Repair Procedures

Operation and Leak Check

Check all of the following items:

Component	Procedure
Brake Booster (A)	Check brake operation by applying the brakes during a test drive. If the brakes do not operate properly, inspect the brake booster. Replace the brake booster assembly if it does not operate properly or if there are signs of leakage.
Piston Cup and Pressure Cup Inspection (B)	Check brake operation by depressing the brake pedal. Check for damage or signs of fluid leakage. Replace the master cylinder assembly if the pedal does not operate properly or if there is damage or signs of fluid leakage. Check the difference in brake pedal travel between quick and slow braking. Replace the master cylinder if there is a difference in pedal travel.
Brake Hoses (C)	Check for damage or signs of fluid leakage. Replace the brake hose with a new one if it is damaged or leaking.
Caliper Piston Seal and Piston Boots (D)	Check brake operation by depressing the brake pedal. Check for damage or signs of fluid leakage. If the pedal does not operate properly, the brakes do not brake properly, or there is damage or signs of fluid leakage, disassemble and inspect the brake caliper. Replace the boots and seals with new ones whenever the brake caliper is disassembled.

Brake Bleeding

Do not reuse drained brake fluid. Always use genuine DOT3/DOT4 brake fluid. Using non-genuine DOT3/DOT4 brake fluid may cause corrosion and shorten the service life of the system. Make sure dirt or other foreign matter does not contaminate the brake fluid. Do not spill brake fluid on the vehicle, as it may damage the paint. If brake fluid gets on the paint, wash it off immediately with water. The brake fluid reservoir must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding each brake caliper. Add fluid as necessary.

1. 1
   Make sure the brake fluid level in the reservoir is at the MAX (upper) mark.
2. 2
   Have an assistant slowly depress the brake pedal several times, then hold it down.
3. 3
   Loosen the right rear brake bleeder screw (A) to allow air to escape from the system. Then securely tighten the bleeder screw. Front

   

   Rear

   

4. 4
   Repeat the procedure for each wheel in the sequence shown below until no air bubbles appear in the fluid.

   

5. 5
   Fill the master cylinder reservoir to the MAX (upper) level mark.
6. 6
   Remove the reservoir cap and fill the reservoir with brake fluid.

   If brake fluid gets on any painted surface, wipe it off immediately.

   Do not depress the brake pedal while releasing pressure. Recommended fluid: DOT3 or DOT4

7. 7
   Connect a clear plastic tube to the bleeder valve of the wheel cylinder. Insert the other end of the tube into a clear plastic bottle half filled with brake fluid.
8. 8
   Connect the GDS to the Data Link Connector (DLC) located under the instrument panel.
9. 9
   Select and follow the instructions on the GDS screen.

   Observe the maximum operating time of the ABS motor with GDS to prevent the pump motor from burning out.

   1. Select the vehicle model name.
   2. Select the Anti-lock Brake System.
   3. Select the HCU air bleeding mode.

      

   4. Press "OK" to operate the motor pump and solenoid valve.

      

   5. Wait 60 seconds before performing the air bleeding operation. (Otherwise, the engine may be damaged.)

      

   6. Perform air bleeding.

      

10. 10
    Depress the brake pedal several times, then loosen the bleeder screw until fluid flows out without bubbles. Then close the bleeder screw (A). Front

    

    Rear

    

11. 11
    Repeat step 5 until there are no air bubbles in the fluid for each wheel.

    

12. 12
    Tighten the bleeder screw. Bleeder screw tightening torque: 7 ~ 13 N·m

Brake Bleeding: This procedure must be performed to properly bleed air and fill the ESC unit, brake lines, and master cylinder with brake fluid.