Kia Cee'd: Brake System / Brake Booster Repair procedures

Kia Cee'd JD Service Manual / Brake System / Brake System / Brake Booster Repair procedures

Brake Booster Operating Test

For simple checking of the brake booster operation, carry out the following tests.

1.	Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the booster is inoperative.

2.	With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is inoperative.

With the engine running, step on the brake pedal and then stop the engine.Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if the pedal rises, the booster is inoperative.

If the above three tests are okay, the booster performance can be determined as good.

Even if one of the above three tests is not okay, check the check valve, vacuum hose and booster for malfunction.

Removal [LHD]

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Remove the battery. (Refer to Engine Electrical system-"Battery")

3.	Remove the ECM. (Refer to Engine control / Fuel System -"Engine Control Module")

4.	Remove the master cylinder. (Refer to Master Cylinder)

5.	Disconnect the vacuum hose (A) from the brake booster. [Kappa 1.0 T-GDI] [Kappa 1.4 MPI] [Gamma 1.6 MPI ] [Gamma 1.6 GDI ] [Gamma 1.6 T-GDI ] [U-ll 1.4 / 1.6 TCI ]

6.	Remove the snap pin (A) and clevis pin (B).

Remove the mounting nuts (A).

Tightening torque:

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

8.	Remove the brake booster (A).

Removal [RHD]

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Disconnect the vacuum hose (A) from the brake booster.

3.	Remove the master cylinder. (Refer to Master cylinder)

4.	Remove the snap pin (A) and clevis pin (B).

Remove the mounting nuts (A).

Tightening torque :

16.7 ~ 25.4 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft)

6.	Remove the connector bracket (A).

7.	Remove the clutch regulator assembly (A). [MT only]

Install the jack to the edge of oil pan to support the engine.

Insert the rubber block between jack and oil pan.

9.	Remove the engine mounting support bracket. (Refer to Engine Mechanical System – “Engine mounting”)

10.	Slowly lower the jack and make space to remove the brake booster.

11.	Remove the brake booster.

Inspection

Inspect the check valve in the vacuum hose.

Do not remove the check valve from the vacuum hose.

2.	Check the boot for damage.

Installation

Install in the reverse order of removal.

•	Before installing the pin, apply the grease to the joint pin.

•	Use a new snap pin whenever installing.

2.	After installing, bleed the brake system. (Refer to Brake system bleeding)

3.	After be equipped perform bleeding air procedure in clutch release cylinder after pouring the brake fluid. [MT only] (Refer to Clutch - "Clutch Release Cylinder")

Brake Booster Components and components location

Components [LHD] 1. Brake booster 2. Master cylinder assembly 3. O-ring Components [RHD] 1. Brake booster ...

Vacuum Pump Components and components location

Components Gamma 1.6 T-GDI 1. Vacuum pump 2. Bracket 3. Lead wire assembly Kappa 1.0 T-GDI 1. Cylinder head ...

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