6.1. Details of the brake booster unit, brake booster and brake fluid reservoir 1. Brake pedal with bracket; 2, 10. Self-locking nut, subject to replacement, 25 Nm; 3. Vacuum booster gasket; 4. Brake booster; 5. Sealing ring; 6. Master brake cylinder, no repairs provided; 7. Assembly of D/V "F" brake lights and sensor "F47" of brake pedal position; 8. Bolt, 5 Nm; 9. Heat shield; 11. Brake line, from the secondary piston circuit of the CGT to the hydraulic modulator, 14 Nm; 12. Brake line, from the primary piston circuit of the GHZ to the hydraulic modulator, 14 Nm; 13. Compaction; 14. Brake fluid reservoir; 15. Cover, the connector should be in the recess; 16. Sealing the vacuum hose connection; 17. Vacuum hose, on AWD models - with vacuum sensor "G608"
Brake fluid reservoir and master cylinder
2. Remove the air cleaner (see Chapter 4).
3. Remove the battery together with its holder (see Chapter 5).
4. Place a lint-free cloth under the brake master cylinder to absorb brake fluid in the area where the engine and transmission meet.
5. Open the cap and pump out as much brake fluid as possible from the reservoir.
6. On models with manual transmission, disconnect the supply hose (In the illustration) clutch master cylinder, lift it up and tie it up so it doesn't get in the way. Alternatively, you can pinch the hose to prevent fluid from leaking out and then disconnect it from the reservoir.
6.6 Brake fluid reservoir connections
7. Disconnect the connector (And in illustration 6.6) low brake fluid level sensor and connector (C) D/W brake lights.
8. Remove the brake fluid reservoir by pressing its locking tabs outward and simultaneously pulling it out of the seals in the master cylinder.
9. Mark the brake pipes (1 in the illustration), disconnect them from the master cylinder and seal them. Loosen the nuts (2), remove the heat shield (if available) and carefully remove the master cylinder from the vacuum booster. If necessary, remove the sensor assembly from the master cylinder (see section 5).
6.9. Connections and fasteners of the GTZ
10. Installation is carried out in reverse order. When installing the brake master cylinder on the vacuum booster, make sure that the booster rod is correctly positioned in the brake master cylinder. Use new nuts to secure the brake master cylinder, tighten them with a force of 25 Nm. Tighten the nuts securing the brake lines to the brake master cylinder with a force of 14 Nm.
11. Finally, bleed the brake hydraulic drive and, on models with a manual transmission, the clutch hydraulic drive (see Chapter 1).
Removal and installation the vacuum booster
12. Remove the master cylinder (see subsection above).
13. Remove the vacuum hose from the vacuum booster.
14. Separate the brake pedal from the vacuum booster (see Section 5).
15. Give the nuts (1 in the illustration) and carefully remove the vacuum booster.
6.15. Fastening the vacuum booster
16. Installation is carried out in reverse order. Use new vacuum booster mounting nuts, tighten them to 25 Nm.
17. Finally, bleed the brake hydraulic drive and, on models with a manual transmission, the clutch hydraulic drive (see Chapter 1).