Power Brake Booster: Notes

Remove piston rod from booster. Remove push rod clevis and nut. Set booster in Booster Overhaul Tool (09950-88210). See Fig 1 . Ensure that vacuum check valve is not in contact with base of overhaul tool. Tighten 2 nuts on upper part of tool evenly to 26-43 INCH lbs. (3-5 N.m).

Fig 1: Separating Booster Bodies
Courtesy of SUZUKI OF AMERICA CORP.
Turn overhaul tool bolt clockwise until indentations on cover No. 2 line-up with projections on body No. 1. After indentations line-up with projections. Scribe matching marks on the 2 bodies to facilitate installation. Remove booster from overhaul tool. Separate booster body No. 1 and No. 2. See Fig 2 .

Fig 2: Exploded View of Power Booster
Courtesy of SUZUKI OF AMERICA CORP.
Remove piston return spring. From booster body No. 2, remove boot, air cleaner elements, and air cleaner separator in order. Using Camshaft Pulley Holder (09917-68210), turn booster piston counterclockwise and remove piston.
While compressing air valve spring (by moving rod up and down), remove valve stopper key. See Fig 3 . Remove booster air valve assembly from booster piston.

Fig 3: Exploded View of Air Valve Assembly
Courtesy of SUZUKI OF AMERICA CORP.

NOTE: Booster air valve assembly cannot be disassembled.
Remove diaphragm from pressure plate carefully by hand. Remove reaction disc from booster piston using finger pressure. Drive oil seal from booster body No. 2 using Driver (09951-08210) and Receiver (09951-18210).