Procedure

Care point: Before disconnecting brake pipe joints ensure that they are free from dirt and grease.

1) Ensure the ignition is off and the ignition key is removed from the vehicle.

2) Depress the brake pedal 30 times to deplete the accumulator. Pedal feel may change during this operation. Upon completion it should be possible to push the pedal to the floor, if not, continue to depress the pedal until this is possible.

3) Ensure any local painted body surfaces are protected against brake fluid spillage.

4) Release the banjo bolts at either end of the high pressure hose (between booster and pump) and remove the hose. Immediately wipe up any spilled brake fluid.

5) Ensure the copper washers from the banjo bolts are removed and not stuck to the sealing face of either the pump or booster and that these faces are free from damage.





6) Before fitting the new hose, ensure that the new hose is clean and free from contamination and that the copper sealing washers (two per bolt) are fitted to the banjo bolts and are not damaged in any way. Use the new copper washers and bolts as supplied in the kit. DO NOT reuse copper sealing washers.





7) Fit the new hose to the booster first when fitting the hose to the pump, ensure that the alignment pin on the banjo is located between the two location lugs on the pump.

8) When the hose is fitted ensure it follows its natural path in the engine bay and is not touching any other under bonnet component, especially brake pipes.

9) Torque the booster banjo bolt to 15-18 lb.ft (20-24 Nm) using a torque wrench. Due to limited access to the pump banjo bolt, use a 13/16" (20 mm) offset crows foot and torque to 16 Lb.ft (21 Nm). DO NOT OVERTIGHTEN.

10) Wipe any excess brake fluid from the joints and from the paintwork below the pump and booster.

11) To bleed the system, replace the ignition key and turn to position II. Wait for the pump to stop (approx 30/40 seconds). Depress the brake pedal firmly 4 times which will cause the pump to run again. Wait for the pump to stop again (approx 15/20 seconds) and depress the brake pedal 4 times as before.

Repeat this operation 10 times ensuring that the pump stops after every cycle of 4 pedal applications.

12) Check the joints for leaks. If leaks are detected recheck the sealing and copper washers and ensure the joints are not over torqued.

13) Ensuring that the ignition key is retained in position II and the vehicle is on level ground check the brake fluid level. Depress the brake pedal 4 times and wait for the pump to stop (approx 15/20 seconds). Before removing the filler cap ensure it and the Surrounding area are clean. Top up the brake fluid reservoir to the "MAX" level using DOT 4 brake fluid and replace reservoir cap.

14) MARK THE BANJO BOLT HEAD AT THE ABS PUMP WITH RED PAINT TO IDENTIFY THAT THIS REWORK HAS BEEN UNDERTAKEN.

15) Complete a Service Campaign label, and stick it onto the hood locking panel just above the vacuum routing label. Apply the clear plastic protective film over the top of the label.

16) Complete the Service Action Record located in the back of the Passport to Service booklet.

17) Check one more time for any brake fluid spills. Clean off all painted surfaces, and brake, steering and chassis components.