Table of contents: Brake fluid reservoir and master… ↓ Removal and installation the vacuum… ↓
1. The parts of the brake master cylinder, brake booster and brake fluid reservoir are shown in the illustration.
6.1. Details of the brake master cylinder, brake booster and brake fluid reservoir:
1 - Vacuum booster gasket;
2 - Vacuum booster;
3 - Pedal bracket;
4 - Brake fluid pipe to the master cylinder;
5 - Brake fluid hose to the pedal;
6 - Bracket;
7 - Brake fluid pipe from the secondary piston of the master cylinder to the hydraulic modulator (port "SK"), 14 Nm;
8 - Brake fluid pipe from the primary piston of the master cylinder to the hydraulic modulator (port "DK"), 14 Nm;
9 - Sealing ring;
10 - Self-locking nut, replaceable, 49 Nm;
11 - Bolt, screwed into the pedal bracket, 25 Nm;
12 - Tandem master cylinder, not repairable;
13 - Install seals soaked in brake fluid;
14 - Brake fluid reservoir;
15 - Cap with low brake fluid level indicator;
16 - Vacuum hose;
17 - Vacuum hose connection seal.
Brake fluid reservoir and master cylinder
2. Remove the air intake chamber cover (see Section 19 of Chapter 1), vacuum compartment seal and cover plate next to the vacuum booster. Remove the front wall of the air intake chamber.
3. Open the brake fluid reservoir and pump out as much fluid as possible. Close the reservoir and disconnect the low brake fluid level sensor connector.
4. Press the reservoir locking tabs outward and pull it away from the seals in the master cylinder to remove it.
5. Pull the front left tube out of the holder on the master cylinder. Disconnect the brake pipes from the master cylinder and plug the ports to prevent dirt from getting into the master cylinder.
6. Give the nuts (10 in illustration 6.1) and carefully remove the master cylinder from the vacuum booster.
7. Installation is carried out in reverse order. When installing the brake master cylinder on the vacuum booster, make sure the booster rod is correctly positioned in the brake master cylinder. Finally, bleed the brake hydraulic system (see Chapter 1).
Removal and installation the vacuum booster
8. Remove the instrument panel trim on the driver's side (see Chapter 10).
9. Remove the brake light bulbs (see Section 5) and its bracket. Separate the brake pedal from the brake booster (see Section 5).
10. Remove the support on the bracket (the amplifier rod passes through the support).
11. Remove the air intake chamber cover (see Section 19 of Chapter 1), vacuum compartment seal and cover plate next to the vacuum booster. Remove the front wall of the air intake chamber.
12. Disconnect the low brake fluid level sensor connector. Disconnect the ground wire from the ground point on the body, behind the mounting block. Release the wiring from the holder and move it to the side.
13. Remove the left mounting block from the holder and set it aside.
14. Remove the air intake chamber cover (see Section 19 of Chapter 1), open the brake fluid reservoir and pump out as much fluid as possible. Close the tank.
15. Follow the steps described in paragraphs 4-6.
16. Disconnect the vacuum hose from the booster. Remove the brake lines from the triple bracket on the booster. Disconnect the front left brake pipe from the connection in the front left wheel arch.
17. Unscrew the amplifier mounting bolt and remove it.
18. Installation is carried out in reverse order. When installing the brake master cylinder on the vacuum booster, make sure the booster rod is correctly positioned in the brake master cylinder. Finally, bleed the brake hydraulic system (see Chapter 1).