Hyundai Genesis: Brake System / Brake Booster Repair procedures

Brake Booster Operating Test

1.	Run the engine for one or two minutes, and then stop it.Depress the pedal several times, and if the pedal stroke gradually decreases, the brake booster operates properly. If there is no change, the booster is faulty.

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.

3.

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 three tests mentioned above result in good condition, the booster performance can be determined as good. Even if one of the three tests mentioned above is not in good condition, check the check valve, vacuum hose and booster for malfunction.

Removal

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

2.	Disconnect the ECM connector (A) and TCM connector (B). IDB (C) and then remove the noise barrier (D).

3.	Remove the Cowl Top Cover. (Refer to Body - "Cowl Top Cover")

4.	Remove the ECM, TCM & IDB.

5.	Remove the clamp (A) and brake vacuum hose (B).

6.	Remove the clip (A) and then disconnect brake fluid level switch connector (B).

7.	Remove the brake fluid from the master cylinder reservoir with a syringe. Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

8.

Loosen the hose connecting bolt(A) and disconnect the brake tube. Tightening torque : 29.4 ~ 34.3 N.m (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft) DO not reuse the washers. Be sure to install a new one. If a washer is reused, it would cause failure of the brake performance or accidents by oil leakage. Tighten to the specified torque by torque wrench. Do not use air ratchet or power tools.

9.	Remove the master cylinder (B) from the brake booster after loosening the mounting nuts (A). Tightening torque : 12.8 ~ 16.7 N.m (1.3 ~ 1.7 kgf.m, 9.4 ~ 12.3 lb-ft)

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

11.	Remove the mounting nuts. Tightening torque : 16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.31 ~ 18.8 lb-ft)

12.	Remove the brake booster.

Inspection

1.	Inspect the vacuum hose. Do not disconnect the vacuum amplifier from the vacuum hose.

2.	Check the boot for damage.

Installation

1.	To install, reverse the removal procedure. • Before installing the pin, apply the grease to the joint pin. • Use a new snap pin and washer whenever installing.

2.	After installing, bleed the brake system. (Refer to Brake System - "Brake System Bleeding")

Brake Booster Components and Components Location

Components 1. Brake booster2. Master cylinder assembly3. Vacuum hose4. Reservoir ...

Master Cylinder Components and Components Location

Components 1. Reservoir cap2. Reservoir3. Grommet4. Master cylinder ...

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