2025-04-09

Brake Lines - Master Cylinder to ABS (RWD) (RHD) (Remove and Replace)

Correction Code 33034212

  • 2025-04-09: Added not to separately add correction code 18200102 and added some routines to be run after reinstalling the brake lines.
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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 coolant hose from 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. Remove the bolts (x2) that attach the fuse box to the body (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. Release the clip that secures the RH body harness to the bottom of the front crossmember.
  13. Remove the nut (torque 6 Nm) that secures the intelligent battery (IBS) sensor harness to the battery negative cable clamp and release the clip that secures the intelligent battery (IBS) sensor harness to the body.
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    Note
    Discard the nut after removal.
  14. Disconnect the high side A/C PT sensor connector and the LH front impact sensor harness and set the harness aside.
  15. Release the clips (x3) that secure the brake lines to the LH frame rail.
  16. Release the clips (x2) that secure the brake lines to the front crossmember.
  17. Clean the area around the brake fluid reservoir and master cylinder.
  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.
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    Note
    Put absorbent material below the master cylinder to catch residual fluid.
  19. Clean the area around the ABS module.
  20. Loosen the nuts (x2) (torque 12 Nm) that attach the brake lines to the ABS module, and then remove the brake lines from the ABS module.
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    Note
    Place absorbent material below the ANS module to catch residual fluid.
  21. Place fender cover over painted areas.
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    Note
    If brake fluid is spilled on a painted surface, wash it off immediately with clean water.
  22. Remove the brake lines from the LH frame rail.
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    Note
    Pull the 2-line brake bundle upward while bending the flexible lines around the 4-line brake bundle and the coolant hose.
  23. Remove the 2 line brake bundle from the vehicle.
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    Note
    Slide the lines underneath the A/C lines and coolant hose. Rotate upside down, gently pull up and out while guiding the brake lines between the coolant and A/C lines.