Hyundai Kona: Brake System / Brake Booster 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
1.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
2.
Remove the air cleaner.
(Refer to Engine Mechanical System - "Air Cleaner")
3.
Remove the battery.
(Refer to Engine Electrical System - "Battery")
4.
Remove the ECM.
(Refer to Engine Control System - "ECM")
5.
Disconnect the brake fluid level switch connector (A).

6.
Remove the vacuum hose (A) after disconector fixing clip.

7.
Remove the master cylinder.
(Refer to Brake System - "Master Cylinder")
8.
Remove the snap pin (A) and clevis pin (B).

9.
Remove the brake booster after loosening the booster mounting nuts (A).
Tightening torque :
16.7 - 25.5 N.m (1.7 - 2.6 kgf.m 12.3 - 18.8 lb-ft)

Inspection
1.
Inspect the vacuum hose of damage.
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")
3.
Check the brake oil leakage and pedal operating condition.
Brake Booster Components and components location
Components 1. Reservoir cap 2. Reservoir 3. Brake booster 4. Master cylinder 5. Booster presure senser ...

Vacuum Pump Components and components location
Components 1. Vacuum pump bracket 2. Vacuum pump connector 3. Vacuum pump ...

Other information:

Hyundai Kona (OS) 2018-2021 Service Manual: Steering Gear Box Repair procedures
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Hyundai Kona (OS) 2018-2021 Owners Manual: Before driving
Before entering the vehicle Be sure all windows, outside mirror( s), and outside lights are clean and unobstructed. Remove frost, snow, or ice. Visually check the tires for uneven wear and damage. Check under the vehicle for any sign of leaks. Be sure there are no obstacles behind you if you ...

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