Removing
1. Models with YD25DDTi engine: Remove the intercooler and vacuum reservoir.
2. Disconnect the vacuum hose from the brake booster.
3. Remove the master cylinder.
4. Take out cotter pin and pin from an earring from outside salon. Disconnect the pressure rod from the brake pedal.
5. Turn off fixing nuts of an arm of a pedal of a brake.
6. Remove the brake booster assembly from the engine compartment.
Examination
1. Using a manual vacuum pump, create a vacuum of -66.7 kPa in the brake booster (-500 mmHg).
2. Install the stem protrusion gauge (special tool) into the master cylinder. Turn the screw until the gauge rests against the primary piston.
3. Turn the stem protrusion gauge upside down and lock in area A. Adjust in area B until the clearance between the stem protrusion and the screw is 0 mm.
- Nominal size «L» at vacuum -66.7 kPa (-500 mmHg): 10.4mm
The switch of a control lamp of the amplifier of a brake (models with YD25DDTi engine)
Using a vacuum pump and a tester, check the continuity of the switch
- There is no vacuum: there is conductivity
- Vacuum -66.7 kPa (-500 mmHg): no conductivity
Installation
1. Loosen the lock nut and adjust the length of the push rod so that dimension B (on the image) became equal to the set value.
- Standard size H: 125 mm
2. Having adjusted dimension B, tighten the locknut by hand and install the brake booster on the vehicle.
3. Connect the brake pedal to the pressure rod earring.
4. Establish fixing nuts of a pedal of a brake and tighten them with the demanded effort.
5. Connect the master cylinder to the brake booster.
6. Connect the vacuum hose.
7. Models with YD25DDTi engine: Install intercooler and vacuum reservoir.
8. Adjust the height and free play of the brake pedal.
9. Tighten the push rod locknut to specification.
10. Bleed the system.