2026-05-19

Pipe - Brake - Side Sill(Model YL) (Remove and Replace)

Correction code 33030100002 FRT 4.92 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Equipment:
  • 1080578-00-B - Brake Bleed Adapter M3/Y
  • 1080579-00-A - POWER PROBE BRAKE BLEEDER 4.0

Torque Specifications

Table 1. Torque Specifications: Pipe - Brake - Side Sill(Model YL) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nuts (x2) that attach the brake pipes to the coupling
16 Nm (11.8 lbs-ft)
  • Combination Wrench 12pt 12mm
  • 3/8in Dr. Flare Nut Crowfoot 13 mm socket
 Reuse
LH rear brake line tube outer/inner nut
16 Nm (11.8 lbs-ft)
  • 3/8in Dr. Flare Nut Crowfoot 12 mm socket
 Reuse

Remove

  1. Remove the HV battery. See HV Battery (AWD) (3-Phase) (Model YL) (Remove and Install).
  2. Remove all the four wheels. See Wheel Assembly (Remove and Install).
  3. Remove the LH front fender garnish. See Fender Garnish - Front - LH (Remove and Replace).
  4. Remove the LH front wheel liner. See Wheel Liner - Front - LH (Remove and Replace).
  5. Remove the LH rear wheel liner. See Wheel Liner - Rear - LH (Remove and Replace).
  6. Place the oil drain under the front brake line junction area.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower the vehicle if necessary.
  7. Release the nuts (x2) that attach the brake pipes to the coupling.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Combination Wrench 12pt 12mm
    • 3/8in Dr. Flare Nut Crowfoot 13 mm socket
  8. Place the oil drain pan under the LH rear brake line junction block.
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise the vehicle if necessary.
  9. Remove the LH rear brake line tube outer nut.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 3/8in Dr. Flare Nut Crowfoot 12 mm socket
  10. Remove the LH rear brake line tube inner nut.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 3/8in Dr. Flare Nut Crowfoot 12 mm socket
  11. Remove the black clip from the LH rear junction block.
  12. Release the brake lines (x2) from the LH rear junction block.
  13. Release the clips (x5) to remove the side sill brake lines from the vehicle.

Install

  1. Install the clips (x5) to secure the side sill brake lines to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Replace the damaged clips.
  2. Position the brake lines (x2) into the LH rear brake junction block.
  3. Install the black clip that attaches the brake lines to the LH rear junction block.
  4. Install the LH rear brake line tube inner nut.
    16 Nm (11.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Start the nut by hand to avoid cross threading.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 3/8in Dr. Flare Nut Crowfoot 12 mm socket
  5. Install the LH rear brake line tube outer nut.
    16 Nm (11.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Start the nut by hand to avoid cross threading.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 3/8in Dr. Flare Nut Crowfoot 12 mm socket
  6. Remove the oil drain under the LH rear brake line junction block.
  7. Install the nuts (x2) that attach the brake pipes to the coupling.
    16 Nm (11.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Start the nut by hand to avoid cross threading.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Combination Wrench 12pt 12mm
    • 3/8in Dr. Flare Nut Crowfoot 13 mm socket
  8. Remove the oil drain under the LH front brake line junction area.
  9. Install the HV battery. See HV Battery (AWD) (3-Phase) (Model YL) (Remove and Install).
    Informational PurposesAn informational icon, calling your attention
    Note
    Back to current procedure before performing the routines. The current procedure needs to perform more routines than the HV battery procedure.
  10. Unlock the vehicle gateway. See Gateway (Unlock).
  11. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Actions > Stop Refrigerant Fill/Drain > Run, and allow the routine to complete.
  12. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_DPB_X_ASSEMBLY-MODEvia Service Mode Plus:Chassis ➜ Brakes ➜ Enter/Exit Assembly Modevia Toolbox:(link)
  13. Place absorbent material underneath the brake lines and the brake fluid reservoir to catch any fluid lost.
  14. Clean the area around the brake fluid reservoir breather cap and remove the cap.
  15. Add clean brake fluid to the MAX level in the reservoir.
  16. Fill the brake bleeder reservoir to full level.
  17. Install the pressure bleeder adapter onto the vehicle brake reservoir.
  18. Connect power supply to the bleeder tool, and then turn the bleeder tool on.
  19. Set the brake bleed reservoir pressure to 30 PSI, and then attach the brake bleed reservoir to the brake bleed adapter.
  20. Bleed the LH front caliper.
    1. Remove the LH front caliper bleed valve covers (x2), and then install the fluid catcher to the outer bleed valve.
    2. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_ESP_FRONT-L-REAR-R_BRAKE-BLEEDvia Service Mode:Chassis ➜ Brakes ➜ Brake Bleed FL-RRvia Toolbox:(link)
      Informational PurposesAn informational icon, calling your attention
      Note
      For the RH front caliper, run PROC_ESP_FRONT-R-REAR-L_BRAKE-BLEEDvia Service Mode:Chassis ➜ Brakes ➜ Brake Bleed FR-RLvia Toolbox:(link).
    3. Close the bleed valve when the pump stops, or when clean fluid without bubbles flows out of the caliper.
    4. Make sure that the reservoir does not go empty, or that the catch bottle does not overfill.
    5. Repeat step 20.c and 20.d until clean fluid without bubbles flows out of the caliper.
    6. Remove the fluid catcher, and then torque the LH front caliper outer bleed valve and install the valve covers.

      Mando brake calipers

      10 Nm (7.4 lbs-ft)

      Hitachi brake calipers

      12 Nm (8.8 lbs-ft)

      Brembo brake calipers

      18.5 Nm (13.6 lbs-ft)
      Informational PurposesAn informational icon, calling your attention
      TIp
      Use of the following tool(s) is recommended:
      • 11 mm socket
  21. Repeat step 20 for the RH front caliper.
  22. Bleed the RH rear caliper.
    1. Remove the RH rear caliper bleed valve cover, and then install the fluid catcher.
    2. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_ESP_FRONT-L-REAR-R_BRAKE-BLEEDvia Service Mode:Chassis ➜ Brakes ➜ Brake Bleed FL-RRvia Toolbox:(link)
      Informational PurposesAn informational icon, calling your attention
      Note
      For the LH rear caliper, run PROC_ESP_FRONT-R-REAR-L_BRAKE-BLEEDvia Service Mode:Chassis ➜ Brakes ➜ Brake Bleed FR-RLvia Toolbox:(link).
    3. Close the bleed valve when the pump stops, or when clean fluid without bubbles flows out of the caliper.
    4. Make sure that the reservoir does not go empty, or that the catch bottle does not overfill.
    5. Repeat step 22.c and 22.d until clean fluid without bubbles flows out of the caliper.
    6. Remove the fluid catcher, and then torque the RH rear caliper bleed valve and install the valve cover.
      10 Nm (7.4 lbs-ft)
      Informational PurposesAn informational icon, calling your attention
      TIp
      Use of the following tool(s) is recommended:
      • 11 mm socket
  23. Repeat step 22 for the LH rear caliper.
  24. Turn off and remove the pressure brake bleeder kit from the vehicle.
  25. Check the brake fluid level and top off as necessary.
  26. Install the service brake reservoir cap.
  27. Remove the absorbent material from underneath the brake fluid reservoir.
  28. Press the brake pedal several times to verify proper feel and action.
  29. Locally connect a laptop with Toolbox 3 to the vehicle. See Toolbox (Connect and Disconnect).
  30. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_DPB_TMC-BRAKE-PEDAL-PRESSvia Service Mode Plus:chassis ➜ DPB Post Replacement ➜ Master Cylinder Stiffness Testvia Toolbox:(link)
    Informational PurposesAn informational icon, calling your attention
    Note
  31. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_BRAKE_X_DPB-ESP-CORNER-STIFFNESS-TESTvia Service Mode Plus:
    • chassis ➜ DPB Post Replacement ➜ Corner Stiffness Test
    • chassis ➜ ESP Post Replacement ➜ Corner Stiffness Test
    via Toolbox:(link)
    Informational PurposesAn informational icon, calling your attention
    Note

    If the test fails due to leakage, identify and address the root cause of the leak.

    If the test fails due to stiffness, perform a brake fluid bleed procedure on the failed caliper.

    If the test still fails after completing the brake fluid bleed procedure on the failed caliper, proceed with the Brake Fluid Bleed/Flush (DPB) (Maintenance) Procedure.

  32. Disconnect the laptop.
  33. Install the LH rear wheel liner. See Wheel Liner - Rear - LH (Remove and Replace).
  34. Install the LH front wheel liner. See Wheel Liner - Front - LH (Remove and Replace).
  35. Install the LH front fender garnish. See Fender Garnish - Front - LH (Remove and Replace).
  36. Install all the four wheels. See Wheel Assembly (Remove and Install).
  37. Move the rack arms away from the vehicle.
  38. Install new butyl patches (x4) (1120356-00-A) to cover the LH and RH rocker access holes, and use IPA wipes to clean excess butyl from the area.
    Informational PurposesAn informational icon, calling your attention
    Note
    The butyl patches need to be cut to the required size, roughly 2" x 2 1/2".
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply pressure along each patch to verify it is fully secured to the body.
  39. Install the LH and RH rocker carriers. See Rocker Carrier - LH (Model YL) (Remove and Replace).
  40. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Coolant Purge Start > Run, and allow the routine to complete.
  41. Continue to install the HV battery, starting from installing the front inner HV battery bolts (x4). See HV Battery (AWD) (3-Phase) (Model YL) (Remove and Install).
  42. Perform a road test to make sure there is proper pedal feel and brake performance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Add test drive correction code 00040100 as a separate activity to the Service Visit.