Removal and Installation (Right Hand Drive)
REMOVAL - RHD1. Disconnect and isolate the negative battery cable.
CAUTION: Pump the brake pedal several times to relieve the vacuum in the power brake booster. This will prevent the booster from sucking in any contamination when the master cylinder is removed.
2. Remove the master cylinder from the vehicle (Fig. 110).
3. Remove the air cleaner assembly.
4. Remove the battery and battery tray from the vehicle.
5. Remove the heater core coolant supply tube support bracket bolts (Fig. 111).
6. Remove the (2) coolant reservoir retaining bolts from the dash panel. Disconnect the coolant overflow hose from the thermostat housing and remove the coolant reservoir from the dash panel.
7. Working from underneath the instrument panel, disconnect the brake pedal push rod. Remove the retaining clip from the end of the brake pedal mounted stud, then slide the push rod straight off the pin.
8. If equipped, disconnect the clutch pedal push rod. Depress the plastic retention clip on the end of the clutch pedal mounted stud, while sliding the push rod straight off the stud.
9. Rotate the clutch master cylinder to line up the square shaped retaining boss with the square shaped opening in the brake pedal support bracket.
10. Remove the (4) brake booster retaining nuts.
11. Working from inside the engine compartment, remove the (2) clutch fluid reservoir retaining bolts from the dash panel.
12. Remove the clutch master cylinder from the dash panel by pulling it straight out. Position the reservoir and line assembly out of the way.
13. Remove the brake booster from the dash panel by pulling it straight out, then rotate the booster and slide it between the engine and the dash panel towards the battery tray. Slide the booster under the heater core coolant supply hoses and out of the engine bay.
INSTALLATION - RHD
1. Position the brake booster on the dash panel by reversing the path taken to remove the booster. Slide the booster under the plenum on the battery tray side of the engine compartment. Slide the booster between the engine and dash panel until it can be installed on the right side of the dash panel.
2. Reinstall the vacuum supply hose on the booster check valve. Make sure the booster check valve is firmly seated in the rubber grommet and did not become dislodged during the booster installation.
3. If equipped, install the clutch master cylinder through the dash panel.
4. Install the clutch fluid reservoir. Torque the retaining bolts to 7 Nm (62 inch lbs.).
5. Working from underneath the instrument panel, install the four brake booster retaining nuts. Torque the nuts to 34 Nm (25 ft. lbs.).
6. Grease the brake pedal pin and slide the brake booster push rod onto the pedal pin. Install the retaining clip.
7. If equipped, lock the clutch master cylinder in position. Rotate the clutch master cylinder to line up the square shaped retaining boss with the square shaped opening in the brake pedal support bracket. Once the cylinder is inserted through the brake pedal support bracket rotate 90° to lock it in position.
8. Connect the clutch pedal push rod. Slide the push rod on the clutch pedal mounted stud until the plastic retention clip locks it in place.
9. Install the coolant reservoir. Torque the retaining bolts to 7 Nm (62 inch lbs.). Connect the coolant overflow hose on the thermostat housing.
10. Install the heater core coolant supply tube support bracket bolts (Fig. 111). Torque the bolts to 36 Nm (27 ft. lbs.).
11. Install the battery and battery tray in the vehicle.
12. Install the air cleaner assembly.
13. Install the master cylinder on the vehicle.
14. Fill the brake fluid reservoir to specification.
15. Bleed the air from the brake hydraulic system.
WARNING: Be certain a firm brake pedal is achieved before attempting to move the vehicle.