Kia Soul EV: AHB(Active Hydraulic Boost) System / Brake Actuation Unit Repair procedures

Kia Soul EV (PS EV) 2015-2020 Service Manual / Brake System / AHB(Active Hydraulic Boost) System / Brake Actuation Unit Repair procedures

Removal
1.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
2.
Disconnect the brake fluid level switch connector (A), and remove the reservoir cap.

   
Be sure to completely remove foreign substances around brake fluid reservoir and cap before opening the reservoir cap to prevent any contamination of brake fluid and deterioration in braking performance.
3.
Using a syringe, remove the brake fluid from the reservoir.
   
Do not spill brake fluid on the vehicle as it may damage the paint. If brake fluid comes in contact with the paint, wash off immediately with water.
To prevent dust entering the reservoir, the reservoir cap should be closed again after removing brake fluid.
4.
Disconnect reservoir hose from the reservoir and IBAU connecter (A).

5.
Disconnect the brake tube from the IBAU by loosening the tube flare nut (B).
   
Before removing the IBAU, high pressure in an accumulator of PSU should be reduced for safety by conducting "High pressure release mode" of GDS connected to SOUL EV.

Tightening torque:
13.7 ~ 16.7 N.m (1.4 ~ 1.7 kgf.m, 10.1 ~ 12.3 lb-ft)

6.
Remove the brake pedal assembly. (Refer to the brake system group - brake pedal)
7.
Remove the IBAU mounting nuts (A) and then remove the IBAU.

Tightening torque:
12.7 ~ 15.7 N.m (1.3 ~ 1.6 kgf.m, 9.4 ~ 11.6 lb-ft)

Installation
1.
Install in the reverse order of removal.
2.
Check the brake pedal operation.
3.
After filling the brake fluid in the reservoir, perform the air bleed. (Refer to the AHB system - AHB system air bleeding)
4.
Conduct calibration after removing the brake pedal assembly. (Refer to the brake pedal - calibration)
Brake Actuation Unit Components and Components Location
Components     IBAU must not be disassembled. 1. ECU2. Reservoir3. Master cylinder Assembly4. Valve block ...

Pressure Source Unit Components and Components Location
Components     PSU must not be disassembled. 1. Motor connector2. Bracket3. Block4. Accumulator5. Damper6. Motor ...

Other information:

Kia Soul EV (PS EV) 2015-2020 Service Manual: High Voltage Shut-off Procedures


High Voltage Shut-off Procedure     Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries. ...

Kia Soul EV (PS EV) 2015-2020 Service Manual: Components and Components Location


Component Location 1. Driver power window main switch2. BCM (Body Control Module)3. Door lock switch4. Front door lock actuator & switch5. Rear door lock actuator & switch6. Tailgate lock actuator & switch ...

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