REMOVAL AND INSTALLATION



Pre-removal Operation
  • Brake Fluid Draining

Post-installation Operation
  • Brake Fluid Supplying and Air Bleeding (Refer to ).
  • Brake Pedal Adjustment (Refer to ).


<LH drive vehicles>



Removal steps


1.
Brake fluid level sensor connector


2.
Master cylinder and brake pipe connection


3.
Master cylinder mounting nut


4.
Master cylinder

>>B<<
·
Push rod protrusion amount check and adjustment

>>A<<
5.
Hose clip

>>A<<
6.
Vacuum hose (with built-in check valve)


7.
Vacuum hose B


8.
Vacuum pipe B


9.
Hose clip


10.
Vacuum hose A


11.
Vacuum pipe A


12.
Snap pin


13.
Pin assembly


14.
Brake booster mounting nut


15.
Sealer


16.
Brake booster

<RH drive vehicles>



Removal steps


1.
Brake fluid level sensor connector


2.
Master cylinder and brake pipe connection


3.
Master cylinder mounting nut


4.
Master cylinder

>>B<<
·
Push rod protrusion amount check and adjustment

>>A<<
5.
Hose clip

>>A<<
6.
Vacuum hose (with built-in check valve)

>>A<<
7.
Hose clip

>>A<<
8.
Vacuum hose


9.
Clamp


10.
Vacuum pipe


11.
Snap pin


12.
Pin assembly


13.
Brake booster mounting nut


14.
Sealer


15.
Brake booster

INSTALLATION SERVICE POINTS



>>A<< VACUUM HOSE AND HOSE CLIP CONNECTION



<LH drive vehicles>
  1. Install the vacuum hose and the clip so that the paint mark on the vacuum hose and the clip are in the position shown in the figure.


<RH drive vehicles>
  1. Install the vacuum hose and the clip so that the paint mark on the vacuum hose and the clip are in the position shown in the figure.

>>B<< PUSH ROD PROTRUSION AMOUNT CHECK AND ADJUSTMENT




1.Use the vacuum pump to measure dimension "A" applying a negative pressure of 66.7 kPa to the brake booster.
Standard value (A):
9.925 - 10.175 mm <Vehicles without ASC>
6.675 - 6.925 mm <Vehicles with ASC>
note When a negative pressure of 66.7 kPa is not applied to the brake booster, the push rod protrusion amount (A) should be 8.925 - 9.175 mm <Vehicles without ASC> , 7.675 - 7.925 mm <Vehicles with ASC>.


2.If the protrusion amount is not within the standard value range, adjust the push rod length by turning the push rod. Use the special tool push rod adjusting socket (MB991568) to turn the push rod while holding the rod spline with angle-nose pliers.