Vacuum Brake Booster: Service and Repair
VACUUM BOOSTERIMPORTANT: The vacuum booster and pushpin are a matched set. Boosters are measured during manufacturing and a pushpin of the correct length is selected and fitted to the booster. Boosters and pushpins are not interchangeable and must always be installed as a set.
REMOVAL
1. Disconnect negative battery cable.
2. Remove air cleaner from vehicle.
3. Disconnect positive battery cable from terminal.
4. Remove battery hold-down retaining nut and screw, and lift off battery hold-down retainer.
5. Lift the battery off vehicle, and place in a safe location.
NOTICE: On manual transaxle equipped vehicles, the clutch reservoir and bracket need to be removed and put aside.
6. Remove master cylinder-to-brake booster nuts.
NOTICE: Do not bend brake pipes.
7. Move master cylinder control assembly away from booster, far enough that brake booster can be removed.
8. Disconnect vacuum check valve and hose from booster.
9. Remove booster push rod retainer and washer.
10. Remove four nuts attaching vacuum booster to vehicle interior.
11. From under hood, remove booster; tilt booster to disengage push rod from brake pedal pin.
INSTALLATION
1. Position booster in vehicle. Do not install fasteners at this time.
2. Lubricate brake pedal push rod pin.
3. Install booster push rod onto brake pedal pushrod pin with retainer and washer.
4. Install four booster-to-body fasteners.
Torque: Booster-to-Body Nuts: 27 Nm (20 ft. lbs.)
5. Connect vacuum hose and check valve-to-booster.
NOTICE: Do not bend brake pipes. On manual transaxle equipped vehicles, install the clutch reservoir bracket prior to installing fasteners.
6. Position master cylinder onto brake booster studs and install fasteners.
Torque: Master Cylinder-to-Brake Booster Nut: 27 Nm (20 ft. lbs.)
NOTICE: Make sure battery tray is clean. Make sure that the battery cable ends are clean and free of corrosion. (Clean with a wire brush.) Make sure that the battery is in good physical condition (e.g., no cracks, or obvious damage) and that the terminals are clean.
7. Install battery carefully in the battery tray; make sure that the terminals do not short against any metal during the installation.
8. Install the battery hold-down retainer, locking the battery into the tray. Install and tighten the hold-down retainer nut and screw.
Torque: Battery Retainer Nut Screw: 9 Nm (80 inch lbs.)
9. Install the positive battery cable first.
Torque: Positive Battery Cable: 17 Nm (13 ft. lbs.)
10. Install the negative battery cable last.
Torque: Negative Battery Cable: 17 Nm (13 ft. lbs.)
11. Install air cleaner assembly in vehicle.
12. Check and adjust stop lamp switch.