REMOVAL AND INSTALLATION <RHD>


MASTER CYLINDER AND BRAKE BOOSTER


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




Removal steps


1.
 Brake fluid level switch connector connection


2.
 Master cylinder and brake pipe connection


3.
 Hydraulic unit assembly and brake pipe connection <vehicles with ABS>


4.
 Brake pipe assembly <vehicles with ABS>

>>C<<
 ·
 Bleeding of master cylinder assembly (only at installation)


5.
 Master cylinder mounting nut


6.
 Master cylinder assembly

>>B<<
 ·
 Push rod protrusion amount check and adjustment (only at installation)

>>A<<
 7.
 Vacuum hose connection (with built-in check valve)


8.
 Hose clip


9.
 Snap pin


10.
 Pin assembly


11.
 Brake booster mounting nut


12.
 Brake booster assembly


13.
 Sealer

VACUUM HOSE AND VACUUM PIPE



Removal steps

>>A<<
 1.
 Vacuum hose (with built-in check valve)


2.
 Hose clip

>>A<<
 3.
 Vacuum hose


4.
 Hose clip


5.
 Vacuum pipe


6.
 Clamp

INSTALLATION SERVICE POINTS

>>A<< VACUUM HOSE INSTALLATION


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):
10.0 - 10.1 mm <Vehicles without ASTC>
6.6 - 6.9 mm <Vehicles with ASTC>
note When a negative pressure of 66.7 kPa is not applied to the brake booster, the push rod protrusion amount (A) should be 9.0 - 9.1 mm <Vehicles without ASTC> , 7.7 - 7.9 mm <Vehicles with ASTC>.

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.

>>C<< BLEEDING OF MASTER CYLINDER ASSEMBLY
caution Be sure to use the specified brand and type of brake fluid. Avoid mixing with other type of brake fluid.
Brake fluid: DOT3 or DOT4
When removed the master cylinder assembly, bleed the master cylinder in the following procedure to make bleeding of the brake pipeline easier (When no brake fluid is in the master cylinder).
1.Fill the brake fluid reservoir with the brake fluid.
2.Depress and hold the brake pedal.

3.Another operator closes the master cylinder outlets with his fingers.
4.In this condition, release the brake pedal.
5.Repeat Steps 2 to 4 for 3 or 4 times to fill the master cylinder with the brake fluid.