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BRAKES

TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION
POWER BRAKE VACUUM BOOSTER –
R. H. D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MASTER CYLINDER – R. H. D. . . . . . . . . . . . . . . 3
SPECIFICATIONS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 4
REMOVAL AND INSTALLATION
POWER BRAKE VACUUM BOOSTER – R. H. D.
REMOVAL
(1) Di sconnect the posi ti ve and negati ve battery
cabl es.
CAUTION: Pump the brake pedal several times to
relieve the vacuum in the power brake booster. This
will prevent the booster from sucking in any con-
tamination when the master cylinder is removed.
(2) Di sconnect the brake fl ui d l evel sensor el ectri -
cal connector (Fi g. 1).
(3) Di sconnect the booster vacuum suppl y l i ne
from the booster check val ve.
(4) Remove the brake l i nes from the master cyl i n-
der (Fi g. 1).
(5) Remove the (2) master cyl i nder retai ni ng nuts
(Fi g. 1).
(6) Sl i de the master cyl i nder assembl y strai ght out
of the power brake booster.
(7) Remove the ai r cl eaner assembl y.
(8) Remove the battery and battery tray from the
vehi cl e.
(9) Remove the heater core cool ant suppl y tube
support bracket bol ts (Fi g. 2).
Fig. 1 Brake Master Cylinder
1 – POWER BRAKE VACUUM BOOSTER
2 – BRAKE FLUID LEVEL SENSOR ELECTRICAL CONNECTOR
3 – BRAKE MASTER CYLINDER
4 – BRAKE FLUID RESERVOIR
Fig. 2 Heater Core Coolant Supply Lines
1 – HEATER CORE COOLANT LINE SUPPORT BRACKETS
BOLTS
2 – HEATER CORE COOLANT SUPPLY LINES
PL BRAKES 5 - 1
(10) Remove the (2) cool ant reservoi r retai ni ng
bol ts from the dash panel . Di sconnect the cool ant
overfl ow hose from the thermostat housi ng and
remove the cool ant reservoi r from the dash panel .
(11) Worki ng from underneath the i nstrument
panel , di sconnect the brake pedal push rod. Remove
the retai ni ng cl i p from the end of the brake pedal
mounted stud, then sl i de the push rod strai ght off
the pi n.
(12) Di sconnect the cl utch pedal push rod. Depress
the pl asti c retenti on cl i p on the end of the cl utch
pedal mounted stud, whi l e sl i di ng the push rod
strai ght off the stud.
(13) Rotate the cl utch master cyl i nder to l i ne up
the square shaped retai ni ng boss wi th the square
shaped openi ng i n the brake pedal support bracket.
(14) Remove the (4) brake booster retai ni ng nuts.
(15) Worki ng from i nsi de the engi ne compartment,
remove the (2) cl utch fl ui d reservoi r retai ni ng bol ts
from the dash panel .
(16) Remove the cl utch master cyl i nder from the
dash panel by pul l i ng i t strai ght out. Posi ti on the
reservoi r and l i ne assembl y out of the way.
(17) Remove the brake booster from the dash
panel by pul l i ng i t strai ght out, then rotate the
booster and sl i de i t between the engi ne and the dash
panel towards the battery tray. Sl i de the booster
under the heater core cool ant suppl y hoses and out of
the engi ne bay.
INSTALLATION
(1) Posi ti on the brake booster on the dash panel by
reversi ng the path taken to remove the booster. Sl i de
the booster under the pl enum on the battery tray
si de of the engi ne compartment. Sl i de the booster
between the engi ne and dash panel unti l i t can be
i nstal l ed on the ri ght si de of the dash panel .
(2) Rei nstal l the vacuum suppl y hose on the
booster check val ve. Make sure the booster check
val ve i s fi rml y seated i n the rubber grommet and di d
not become di sl odged duri ng the booster i nstal l ati on.
(3) I nstal l the cl utch master cyl i nder through the
dash panel .
(4) I nstal l the cl utch fl ui d reservoi r. Torque the
retai ni ng bol ts to 7 N·m (62 i n. l bs.).
(5) Worki ng from underneath the i nstrument
panel , i nstal l the (4) brake booster retai ni ng nuts.
Torque the nuts to 29 N·m (250 i n. l bs.).
(6) Grease the brake pedal pi n and sl i de the brake
booster push rod onto the pedal pi n. I nstal l the
retai ni ng cl i p.
(7) Lock the cl utch master cyl i nder i n posi ti on.
Rotate the cl utch master cyl i nder to l i ne up the
square shaped retai ni ng boss wi th the square shaped
openi ng i n the brake pedal support bracket. Once the
cyl i nder i s i nserted through the brake pedal support
bracket rotate 90° to l ock i t i n posi ti on.
(8) Connect the cl utch pedal push rod. Sl i de the
push rod on the cl utch pedal mounted stud unti l the
pl asti c retenti on cl i p l ocks i t i n pl ace.
(9) I nstal l the cool ant reservoi r. Torque the retai n-
i ng bol ts to 7 N·m (62 i n. l bs.). Connect the cool ant
overfl ow hose on the thermostat housi ng.
(10) I nstal l the heater core cool ant suppl y tube
support bracket bol ts. Torque the bol ts to 36 N·m (27
ft. l bs.).
(11) I nstal l the battery and battery tray i n the
vehi cl e.
(12) I nstal l the ai r cl eaner assembl y.
CAUTION: Be certain the vacuum seal is installed
in the master cylinder mounting flange before
installation.
(13) I nstal l the brake master cyl i nder assembl y
(Fi g. 3). Torque the retai ni ng nuts to 29 N·m (250 i n.
l bs.).
(14) I nstal l the brake l i nes on the master cyl i nder
(Fi g. 3). Torque the tube nuts to 17 N·m (145 i n. l bs.).
(15) Connect the brake fl ui d l evel sensor el ectri cal
connector.
(16) Fi l l the brake fl ui d reservoi r to speci fi cati on.
(17) Bl eed the brake system.
Fig. 3 Brake Master Cylinder
1 – POWER BRAKE VACUUM BOOSTER
2 – BRAKE FLUID LEVEL SENSOR ELECTRICAL CONNECTOR
3 – BRAKE MASTER CYLINDER
4 – BRAKE FLUID RESERVOIR
5 - 2 BRAKES PL
REMOVAL AND INSTALLATION (Continued)
WARNING: Be certain a firm brake pedal is
achieved before attempting to move the vehicle.
MASTER CYLINDER – R. H. D.
REMOVE
(1) Di sconnect the negati ve battery cabl e.
CAUTION: Pump the brake pedal several times to
relieve the vacuum in the power brake booster. This
will prevent the booster from sucking in any con-
tamination when the master cylinder is removed.
(2) Di sconnect the brake fl ui d l evel sensor el ectri -
cal connector (Fi g. 4).
(3) Remove the brake l i nes from the master cyl i n-
der (Fi g. 4).
(4) Remove the (2) master cyl i nder retai ni ng nuts
(Fi g. 4).
(5) Sl i de the master cyl i nder assembl y strai ght out
of the power brake booster.
INSTALLATION
CAUTION: Be certain the rubber 0-ring vacuum seal
is installed in the master cylinder mounting flange
prior to installation.
CAUTION: If a new master cylinder is being
installed, the cylinder must be bench bleed prior to
installation.
(1) Sl i de the master cyl i nder assembl y strai ght i n
the power brake booster.
(2) I nstal l the (2) master cyl i nder retai ni ng nuts
(Fi g. 5). Torque the nuts to 28 N·m (250 i n. l bs.).
(3) I nstal l the brake l i nes on the master cyl i nder
(Fi g. 5). Torque the tube nuts to 17 N·m (145 i n. l bs.).
(4) Connect the brake fl ui d l evel sensor el ectri cal
connector (Fi g. 5).
(5) Fi l l the brake fl ui d reservoi r (Fi g. 5) to speci fi -
cati on.
(6) Bl eed the brake system.
WARNING: Be certain a firm brake pedal is
achieved prior to attempting to operate the vehicle.
Fig. 4 Master Cylinder – R. H. D.
1 – POWER BRAKE VACUUM BOOSTER
2 – BRAKE FLUID LEVEL SENSOR ELECTRICAL CONNECTOR
3 – BRAKE MASTER CYLINDER
4 – BRAKE FLUID RESERVOIR
Fig. 5 Master Cylinder – R. H. D.
1 – POWER BRAKE VACUUM BOOSTER
2 – BRAKE FLUID LEVEL SENSOR ELECTRICAL CONNECTOR
3 – BRAKE MASTER CYLINDER
4 – BRAKE FLUID RESERVOIR
PL BRAKES 5 - 3
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Clutch Fluid Reservoir
Bol ts . . . . . . . . . . . . . . . . . . . . . . 7 N·m (62 i n. l bs.)
Coolant Reservoir on Dash Panel
Bol ts . . . . . . . . . . . . . . . . . . . . . . 7 N·m (62 i n. l bs.)
Brake Booster to Cowl Panel
Nuts . . . . . . . . . . . . . . . . . . . . 29 N·m (250 i n. l bs.)
Brake Lines at Master Cylinder
Tube Nuts . . . . . . . . . . . . . . . . 17 N·m (145 i n. l bs.)
Heater Core Coolant Supply Tubes
Bol ts . . . . . . . . . . . . . . . . . . . . . 36 N·m (27 ft. l bs.)
Master Cylinder to VacuumBooster
Nuts . . . . . . . . . . . . . . . . . . . . 29 N·m (250 i n. l bs.)
5 - 4 BRAKES PL