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Repair Procedures: Installation

WARNING: This page is about a different car, the 2009 Kia Optima and 2009 Kia Magentis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Adjust push rod length of the booster, and then install the seal on the booster assembly.

    Standard length (A) : 108 ± 0.5 mm (4.25 ± 0.02 in.)

    Fig 1: Identifying Push Rod Length Of Booster
    G06366774Courtesy of KIA MOTORS AMERICA, INC.
  2. Insert the booster and tighten the nuts (C).
    Fig 2: Clevis Pin, Snap Pin And Booster Mounting Nuts With Torque Specifications
    G06366775Courtesy of KIA MOTORS AMERICA, INC.
  3. Connect the booster push rod and brake pedal with a clevis pin (A) and install a snap pin (B) to the clevis pin (A).
    CAUTION: Grease the pin before installing the snap pin.
    Always use a new snap pin.
  4. Install the master cylinder, then install the brake tubes to the master cylinder.
  5. Connect the vacuum hose to the brake booster.
  6. After filling the brake reservoir with brake fluid, bleed the system.
  7. Check for fluid leakage.
  8. Check and adjust the brake pedal for proper operation.
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