REMOVAL & INSTALLATION
See Figures 1 and 2
- Remove the master cylinder from the booster. It is not necessary to disconnect the lines from the master cylinder. Just move the cylinder aside, make sure not to bend or distort any of the brake pipes.
- Disconnect the vacuum booster pushrod from the brake pedal inside the car. It is retained by a bolt. A spring washer lies under the bolt head, and a flat washer goes on the other side of the pushrod eye, next to the pedal arm.
- Remove the vacuum hose connected from the booster to the check valve.
- Remove the four attaching nuts from inside the car. Remove the booster.
- Install the booster on the firewall.
- Connect the pushrod to the brake pedal. You may need to tilt the entire booster slightly to work the booster pushrod onto the pedal clevis pin without forcing unneeded side pressure on the pushrod.
- Tighten the mounting nuts for the brake booster to 15-20 ft. lbs. (21-30 Nm).
- Install the check valve and hose.
- Install the master cylinder, then tighten the nuts to 29 ft. lbs. (40 Nm) for 1982-84 models or 20-22 ft. lbs. (28-30 Nm) for 1985-96 models. Bleed the brake system, then check the system for proper operation. Do not move the car until a "hard" brake pedal is obtained and the brake system has been thoroughly checked for soundness.
This job can be difficult, and requires a number of special tools which are expensive, (especially if they're to be used only once). Generally, it's better to leave this job to your dealer, or buy a rebuilt vacuum booster and install it yourself.