Pedal Housing, Brake Booster and Master Cylinder Assembly

Pedal Housing, Brake Booster and Master Cylinder Assembly

Removal

CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. Remove brake fluid spillage immediately from paint work, with clean water.

1. Position vehicle on a four-post lift.

2. Open engine compartment and fit paint work protection covers to fenders.

3. Disconnect battery ground cable.





4. Disconnect stop lamp switch connector.
- Move carpet.
- Disconnect electrical connector.





5. Disconnect low-level warning connector from master cylinder.





6. Disconnect vacuum pipe from brake booster.
- Disconnect pipe.
- Remove and discard seal.

7. Position absorbent cloth underneath master cylinder to collect brake fluid spillage.





8. Disconnect brake tubes from master cylinder.
- Install plugs to brake tubes and master cylinder ports.

9. Remove windshield wiper arm and blade assembly for access.

10. Remove plenum cover for access.





11. Remove pedal housing, brake booster and master cylinder assembly from vehicle.
- Remove nuts and bolts.
- Remove assembly from vehicle.





12. Remove and discard gasket from pedal housing.

13. Clean components and mating surfaces.

Installation





1. Install gasket to pedal housing assembly.

CAUTION: Make sure no pipes or cables become trapped when fitting the pedal housing assembly.





2. Install pedal housing to vehicle.
- Install nuts and bolts.
- Tighten bolts to 15 - 20 Nm.
- Tighten nuts to 15 - 20 Nm.

3. Position cloth underneath master cylinder to collect brake fluid spillage.





4. Install brake tubes to master cylinder.
- Remove plugs.
- Connect brake tubes and tighten unions to specification.
- Remove cloth from underneath master cylinder.





5. Connect low-level warning connector to master cylinder.





6. Connect vacuum pipe elbow to brake booster.
- Install new seal.
- Connect pipe.

7. Install plenum cover.

8. Install windshield wiper arm and blade assembly.





9. Connect stop lamp switch connector.
- Connect electrical connector.
- Reposition carpet.

10. Reconnect battery ground cable.

11. Bleed brake system.

12. Remove paint-work protection covers and close engine compartment.