46 BRAKES Use always a wooden mallet to tap Seal into the Rear housing. 4. Apply grease on the Seal. 5. Push Operating rod assembly in theValve body and assemble Key. Place Key retainer over Key and press it. 6. Place and position the Diaphragm, Diaphragm disc and Valve body assembly on the Rear housing. 7. Place Diaphragm over Rear housing groove. 8. Place the Rear housing assembly with valve body and operating rod assembly with Key on locking fixture. 9. Place Rubber reaction disc, Push rod, Spring seat and Spring. 10. Place and Front housing on the Spring and match its notches with Rear housing notches. 11. Tighten the fixture handle simultaneously aligning the notches of Front housing and Rear housing notches in line. Continue tightening to allow the Front housing notch groove matches with rear housing. 12. Rotate the rods uniformly without jerk to avoid twisting of Diaphragm and lock the housings and match the marking. 13. Avoid grease / Oil contact with diaphragm during assembly. 14. Loosen the handle and remove the unit from the fixture. 15. Assemble the Grommet and Non return valve in Front housing. 16. Assembly the Filters, Retainer and Gaiter. Ensure Gaiter is located properly on Rear housing groove. 17. Assemble Nut on Operating rod assembly and assemble Fork on Operating rod assembly. Ensure that booster input rod standout dim is 111 + 0.5 mm Fig. 53 18. Place Sealing ring , Spacer on Front housing and tighten Nuts. 19. Mount the unit on the vehicle and connect brake pedal return spring. Adjust pedal position and free play. Install the eccentric pin (smear pin with molycoat grease) 20. Connect the vacuum pump line with the Non return valve of vacuum brake valve. 21. Mount the Master cylinder on the vacuum brake valve and connect the hydraulic lines. TEST PROCEDURE 1. Bleed the hydraulic lines. Ref. brake bleeding procedure. 2. Apply / release the brake without vacuum assistance and check for free return if brake pedal. 3. Depress the brake pedal fully before starting the engine (i.e. without vacuum in the system). Start the engine. As vacuum builds up in the system, the brake pedal becomes light indicating proper function of the brake valve and the brake system. 4. Check for vacuum leak in brakes on/off positions by observing the vacuum gauge. 5. Apply / Release the brake with vacuum and check for free return of brake pedal.
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