booster vacuum sensor electrical connector.

7. Release the power brake booster vacuum rear pipe from the retainer (1) on the dash panel.

8. Remove the power brake booster vacuum rear pipe and power brake booster vacuum sensor (2) from the power vacuum brake booster and position aside.

9. Disconnect the brake fluid level indicator switch electrical connector.

10. Remove the electronic brake and traction control module (EBTCM). Refer to Electronic Brake and Traction Control Module with Brake Pressure Modulator Valve Replacement Electronic Brake and Traction Control Module with Brake Pressure Modulator Valve Replacement.





11. Remove the master cylinder nuts (1).





12. Remove the master cylinder (1).

13. Inspect the master cylinder O-ring seal for damage and replace, if necessary.





14. Completely loosen the power vacuum brake booster bolts (1).





15. Remove the power vacuum brake booster (1).

16. Inspect the power vacuum brake booster gasket (2) for damage and replace, if necessary.

Installation Procedure





1. Install the power vacuum brake booster (1) and gasket (2).





Caution:
Refer to Fastener Caution Fastener Caution.

Note:
Do not over tighten the power vacuum brake booster bolts. If the power vacuum brake booster bolts are over tightened, the brake pedal may remain applied after a high pressure brake pedal application.

2. Install the power vacuum brake booster bolts (1) and tighten to 19 Nm (14 lb ft).





3. Install the master cylinder (1) to the power vacuum brake booster.





4. Install the master cylinder nuts (1) and tighten to 50 Nm (37 lb ft).

5. Connect the brake fluid level indicator switch electrical connector.

6. Install the EBTCM. Refer to Electronic Brake and Traction Control Module with Brake Pressure Modulator Valve Replacement Electronic Brake and Traction Control Module with Brake Pressure Modulator Valve Replacement.





7. Install the power brake booster vacuum rear pipe to the retainer (1) on the dash panel.

Note:
A small amount of denatured alcohol may be used as a lubricant to assist the installation of the power brake booster vacuum sensor.

8. Install the power brake booster vacuum rear pipe and power brake booster vacuum sensor (2) to the power vacuum brake booster.

9. Connect the power vacuum brake booster vacuum sensor electrical connector.





Note:
Install a new power vacuum brake booster pushrod retainer.

10. Install a new power vacuum brake booster pushrod retainer to the power vacuum brake booster pushrod.

Note:
Ensure the power vacuum brake booster pushrod retainer is fully seated in the brake pedal arm.

11. Connect the power vacuum brake booster pushrod retainer (1) to the brake pedal.

12. Connect the brake pedal position sensor electrical connector. Refer to Brake Pedal Position Sensor Replacement .

13. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.