Hyundai Coupes/Sedans 1994-1998 Repair Guide

Power Brake Booster

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: Power booster assembly-Excel, Scoupe, Accent and 1994-95 Elantra



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Fig. Fig. 2: Power booster assembly-Sonata



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Fig. Fig. 3: Power booster assembly-Tiburon and 1996-98 Elantra

  1. Disconnect the vacuum hose from the power booster.
  2.  
  3. Remove the master cylinder.
  4.  
  5. Disconnect the pushrod at the brake pedal.
  6.  
  7. Remove the power booster mounting bolts
  8.  
  9. Carefully remove the power booster from the firewall.
  10.  

To install:
  1. Install the brake booster on the firewall and tighten the mounting nuts to 15-21 ft. lbs. (21-28 Nm) on Sonata and 6-9 ft. lbs. (8-12 Nm) except Sonata.
  2.  
  3. Connect the vacuum hose to the power booster.
  4.  
  5. Install the master cylinder.
  6.  

TESTING



  1. Operate the engine at idle with the transmission in Neutral without touching the brake pedal for at least two minutes.
  2.  
  3. Turn the engine off, and wait one minute.
  4.  
  5. Test for the presence of assist vacuum by depressing the brake pedal and releasing it several times. Light application will produce less and less pedal travel, if vacuum is present.
  6.  
  7. Pump the brake pedal (with engine off) until the supply vacuum is entirely gone.
  8.  
  9. Put a light, steady pressure on the pedal.
  10.  
  11. Start the engine, and allow it to idle with the transaxle in neutral (manual transaxle) or park (automatic transaxle)
  12.  
  13. If the brake booster is operating properly, the brake pedal should fall toward the floor when constant pressure is maintained on the pedal.
  14.  
  15. Power brake systems may be tested for hydraulic leaks just as ordinary systems are tested, except that the engine should be idling with the transmission in neutral (manual transaxle) or park (automatic transaxle).
  16.  

 
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