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Home >> Hyundai >> 2018 >> Kona Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 259 (Brake System) >> Brake Booster >> Repair Procedures >> Removal And Installation

Removal And Installation

WARNING: This page is about a different car, the 2022 Kia Seltos. However, it is still accessible from the selected car via links, so may be relevant.
  1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
  2. Remove the engine control module (ECM).

    G 1.6 T-GDI GAMMA  (Refer to Engine Control/Fuel System - "ENGINE CONTROL MODULE (ECM) ")

    G 2.0 MPI NU  (Refer to Engine Control/Fuel System - "ENGINE CONTROL MODULE (ECM) ")

  3. Disconnect the brake fluid level sensor connector (A) and wiring fastener (B).
    G13481633Courtesy of KIA MOTORS AMERICA, INC.
  4. Separate the brake tube (A) from the master cylinder by loosening the tube flare nut.

    Tightening torque: 

    ABS: 12.7 - 16.7 N.m (1.3 - 1.7 kgf.m, 9.4 - 12.3 lb.ft)

    ESC: 18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb.ft)

    G13481634Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the brake fluid from the master cylinder reservoir with a syringe.
    G13481635Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Do not spill brake fluid on the vehicle as it may damage the paint. If brake fluid comes in contact with the paint, wash off immediately with water.
  6. Remove the master cylinder (B) from the brake booster after loosening the mounting nuts (A).

    Tightening torque: 

    9.8 - 15.7 N.m (1.0 - 1.6 kgf.m, 7.2 - 11.6 lb.ft)

    G13481636Courtesy of KIA MOTORS AMERICA, INC.
  7. Disconnect the vacuum sensor connector (A).
    G13481637Courtesy of KIA MOTORS AMERICA, INC.
  8. Disconnect the brake vacuum hose (A).
    G13481638Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the crash pad lower panel.

    (Refer to Body - "CRASH PAD LOWER PANEL ")

  10. Remove the snap pin (A) and clevis pin (B).
    G13481639Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Before installing the pin, apply the grease to the joint pin.
    • Use a new snap pin whenever installing.
  11. Remove the brake booster mounting nuts (A).

    Tightening torque: 

    16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb.ft)

    G13481640Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the brake booster (A).
    G13481641Courtesy of KIA MOTORS AMERICA, INC.
  13. Install in the reverse order of removal.
  14. After installation, bleed the brake system.

    (Refer to Brake system - "BRAKE BLEEDING PROCEDURES ")

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