25/06/2024 04:49:34
Electromechanical Brake Booster Assembly (LHD) (Remove and Replace)
Correction Code 33201002
- 2024-06-25: Updated installation procedure and revised references.
- 2023-06-16: Replaced steps for the Toolbox 3 Tools tab.
Removal
- Open the driver's door.
- Move the steering wheel fully downwards and away from the instrument panel.
- Move the driver's seat fully rearward.
- Remove the wiper motor. See Wiper Module (LHD) (Remove and Replace).
- Remove the driver's side lower dash trim. See Trim - Dash - Driver's Side - Lower (Remove and Replace).
- Remove and discard the brake light switch. See Switch - Brake Light (Remove and Replace).
-
From inside the vehicle, remove
the spring clip from the clevis pin.
- Depress the brake pedal for clearance and remove the clevis pin.
- Place suitable absorbent material underneath the brake booster assembly and hydraulic lines.
-
Using a syringe, remove all fluid
from the reservoir.
WarningDo 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.CAUTIONIf brake fluid is spilled on a painted surface, wash off immediately with clean water.NotePlace suitable absorbent material around the affected area to absorb any possible fluid spillage.
-
Disconnect the brake fluid level
sensor electrical connector.
-
Disconnect the pedal travel
sensor and ECU connectors from the brake booster.
-
From inside the vehicle, remove
and discard the nuts (x4) that secure the pedal to the brake booster assembly
(torque 23 Nm).
CAUTIONReplace all nylon-insert locknuts.
-
Release the flare fittings (x2)
that secure the front and rear hydraulic lines to the master cylinder (torque 18
Nm).
CAUTIONIf brake fluid is spilled on a painted surface, wash off immediately with clean water.
- Remove the booster from the underhood area by pulling it forward and rotating it clockwise.
Installation
CAUTION
Ensure that 12V
power is disconnected before installing the brake booster assembly.
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.
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.
-
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.
CAUTIONDo not allow the input rod to contact the bulkhead.
- Use new fasteners to secure the booster to the bulkhead (torque 23 Nm).
- Install the clevis pin.
- Install the spring clip into the clevis pin.
- Secure the front and rear hydraulic lines to the master cylinder (torque 18 Nm).
- Fill the booster reservoir with fluid.
- Connect the 3 electrical connectors to the booster.
- Install a new brake light switch. See Switch - Brake Light (Remove and Replace).
- Install the wiper motor assembly. See Wiper Module (LHD) (Remove and Replace).
- Reconnect 12V power. See Disconnect 12V Power.
- Bleed the brakes. See Bleed or Flush Procedure - System (Remove and Replace).
- Update the vehicle firmware. See Firmware Update.
- Install the driver's side lower dash trim. See Trim - Dash - Driver's Side - Lower (Remove and Replace).
- Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
- Unlock the vehicle gateway. See Gateway Unlock.
- In Toolbox 3, click the Actions tab, type "IBST-Pedal" into the search field, click PROC_IBST_X_IBST-PEDALSearch for routine in ToolboxiBooster Initialization, click Run, and allow the routine to complete.
- In Toolbox 3, click IBST. , and then click
- Click Read DTCs to display the DTCs.
- If necessary, power cycle the vehicle.
- Click Clear DTCs to clear the DTCs.
- Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
- Sit in the driver's seat and pump the brake pedal several times. Check for a short, firm travel when the brakes are applied.
- 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.