Brake booster ASSY (RHD model)
Components Inspection Removal / installation
BRAKE SYSTEM/PEDAL/BRAKE BOOSTER DEVICE
BRAKE BOOSTER ASSY (RHD MODEL)
EXPLODED VIEW
REMOVAL
1. Removal of front strut bar (Refer to 
)
)2. Removal of brake master cylinder SUB-ASSY (Refer to )
)3. Removal of seal SUB-ASSY (Refer to )
)4. Removal of side cover ASSY RH (Refer to )
)5. Removal of instrument panel under cover SUB-ASSY No.1 (Refer to )
)6. Removal of instrument panel under cover SUB-ASSY No.2 (Refer to )
)7. Removal of knee air bag module (Refer to )
)8. Removal of push rod clevis pin (Refer to )
)9. Removal of brake booster ASSY
(1) Release clamps shown in the figure.
(2) Displace the clamp, and disconnect the vacuum hose from the brake booster ASSY.
(3) Remove 4 nuts, and remove the brake booster ASSY.
CAUTION:
Do not apply excessive force to the brake tube on the engine room side.
(4) Remove the push rod clevis and lock nut.
10. Removal of brake booster gasket
(1) Remove the brake booster gasket.
INSTALLATION
1. Installation of brake booster gasket
(1) Install new brake booster gasket to the brake booster ASSY.
2. Installation of brake booster ASSY
(1) Temporarily attach the push rod clevis with a lock nut.
(2) Measure the length between the vacuum booster assembly mounting surface and clevis pin hole.
Standard value (A)
: 155.2 mm {6.11 in}
NOTE:
If it is not within the specification, loosen the lock nut, rotate the vacuum booster operating rod to perform adjustment.
(3) Tighten the lock nut securely.
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14.0ft·lbf}
(4) Install the brake booster ASSY with 4 nuts.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{14.0ft·lbf}
CAUTION:
Do not apply excessive force to the brake tube on the engine room side.
(5) Using the clamp, connect the vacuum hose.
3. Installation of front brake tube
(1) Engage each clamp, and install the front brake tube.
4. Installation of push rod pin (Refer to )
)5. Installation of knee air bag module (Refer to )
)6. Installation of instrument panel under cover SUB-ASSY No.2 (Refer to )
)7. Installation of instrument panel under cover SUB-ASSY No.1 (Refer to )
)8. Installation of instrument side panel RH (Refer to )
)9. Installation of brake master cylinder SUB-ASSY (Refer to )
)10. Installation of front strut bar (Refer to )
)11. Brake fluid refill (Refer to )
)12. Air bleeding of brake master cylinder SUB-ASSY (Refer to )
)13. Air bleeding of brake system (Refer to )
)14. Brake fluid leak check
15. Brake fluid level check (Refer to )
)16. Brake pedal height check/adjustment (Refer to )
)17. Brake pedal free play check (Refer to )
)18. Brake pedal clearance check (Refer to )
)UNIT INSPECTION
1. Brake vacuum check valve ASSY check
(1) Slide 2 clamps to remove the vacuum hose ASSY.
(2) Using vacuum gauge, check that there is a ventilation from the brake booster ASSY to the engine side. Also, check that there is no ventilation from the engine side to the brake booster ASSY side.
Captions in illustration
| *a |
Booster side |
| *b |
Engine side |
NOTE:
If it is faulty, replace the vacuum hose ASSY.
(3) Face the engine stamp to the engine side as shown in the figure, and then install it to the engine side.
Captions in illustration
| *1 |
Paint |
| *a |
Engine side |
| *b |
Booster side |
(4) Face the paint to the front side of the vehicle and install it to the brake booster side.
NOTE:
If the paint is worn off, check the ventilation and connect them so that there is a ventilation from the brake booster side to the engine side.
(5) Install the vacuum hose with 2 clamps.