Kia Sportage: Brake System / Vacuum Pump Repair procedures

Kia Sportage QL (2015-2019) Service Manual / Brake System / Brake System / Vacuum Pump Repair procedures

Remove
[Nu 2.0 MPI/ FFV, THETA II 2.4 GDI]
1.
Turn ignition switch OFF and disconnect the negative (-) battery terminal.
2.
Remove the under cover. (Refer to Engine Mechanical System - "Engine room under cover')
3.
Disconnect the vacuum pumb connector (A).

4.
Disconnect the vacuum hose (A).

5.
Loosen the vacuum pump bolt (A) and then remove the vaccum pump and bracket.
Tightening torque:
19.6 - 29.4 N·m (2.0 - 3.0 kgf·m, 14.5 - 21.7 lb·ft)

6.
Remove the bolts, and then remove the bracket from vacuum pump.
7.
Install in the reverse order of removal.
[R Engine]
1.
Remove the air cleaner assembly.
(Refer to Engine Mechanical System - "Air cleaner")
2.
Remove the battery and battery tray.
(Refer to Engine Electrical System - "Battery")
3.
After loosening the installation bolt (A), separate the function block bracket and fuel line (B).

4.
After separating the booster hose (A), remove the vacuum hose (B).

5.
After removing the clamp (A) from the intercooler hose, loosen the bolt (B) and separate the intercooler hose (C).
Tightening torque:
Clamps :
4.9 - 6.9 N·m (0.5 - 0.7 kgf·m, 3.6 - 5.1 lb·ft)
(If equipped with a cap, tighten it until the cap is removed.)
Bolt :
9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)
6.
Remove the engine cooling water temperature sensor(A).

7.
Loosen the bolts (B) and then remove the vacuum pump (A).

  
Do not disassemble the vacuum pump.
Be careful so that the O-ring (A) does not come loose during installation.

Installation
1.
Install in the reverse order of removal.
2.
Tighten the vacuum pump installation bolt to the specified torque.
  
After installing the coolant temperature sensor, refill the coolant to the same amount leaked during removal.
Inspection
1.
Check the brake warning lamp in the IGN ON position.
  
Brake warning lamp is ON in the following conditions:
1)
Parking brake warning
2)
Low brake fluid level warning
3)
Low brake vacuum pressure warning
Vacuum pump is abnormal
Vacuum pump CAN communication is abnormal
Vacuum switch is abnormal
2.
Check that the brake warning lamp is ON after releasing the parking brake with a sufficient brake fluid level.
If the brake warning lamp is ON, check the below points.
(1)
Is the brake warning lamp ON within 5 seconds after IGN ON? (CAN Timeout Error)
  
CAN Timeout Error ; The brake warning lamp is ON when the communication fails more than 2 seconds between vacuum pump and cluster.

▶ Reinstall the vacuum pump connector after removing it. And if the brake warning lamp is ON within 5 seconds after IGN ON, replace the vacuum pump.

▶ Go to Step 2).

(2)
Does the brake warning lamp turn ON within 45 - 55 seconds?

Brake vacuum switch is in normal condition.

▶ Go to Step 3).

(3)
Does the brake warning lamp turn ON within 15 - 35 seconds after removing the vacuum hose from the brake booster?

▶ Replace the vacuum pump.

▶ Vacuum pump is in normal condition.

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