KIA Forte Rio Spectra Brake Vacuum Booster Pump

Description

Installation Steps

1. Prepare the Vehicle

• Park on a flat surface, engage the parking brake, and disconnect the negative battery cable.
• Loosen the lug nuts and lift the front of the vehicle with a jack. Secure it with jack stands.

2. Drain Brake Fluid

• Use a turkey baster to remove brake fluid from the master cylinder reservoir. Dispose of the fluid properly.

3. Remove the Master Cylinder

• Front Brakes (All Models):
  • Disconnect the brake lines from the master cylinder using line wrenches. Plug the lines and cylinder ports to prevent fluid loss.
  • Remove the two mounting bolts (10mm or 12mm) securing the master cylinder to the booster. Set the cylinder aside.

4. Detach the Vacuum Booster

• Forte/Spectra:
  • Remove the vacuum hose from the booster check valve.
  • Under the dashboard, disconnect the pushrod from the brake pedal.
  • Remove the four bolts (10mm) securing the booster to the firewall. Pull the booster out from under the hood.
• Rio:
  • Follow similar steps, ensuring the vacuum hose and pushrod are disconnected before removing the booster.

5. Install the New Booster

• Align the new booster with the firewall and secure it with the mounting bolts. Tighten to the manufacturer’s torque specs (typically 10–12 N·m).
• Reconnect the pushrod to the brake pedal and adjust its length for proper free play (refer to your service manual for exact measurements).

6. Reinstall the Master Cylinder

• Mount the master cylinder to the booster. Tighten the mounting bolts to 10–12 N·m.
• Reattach the brake lines and tighten with line wrenches.

7. Bleed the Brake System

• Fill the master cylinder with fresh brake fluid.
• Bleed air from the brake lines starting with the wheel farthest from the master cylinder (usually the right rear).
• Have an assistant pump the brake pedal while you open the bleeder screw, repeating until fluid flows clear.

8. Test and Adjust

• Start the engine and check for vacuum leaks at the booster hose.
• Pump the brake pedal to build pressure. Adjust pedal height and free play if necessary.
• Test drive the vehicle to ensure smooth braking and no sponginess.