2025-04-11

Brake Lines - Booster to ABS (Dual Motor) (RHD) (Remove and Replace)

Correction Code 33034502

  • 2025-04-11: Added step to separately add correction code 18200102 as a separate activity to the Service Visit, updated procedure and added post replacement routines.
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Note
This procedure requires the A/C Refrigerant (Recovery and Recharge) procedure to be performed. If not already automatically added to the Service Visit, add correction code 18200102 as a separate activity to the Service Visit.

Removal

  1. Recover the A/C refrigerant from the vehicle. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
  2. Remove the 12V battery bracket beam. See 12V Battery Bracket Beam (Remove and Replace).
  3. Release the bolts (x4) that secure the coolant reservoir to the front crossmember (torque 6 Nm). Do not remove the reservoir at this time.
  4. Carefully lift up the coolant reservoir and disconnect the coolant level sensor harness.
  5. Release the coolant hose clamp at the coolant pump.
  6. Remove the coolant hose from the pump.
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    Note
    Pinch hose with clamps and gently pry the hose off the pump. Leave hose clamps fully engaged on hose to prevent coolant spillage.
  7. Set the coolant reservoir aside.
  8. Remove the nut (10 Nm) that attaches the A/C line to the compressor.
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    Note
    Discard the O-ring and replace with a new one during installation.
  9. Release the fasteners (x2) that secure the fuse box to the front crossmember (torque 6 Nm).
  10. Release the clip that attaches the 12V battery supply cable to the fuse box.
  11. Remove the bolt that attaches the PT pump 1 bracket to the body.
  12. Set PT1 pump and fuse box aside.
  13. Release the clip that secures the RH body harness to the bottom of the front crossmember.
  14. Release the nut that secures the front drive unit ground strap to the body (torque 6 Nm), then release the clip that secures the intelligent battery sensor (IBS) harness to the body.
  15. Disconnect the high side A/C PT sensor connector and the LH front impact sensor harness and set the harness aside.
  16. Release the clips (x3) that secure the brake lines to the LH frame rail.
  17. Release the clips (x2) that secure the brake lines to the front crossmember.
  18. Loosen the nuts (x2) (torque 18 Nm) that attach the brake lines to the master cylinder, and then remove the brake lines from the master cylinder.
    Informational PurposesAn informational icon, calling your attention
    Note
    Put absorbent material below the master cylinder to catch residual fluid.
  19. Place suitable absorbent material underneath the ABS module and brake lines.
  20. Release the front brake lines from the ABS module (torque 23 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If brake fluid is spilled on a painted surface, wash off immediately with clean water.
  21. Plug the brake line connections to prevent contamination.
  22. Remove the brake line from the LH frame rail.
  23. Remove the 2 line brake bundle from the vehicle.