Vacuum Brake Booster: Service and Repair

Brake Booster
This is a "Trustmark Authoring Standards (TAS) Repair Procedure"
- TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
- TAS removal and installation procedures use a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.
- Many of the TAS procedures will have the installation information within the removal steps.
- The TAS color illustrations use a variety of symbols to indicate important details of the procedures. It is important to understand these symbols in order to properly used the TAS procedures.
Refer to How to Use TAS Procedures and TAS Symbol Glossary at Vehicle | Description and Operation for additional information on these TAS procedures.
For additional information, refer to How to Use TAS Procedures How to Use TAS Procedures

Removal

CAUTION: Extreme cleanliness must be exercised when handling these components.

CAUTION: If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.

All vehicles

WARNING: Make sure to support the vehicle with axle stands.
1 Raise and support the vehicle.
2 Disconnect the battery ground cable.
For additional information, refer to Specifications Vehicle Jump Starting
3 Remove the windshield wiper motor and linkage.
For additional information, refer to Windshield Wiper Motor Service and Repair
4 Remove the driver lower air bag module.
For additional information, refer to Driver Lower Air Bag Module Driver Lower Air Bag Module

Left-hand drive vehicles









All vehicles





CAUTION: Make sure that all openings are sealed.

Vehicles with manual transmission





CAUTION: Be prepared to collect escaping fluids.

CAUTION: Make sure that all openings are sealed.

Right-hand drive vehicles





CAUTION: Be prepared to collect escaping fluids.

CAUTION: Make sure that all openings are sealed.

Left-hand drive vehicles





CAUTION: Be prepared to collect escaping fluids.

CAUTION: Make sure that all openings are sealed.

All vehicles





CAUTION: The seal is to be reused unless damaged.





CAUTION: The seal is to be reused unless damaged.

Installation
All vehicles

CAUTION: Make sure that the mating faces are clean and free of foreign material.
1 Install the brake master cylinder.
Torque to: 26 Nm

CAUTION: Make sure that the mating faces are clean and free of foreign material.
2 Install the brake booster.
Torque to: 22 Nm

CAUTION: Make sure that the mating faces are clean and free of foreign material.
3 Install the brake fluid tubes.
Torque to: 15 Nm

Vehicles with manual transmission

CAUTION: Make sure that the mating faces are clean and free of foreign material.
4 Connect the clutch fluid line.

All vehicles
5 Connect the brake booster vacuum line.
6 Connect the low brake fluid warning indicator switch electrical connector.

Left-hand drive vehicles
7 Install the ECM bracket.
Torque to: 10 Nm
8 Install the ECM.

All vehicles
9 Install the driver lower air bag module.
For additional information, refer to Driver Lower Air Bag Module Driver Lower Air Bag Module

10 Install the windshield wiper motor and linkage.
For additional information, refer to Windshield Wiper Motor Service and Repair

11 Connect the battery ground cable.
For additional information, refer to Specifications Vehicle Jump Starting

12 Bleed the brake system.
For additional information, refer to Brake System Bleeding Service and Repair

Vehicles with manual transmission

13 Bleed the clutch system.
For additional information, refer to Clutch System Bleeding