Removal
1. Remove the clutch master cylinder.
2. Disconnect the vacuum hose from the booster.
3. Disconnect the supply pipe and vacuum hose clamp bolts.
4. Remove the cotter pin and pin.
5. Unscrew the nuts (from the passenger compartment) and remove the clutch booster from the engine compartment side.
Checking the check valve
1. Check that air is flowing through the valve from the booster to the vacuum hose.
2. Check that air does not pass through the valve from the vacuum hose to the booster.
Installation
1. Adjusting the length of the pusher.
a) Install the gasket on the clutch master cylinder.
b) Install the special device on the gasket. Lower the rod down until its tip touches the piston.
c) Turn the special device upside down and install it on the amplifier.
d) Measure the gap between the pusher and the head of the special tool rod.
Gap - 0 mm
d) Adjust the length of the push rod so that the push rod touches the head of the piston rod.
Note: When adjusting the push rod length, press on the fork until the push rod extends outward.
2. Install the clutch booster and secure it with nuts.
3. Connect the rod fork to the clutch pedal, install the pin and cotter pin.
4. Install the master cylinder onto the booster and secure it with nuts.
Tightening torque - 13 Nm
5. Connect the supply pipe to the clutch master cylinder.
6. Connect the vacuum hose to the clutch booster.
7. Adjust the position and travel of the clutch pedal.
8. Bleed the clutch hydraulic system and check for leaks.
Clutch booster assembly. 1 - clutch master cylinder, 2 - gasket, 3 - vacuum hose, 4 - pin, 5 - cotter pin, 6 - clutch booster.
Clutch booster. 1 - ring, 2 - pusher seal, 3 - amplifier housing No.1, 4 - spring, 5 - pusher, 6 - buffer, 7 - piston, 8 - diaphragm, 9 - check valve assembly (with pusher), 10 - air filter, 11 - felt washer, 12 - retaining ring, 13 - stopper, 14 - amplifier housing No.2, 15 - seal, 16 - air filter, 17 - cover, 18 - boot, 19 - fork.