Replacing the booster
■ Remove the master cylinder
■ Unscrew the cap nut securing the vacuum hose.
■ Remove the windscreen washer reservoir.
■ Unscrew the brake light switch from the pedal support.
■ Disengage the brake pedal return spring.
■ Remove the piston follower pin protection and take out the pin.
■ Remove the three nuts securing the booster base to the front body wall. If the car is equipped with a power steering mechanism, instead of nuts, unscrew the lower bolt behind the oil lines with the articulated wrench.
■ Remove the booster with the base from the body wall
■ Place the base in a vice and unscrew the nuts that secure the booster
■ Remove the rubber sealing ring.
■ Remove the plunger safety device from the adjusting element by levering it.
■ Remove the fork with pin.
■ Unscrew and remove the adjusting sleeve from the piston rod.
■ Unscrew the hexagonal nut.
The assembly of the booster is carried out in the following sequence.
■ Clamp the new support device in a vice with jaw protectors.
■ Place the hexagonal nut and the adjustment sleeve on the piston rod.
■ Insert the fork in the sleeve and fit the lock
■ Position the adjusting sleeve in this way, that there is a distance between the assist device and the axis of the hole in the fork 278.5 Mm.
■ Place the rubber ring on the booster.
■ Applying torque 22 Tighten the following nuts N m: the lower nut that connects the left base to the bracket on the servo, both nuts on the strut of the right base, new self-locking nuts on the servos and base on the strut, the upper nut of the left support.
■ Torque the master cylinder to the booster 18 N • m.
■ Tighten the cap nut of the vacuum hose to the torque 15 N m m.
■ Insert the pin and the piston pusher into the pedal and forks, insert the safety device and hook the spring. The spring acts in the direction of pressing the pedal
■ Insert and turn the brake light switch. Before that, pull out the switch actuator as far as it will go.
At the end of all activities, you should bleed the brake system.