Change

Hint: after assembling, check and adjust the height, free travel of brake pedal and the height from

pedal to floor.

Brake--Remove malfunction

Brake pedal bracket

Brake pedal bushing

Brake pedal shaft

Locking shaft

Brake main pump lever pin

Brake pedal

Brake pedal

Rubber gasket

137

N.m: 

Regulated torque

Do not use the part repeatedly

Lithium soap base glycol lubricating grease

Brake--Vacuum booster assembly

Vacuum booster assembly

Inspection on automobile

1. Check the vacuum booster

(a) Check the gas sealed performance.

(1) Start the engine, and extinguish after one or two minutes,

then step and release brake pedal slowly several times.

Hint: if the first step is lowest, second and third step

rise gradually, and this shows the gas sealed per-

formance of booster is normal.

(2) Step down brake pedal when engine is running, then

extinguish the engine.

Hint: if the distance from pedal to floor does not

change in 30 seconds, this shows gas seal perfor-

mance of booster is normal.

(b) Working inspection.

(1) When engine is at parking state, step brake pedal sev-

eral times to check brake pedal.

The height from floor should not change.

(2) Step down brake pedal, then start the engine.

Hint: if pedal drops a little, this shows working is

normal.

2. Check vacuum check valve

(a) Check vacuum check valve.

(1) Remove pipe clamp, and disassemble vacuum pipe.

(2) Disassemble vacuum check valve.

(3) Blow air to check: in the direction from booster to engine,

the check valve should ventilate, but its opposite direc-

tion should not ventilate.

(4) If finding any malfunction, change vacuum check valve.

Change

1. Discharge brake liquid

Note: do not spill the brake liquid on paint surface of automobile body, if having, wash it cleanly.

2. Disassemble air filter assembly [64000033]

3. Disassemble carbon canister assembly [4G18-1129020]

4. Disassemble brake main pump subassembly

Good

Bad

First

Second

Third

Con-

duction

Not con-

duction

138

5. Disconnect the U-shaped joint of brake main pump

lever

(a) Release fixing screw cap of lever U-shaped joint.

(b) Disassemble locking pin of U-shaped joint and lever pin of

brake main pump.

6. Disassemble left front wheel

7. Disassemble vacuum booster

(a) Use special tool and wrench to disassemble brake hose of

left front wheel.

(b) Disassemble the bolts, two screw caps and activated car-

bon canister bracket.

(c) Disassemble vacuum hose on vacuum booster.

(d) Disassemble four screw caps and U-shaped joint.

(e) Take out vacuum booster and gasket.

8. Assemble vacuum booster with brake pump assem-

bly [64000164]

(a) Assemble U-shaped joint on booster lever.

(b) Assemble new gasket and vacuum booster with four nuts.

Torque: 13 N

⋅⋅⋅⋅⋅m

(c) Connect vacuum hose to vacuum booster.

(d) Use the bolts and nuts to assemble carbon canister bracket.

Torque: 5.4 N

⋅⋅⋅⋅⋅m

(e) Use special tool and wrench to connect brake hose of left

front wheel.

Torque: 15 

±±±±± 2 N⋅⋅⋅⋅⋅m

9. Assemble left front wheel

Torque: 103 

±±±±± 10 N⋅⋅⋅⋅⋅m

Brake--Vacuum booster assembly

139

Brake--Vacuum booster assembly

140

10. Connect brake main pump

Assemble U-shaped joint pin in U-shaped joint and brake pedal, and assemble fixing clamp to U-shaped

joint pin.

11. Assemble brake main pump

12. Assemble carbon canister assembly [4G18-1129020]

13. Assemble air filter assembly [64000033]

14. Add brake liquid in liquid storage tank

15. Discharge the air in brake main pump

16. Discharge the air in brake system

17. Check and adjust the height of brake pedal

18. Check the pedal free travel

19. Check the height from pedal to floor

20. Check the liquid level in storage tank

21. Check whether the brake liquid leaks