Remove the battery.
Remove the air resonator.
Remove the battery tray.
Remove the injection computer.
Remove the air intake pipe, air pipe and air filter housing.
Remove the left front wheel, fender liner and both intake silencers (vehicles with H4J engine).
Disconnect select and shift cables from transmission.
Disconnect both cables from the levers on the gearbox.
Squeeze the tip of the rope at points (A), pull the lock towards (IN) and lift the rope at the point (WITH).
Insert plugs into gear selector cable ends.
Remove the brake pedal switch.
Use a syringe to remove the brake fluid from the reservoir so that its level is below the fluid supply hole in the clutch master cylinder. Disconnect the brake fluid level sensor connector.
Remove the vacuum brake booster valve. Partially remove the noise insulation of the bulkhead shield.
Disconnect the clutch master cylinder pipe.
Remove the upper ball joint of the transmission control mechanism.
From the interior side, remove the brake pedal fork axle A from the brake booster push rod.
Remove the two nuts securing the master cylinder to the vacuum brake booster.
Tilt the brake master cylinder forward to separate it from the booster without applying force to the brake lines.
Remove two fixing screws (IN) vacuum brake booster.
Installation
Installation is made in an order, the return to removal.
Before installation, measure the length of the fork stem:
- for left-hand drive vehicles: X1 = 163.7 mm;
- for right-hand drive vehicles: X1 = 133.2 mm.
If the length is not as specified, replace the amplifier.
Attention. Check the presence and blocking of the connecting shaft between the push rod of the vacuum brake booster and the brake pedal.
Establish the vacuum amplifier of brakes, without fixing on it a pusher.
Tighten the two brake booster mounting bolts to 21 Nm.
Install the master brake cylinder to the vacuum brake booster.
Tighten the two nuts securing the brake master cylinder to 50 Nm.
Check the position and security of holder C on the bulkhead, as well as the position and security of fixation of the brake pipes in this holder. Make sure that the spacer holder D is in place.
From the cabin side, install the pusher into the vacuum brake booster and onto the brake pedal.
Step on the brake pedal to connect the pushrod and booster.
Reinstall the brake pedal fork axle.
Be convinced of reliability of fixing of an axis of a plug of a pedal of a brake on a pusher.
Reinstall the brake pedal switch.
Check the operation of the brake pedal switch (brake lights should go out when the brake pedal is released).
Add brake fluid.
Replace the brake master cylinder reservoir cap.
Install the remaining removed parts in the reverse order of removal. Attach the wires to the battery terminals, starting with the positive terminal.
Carry out a road test.