Master Cylinder and Brake Booster Replacement

REMOVAL
Pre-removal Operation:
- Brake Fluid Draining.
- Clutch Fluid Reservoir Bracket .
- Battery Removal <2.0L Engine (Non-turbo)>
- Relay Assembly Mounting Bolts Removal <2.0L Engine (Non-turbo)>.
- Washer Tank Mounting Bolts Removal <2.0L Engine (Non-turbo)>.
- Centermember Assembly Mounting Bolts Removal <2.0L Engine (Turbo) and 2.4L Engine> Engine Mount Bracket Removal <2.0L Engine (Turbo) and 2.4L Engine>.
- Air Conditioning Compressor Mounting Bolts Removal <2.0L Engine (Turbo) and 2.4L Engine>.
- Air Conditioning High Pressure Hose Clamp Mounting Bolts Removal<2.0L Engine (Turbo) and 2.4L Engine>
- Power Steering Pressure Hose, Pipe and Return Pipe Clamp Mounting Bolts Removal <2.0L Engine (Turbo) and 2.4L Engine>.

Follow removal steps outlined in illustration.

Removal Service Point

Remove Brake Booster:

Brake Booster Removal <2.0L Engine turboo) and 2.4L Engines.
Slide the engine forward and remove the brake booster from the body.

GREASE POINTS

INSTALLATION
Installation in reverse order as removal.

Installation Service Points

Install Vacuum Hose:

>A< Vacuum Hose Connection.
1) Install the vacuum hose to the brake booster nipple as shown in the figure. Secure the hose with the hose clip.

CAUTION:
1. The check valve and the pipe part of the brake booster must not contact each other.
2. Connect so that the marking faces upwards.

2) Install the other end of the vacuum hose fully onto its port on the engine. Secure the hose using the hose clip.

>B< Clearance Adjustment Between Brake Booster Push Rod And Primary Piston.

1) Attach the special tool to the master cylinder.
2) Place the shaft of the special tool gently against the piston of the master cylinder.
3) Turn the wing bolt to secure the shaft.

4) Use a hand vacuum pump to apply -66.7 kPa (9.7 psi) of negative pressure to the brake booster.
5) Turn the special tool upside down and attach it so that it is offset from the center of the brake booster.

6) Slide the special tool around its center and check that the shaft projection touches the end of the brake booster push rod as shown at A in the illustration at left.
If it is as shown at B or C, adjust the length of the push rod as follows so that it touches as shown at A.
B: If it touches some part other than the shaft projection, shorten the push rod.
C: If it does not touch the shaft at all, lengthen the push rod.

Post-installation Operation:
- Power Steering Pressure Hose, Pipe and Return Pipe Clamp Mounting Bolts Installation <2.0L Engine (Turbo) and 2.4L Engine>.
- Air Conditioning High Pressure Hose Clamp Mounting Bolts Installation <2.0L Engine (Turbo) and 2.4L Engine>.
- Air Conditioning Compressor Mounting Bolts Installation <2.0L Engine (Turbo) and 2.4L Engine>.
- Engine Mount Bracket Installation <2.0L Engine (Turbo) and 2.4L Engine>.
- Centemember Assembly Mounting Bolts Installation <2.0L Engine (Turbo) and 2.4L Engine>.
- Washer Tank Mounting Bolts Installation <2.0L Engine (Non-turbo)>.
- Relay Assembly Mounting Bolts Installation <2.0L Engine (Non-turbo)>.
- Battery Installation<2.0L Engine (Non-turbo)>.
- Clutch Fluid Reservoir Bracket .
- Brake Fluid Supplying Brake Line Bleeding.
- Brake Pedal Adjustment.

CAUTION: The check valve should not be removed from the vacuum hose. If the check valve is defective, replace it together with the vacuum hose.