Brake Booster Removal and Installation: Installation

Reference: BRAKE BOOSTER INSPECTION 

1. Install booster to dash panel. Then connect push rod clevis pin (2) and clip (1).
2. Tighten booster mounting nuts (3) to specified torque, and then install steering joint cover.

   Tightening torque 

   Booster mounting nut (a): 13 N.m (1.3 kg-m, 9.5 lbf-ft) 

   Fig 1: Identifying Booster Mounting Nuts

   Courtesy of SUZUKI OF AMERICA CORP.
3. Connect vacuum hose to booster referring to MASTER CYLINDER AND BRAKE BOOSTER COMPONENTS .
4. Install the following brake pipes. See Front Brake Hose and Pipe Removal and Installation 
   • Master cylinder primary to ABS (ESP®) hydraulic unit pipe
   • Master cylinder secondary to ABS (ESP®) hydraulic unit pipe
   • ABS (ESP®) hydraulic unit to left front brake pipe
5. Install master cylinder assembly to booster referring to MASTER CYLINDER REMOVAL AND INSTALLATION .
6. Install intake manifold referring to INTAKE MANIFOLD REMOVAL AND INSTALLATION .
7. Install air cleaner assembly referring to AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION .
8. Install battery referring to BATTERY REMOVAL AND INSTALLATION .
9. Fill reservoir with specified fluid.
10. Bleed air from brake system referring to AIR BLEEDING OF BRAKE SYSTEM  and bleed air from clutch system referring to AIR BLEEDING OF CLUTCH SYSTEM (M/T MODEL) .
11. Check pedal height and play referring to BRAKE PEDAL FREE HEIGHT INSPECTION  and BRAKE PEDAL PLAY INSPECTION .
12. Check each installed part for fluid leakage and perform brake test.