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.

CAUTION: 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. Remove windshield wiper arm and blade assembly for access.

5. Remove plenum cover for access.

6. Remove pedal housing, brake booster and master cylinder assembly.

7. Remove reservoir filler cap and pour residual brake fluid into a container. Refit cap.





8. Remove stoplamp switch from pedal housing.
- Remove nuts.





9. Release brake pedal from brake booster push-rod.
- Remove clip from clevis pin.
- Remove clevis pin,





10. Separate brake booster and master cylinder assembly from pedal housing.
- Remove nuts.





11. Remove and discard gasket.

12. Clean components and mating surfaces.

Installation





1. Install brake booster and master cylinder assembly to pedal housing.
- Apply grease to forked end of brake booster push-rod.
- Install gasket to brake booster.





2. Align brake booster assembly to pedal housing, make sure push-rod fork straddles brake pedal.
- Install nuts and tighten to 22 - 28 Nm.





3. Connect brake pedal to brake booster push-rod.
- Apply grease and install clevis pin.
- Install clevis-pin clip





4. Install stoplamp switch to pedal housing.
- Install nuts and tighten to 3 Nm.

5. Install pedal housing, brake booster and master cylinder assembly.

6. Install plenum cover.

7. Install windshield wiper arm and blade assembly.

8. Reconnect battery ground cable.

9. Bleed brake system.

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