Booster - RHD

Fig 1: BOOSTER SEAL

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Install a NEW booster seal (2) over push rod and mounting studs on rear of booster (1).

Fig 2: BOOSTER AND PEDAL MOUNTING - RHD
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Install power brake booster through opening between cross-brace and windshield. Guide booster (2) push rod and mounting studs through dash panel (3).
NOTE: Be sure to evenly tighten all four booster mounting nuts to specifications or a vacuum leak can result.
Install four power brake booster mounting nuts (5). Tighten nuts to 25 N.m (18 ft. lbs.).
CAUTION: When installing booster push rod on brake pedal pin, be careful not to damage rubber O-ring on pin.
Slide booster push rod onto brake pedal pin. Install NEW retaining clip securing push rod to brake pedal.

Fig 3: STOP LAMP SWITCH MOUNTING - RHD
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Install and adjust brake lamp switch (2). Refer to Electrical - Lamps and Lighting/Lamps/Lighting - Exterior/SWITCH, Stop Lamp - Installation .
Install steering column opening cover. Refer to Body/Instrument Panel/COVER, Steering Column Opening - Installation .
Install driver side silencer under instrument panel. Refer to Body/Instrument Panel/PANEL, Silencer - Installation .

Fig 4: VACUUM HOSE CONNECTION - RHD
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Connect vacuum hose (1) to check valve on face of booster (2). Do not remove check valve from booster.

Fig 5: MASTER CYLINDER AND VACUUM SEAL
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CAUTION: When replacing master cylinder on vehicle, a NEW vacuum seal (2) MUST be installed on master cylinder.
Install NEW vacuum seal (1) on rear of master cylinder (2) making sure seal fits squarely in mounting groove.

Fig 6: MASTER CYLINDER TO VACUUM BOOSTER FASTENERS
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Position master cylinder (3) on studs of power brake booster, aligning booster push rod with master cylinder piston.
Install two master cylinder mounting nuts (1). Tighten mounting nuts to 15 N.m (133 in. lbs.).

Fig 7: MASTER CYLINDER, PRIMARY AND SECONDARY BRAKE TUBES
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Thread primary (3) and secondary (2) brake tubes into master cylinder primary and secondary ports. Tighten tube nuts to 20 N.m (177 in. lbs.).

Fig 8: BRAKE FLUID LEVEL SENSOR CONNECTION
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Connect wiring harness connector (4) to brake fluid level sensor (2) mounted in brake fluid reservoir (1).
Install windshield wiper module and components. Refer to Electrical - Wipers/Washers/Wipers/Washers/LINKAGE, Wiper Arm - Installation .

Fig 9: BATTERY AND CABLES
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Connect battery negative cable (2) to battery post. It is important that this is performed properly. Refer to Electrical - Engine Systems/Battery System - Standard Procedure .
Fill and bleed brakes as necessary.
Road test vehicle to ensure proper operation of brakes.