Vacuum Brake Booster: Service and Repair

Brake Booster

Removal
1 Pump the brake pedal until the brake vacuum assistance is exhausted.




2 Remove the auxiliary battery cover.
- Release the 2 clips.
3 If installed, remove the auxiliary battery.




4 Detach the automatic transmission module bracket and position it to one side.
- Remove the 2 bolts.




5 Remove the auxiliary battery compartment side wall.
- Release the four clips.




6 Release the Air Conditioning (A/C) pipes.
- Remove the retaining screw.




7 Remove the auxiliary battery tray.
- Remove the 3 bolts.




8 Release the Anti-lock Brake System (ABS) module.
- Remove the 3 nuts.
- Release the brake tubes from the clip.
9 Disconnect the low brake fluid warning indicator switch electrical connector.

10
CAUTION: Brake fluid will damage paint finished surfaces. If spilled, immediately remove the fluid and clean the area with water.
Position an absorbent cloth to collect fluid spillage.





11 Disconnect the brake booster vacuum hose from the brake booster.





12
CAUTION: Make sure that excessive force is not used. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: Make sure the wings and trim panels are covered and protected, failure to follow this instruction may result in damage to the vehicle.
CAUTION: Make sure the brake pipes are not damaged when displacing the brake master cylinder and ABS module. Failure to follow this instruction may result in damage to the vehicle.
Displace the brake master cylinder and ABS module as a complete assembly.
- Remove the 2 nuts.
- Discard the master cylinder seals.





13 Remove the outer plenum base.
- Remove the 3 nuts.





14 Remove the driver side closing trim panel.
- Release the clip.
- Remove the 2 screws.
- Disconnect the electrical connector.





15
NOTE:
The cover is shown removed for clarity.
Remove the brake booster push rod clevis pin.
- Remove the retaining clip.





16 Remove the brake booster.
- Remove the 4 nuts.

Installation
1 Install the brake booster.
- Tighten the nuts to 23 Nm (17 lb.ft).
2 Install the brake booster push rod clevis pin.
- Install the retaining clip.
3 Connect the brake booster vacuum hose.
4 Install the outer plenum base.
- Carefully lift the anti-lock brake system modulator for access.
- Install the 3 nuts.
5
CAUTION: Make sure the master cylinder is correctly aligned.
NOTE:
Install new seals and nuts.
Install the the brake master cylinder and ABS module.
- Tighten the nuts to 23 Nm (17 lb.ft).
6 Secure the anti-lock brake system modulator.
- Install the 3 nuts.
- Secure the brake tubes to the clip.
7 Connect the low brake fluid warning indicator switch electrical connector.
8 Install the auxiliary battery tray.
- Install the 3 bolts.
9 Install the auxiliary battery compartment side wall.
- Secure with the four retaining clips.

10 Secure the A/C pipes.
- Install the retaining screw.

11 Secure the automatic transmission module bracket
- Install the 2 bolts.

12 If installed, install the auxiliary battery.

13
NOTE:
This step is to check the tightness of the retaining nuts after the initial tighten to make sure that torque has not relaxed.
Check the brake booster retaining nuts.
- Tighten the nuts to 23 Nm (17 lb.ft).

14 Install the closing trim panel.
- Connect the electrical connector.
- Secure the clip.
- Tighten the screws.

15 Start engine and check the brake booster operation.