2024-06-25

Electromechanical Brake Booster Assembly (Remove and Replace)

FRT No: 33201002

  • 2024-06-25: Updated installation procedure and revised references.
  • 2023-06-16: Replaced steps for the Toolbox 3 Tools tab.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
If the 12V power supply is disconnected, do not attempt to open any doors with door glass in closed position. Failure to follow this instruction could result in door glass shatter.
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Note
Before disconnecting the 12V power supply, ensure that the driver’s door window is fully open. Failure to follow this instruction could result in vehicle lockout.
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CAUTION
Use extreme caution when handling the electromechanical brake booster assembly. Do not touch the input rod, pedal travel sensor connector, or ECU connector unless otherwise noted.

Removal

Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Use extreme caution when handling the electromechanical brake booster assembly. Do not touch the input rod, pedal travel sensor, or ECU connector unless otherwise noted.
  1. Disconnect 12V power. See Disconnect 12V Power .
  2. Remove the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
  3. Remove the bolts (x3) that secure the wiper motor assembly to the bulkhead (torque 6 Nm).
  4. Carefully lean the wiper motor assembly away from the brake booster assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not disconnect the harness connector from the wiper motor assembly.
    1 Wiper motor leaned away from the brake booster assembly
  5. Remove the brake light switch. See Switch - Brake Light (Remove and Replace).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The brake light switch is a one time use component. Ensure that a new switch is used during reinstallation.
  6. From inside the vehicle, remove the spring clip from the clevis pin.
  7. Depress the brake pedal for clearance and remove the clevis pin.
  8. Place suitable absorbent material underneath the brake booster assembly and hydraulic lines.
  9. Remove the brake fluid reservoir cap.
  10. Using a syringe, remove all fluid from the reservoir.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not use a syringe that has been used for oils or other petroleum products. Even trace amounts of petroleum-based fluids can damage seals throughout the brake system, leading to brake failure.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If brake fluid is spilled on a painted surface, wash off immediately with clean water.
    Informational PurposesAn informational icon, calling your attention
    Note
    Place suitable absorbent material around the affected area to absorb any possible fluid spillage.
  11. Release the nuts (x2) that secure the front and rear hydraulic lines to the master cylinder (torque 20 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If brake fluid is spilled on a painted surface, wash off immediately with clean water.
  12. Plug the pipe connections to prevent ingress of moisture or dirt.
  13. Remove the clip that secures the LH side of the washer fluid reservoir to the crossmember.
  14. Disconnect the brake fluid level sensor connector, pedal travel sensor connector, and ECU connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    If it is difficult to access the sensor connectors, gently push the master cylinder towards the passenger side of the vehicle for better access.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage component(s).
    1 Brake fluid level sensor connector
    2 Pedal travel sensor connector
    3 ECU connector
  15. From inside the vehicle, remove the nuts (x4) that secure the pedal to the brake booster assembly (torque 23 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Replace all nylon-insert locknuts.
  16. Using an upward motion, remove the brake booster assembly.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use extreme caution when handling the electromechanical brake booster assembly.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The electromechanical brake booster can only be supported by the ECU housing, adapter plate, and metal housing.

Installation

Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Ensure that 12V power is disconnected before installing the brake booster assembly.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Use extreme caution when handling the brake booster assembly. Do not touch the input rod, pedal travel sensor connector, or ECU connector unless otherwise noted.
Informational PurposesAn informational icon, calling your attention
Note
Handle the booster so that the ECU faces upward; use your left hand to support the ECU and your right hand to support the casting.
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Note
Clean the affected areas before installation.
  1. Have an assistant hold the brake pedal assembly away from the booster assembly input shaft, then carefully insert the input rod through the hole in the bulkhead.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not allow the input rod to contact the bulkhead.
  2. Use new fasteners to secure the booster to the bulkhead (torque 23 Nm).
  3. Install the clevis pin.
  4. Install the spring clip into the clevis pin.
  5. Secure the front and rear hydraulic lines to the master cylinder (torque 18 Nm).
  6. Fill the booster reservoir with fluid.
  7. Connect the 3 electrical connectors to the booster.
  8. Install a new brake light switch. See Switch - Brake Light (Remove and Replace).
  9. Install the clip that secures the LH side of the washer fluid reservoir to the crossmember.
  10. Move the wiper motor assembly back into position, and then install the bolts (x3) that secure the wiper motor assembly to the bulkhead (torque 6 Nm).
  11. Install the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
  12. Reconnect 12V power.
  13. Bleed the brakes Bleed or Flush Procedure - System (Remove and Replace).
  14. Update the vehicle firmware. See Firmware Update.
  15. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  16. Unlock the vehicle gateway. See Gateway Unlock.
  17. In Toolbox 3, click the Actions tab, type "IBST-Pedal" into the search field, click PROC_IBST_X_IBST-PEDALvia Toolbox: (link), click Run, and allow the routine to complete.
  18. In Toolbox 3, click Dashboards > Service Tools > DTCs, and then click IBST.
  19. Click Read DTCs to display the DTCs.
  20. If necessary, power cycle the vehicle.
  21. Click Clear DTCs to clear the DTCs.
  22. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  23. Sit in the driver's seat and pump the brake pedal several times. Check for a short, firm travel when the brakes are applied.
  24. Perform a road test using a series of brake stops, including at least one full ABS stop. Ensure that there is proper brake pedal feel and performance. If brake pedal feel is not firm, repeat the bleed procedure.