Power Brake Booster - Installation - RHD

BOOSTER - RHD





1. Install a NEW booster seal (2) over push rod and mounting studs on rear of booster (1).





2. Install power brake booster through opening between cross-brace and windshield. Guide booster (2) push rod and mounting studs through dash panel (3).

NOTE: Be sure to evenly tighten all four booster mounting nuts to specifications or a vacuum leak can result.

3. Install four power brake booster mounting nuts (5). Tighten nuts to 25 Nm (18 ft. lbs.).

CAUTION: When installing booster push rod on brake pedal pin, be careful not to damage rubber O-ring on pin.

4. Slide booster push rod onto brake pedal pin. Install NEW retaining clip securing push rod to brake pedal.





5. Install and adjust brake lamp switch (2) Stop Lamp Switch - Installation.
6. Install steering column opening cover Steering Column Opening Cover - Installation.
7. Install driver side silencer under instrument panel Silencer Panel - Installation.





8. Connect vacuum hose (1) to check valve on face of booster (2). Do not remove check valve from booster.






CAUTION: When replacing master cylinder on vehicle, a NEW vacuum seal (2) MUST be installed on master cylinder.

9. Install NEW vacuum seal (1) on rear of master cylinder (2) making sure seal fits squarely in mounting groove.





10. Position master cylinder (3) on studs of power brake booster, aligning booster push rod with master cylinder piston.
11. Install two master cylinder mounting nuts (1). Tighten mounting nuts to 15 Nm (133 in. lbs.).





12. Thread primary (3) and secondary (2) brake tubes into master cylinder primary and secondary ports. Tighten tube nuts to 20 Nm (177 in. lbs.).





13. Connect wiring harness connector (4) to brake fluid level sensor (2) mounted in brake fluid reservoir (1).
14. Install windshield wiper module and components Wiper Arm Linkage - Installation.





15. Connect battery negative cable (2) to battery post. It is important that this is performed properly.
16. Fill and bleed brakes as necessary.
17. Road test vehicle to ensure proper operation of brakes.