Brake Booster, Removing And Installing: Installing

Install in reverse order of removal and note the following:

Always replace the self-locking nuts and bolts.

Replace damaged bolts and nuts.

Clean the bolts and nuts before reusing.

• Do not move/transport the brake booster by the actuator rod.
• Make sure that the actuator pin -Item  19- for the brake lamp is pushed into the brake master cylinder. If this pin is missing, the brake lamp will not function.
• Replace the bolts after removing them.
• Check the vacuum hoses for damage before the assembly and replace if necessary.

-- Check that the boot -2- has not slipped out of the surrounding groove -arrow- on the brake booster -1- as shown.

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• The boot -2- must rest securely in the groove all the way around -arrow-.

-- Install the brake booster with the master brake cylinder.

Always replace the self-locking nuts and bolts.

Replace damaged bolts and nuts.

Clean the bolts and nuts before reusing.

-- Install the bolts -arrows- and tighten to the required tightening specification -Item  3-.

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-- Push the vacuum hose into the brake booster.

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-- Install the Vacuum Sensor -G608- -2-. Refer to BRAKE BOOSTER PRESSURE SENSOR, REMOVING AND INSTALLING .

-- Slide the vacuum hose firmly onto the Vacuum Sensor -G608-.

• Make sure the vacuum hose is connected at all of the separating points.

-- Connect the connector -1- for the Vacuum Sensor -G608- and connector -4- for the Brake Lamp Switch -F-.

-- Insert the brake lines into the brake master cylinder by hand.

-- Tighten the union bolts -3- for the brake lines to the required tightening specification -Item  1- and -Item  22-.

-- Install the brake fluid reservoir. Refer to BRAKE FLUID RESERVOIR, REMOVING AND INSTALLING .

-- Install the plenum chamber bulkhead. Refer to PLENUM CHAMBER BULKHEAD, REMOVING AND INSTALLING .

-- Install the windshield wiper arms. Refer to WINDSHIELD WIPER ARMS, REMOVING AND INSTALLING .

-- Fill the brake fluid reservoir up to the "MIN" mark.

Fig 1: Brake Fluid Reservoir

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-- Connect the brake pedal to the brake booster. Refer to BRAKE PEDAL, DISCONNECTING FROM BRAKE BOOSTER .

-- Remove all cloths from the vehicle that were previously placed down.

-- Bleed the brake system. Refer to HYDRAULIC SYSTEM, BLEEDING .

• Make sure the brake lamp functions correctly.