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JKC TYPE

Fig. 9-128

Booster Body, Seal & Bearing

Inspect the booster bodies, seals and bearing for wear or damage.

AISIN TYPE

Fig. 9-129 JKC TYPE

Fig. 9-129 JKC TYPE

Booster Body, Seal & Bearing

Inspect the booster bodies, seals and bearing for wear or damper.

Fig. 9-130

Fig. 9-130

Fig. 9-131

Fig. 9-132

0 Replace The No.1 Body Seal

AISIN TYPE

1. Remove the circular ring and seal from the No.1 body seal.

2. Apply silicon grease onto the seal and install them into the No.1 body.

3. Install a circular ring into the No.1 body.

Fig. 9-133

Fig. 9-133

Fig. 9-134

Fig. 9-134

SST

Fig. 9-135

Replace The No.2 Body Seal

AISIN TYPE

1. Remove the seal from the No.2 body with SST.

SST [09726-35010] No.1 [09753-30020] [09608-20011] No.2

2. Install a new seal to the No.2 body seal with SST.

SST [09726-35010] No.1 [09608-35010] [09753-30020] [09608-20011] No.2 - Note -

Be careful not to crack the bearing during assembly.

Replace The No.2 Body Seal

JKC TYPE

1. Remove the circular ring and seal from the No.2 body seal.

Fig. 9-136

2. Apply silicon grease onto the seal and install them into the No.2 body.

Fig. 9-137

3. Install a circular ring into the No.2 body.

Fig. 9-138 AISIN TYPE

Reaction Disc & Case

Inspect for wear, damage, cracks or corrosion.

Fig. 9-138 AISIN TYPE

JKC TYPE

Fig. 9-139

ASSEMBLY

Assemble the parts in the numerical order shown in the figure.

10 9

1 Fig. 9-141 2 Fig 9-143 9-142 9-144

1

Reaction Disc, Case & Oil Seal

7

Boot & Air Cleaner Element

2

Front Diaphragm, Retainer & No.2 Piston

8

Deflector

3.

Piston Plate & Rear Diaphragm

9

Piston Return Spring

4

No.3 Body

10.

Piston Rod

5

No 3 Body & No.2 Body

11.

No 1 Body

6

Air Cleaner Separater & Element

12.

Clevis

DDM(E- Brake Booster

9-55

Assemble the parts in the numerical order shown in the figure.

Fig. 9-140

"1

1.

Reaction Disc, Case & Oil Seal

7.

Boot & Air Cleaner Element

2.

Front Diaphragm, Retainer & No.2 Piston

8.

E Ring

3.

Piston Plate & Rear Diaphragm

9.

Piston Return Spring

4.

No.3 Body

10.

Piston Rod

5.

No.3 Body & No.2 Body

11.

No. 1 Body

6.

Air Cleaner Separater & Element

12.

Before assembly, coat the parts shown below with silicon grease (furnished in repair kit).

Fig. 9-141

Piston Rod Perimeter Seal Lip

Inner Circumference of Front Diaphragm Inner Surface of No.2 Body Outer Circumference of No.2 Piston Contact Ssurface of Piston Rod & Reaction Disc

Contact Surface of Reaction Disc &

Operating Rod

Control Valve Perimeter

Piston Plate Perimeter

Reaction Disc Perimeter

0 Ring

Contact Surface of Boot & No.2 Body Contact Surface of No 1 Piston & Seal Contact Surface of No.2 Piston & Seal & Bearing of No.3 body

Fig. 9-142

Coat the outer surface of the reaction disc and 0 ring with silicon grease.

Fig. 9-143

Fig. 9-143

0AISIN TYPE

Assemble the No.3 body 1. Clamp SST in a vise and install the reaction disc case. SST [09753-30010]

02. Install the front diaphragm and No.2 piston to the reaction disc case.

3. Install the No.3 body to the No.2 piston.

1. Align the notched holes of the reaction disc case and No.2 piston in a right angle.

2. Coat the outer surface of the piston with silicon grease.

Fig. 9-145

Fig. 9-145

4. Push in the valve operating rod and valve stop key. and install the No.1 piston and No.2 piston.

Align the reaction disc case, No.1 piston and No.2 piston in the same direction.

Fig. 9-146

Fig. 9-146

Install the rear diaphragm and piston plate.

(1)' When assembling, align the key hole of the No.1 piston with the round dent of the piston plate.

(2) Of the 4 ribs, turn two digonal ones clockwise to assemble.

Fig. 9-147

Fig. 9-147

0JKC TYPE

Assemble the No.3 body. 1. Clamp SST in a vise and install the reaction disc case. SST [09753-30010]

Fig. 9-148

Fig. 9-148

Fig. 9-149

2. Install the front diaphragm and No.2 piston to the reaction disc case.

3. Install the No.3 body to the No.2 Piston.

1. Align the notched holes of the reaction disc case and No.2 piston in a right angle.

2. Coat the outer surface of the piston with silicon grease.

Install the retainer and crip as shown in the figure.

Fig. 9-150

Fig. 9-152
Fig. 9-153

-SST

Match the hole and crip.

Assemble the body by turning the joint handle of the SST.

SST [09738-00020]

Match the hole and crip.

AISIN TYPE

Install the No.2 body to the No.3 body assembly.

Coat the inner surface of the No.2 body with silicon grease.

Install the No.1 body return spring, piston rod and No.2 body to SST and tighten the nut. SST [09738-00020]

1. Align the matchmarks on NO.1 body and No.2 body.

2. Tighten the both nuts evenly.

Assemble the body by turning the joint handle of the SST.

SST [09738-00020]

INSTALLATION

Install the parts in the numerical order shown in the figure.

Fig. 9-154

Fig. 9-158

Brake Booster

Clevis Pin, Clip & Spring

Stop Light Switch Connector

Master Cylinder

Brake Tube

Hose

Fig. 9-158

Brake Booster

Clevis Pin, Clip & Spring

Stop Light Switch Connector

Master Cylinder

Brake Tube

Hose

Fig. 9-155

Clearance

Adjust The Booster Push Rod Length

The length of booster push rod is adjusted to provide the specified clearance between the push rod end and the master cylinder piston. Clearance:

STD at Idling vaccum 0.1 - 0.5 mm (0.004 - 0.020 in.)

Fig. 9-156

yfflf1

-SST

1. Set the SST on the master cylinder and push the pin until it contacts the piston. SST [09737-00010]

Measure the master cylinder together with the gasket.

-Gasket

Fig. 9-157

----- SST

Turn the SST upside down and place it on the booster. Adjust the booster push rod length until the rod end contacts the pin head.

SST[09737-00010]

Between SST and push rod

Adjust push rod length. By the above adjustment, the clearance will be 0.1 - 0.5 mm (0.004 - 0.020 in.) under the vacuum.

Fig. 9-158

SEE MASTER CYLINDER INSTALLATION

SECTION Fig. 9-54 to 9-69

0 Install the master cylinder and connect the brake tube with SST. SST [09751-36011]

Fig. 9-159

BRAKE PEDAL ADJUSTMENT & AIR BLEEDING SECTION

After installing, adjust the pedal height and play, and bleed air from the system.

Fig. 9-160

Fig. 9-160

ON-VEHICLE INSPECTION Inspect Booster Operating

Use the brake booster tester to inspect booster operating condition. If tester is not available check the brake booster by the following procedure. It is not necessary to pinpoint the exact place of trouble but sufficient to attain general knowledge of the condition.

Fig. 9-161

2 Minutes Running to Stop m

2 Minutes Running to Stop

Fig. 9-162

NO GOOD

Fig. 9-163

GOOD

Check The Air Tighteness

1. Start the engine.

2. Stop the engine after running for 1 or 2 minutes.

Pump the brake pedal several times. If the pedal goes down deep the 1st time but gradually rises after the 2nd and 3rd times, it is in good condition.

4. If there is no change in pedal height when depressed the 2nd and successive time, it is defective.

If defective, inspect the vacuum lines and sealing parts, and replace any faulty part. When this has been done repeat the entire test!

Fig. 9-164

Stop

Stop

Check The Operation

1. With the engine stopped, pump the brake pedal several times with the same pressure. Insure that the pedal height does not change.

Fig. 9-165

Fig. 9-165

Fig. 9-166

/{Sh

!

A

Running to stop I

Hold

Fig. 9-167

Start the engine while the brake pedal is depressed. If the pedal goes down slightly at this time, it is in good condition. If there is no change in pedal height, it is defective.

Check The Air Tighteness Under The Load

1. With the engine running, depress the brake pedal.

Then stop the engine while keeping the brake pedal depressed.

Hold depressed for 30 seconds. If the pedal height does not change, it is in good condition.

If the pedal rises, it is defective.

Fig. 9-168

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Simple Car Care Tips and Advice

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