Q: How to Perform an Operating Check, Airtightness Check, and replacement of a Power Brake Booster?
A: Operating check involves depressing the brake pedal several times with the engine off and ensuring there's no change in the pedal reserve distance. Depress the pedal and start the engine. If the pedal goes down slightly, operation is normal. For airtightness check, start the engine and turn it off after one or two minutes. Depress the brake pedal slowly several times. If the pedal depresses less each time, the booster is airtight. Depress the brake pedal while the engine is running, then stop the engine with the pedal depressed. If there's no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is airtight. For replacement, note that power brake booster units shouldn't be disassembled. They require special tools not normally found in most automotive repair stations or shops. They're fairly complex and, because of their critical relationship to brake performance, should be replaced with a new or rebuilt one. Remove the master cylinder. Release the clamp and disconnect the vacuum hose from the brake booster. Unclip the Brake Lines from the retainer on the firewall. Remove the bolts securing the filter canister and remove the canister. On 2008 and earlier models, working under the dash, remove the instrument panel brace. Pull out the safety clip, then remove the clevis pin to detach it from the brake pedal. Remove the four mounting nuts securing the booster to the firewall, then remove the booster from the engine compartment. On 2008 and earlier models, before installing the new booster, measure the booster input rod length and adjust it if necessary. Installation is the reverse of removal. Use a new gasket between the booster and the firewall.For adjustment on 2008 and earlier models, measure the distance between the power brake booster and the hole in the input rod clevis and compare it to the dimension. If necessary, loosen the adjusting nut and turn the clevis in or out to the specified length, then install the booster, connect the clevis to the brake pedal, and tighten the nut securely.