15/08/2023 14:27:28

Brake Lines - Master Cylinder to ABS (LHD) (Remove and Replace)

Correction Code 33034002

Removal

  1. Recover refrigerant from the vehicle (refer to procedure).
  2. Remove the wiper motor assembly (refer to procedure).
  3. Disconnect the brake fluid level sensor electrical connector.
  4. Move the coolant reservoir out of the working area:
    1. Ensure that the reservoir cap is fully attached.
    2. Release the 12V harness clip from the coolant reservoir.
    3. Disconnect the coolant fluid level sensor electrical connector.
    4. Remove the bolts (x4) that attach the coolant reservoir to the front crossmember (torque 6 Nm).
    5. Clamp the coolant hose at the rear of the coolant reservoir.
    6. Release the locking ring that attaches the hose to the coolant reservoir. Release the coolant hose from the nipple on the reservoir.
    7. Plug the coolant hole then carefully move the reservoir to the LH side of the front trunk.
  5. Disconnect the low voltage electrical connector from the A/C compressor and the electrical connector from the high pressure pipe.
  6. Release the edge clip that attaches the 12V harness to the compressor bracket.
  7. Remove the screw that attaches the ground strap to the compressor bracket (torque 8 Nm).
  8. Release the nuts (x2) that attach the A/C lines to the compressor (torque 10 Nm).
  9. Have an assistant support the compressor. Release the bolts (x3) that attach the A/C compressor bracket to the front drive unit (torque 10 Nm).
  10. Release the push clip that attaches the A/C compressor HV cable to the body of the vehicle.
  11. Carefully move the A/C compressor to the RH side of the front trunk.
  12. Disconnect the positive terminal from the 12V battery.
  13. Release the fir tree clips that attach the 12V harness to the top of the battery cage.
  14. Vehicles with air suspension: Remove the leftmost bolts (x2) that attach the air tank reservoir bracket to the crossmember (torque 6 Nm).
  15. Remove the bolts (x4) that attach the battery cage to the crossmember (torque 15 Nm).
  16. Release the edge clip that attaches the coolant hose to the battery cage. Remove the battery and battery cage from the vehicle.
  17. Place suitable absorbent material underneath the master cylinder and hydraulic lines.
  18. Remove the brake fluid reservoir cap.
  19. Remove all fluid from the brake fluid reservoir.
    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.
  20. Release the flare fittings (x2) that attach the front and rear hydraulic lines to the master cylinder (torque 18 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.
  21. Plug the pipe connections to prevent ingress of moisture or dirt.
  22. Place suitable absorbent material underneath the ABS module hydraulic lines.
  23. Release the flare fittings (x2) that attach the front and rear hydraulic lines to the ABS module (torque 23 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.
  24. Disconnect the electrical connector from the passive entry antenna on the bottom of the crossmember.
  25. Use a trim tool to release the fir tree clips (x2) that attach the 12V harness to the bottom of the crossmember.
  26. Use a trim tool to release the fir tree clips (x3) that attach the brake line retaining clips to the bottom of the crossmember.
  27. Release the brake lines from the retaining clips.
  28. While carefully lifting up on the LH side of the air tank reservoir (if equipped), maneuver the brake lines out from the bottom of the crossmember.
  29. Remove the brake lines from the vehicle.

Install

Installation procedure is the reverse of removal, except for the following: