GTZ installation details on Diamante models
1 - GTZ assembly; 2 - Vacuum hose (with built-in control valve); 3 - Pin for fastening the split finger of the pusher rod; 4 - Washer; 5 - Cotter pin; 6 - Vacuum booster; 7 - Sealing gasket
Details of GTZ installation on Galant models 1994-1997. issue
1 - Fitting for connecting the brake pipe; 2 - Electrical wiring connector for the brake fluid level sensor; 3 - GTZ assembly; 4 - Vacuum hose (with built-in control valve); 5 - Fitting; 6 - Cotter pin; 7 - Pin for fastening the split finger of the pusher rod; 8 - Vacuum booster; 9 - Sealing gasket
Note. A failed GTZ must be replaced. Manufacturers do not recommend attempting to rebuild the brake master cylinder.
Brake fluid is one of the aggressive chemical compounds and, in contact with body panels, destroys the paintwork. Before proceeding with the procedure, cover the wings and front panel of the car with special covers, or just old blankets.
Removing
1. Details of installation of the main brake cylinder are shown in illustrations.
2. Disconnect the negative cable from the battery.
If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!
3. Remove the plastic cover, use a syringe or a rubber bulb to pump out as much brake fluid as possible from the GTZ reservoir, then reinstall the cover.
4. Disconnect from the GTZ and plug the brake lines immediately.
5. Disconnect the electrical wiring from the brake fluid level sensor-switch, release the fasteners and remove the GTZ reservoir.
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6. On manual transmission models, remove the clutch master cylinder reservoir support bracket.
7. Give the fixing nuts and remove the GTZ from the assembly of the vacuum brake booster.
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Installation
1. Adjust the gap A between the end of the pusher rod of the vacuum booster and the bottom of the socket in the GTZ primary piston. The nominal value is 0.65 ÷ 0.86 mm, with a vacuum depth of 67 kPa in the amplifier, the gap will be reduced to 0.1 ÷ 0.3 mm.
2. Install the GTZ on the brake booster assembly. Screw on the fixing nuts and tighten them to the required torque (10 Nm).
3. Replace and secure the GTZ reservoir.
4. Connect hydraulic lines and brake fluid level sensor wiring to reservoir.
5. Further installation is carried out in the reverse order to the dismantling of the components.
6. Finally, fill the tank with fresh DOT 3 brake fluid, bleed the hydraulic path (see Section Bleeding the brake system) and adjust the foot brake pedal (see Section Foot brake pedal adjustment).