Toyota Celica 1986-1993 Repair Guide

Power Brake Booster

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REMOVAL & INSTALLATION





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Fig. Fig. 1 Removing brake power booster1986-89 Celica shown



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Fig. Fig. 2 Removing brake power booster1990-93 Celica shown



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Fig. Fig. 3 Adjusting brake power booster rod lengthCelica


CAUTION
On vehicles equipped with an air bag system, work must be started at least 90 seconds after the ignition switch is turned to the lock position and the negative battery cable is disconnected.


WARNING
Before the brake booster is reinstalled, the brake booster pushrod must be adjusted so that there is zero clearance between it and the master cylinder. This adjustment requires the use of factory special tool SST No. 09737-00010 or its equivalent.

  1. If necessary, remove the instrument lower finish panel, air duct and floor mats to gain access to the brake booster linkage.
  2.  
  3. Remove the master cylinder from the vehicle.
  4.  
  5. Loosen the hose clamp and disconnect the vacuum hose from the booster.
  6.  
  7. Disconnect the electrical connector from the brake light switch.
  8.  
  9. From inside the passenger compartment, remove the pedal return spring, clip and the clevis pin with the locknut. Remove the four mounting nuts and the clevis.
  10.  
  11. Pull the booster and gasket from the fire wall.
  12.  

To install:

  1. Adjust the length of the brake booster push rod as follows:
    1. Set the special tool on the master cylinder with the gasket and lower the pin of the tool until it lightly contacts the piston.
    2.  
    3. Turn the special tool upside-down and position it onto the booster.
    4.  
    5. Measure the clearance between the booster push rod and the pin head of the tool. There must be zero clearance.
    6.  
    7. To obtain zero clearance, adjust the push rod length until the push rod lightly contacts the head of the pin.
    8.  

  2.  
  3. Connect the clevis pin with locknut to the booster and install the brake booster with a new gasket.
  4.  
  5. Install the mounting nuts and torque them to 9 ft. lbs. (13 Nm).
  6.  
  7. Insert the clevis pin through the clevis and the brake pedal. Secure the pin with the retaining clip.
  8.  
  9. Install the pedal return spring.
  10.  
  11. Install the instrument lower finish panel and air duct.
  12.  
  13. Install the master cylinder and connect the vacuum hose.
  14.  
  15. Fill the brake fluid reservoir to the proper level with clean brake fluid and bleed the master cylinder as described in this Section.
  16.  
  17. Check for leaks. Check and/or adjust the brake pedal.
  18.  
  19. Perform a brake booster operational check and air tightness check as detailed below.
  20.  

OPERATIONAL CHECKS




WARNING
If one is available to you, the use of a brake booster tester is recommended to test the operation of the booster. All vacuum leaks must be repaired, before testing the brake booster.

To perform the operational check, depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. Depress the brake pedal and start the engine. If the pedal goes down a small amount, the booster is functioning normally.

To perform the air tightness check, start the engine and stop it after one or two minutes. Depress the brake pedal slowly several times. If the pedal goes furthest the first time but rises each consecutive time, the booster is air tight. Start the engine again and stop it with the brake pedal depressed. If the pedal reserve travel does not change with the brake pedal held for thirty seconds, the booster is air tight.

 
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