Clearance between Booster Piston Rod and Master Cylinder Piston Adjustment

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

The length of booster piston rod (1) is adjusted to provide specified clearance "a" between piston rod end and master cylinder piston (2).

Before measuring clearance, push piston rod (1) several times so as to make sure reaction disc is in place.

Fig 1: Identifying Clearance Between Booster Piston Rod And Master Cylinder Piston
Courtesy of SUZUKI OF AMERICA CORP.
Keep inside of booster at atmospheric pressure for measurement.

Check clearance between booster piston rod and master cylinder piston.
1. For tandem type brake booster
  1. Set special tool on master cylinder (1) and push pin until contacts piston (2).
    Special tool
    
    (A): 09950-96010
  2. Turn special tool upside down and place it on booster (4). Adjust booster piston rod (5) length until rod end contacts pin head (3).
    Special tool
    
    (A): 09950-96010
Clearance "b" special tool and piston rod

"b": 0 mm (0 in.)

NOTE: Take measurement with booster set vertically or with supporting piston rod by screwdriver so as to piston rod placed at the center.

Fig 2: Identifying Clearance Between Special Tool And Piston Rod
Courtesy of SUZUKI OF AMERICA CORP.
Adjust clearance by turning adjusting screw of piston rod.

Special tool

(F): 09952-16010 (For tandem type brake booster)

Fig 3: Adjusting Clearance By Turning Adjusting Screw Of Piston Rod

Courtesy of SUZUKI OF AMERICA CORP.