Brake booster ASSY (LHD model)
Components Inspection Removal / installation
BRAKE SYSTEM/PEDAL/BRAKE BOOSTER DEVICE
BRAKE BOOSTER ASSY (LHD MODEL)
EXPLODED VIEW
REMOVAL
1. Removal of instrument side panel LH (Refer to 
)
)2. Removal of instrument panel under cover SUB-ASSY No.1 (Refer to )
)3. Removal of instrument panel under cover SUB-ASSY No.2 (Refer to )
)4. Removal of knee air bag module (Refer to )
)5. Removal of transmission control computer bracket (Refer to )
)6. Removal of brake master cylinder SUB-ASSY (Refer to )
)7. Disconnection of vacuum hose
(1) Slide the clip and disconnect the vacuum hose from the brake booster ASSY.
8. Removal of the brake tube front No. 1
(1) Using a flare-nut wrench, disconnect the brake tube front No. 1 from the brake actuator.
(2) Release 2 clips and remove the brake tube front No. 1.
9. Removal of the brake tube front No. 2
(1) Using a flare-nut wrench, disconnect the brake tube front No. 2 from the brake actuator.
(2) Release 2 clips and remove the brake tube front No. 2.
10. Removal of brake booster ASSY
(1) Remove 4 nuts.
(2) Remove the clip and push rod clevis pin, and disconnect the push rod clevis and brake pedal.
(3) Remove the brake booster ASSY.
INSTALLATION
1. 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}
{13.3ft·lbf}
2. Installation of brake tube front No. 2
(1) Engage 2 clips, and install the brake tube front No. 2.
(2) Using a flare-nut wrench, connect the brake tube front No. 2 to the brake actuator.
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14.0ft·lbf}
CAUTION:
·Do not bend or damage the brake tubes.
·When installing the brake tube, make sure that they are not twisted or bent.
·Do not let foreign matter including dirt and dust enter the brake tube.
·When installing the brake tube, make sure that they are not twisted or bent.
·Do not let foreign matter including dirt and dust enter the brake tube.
3. Installation of brake tube front No. 1
(1) Engage 2 clips, and install the brake tube front No. 1.
(2) Using a flare-nut wrench, connect the brake tube front No. 1 to the brake actuator.
CAUTION:
·Do not bend or damage the brake tubes.
·When installing the brake tube, make sure that they are not twisted or bent.
·Do not let foreign matter including dirt and dust enter the brake tube.
·When installing the brake tube, make sure that they are not twisted or bent.
·Do not let foreign matter including dirt and dust enter the brake tube.
4. Installation of vacuum hose
(1) Attach the vacuum hose with the clamp.
5. Installation of push rod clevis pin (Refer to )
)6. Installation of transmission control bracket (Refer to )
)7. Installation of knee air bag module (Refer to )
)8. Installation of instrument panel under cover SUB-ASSY No.2 (Refer to )
)9. Installation of instrument panel under cover SUB-ASSY No.1 (Refer to )
)10. Installation of instrument side panel LH (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.