Warning. Hose marked*1in figures 15.34 and 15.35 and the hose marked * in figure 15.36, after disconnecting from the reservoir, do not lower below the master brake cylinder, otherwise air will enter the hydraulic brake circuits.*2 indicates vehicles with ABS.
Removing
- Drain the brake fluid.
- Remove the air filter.
- Remove the fuse and relay box.
- Remove the activated charcoal canister.
- On a 1.9L LHD diesel vehicle, remove the air filter, relay box, and activated charcoal canister.
- Disconnect the connector from the brake fluid level sensor (pic. 15.34, 15.35).
Pic. 15.34. The main brake cylinder and vacuum brake booster of a car with a left-hand steering wheel: 1 - brake fluid level sensor connector; 2 - hoses; 3 - replenishment tank; 4 - tank bracket; 5 - connecting nut for fastening the brake tube, 15 Nm; 6 - master brake cylinder assembly; 7 - pressure limiter bracket; 8 - vacuum hose (with built-in control valve); 9 - adapter, 15-18 Nm; 10 - vacuum sensor connector; 11 - vacuum sensor; 12 - latch; 13 - washer; 14 - bolt; 15 - vacuum brake booster; 16 - gasket
Pic. 15.35. Brake master cylinder and brake booster for a right-hand drive vehicle: 1 - brake fluid level sensor connector; 2 - hoses; 3 - replenishment tank; 4 - tank bracket; 5 - connecting nut for fastening the brake tube, 15 Nm; 6 - master brake cylinder assembly; 7 - vacuum hose (with built-in control valve); 8 - adapter, 15-18 Nm; 9 - vacuum sensor connector; 10 - vacuum sensor; 11 - latch; 12 - washer; 13 - bolt: 14 - vacuum brake booster; 15 - gasket
Pic. 15.36. Brake master cylinder and brake booster for a 2000 model year car with a 1.9 liter diesel engine: 1 - brake fluid level sensor connector; 2 - hoses; 3 - replenishment tank; 4 - tank bracket; 5 - connecting nut for fastening the brake tube, 15 Nm; 6 - master brake cylinder assembly; 7 - pressure limiter bracket; 8 - vacuum hose (with built-in control valve); 9 - latch; 10 - washer; 11 bolt; 12 - vacuum brake booster; 13 - gasket
- Loosen the clamps and disconnect the hoses from the refill tank.
- Remove the refill tank.
- Turn out bolts and remove an arm of a tank.
- Turn away connecting nuts and disconnect pipes of brake system from the main brake cylinder.
- Loosen the nuts and remove the brake master cylinder assembly and pressure limiter bracket.
- Loosen the clamps and remove the vacuum hose (with built-in control valve).
- Unscrew the adapter from the vacuum brake booster.
- Disconnect the vacuum sensor connector.
- Turn out bolts and remove the vacuum gauge
- Remove the retainer and washer, then remove the bolt.
- Remove the vacuum brake booster and gasket.
Installation
- Installation is carried out in the reverse order of removal, taking into account the following.
- Before screwing the adapter into the vacuum brake booster, apply a thin layer of sealant 3M ATD Part No. 8661 to its threads (pic. 15 37).
Pic. 15.37. Place of application of sealant ZM ATD Part No. 8661 on the thread of the adapter
- When installing the brake master cylinder assembly, the clearance between the brake booster push rod and the primary piston must be adjusted. Gap A (pic. 15.38) defined as the difference between the measurements of B, C and D, A=B-CD.
Pic. 15.38. Checking clearance between brake booster tappet and primary piston
Nominal value: 0.6 - 0.8 mm
- If the clearance does not correspond to the nominal value, adjust it by changing the length of the pusher by turning the adjusting screw of the pusher (pic. 15.39).
Pic. 15.39. Changing the length of the pusher by turning the adjusting screw of the pusher
- Push the vacuum hose all the way into the hexagon of the connecting tube on the engine intake manifold and secure the hose with a clamp.
- Connect the brake pipes to the pressure regulator as shown in Figure 15.40.
Pic. 15.40. Connecting the brake pipes to the pressure regulator: 1 - pressure regulator - brake mechanism of the left rear wheel; 2 - pressure regulator - brake mechanism of the right front wheel; 3 - pressure regulator - brake mechanism of the right rear wheel; 4 - pressure regulator - brake mechanism, left front wheel; 5 - pressure regulator - secondary chamber of the main brake cylinder; 6 - pressure regulator - primary chamber of the main brake cylinder
- Install the activated charcoal canister.
- Install the fuse and relay box.
- Install the air filter.
- Refill with brake fluid.
- Remove air from the hydraulic drive of the brake system.
- Adjust the position of the brake pedal.