REMOVAL AND INSTALLATION


Pre-removal Operation
  • Battery Removal <L.H. drive vehicles>
  • Air Intake Hose and Air Cleaner Removal (Refer to GROUP 15, Air Cleaner <6G7> or <4M4>). <R.H. drive vehicles>
  • Brake Fluid Draining

 Post-installation Operation
  • Brake Fluid Supplying and Air Bleeding (Refer to ).
  • Brake Pedal Adjustment (Refer to ).
  • Air Intake Hose and Air Cleaner Installation (Refer to GROUP 15, Air Cleaner <6G7> or <4M4>). <R.H. drive vehicles>
  • Battery Installation <L.H. drive vehicles>




Removal steps


1.
 Brake pipe connection


2.
 Brake fluid level switch connector


3.
 Bracket


4.
 Connector


5.
 Gasket


6.
 Master cylinder assembly


7.
 O ring

>>B<<
 ·
 Clearance adjustment between brake booster push rod and primary piston.

>>A<<
 8.
 Vacuum hose (with built-in check valve)


9.
 Hose clip


10.
 Vacuum pipe


11.
 Earth connection


12.
 Accelerator cable clamp


13.
 Clamp


14.
 Vacuum hose


15.
 Hose clip


16.
 Snap pin


17.
 Pin assembly


18.
 Brake booster mounting nut


19.
 Brake booster assembly


20.
 Sealer


21.
 Spacer


22.
 Fitting

INSTALLATION SERVICE POINTS

>>A<< VACUUM HOSE CONNECTION




Install the vacuum hose with its marking located as shown in the figure.

>>B<< CLEARANCE ADJUSTMENT BETWEEN BRAKE BOOSTER PUSH ROD AND PRIMARY PISTON

1.Calculate clearance A from the B, C and D measurements. (A = B - C + D)
Standard value (A):

    0.8 - 1.2 mm <2 800
    0.5 - 0.9 mm <3 000>
note
  • When a negative pressure of 93.3 kPa is applied to the brake booster, the clearance value will become 0.10 - 0.50 mm. <2 800>
  • When a negative pressure of 66.7 kPa is applied to the brake booster, the clearance value will become 0.10 - 0.50 mm. <3 000>

2.If the clearance is not within the standard value range, adjust by changing the push rod length by turning the push rod. Use the special tool to turn the push rod while holding the rod spline with angle-nose pliers.