Brake Booster/Brake Master Cylinder, Assembly Overview

Brake booster/brake master cylinder, assembly overview





Note:
^ Complete brake master cylinders and brake boosters can be replaced independently.
^ Brake master cylinders cannot be disassembled, i.e. they are not intended to be serviced.
^ Only use new brake fluid. Refer to label on brake fluid reservoir.

1. T45 Torx, 25 Nm
2. Self-locking hex nut, 49 Nm
3. Brake master cylinder, diameter 23.81 mm
^ Cannot be repaired. Replace as complete unit if malfunctioning
4. Brake line, 15 Nm
^ Master brake cylinder/secondary piston circuit to hydraulic control unit
5. Brake line, 15 Nm
^ Master brake cylinder/primary piston circuit to hydraulic control unit
6. Seal
^ Always replace
7. Brake booster
^ On gasoline engines vacuum is supplied from intake manifold
^ Functional check
- With engine switched off, depress brake pedal firmly several times (to deplete vacuum in brake booster).
- Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working properly, pedal will be felt to give slightly under foot (booster assistance becomes effective).
^ If malfunctioning: replace as complete unit only
^ Check-valve in vacuum hose, item -9
^ Adjusting ball head - Fig 1
8. Seal
9. Vacuum hose
^ Insert in brake booster
10. Brake fluid reservoir
11. Cap
12. Sealing plugs
13. Supply hose
^ From brake fluid reservoir to clutch master cylinder
14. Bulkhead

Fig. 1 Adjusting ball head





For Left Hand Drive (LHD)vehicles:
A= 159 mm + 05 mm
For Right Hand Drive Vehicles (RHD):
A= 1732 mm + 05 mm

Note:
^ When measuring, ball head must be at a right angle to surface of the brake booster.
^ Measure to end of ball head without seal.