1984-85 Accord, 1984-86 Prelude, 1887 Prelude, carburetted
1. Remove the brake booster.
2. Scratch alignment marks on the front and rear shrouds for ease of reassembly.
3. Remove the E-clamps and separate the front and rear shrouds.
4. Remove the washers and seals from the rear casing, then remove the circlip.
5. Remove the spring retainer and booster spring.
6. Remove retainer and through bolt boot.
7. Remove the diaphragm from the rear casing.
8. Remove lug, pusher locknut, star locknut, regulator, and filter.
9. Remove retaining ring and valve holder assembly.
10. Remove the E-clip from the valve holder assembly and disassemble the components.
For assembly:
11. Install the poppet valve on the valve holder.
12. Assemble the valve holder, inner valve spring, outer valve spring, and spring retainer on the pushrod.
13. Install the felt ring with the E-clip.
14. Install the diaphragm on the booster piston. Align the keys with the grooves in the piston.
15. Coat the inside and outside of the piston tube with silicone grease. Insert the valve holder assembly into the piston. Install retaining ring.
16. Install the anti-foam filter on the end of the pusher; screw the adjuster and locknut onto the shaft, but do not tighten.
17. Use silicone grease to seal the piston. Install the seal on the casing. Make sure that the edges of the seal do not protrude.
18. Install the piston seal and bushing into the rear casing. Use a suitable jig to carefully position the retainer 6 mm below the edge of the rear casing. If the retainer is moved more than 6 mm, the piston seal will be damaged.
19. Install both through bolts using o-rings and circlips.
20. Align the booster piston key with the groove in the rear casing and attach the piston.
21. Install covers on through bolts.
22. Lubricate the booster piston bore with silicone grease and install the pusher seat, reaction disc, outer rod, and retainer.
23. Install the booster spring.
24. Compress the booster spring, install the spring retainer and install the circlips on the through bolts.
25. Install washers and seals on through bolts. Assemble the front and rear casings, aligning with the marks made in advance. Press the front cover and install the E-clamps.
26. Adjust pusher clearance. See separate procedure in this Chapter.
1986-89 Accord, 1987 Injected Prelude, 1988-90 Prelude
1. Remove the brake booster.
2. Scratch marks on the front and rear shrouds for easy reassembly.
3. Remove the E-clamps and separate the front and rear shrouds.
4. Remove the seals and washers from the spring retainer; remove the retaining ring.
5. Remove the spring retainer and booster spring.
6. Loosen the four flange locknuts and remove the platform.
7. Remove the valve holder assembly from the rear casing.
8. Remove covers from through bolts.
9. Remove the amplifier platform and diaphragm from the rear casing.
10. Remove diaphragm.
11. Remove the retaining ring; remove the through bolts and o-rings from the rear casing.
12. Remove the retainer, bushing, and piston seal from the rear casing.
13. Disconnect the outer stem, reaction disc and reaction plate from the valve holder.
14. In the valve holder assembly, remove the pusher bracket, locknuts, regulator, and filter.
15. Remove the pusher seat and remove the pusher from the valve holder.
16. Remove the clamp from the pusher.
17. Remove the felt filter, spring retainer, valve springs, retainer, and poppet from the pushrod.
For installation:
18. Install the poppet valve on the valve holder.
19. Install the valve holder, valve springs and spring retainer on the pusher.
20. Install felt filter and clip.
21. Lubricate the inside and outside of the valve holder tube with silicone grease. Press the pusher assembly into the tube. Secure with lock ring.
22. Place a sponge filter on the end of the pusher. Thread the adjuster and star locknut onto the pushrod, but do not overtighten.
23. Use silicone grease on the piston seal. Install the seal in place on the casing. Make sure that the edges of the seal do not protrude.
24. Install the piston seal and bushing into the rear casing. Use the correct size tool to gently position the retainer 6mm below the edge of the rear casing. If the retainer is moved more than 6 mm, the piston seal will be damaged.
25. Install both through bolts using o-rings and circlips.
26. Install the diaphragm on the amplifier platform.
27. Attach the amplifier platform to the rear casing. Make sure the keys and slots are properly aligned.
28. Install the covers on the through bolts.
29. Lubricate the sides of the rear casing and the outside of the valve holder assembly with silicone grease. Install the valve holder assembly into the rear casing.
30. Lubricate the valve body walls with silicone grease. Install reaction plate, disc and outer rod.
31. Position the mounting platform and tighten the four flange nuts to 5.5 Nm.
32. Put on the booster spring. Compress the spring and install the spring retainer; install retaining rings on through bolts.
33. Install washers and seals.
34. Assemble the front and rear shrouds, aligning with the marks made earlier. Press down on the front cover and install the circlips on the through bolts.
35. Adjust pusher clearance. See separate procedure in this Chapter.
1990-91 Accord, 1991 Prelude
The manufacturer does not recommend dismantling the brake booster. If there is an internal fault, the unit must be replaced.