Kia Soul EV: AHB(Active Hydraulic Boost) System / Pressure Source Unit Repair procedures

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

Removal

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

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.

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.	Remove the IBAU (Refer to the AHB system - Intergrated Brake Actuation Unit (IBAU))

5.	Disconnect the connector (A) and after removing a mounting clip, disconnect the reservoir hose(B).

Disconnect the brake tube from the PSU by loosening the bolt (B).

Before removing the PSU, 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)

After disconnecting a connecter, Loosen the PSU bracket bolts and remove the PSU.

Tightening torque:

19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 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)

5.	Tighten the PSU bracket bolts and brake tube to the specified torque.

6.	Conduct calibration after removing or installing the PSU.

Pressure sensor Calibration

The pressure sensor mounted within the PSU calculates the pressure according to initial zeroing. Therefore, initial zero adjustment is required when installed for the first time. After replacing the PSU (cannot replace sensor only), the calibration must be performed.

Calibration procedure

1.	Connect the GDS. (CAN line or OBD connector)

2.	Turn ignition switch on.

3.	Press pressure sensor calibration button.

4.	Pressure sensor calibration procedure is performed (Calibration recorded & DTC erased).

5.	Turn ignition switch off and on after calibration procedure.

6.	Confirm successful calibration.

Pressure Source Unit Components and Components Location

Components PSU must not be disassembled. 1. Motor connector2. Bracket3. Block4. Accumulator5. Damper6. Motor ...

Brake Line Components and Components Location

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