Vacuum Brake Booster: Service and Repair
The content of this article reflects the changes called out by TSB - 02-05-22-003Vacuum Brake Booster Replacement
Removal Procedure
1. Remove the coolant reservoir.
2. Relieve fuel line pressure.
3. Remove cruise control module and cruise control bracket and set aside.
4. Remove the left front cross brace.
5. Remove the PCM cover from the air cleaner housing.
6. Remove the PCM and set aside. Not necessary to disconnect electrical.
7. Remove the air cleaner and the duct.
8. Remove the fuel lines from the pipes and the vapor line.
9. Disconnect fluid level sensor switch from the brake master cylinder.
10. Disconnect brake lines from the master cylinder and remove master cylinder.
11. Remove the vacuum hose from the vacuum check valve.
12. Unclip the wire harness from the ABS module bracket and disconnect the electrical connector at the ABS module.
13. Remove the brake lines from the ABS module.
14. Remove the ABS module and bracket.
Notice:
When disconnecting the push rod from the brake pedal, the brake pedal must be held stationary or damage to the brake may result.
15. Remove the booster push rod retaining clip and washer (2) from the brake pedal assembly.
16. Remove the brake booster push rod (2) from the brake pedal (1).
17. Remove the brake booster mounting nuts.
18. Remove the brake booster.
Installation Procedure
Caution:
When replacing the power booster brake, make sure that the cruise control cable is not routed between the booster and the cowl. If the cable is damaged or pinched, it must be replaced. Failure to do this could result in personal injury.
Notice:
Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear.
1. Install the brake booster and position to the cowl and the mounting plate.
Notice:
Refer to Fastener Notice in Service Precautions.
Install the brake booster mounting nuts.
Tighten the brake booster mounting nuts to 25 N.m (18 lb ft).
2. Install the brake booster push rod (2) to the brake pedal (1).
3. Install the brake booster rod retaining washer and clip to the brake pedal assembly.
4. Adjust the stop lamp switch.
5. Install ABS module bracket and module.
6. Connect the brake lines to the module.
7. Connect the electrical connector to the ABS module and clip the electrical harness to the bracket.
8. Install the vacuum hose to the check valve.
9. Install the brake master cylinder and connect the brake lines.
10. Connect fluid level sensor switch on the master cylinder.
11. Install the fuel lines to the pipes and the vapor line.
12. Install the air cleaner and duct assembly.
13. Install the PCM.
14. Install the PCM cover.
15. Install the left front cross brace.
16. Install the cruise control bracket and the cruise control module.
17. Install the coolant reservoir.
18. Bleed the brake system.