BRAKE BOOSTER(for LHD) REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during brake booster with master cylinder assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link
Auxiliary battery terminal is disconnected/reconnected Memorize steering angle neutral point Lane departure alert system (w/ Steering Control)

Click here

Intelligent clearance sonar system
Simple intelligent parking assist system
Pre-crash safety system
Adaptive high beam system
Parking assist monitor system

Click here

Initialize back door lock Power door lock control system

Click here

Replacement of brake booster with master cylinder assembly
  1. Bleed air

  2. Clear the data stored during previous linear solenoid valve offset learning, ABS holding solenoid valve learning, brake pedal stroke sensor assembly zero point calibration and system information memorization.

  3. Perform linear solenoid valve offset learning, ABS holding solenoid valve learning, brake pedal stroke sensor assembly zero point calibration and system information memorization.


  • DTCs are stored

  • ABS warning light illuminates

  • Brake warning light/yellow (minor malfunction) illuminates

  • Slip indicator light illuminates

  • VSC disabled or malfunctions

Click here for Initialization

Click here for Calibration


  1. Clear zero point calibration data.

  2. Perform yaw rate and acceleration sensor zero point calibration.

CAUTION / NOTICE / HINT

Note

While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch turns on. Therefore, when servicing the brake system components, do not operate the brake pedal or open/close the doors while the auxiliary battery is connected.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Click here

  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  3. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

    Click here

  4. REMOVE WATER GUARD PLATE

    Click here

  5. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  6. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  7. PERFORM ACCUMULATOR PRESSURE ZERO DOWN


    1. Using the GTS, perform the accumulator pressure zero down.


      1. Connect the GTS to the DLC3 with the power switch off.

      2. Turn the power switch on (IG).

      3. Turn the GTS on and enter the following menus: Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Utility.


        Chassis > ABS/VSC/TRC > Utility
        Tester Display
        ECB Utility
      4. Select "Motor Invalid" on the "ECB (Electronically Controlled Brake system) Utility" screen.

      5. Perform "Motor Invalid" according to the display on the GTS.

      6. Enter the following menus: Chassis / ABS/VSC/TRC / Utility / ECB (Electronically Controlled Brake system) Utility.


        Chassis > ABS/VSC/TRC > Utility
        Tester Display
        ECB Utility
      7. Select "ECB (Electronically Controlled Brake system) Invalid" on the "ECB (Electronically Controlled Brake system) Utility" screen.

      8. Perform "ECB (Electronically Controlled Brake system) Invalid" according to the display on the GTS.

      9. Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.

        Tech Tips

        A buzzer may sound due to low accumulator pressure. As this is not a malfunction, continue the procedure.

      10. Check that the brake pedal is firm.

        Note

        If the brake pedal is not firm or the pump motor continues to operate even after depressing the brake pedal 40 times or more, the accumulator pressure zero down is not complete.

      11. Turn the GTS off and turn the power switch off.

      12. Disconnect the GTS from the DLC3.

      13. Disconnect the cable from the negative (-) auxiliary battery terminal.

        Click here

    2. When the accumulator pressure zero down could not be performed using the GTS.

      Note

      If DTCs are output, accumulator pressure zero down may not be complete. In this case, perform the following procedure.


      1. B006IPSC01
        B006IFV Release the lock lever
        B006IV0 Disconnect the connector

        With the power switch off, release the lock lever and disconnect the brake booster pump assembly connector as shown in the illustration.

      2. Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.

      3. Check that the brake pedal is firm.

        Note

        If the brake pedal is not firm or the pump motor continues to operate even after depressing the brake pedal 40 times or more, the accumulator pressure zero down is not complete.

      4. Disconnect the cable from the negative (-) auxiliary battery terminal.

        Click here

  8. DRAIN BRAKE FLUID

    Note

    If brake fluid leaks onto any painted surface, immediately wash it off.

  9. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/o Canister Pump Module)

    Click here

  10. DISCONNECT ENGINE WIRE (w/o Canister Pump Module)

    Click here

  11. DISCONNECT ENGINE ROOM MAIN WIRE


    1. B006IZV

      Disconnect the connector from the brake booster with master cylinder assembly.

    2. B006HA3C01
      *a Lock Lever
      *b Lock Arm
      *c Push
      B006IFV Release the lock lever

      Push the lock arm of the connector to release the lock and rotate the lock lever to the position shown in the illustration.

    3. B006JBDC01
      *a Screwdriver Insertion Point
      *b Pre-lock
      B006IFV Disconnect the connector

      Using a screwdriver, release the pre-lock and disconnect the connector from the brake booster with master cylinder assembly as shown in the illustration.

    4. Disengage the clamp to separate the engine room main wire.

  12. DISCONNECT NO. 2 BRAKE ACTUATOR HOSE


    1. B006J1I

      Slide the clip and disconnect the No. 2 brake actuator hose from the brake booster with master cylinder assembly.

  13. SEPARATE NO. 1 BRAKE ACTUATOR TUBE


    1. B006HQE

      Remove the nut and separate the No. 1 brake actuator tube from the vehicle body.

  14. SEPARATE BRAKE LINE


    1. B006IS2

      Using a union nut wrench, disconnect the 3 brake lines from the brake booster with master cylinder assembly.

      Note


      • Do not kink or damage the brake lines.

      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

    2. B006HUI

      Disengage the clamp and separate the 3 brake lines.

      Note


      • Do not damage the clamp.

      • Do not kink or damage the brake lines.

  15. REMOVE FRONT DOOR SCUFF PLATE LH

    Click here

  16. REMOVE COWL SIDE TRIM BOARD LH

    Click here

  17. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

    Click here

  18. REMOVE BRAKE PEDAL RETURN SPRING

    Click here

  19. REMOVE PUSH ROD PIN

    Click here

  20. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. B006I9IC01
      *a Skid Control ECU
      *b No. 1 Reservoir Hose
      *c Brake Master Cylinder Push Rod Clevis
      *d Boot
      *e Master Cylinder Reservoir Assembly
      *f Brake Actuator Bracket

      Remove the 4 nuts and brake booster with master cylinder assembly.

      Note


      • Do not kink or damage the brake lines.

      • Do not carry the brake booster with master cylinder assembly by the parts shown in the illustration.

      • Be careful not to allow any brake fluid to enter the connector.

  21. REMOVE BRAKE MASTER CYLINDER GASKET