Page 417 of 2490
8. Posi
tion absorbent cloth underneath master cylinder to collect
brake fluid spillage.
9. Di
sconnect brake tubes from master cylinder.
Install plugs to brake tu
bes an
d master cylinder ports.
10
.
From driver footwell, disconne ct throttle inner cable from
pedal.
Re
move grommet.
Relea
se cable from pedal.
11
.
Disconnect stop-lamp-switch connector.
Move carpet.
Disc
onnect electrical connector.
12. From engine compartment, remo ve throttle cable from pedal
housing.
Re
lease grommet.
Page 418 of 2490
In
stallation
Pull cabl
e from
pedal housing.
13 . Remove pedal h
ousing, brake
booster and master cylinder
assembly from vehicle.
F rom
driver footwell, remove nuts.
Carefull
y remove assembly.
14 . Remove an
d discard gask
et from pedal housing.
15. Clean components and mating surfaces.
1. Inst al
l gasket to pe
dal housing assembly.
2. CAUTION: Make sure no pipe s or cables become trapped
when fitting the pedal housing assembly.
Page 419 of 2490
Install peda
l housing to vehicle.
Make sure ped
al housing apertu
re is positioned correctly.
Inst
all and tighten nuts to 15-20 Nm.
3. Position cloth underneath master cylinder to collect brake fluid
spillage.
4. Inst
all brake tubes to master cylinder.
Re
move plugs.
Connect
and tighten brake tubes. Refer to Specification
section 206-06 for torque setting.
R
emove cloth from underneath master cylinder.
5. Con
nect throttle cabl
e to pedal housing.
Inst
all cable to grommet.
Inst
all cable to
pedal housing.
6. Conne
ct throttle inner ca
ble to pedal grommet.
7. Connect vacuum pipe elbow to brake booster.
1. Install new seal.
2. Connect pipe.
Page 420 of 2490
8. Conne ct
low-level warning connector to master cylinder.
9. Inst al
l cruise control vacuum-valves, mounting bracket.
Install and tigh
ten bolts.
10 . Conne
ct stop lamp switch connector.
Conne
ct
connector.
Re
posi
tion carpet.
11. Connect battery ground cable (IMPORTANT, see operation
86.15.15 for further information).
12. Bleed brake system. See operation 70.25.03.
13. Install engine compartment rear cover. Refer to operation
76.11.35.
14. Remove paint-work protection covers and close engine
compartment.
15 . Conne
ct battery ground cable (I
MPORTANT, refer to operation
86.15.19 for further information).
Page 421 of 2490

Power Brake Actuation -
Lubri
cants, Fluids, Sealants and Adhesives
Brake Ratio
Torques
CAUTI
ON: Replacement of
nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the
vehicle. These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
B
rake Tube, Hoses and Bracket Torques
CAUTI
ON: Replacement of
nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the
vehicle. These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
UnitS
pecification
Brake flu
id
ITT Supe
r Dot 4
Fr
ont Brakes
6
5 per cent
Rear B
rakes
3
5 per cent
Com
ponent
Nm
N
ut - master cylinder to brake booster
21
-29
Nu
t - brake pedal pivot-pin to pedal housing
17
-23
Nu
t - brake switch to pedal housing
3
Nu
t - pedal housing to body
15
-20
Nu
t - brake booster to pedal housing
22
-28
Com
ponent
Nm
Bleed n
ipple - front
4-
6
Bleed n
ipple - rear
8-
11
Hose to fr
ont caliper
10
-14
Hose banjo to rear caliper -
bolt
30
-40
M1
0 hose locknut
15
-20
M10
brake tube female-nut
13
-17
M10
brake tube male-nut
13
-17
M12
brake tube male-nut
15
-20
Bolt -
3-way tube connector to body
9-
12
Page 422 of 2490
Power Brake Actuation - Brake Booster
Description and Operation
The brake b
ooster provides assi
stance by reinforcing the driver's effort when brakin g. The reinforced assistance
provided by the booster is proportional to the driver's effort applied to the brake pedal.
The brake force applied by
the driver is incr
eased by the booster in a ratio of 6.5:1.
Th
e vacuum used to operate the booster
is formed in the engine's intake manifold. The booster is connected to the
intake manifold by a hose.
The boost
er is fail-safe therefore, if a fault develops in
the vacuum unit, the braking system will still function.
However, the driver will have to apply a greater fo rce to the brake pedal to slow down the vehicle.
It e
m
Par
t
Number
De
scr
iption
1—Mas
t
er Cylinder / Reservoir - refer to 206-06
2—Booster
3—Pedal Box
- refer to 206-06
4—Vacuu
m
Hose
5—No
n
-Return Valve
Page 423 of 2490

Power Brake Actuatio
n - Brake Booster
Re
moval and Installation
Remov
al
• C
AUTIONS:
Replacement of nuts and bolts: Various thread-locking de vices are used on nuts and bolts throughout the vehicle.
These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
Remove brake fluid spilla ge immediately from paint work, with clean water.
I
nstallation
1.
Position vehi
cle on a four-post lift.
2. Open engine compartment and fit paint work protection covers
to fenders.
3. Disconnect battery ground cable (IMPORTANT, see operation
86.15.19 for further information).
4. Remove engine compartment rear cover. Refer to operation
76.11.35.
5. Remove pedal housing, brake booster and master cylinder
assembly. Refer to operation 70.35.39.
6. Remove brake booster and master cylinder assembly. Refer to
operation 70.50.18.
7. R
emove nuts securing master cylinder to brake booster.
8. R
emove master cylinder from brake booster.
Re
move master cylinder.
Remove an
d discard seal.
9. Remove filler cap and empty residual brake fluid into a
container.
10. Clean components and mating surfaces.
1. Install master cylinder to brake booster.
Inst
all seal to master cylinder.
Page 424 of 2490
Instal
l master cylinder, make sure master cylinder rod
locates brake booster rod.
2. Inst al
l and tighten nuts to 21-29 Nm.
3. Install brake booster and master cylinder assembly. Refer to
operation 70.50.18.
4. Install pedal housing, brake booster and master cylinder
assembly. Refer to operation 70.35.39.
5. Install engine compartment rear cover. Refer to operation
76.11.35.
6. Reconnect battery ground cable (IMPORTANT, see operation
86.15.15 for further information).
7. Bleed brake system. Refer to operation 70.25.03.
8. Remove paint-work protection covers and close engine
compartment.