REMOVAL AND INSTALLATION <RALLIART>


<MASTER CYLINDER AND BRAKE BOOSTER>


Pre-removal operation
  • Brake Fluid Draining
  • Air Cleaner Cover Removal <LHD> (Refer to GROUP 15 - Air Cleaner ).

 Post-installation operation
  • Air Cleaner Cover Installation <LHD> (Refer to GROUP 15 - Air Cleaner >).
  • Brake Fluid Refilling and Air Bleeding (Refer to ).




Master cylinder removal steps


1.
 Brake fluid level switch connector connection


2.
 Reservoir cap


3.
 Brake pipe connection

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


4.
 Master cylinder mounting nuts


5.
 Reservoir assembly and master cylinder assembly


6.
 Torx bolt


7.
 Reservoir assembly


8.
 O-ring


9.
 Master cylinder assembly



Brake booster removal steps


1.
 Brake fluid level switch connector connection


3.
 Brake pipe connection

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


4.
 Master cylinder mounting nuts


5.
 Reservoir assembly and master cylinder assembly

>>A<<
 10.
 Vacuum hose connection


11.
 Hose clip


12.
 Check valve


13.
 Dash panel heat protector


14.
 Brake fluid line clip connection <RHD>


15.
 Snap pin


16.
 Pin assembly


·
 Instrument panel cover lower (Refer to GROUP 52A, Instrument Lower Panel )


17.
 Brake booster mounting nut


·
 Cowl top panel (Refer to GROUP 42A, Loose Panel .)


·
 Strut tower bar (Refer to GROUP 42A, Strut Tower Bar .)


18.
 Brake booster assembly


19.
 Seal

<VACUUM HOSE AND VACUUM PIPE >


Pre-removal operation
  • Intercooler Intake Hose A Removal (Refer to GROUP 15 - Intercooler ).
  • Air Cleaner to Turbocharger Duct Removal (Refer to GROUP 15 - Air Cleaner )

 Post-installation operation
  • Air Cleaner to Turbocharger Duct Installation (Refer to GROUP 15 - Air Cleaner )
  • Intercooler intake hose A Installation (Refer to GROUP 15 - Intercooler ).




Removal steps

>>A<<
 1.
 Vacuum hose <RHD>


2.
 Hose clip <RHD>

>>A<<
 3.
 Vacuum hose


4.
 Hose clip

>>A<<
 5.
 Vacuum hose


6.
 Hose clip


7.
 Dash panel heat protector


8.
 Vacuum pipe <RHD>


9.
 Emission vacuum hose connection


10.
 Vacuum pipe assembly

INSTALLATION SERVICE POINTS

>>A<< VACUUM HOSE INSTALLATION


Align the mark as shown in the figure to assemble the vacuum hose.

>>B<< BLEEDING OF MASTER CYLINDER ASSEMBLY
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.