Orlando

Power Brake Booster Replacement — Left Hand Drive

Special Tools

CH-558-10 Closure Cap

For equivalent regional tools, refer to Special Tools .

Warning: Refer to Brake Fluid Irritant Warning in the Preface section.

Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface section.

1. Turn the ignition to the OFF position.
2. Remove battery tray. Refer to Battery Tray Replacement .
3. Remove dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement .




Note: Do NOT disconnect engine coolant hoses.

4. Remove the radiator surge tank clip (2).
5. Remove the radiator surge tank (1).

Position the radiator surge tank (1) aside.




6. Remove the brake fluid reservoir cap and install CH-558-10 cap (1) in order to prevent fluid loss and contamination.

Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM.

7. Disconnect the electrical connector from the EBCM/EBTCM.




Note: Cap the brake pipe fittings to prevent brake fluid loss and contamination.

8. Remove the 6 brake pipes (1, 2) from the BPMV.




Note: Cap the brake pipe fittings to prevent brake fluid loss and contamination.

9. Disconnect the master cylinder secondary brake pipe fitting (1).




Note: Cap the brake pipe fittings to prevent brake fluid loss and contamination.

10. Disconnect the master cylinder primary brake pipe fitting (1).



11. Remove the BPMV bracket bolts (2).
12. Remove the BPMV bracket assembly (1).
13. Remove the brake master cylinder assembly from the booster. Refer to Master Cylinder Replacement : Left Hand Drive .



14. Remove the booster vacuum pipe (1) from the booster.



15. Disconnect the brake pedal pushrod (1) from the brake pedal.



16. Replace click fit connector (1) between servo pushrod and brake pedal with NEW part.



17. Remove the brake booster bolts (1).
18. Remove the booster from the vehicle.

1. Install the booster to the vehicle.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the brake servo unit bolts (1) and tighten to 19 N·m (14 lb ft).



3. Connect the brake pedal pushrod (1) to the brake pedal.



4. Install the booster vacuum pipe (1) to the booster.
5. Install the master cylinder assembly to the booster. Refer to  Master Cylinder Replacement : Left Hand Drive .



6. Install the BPMV bracket assembly (1).
7. Install the BPMV bracket bolts (2) and tighten to 20 N·m (15 lb ft).



8. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 N·m (13 lb ft).



9. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 N·m (13 lb ft).




Note: Cap the brake pipe fittings to prevent brake fluid loss and contamination.

10. Install the 6 brake pipes (1, 2) to the BPMV and tighten to 18 N·m (13 lb ft).
11. Connect the electrical connector with to the EBCM/EBTCM.



12. Remove the CH-558-10 cap (1) and install the brake fluid reservoir cap.



13. Install the radiator surge tank (1).
14. Install the radiator surge tank clip (2).
15. Install the battery tray. Refer to Battery Tray Replacement .
16. Install dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement .
17. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .