Page 202 of 281

37A-23
MECHANICAL COMPONENT CONTROLS
Brake servo: Removal - Refitting
RIGHT-HAND DRIVE
37A
II - REFITTING OPERATION FOR PART
CONCERNED
aPosition the brake servo by moving the engine for-
ward as far as possible and tilting the pushrod up-
wards.
aRefit the brake servo from underneath the vehicle.
aRefit the brake servo.
aPosition the “brake - clutch pedal” assembly on the
bulkhead.
aTorque tighten the “brake - clutch pedal” assem-
bly nuts (21 Nm).
aRefit:
-the new dual safety connecting shaft between the
brake servo pushrod and the brake pedal from right
to left and from top to bottom,
-the brake servo nuts.
aTorque tighten the brake servo nuts (21 Nm).
III - FINAL OPERATION.
aRefit:
-the clutch master cylinder support,
-the clutch master cylinder support bolts,
-the clutch master cylinder rod on the clutch pedal.
aRefit the exhaust manifold (see Exhaust manifold:
Removal - Refitting) (12A, Fuel mixture).aRefit the catalytic converter (see Catalytic convert-
er: Removal - Refitting) (19B, Exhaust).
aRefit:
-the right-hand suspended engine mounting (see
Right-hand suspended engine mounting: Re-
moval - Refitting) (19D, Engine mounting),
-the rear suspended engine mounting (see Lower
engine tie-bar: Removal - Refitting) (19D, En-
gine mounting).
aRefit:
-the air filter box heat-resistant protector,
-the air filter box heat-resistant protector bolts,
-the air filter (see Air filter: Removal - Refitting)
(12A, Fuel mixture).
aRefit the "dehydrator reservoir - expansion valve"
connection (see Dehydrator reservoir - expansion
valve connecting pipe: Removal - Refitting) (62A,
Air conditioning).
aFill the refrigerant circuit using a refrigerant charg-
ing station (see Refrigerant circuit: Draining -
Filling) (62A, Air conditioning).
aRefit the ignition coil (see Coils: Removal - Refit-
ting) (17A, Ignition). D4F
K4M
JH3 or JR5
K4M
D4F, and 780
D4F
D7F
AIR CONDITIONING or CLIMATE CONTROL
D4F or D7F
Page 264 of 281

38C-5
ANTI-LOCK BRAKING SYSTEM
Hydraulic brake unit: Removal - Refitting
D4F or D7F, and LEFT-HAND DRIVE
38C
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (MR 411, 80A, Battery).
aPosition the pedal press on the brake pedal to limit
the outflow of brake fluid.
aRemove:
-the front wheel on the passenger side (see 35A,
Wheels and tyres, Wheel: Removal - Refitting,
page 35A-1) ,
-the front wheel arch liner, on the passenger side
(see Front wheel arch liner: Removal - Refitting)
(MR 412, 55A, Exterior protection),
-the ignition coil (see Coils: Removal - Refitting)
(MR 411, 17A, Ignition),
-the fuel vapour recirculation circuit solenoid valve
(see Fuel vapour absorber: Removal - Refitting)
(MR 411, 14A, Emission control),
-the air filter box (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture).aDisconnect the hydraulic unit computer connector
(1) .
aUndo the rigid brake pipe unions (2) on the hydraulic
unit.
aInsert the blanking plugs. Equipment required
pedal press
Tightening torquesm
hydraulic unit bolts on
its inter mediate bracket8 Nm
hydraulic unit inter medi-
ate bracket bolts on the
main hydraulic unit
mounting6.5 Nm
hydraulic unit main
mounting bolts on the
body8 Nm
rigid brake pipe unions
on the hydraulic unit13 Nm
121359
121360
WARNING
Prepare for the flow of fluid, and protect the sur-
rounding components.
Page 266 of 281

38C-7
ANTI-LOCK BRAKING SYSTEM
Hydraulic brake unit: Removal - Refitting
D4F or D7F, and LEFT-HAND DRIVE
38C
-the hydraulic unit main mounting bolts on the body.
aTorque tighten the hydraulic unit main mounting
bolts on the body (8 Nm).
II - FINAL OPERATION.
aRemove the blanking plugs.
aFit and tighten the rigid brake pipe unions on the hy-
draulic unit.
aTorque tighten the rigid brake pipe unions on the
hydraulic unit (13 Nm).
aConnect the computer connector on the hydraulic
unit.
aRefit:
-the air filter box (see Air filter unit: Removal - Re-
fitting) (MR 411, 12A, Fuel mixture),
-the fuel vapour recirculation circuit solenoid valve
(see Fuel vapour absorber: Removal - Refitting)
(MR 411, 14A, Emission control),
-the ignition coil (see Coils: Removal - Refitting)
(MR 411, 17A, Ignition),
-the front wheel arch liner, on the passenger side
(see Front wheel arch liner: Removal - Refitting)
(MR 412, 55A, Exterior protection),
-the front wheel on the passenger side (see 35A,
Wheels and tyres, Wheel: Removal - Refitting,
page 35A-1) .
aRemove the pedal press from the brake pedal.
aConnect the battery (see Battery: Removal - Refit-
ting) (MR 411, 80A, Battery).
aBleed the braking circuit (see 30A, General infor-
mation, Braking circuit: Bleed, page 30A-4) .