Brake Booster Assembly Onvehicle Inspection

1. OPERATING CHECK

(a) Depress the brake pedal several times with the engine oft and check that there is no change in the pedal reserve distance.

(b) Depress the brake pedai and start the engine. If the pedal goes down slightly, operation is normal.

2. AIR TIGHTNESS CHECK

(a) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly.

If the pedal goes down farthest the 1st time, but gradually rises after the 2nd or 3rd time, the booster is air tight.

(b) Depress the brake pedal white the engine is running, and stop the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is air tight.

COMPONENTS

Return Spring

Hold-down Cfamp

Battery Tray

Hold-down Cfamp

Battery Tray

Master Cylinder

Check Valve Bracket

Master Cylinder

Return Spring

25(260,19)

Clevis

Brake Booster

Clevis

25(260,19)

Brake Booster

Front LH Brake Line

Front LH Brake Line

19(195,14)

ABS Actuator Assembly

Clamp

19(195,14)

ECM Bracket f N m (kgf-cro, fHbf) | : Specified torque ♦ Non-reusable part

Lower No. 1 Panel

Finish Panel

Lower No. 1 Panel

Finish Panel

REMOVAL

1. REMOVE FRONT LH WHEEL Torque: 103 N m (1,050 kgfcm, 76 ft Ibt)

2. REMOVE MASTER CYLINDER (See page BR-10)

3. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER

REMOVE ABS ACTUATOR ASSEMBLY (See page BR-53)

5. REMOVE FRONT LH BRAKE LINE

(a) Using SST and spanner, disconnect the brake line from the flexible hose of front LH brake.

SST 09751-36011

(b) Puli out the brake line with the grommet from the body.

6. REMOVE BRAKE BOOSTER

(a) Remove the lower No. t panel and finish panel.

(b) Remove the return spring, clip and clevis pin.

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(c) Remove the clevis and 4 nuts.

(d) Pull out the brake booster and gasket.

(c) Remove the clevis and 4 nuts.

(d) Pull out the brake booster and gasket.

INSTALLATION

INSTALL BRAKE BOOSTER

Install a new gasket and brake booster with 4 nuts. Torque: 13 Nm (130 kgf-cm, 9 ftlbf) Install the clevis, and torque the lock nut-Torque: 25 N m (260 kgf-cm, 19 ft lbf) Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin. Install the pedal return spring. INSTALL FRONT LH BRAKE LINE Insert the brake line with the gromrnet into the body, and install the gromrnet to the body.

Using SST and spanner, connect the brake line to the flexible hose of front LH brake. SST 09751-36011 Torque: 15 N m (155 kgfcm, 11 ftlbf) w1 ABS:

INSTALL ABS ACTUATOR ASSEMBLY (See page BR-54)

When replacing the brake master cylinder only: ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD

Apply chalk to the tip of an accessory tool. Place the accessory tool to the brake booster. Measure the clearance between the brake booster push rod and accessory tool. Clearance; 0 mm (0 in.)

t the clearance in following cases: If there is a clearance between the accessory toot and the shell of the booster (floating accessory tool), the clearance is small.

If the chalk does not stick on the tip of the push rod. the clearance is large, (d) If the clearance is outside of the specified range, depress the brake pedal and adjust the length of the protruding push rod of the brake booster. NOTICE:

Make an adjustment with the booster having no vacuum. (Depress the brake pedal several times with the engine stopped.)

5. CONNECT VACUUM HOSE TO BRAKE BOOSTER

6. INSTALL MASTER CYLINDER (See page BR-12)

1. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR--4)

8. CHECK FOR FLUID LEAKAGE

9. CHECK AND ADJUST BRAKE PEDAL

(a) Check and adjust the brake pedal (See page BR-6).

(b) Install the finish panel and lower No. 1 panel.

10. DO OPERATIONAL CHECK (See page BR-13)

Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

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