Honda 8-97288-243-1 Master Vacuum Assembly Brake

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During an operating check the brakes must be tested in an engine off condition by depressing the brake pedal several time, and there should be no variation in the amount of reserve pedal travel observed. The pedal must be pressed while starting the engine; if it lowers slightly, the operation is normal. For an airtightness check: switch on the engine for one or two minutes and switch it off, then press the brake pedal several times gently. In other words, if the pedal goes down farther the first time you press but does not rise, or rises gradually after the second or third attempt, then the booster is leak proof. When the engine is running step on the brake pedal and then shut off the engine with the brake pedal depressed; if no change in the pedal reserve depression after 30 seconds is noticed, then the booster is said to be airtight. When removing the booster, never disassemble power brake booster units, as they are tough to assemble requiring special tools and are normally best dealt with by swapping a bad one for a new or, if need be, a rebuilt one. The operation starts with the removal of the brake master cylinder while, in certain instances, the least may not have to take the brake lines off. Pull down the booster in a manner that you can reach the pushrod clevis that connects it to the brake, set aside the booster's retaining clip that is on the clevis pin then remove the clevis pin. Loosen the clevis locknut by turning the nut with a wrench while holding onto the clevis with pliers to prevent dropping, then remove the hose connecting the engine to the booster controlling not to harm the hose. It is necessary to take out the four nuts and washers by which the brake booster is fixed to the firewall, and search for them with the help of a flashlight, and then take out the booster straight backward along the firewall. To put the clevis and booster in, it is just the reverse of the removal process but the clevis locknut and the booster mounting nuts must be tightened firmly. If replacing the power booster unit, check and if necessary set the pushrod protrusion by applying vacuum and measuring from the master cylinder flange face to the end of the pushrod and adjust as needed. Last, while assembling, place the master cylinder and refer to the brake pedal height and free play and bleed the system.