Note. part number for this assembly see here.
Vacuum brake booster: 1 - pusher; 2 - protective cover with a filter; 3 - amplifier mounting stud; 4 - amplifier case
The vacuum brake booster is located under the hood on the front shield of the body, it is located between the brake pedal and the brake master cylinder.
Pedal assembly with vacuum booster and brake master cylinder: 1 - clutch pedal: 2 - brake signal switch: 3 - pedal assembly bracket; 4 - vacuum brake booster: 5 - system hydraulic reservoir; 6 - main brake cylinder; 7 - brake pedal
Removing
Put the car on the working place, brake with the parking brake and turn off the ignition.
Loosen the brake master cylinder nuts (see here).
Note: the brake pipes can be left on the brake cylinder - this will prevent air from entering the system.
Carefully remove the brake cylinder assembly with the reservoir from the amplifier studs and set aside.
Remove check valve from vacuum booster housing (see here).
Then, inside the car...
... disconnect the vacuum booster from the brake pedal, to do this, turn the spring clip pin 3, Figure 4-1,
pry off with a screwdriver and remove the plastic retaining ring
up and remove your finger (axis) from the holes of the pusher of the vacuum booster and the brake pedal.
Note: if the finger (axis) spring retainer is worn out, replace it.
Figure 4-1 - Removing the vacuum brake booster: 1 - vacuum brake booster; 2 - gasket; 3 - finger (connecting axis)
Remove two spring washers from the mounting pins of the pedal assembly (flat screwdriver).
and remove the cover
Unscrew four nuts 2, Figure 4-2, fastening the vacuum booster to the bracket 1 of the pedal assembly (interchangeable head 13, extension, ratchet wrench).
Figure 4-2 - Removing the vacuum brake booster: 1 - pedal assembly bracket; 2 - nuts for fastening the vacuum booster; 3 - brake pedal
... and remove the vacuum brake booster
Installation
Attention. Before installation, check the presence and condition of the gasket 2, Figure 41, between the vacuum booster and the bulkhead, replace if necessary.
Attention. Connecting axle (finger) 3 between the pusher of the vacuum booster and the brake pedal must be replaced.
Figure 4-3 - Adjusting the protrusion of the vacuum brake booster rod: X1 - rod overhang
Attention. Before installation, figure 4-3, check dimension X1 = 145.8±0.5 mm, adjust if necessary.
Note. The adjusting bolt of the booster rod is secured against self-retraction with a thread lock.
Install the vacuum brake booster in place and secure it to the bulkhead and pedal assembly bracket with four nuts. Nut tightening torque 21 Nm (2.1 kgf·m) (interchangeable head 13, extension, ratchet wrench, torque wrench).
Connect the vacuum booster to the brake pedal, for which install a new connecting axle (finger) into the holes of the pusher of the amplifier and the brake pedal and snap the axle flag onto the pusher rod. The axis is set only by moving from right to left and from top to bottom. Before installing on the axle, apply MOLYCOTE ZZM grease in an amount of 1g (grease MOLYCOTE ZZM in accordance with the current "Codifier of the main and auxiliary materials used in the maintenance and repair of LADA vehicles" K 3100.25100.00018).
Install the sound deadening pad and secure it with two spring washers (technological tube).
Install the brake booster check valve.
Install the brake master cylinder.
Bleed the brake system and hydraulic clutch. (see here).
Adjust the brake light switch. (see here).
Check the efficiency of the service brake system.