Installing Brake Servo

^ disconnect return line from reservoir
^ remove hose and shorten by approx. 20 mm
^ position new gasket onto new brake servo
^ for sealing between brake servo and bulkhead
^ install new brake servo at bulkhead
^ tightening torque: 20 N-m (15 N-m)

Note
In the new servo design, the weep hole located next to the warning light switch must face downward (toward the ground).

CAUTION
When routing the pressure and return lines, carefully bend them in large arcs. Do not kink the lines.

^ loosely install return line 1 to new brake servo

^ install return line 1 on reservoir
^ check that routing of return line 1 is free of kinks and interference
^ tighten return line 1 at brake servo
^ position clevis at brake pedal and fasten with pin

^ install new securing clip onto clevis pin
^ install footwell outlet
^ install storage compartment, driver's side
^ connect wiring 2 at switch

CAUTION
When routing the pressure and return lines, carefully bend them in large arcs. Do not kink the lines.





route pressure line 3 as shown, free of interference, then tighten

CAUTION
Pressure and return lines MUST be connected to their proper locations, or damage and leakage will result. for LONG-version master cylinders:
^ position intermediate piece 4 on push rod
^ do NOT re-install O-ring

Note




For SHORT-version master cylinders:
^ do not re-install flange a (see illustration 47-800)
^ do not re-install O-ring

^ install master cylinder on brake servo
^ remove sealing plug from brake master cylinder
^ install brake fluid reservoir
^ for vehicles with manual transmission ONLY:

^ install hose (for clutch master cylinder), onto brake fluid reservoir

^ refill brake fluid reservoir and bleed brakes
^ for vehicles with manual transmission ONLY:
^ bleed clutch

^ re-connect battery GND strap
^ start engine and check hydraulic brake servo system for leaks

^ check hydraulic oil level; refill as necessary