Hyundai i-30: Brake System / Brake Booster

Hyundai i30 (PD) 2018-2023 Service Manual / Brake System / Brake System / Brake Booster

Components and components location
Components
[LHD]

1. Reservoir cap
2. Reservoir
3. Brake booster
4. Master cylinder
5. Push rod

[RHD]

1. Reservoir cap
2. Reservoir
3. Brake booster
4. Master cylinder
5. Push rod

Repair procedures
Brake Booster Operating Test
For simple checking of the brake booster operation, carry out the following tests.
1.
Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the booster is inoperative.

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

Removal
[LHD]
1.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
2.
Remove the battery tray.
(Refer to Engine Electrical System - "Battery")
3.
Loosen the mounting bolts (A) and then remova the ECM bracket (B).

4.
Loosen the mounting bolt (A) and remove the wiring harness.

5.
Disconnect the brake fluid level switch connector.

6.
Disconnect the booster pressure sensor connector.

7.
Remove the vacuum hose (A).

8.
Remove the master cylinder.
(Refer to Brake System -" Master Cylinder")
9.
Remove the snap pin (A).

10.
Remove the clevis pin (A).

11.
Remove the mounting nuts (A).
Tightening torque :
16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

12.
Remove the brake booster.
[RHD]
1.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
2.
Disconnect the brake fluid level sensor connector (A).

3.
Disconnect the vacuum hose from the brake booster.

4.
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.
5.
Remove the brake fluid hose from the reservoir. [M/T only]

6.
Remove the brake master cylinder.
(Refer to Brake System - "Master Cylinder")
7.
Remove the snap pin (A) and clevis pin (B).

8.
Remove the mounting nuts.
Tightening torque :
16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

9.
Remove the brake booster.
Inspection
1.
Inspect 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 whenever installing.
2.
After installing, bleed the brake system.
(Refer to Brake System -"Brake System Bleeding")
(Refer to Brake System - "ABS System Bleeding)
(Refer to Brake System - "ESP System Bleeding)

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