1. Press the brake pedal down hard to the stop at least five times with the engine off, then start the engine with the brake pedal pressed. Now the pedal should move down noticeably under your foot.
2. Remove the hose from the brake booster if the desired effect is not achieved.
3. Start the engine. Place your finger on the end of the hose and check for low pressure. If there is no low pressure, check the condition of the vacuum hose and make sure it is not damaged. Replace the hose if necessary. Tighten all hose clamps.
Diesel Engine Cars
4 Disconnect the hose from the brake booster vacuum pump and, by placing your finger on the end of the hose, check for a vacuum. If there is a vacuum, measure it. Otherwise, replace the vacuum booster.
Removal
5. Press the brake pedal several times to remove the vacuum from the booster.
6. Disconnect the brake fluid level sensor plug from the expansion tank cap.
7. Remove both wiper arms from their shafts.
8. Carefully bend and pull the rubber seals off the rear edge of the engine compartment bulkhead, then unscrew the mounting screws and remove the fairing from the lower edge of the windshield.
9. Loosen the master cylinder mounting nuts and remove it from the studs on the brake booster unit to create working space for removing the unit. Do not separate the brake lines from the master cylinder.
10. Remove the vacuum booster hose from the elbow and move the wiring harness away from the engine compartment bulkhead.
11. Unscrew the bolts and remove the trim panel located under the instrument panel in the footwell on the driver's side.
12. Remove the air ducts.
13. Disconnect the return spring from the brake pedal. Remove the brake light switch from the mounting bracket (see the relevant chapter).
14. Remove the spring clip and push out the pushrod fork pin to separate the rod from the brake pedal.
15. Remove the nuts, then tilt the booster and lift it off the bulkhead into the engine bay. Remove the gasket. Note that these nuts also secure the brake pedal bracket.
16. Loosen the lock nut and disconnect the push rod fork.
17. Unscrew the nuts and remove the bracket and gaskets from the amplifier.
Installation
16. Install the bracket together with the new gasket onto the amplifier and tighten the nuts to the specified torque.
17. Screw the lock nut and fork onto the push rod. Adjust the fork position so that the distance between the surface of the booster bracket and the center of the fork pin is 106.0±0.5 mm. Tighten the lock nut.
18. Install the amplifier into the bulkhead using a new gasket. Install the mounting nuts and tighten them.
19. Connect the push rod to the brake pedal with a pin and spring clip.
20. Secure the brake pedal return springs, then install the brake light switch.
21. Install the air ducts in the driver's footwell and the lower instrument panel trim panel.
22. Install the vacuum hose elbow into the booster sealing ring.
23. Replace the O-ring on the master cylinder flange if necessary, then install the block onto the booster studs and tighten the nuts.
24. Secure the brake pipes to the holders on the engine compartment bulkhead.
25. Connect the fluid level sensor plug to the expansion tank cap.
26. Place the fairing on the lower edge of the windshield and secure it with screws.
27. Install the wiper arms.
28. Check the operation of the vacuum booster and brake system.
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