Hyundai Ioniq: AHB(Active Hydraulic Boost) System / Brake Actuation Unit. Repair procedures

Hyundai Ioniq (AE) 2017-2024 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.
Disconnector TCM connector (A).
3.
Disconnector TCM connector (B).

4.
Loosen the bolt & nut (A) then remove the ECM, TCM with bracket (B).

5.
Remove the air cleaner.
(Refer to Engine Mechanical System - "Air Cleaner")
6.
In case of RHD vehicle, remove the engine and transmission assembly.
(Refer to Engine Mechanical System - "Engine and Transmission Assembly")
7.
Remove the brake fluid from the reservoir with a syringe.
   
•
Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
•
To prevent any dust entering in the reservoir, the reservoir cap should be closed again after removing brake fluid.
8.
Disconnect the brake hose from the reservoir.

9.
Disconnect the brake fluid level switch connector (A).

10.
Disconnect IBAU connecter.

11.
Disconnect the brake tube from the IBAU (Intergrated Brake Actuation Unit) by loosening the tube flare nut.
Tighten torque :
13.7 - 16.7 N.m (1.4 - 1.7 kgf.m, 10.1 - 12.3 lb-ft)

   
•
Before removing the brake tube, high pressure in an accumulator of PSU should be reduced for safety by conducting "High pressure release mode" of GDS connected.
12.
Disconnect the brake tube from the IBAU (Intergrated Brake Actuation Unit) by loosening the tube flare nut.
Tighten torque :
13.7 - 16.7 N.m (1.4 - 1.7 kgf.m, 10.1 - 12.3 lb-ft)

13.
Remove the rear brake tube.

14.
Remove the snap pin (A) and clevis pin (B).

15.
Remove the mounting nuts (A) and then remove the brake pedal.
Tightening torque :
16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

Installation
1.
Installation is the reverse 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 Brake Pedal Traval sensor(PTS) calibration.
(Refer to the Brake System - "Brake Pedal")
5.
Conduct Longitidinal G Sensor Clibration. [HAC/DBC only]
6.
Conduct Pressure sensor Calibration.
Diagnostic Procedure Using GDS
The following section describes how to diagnose faults using a diagnostic instrument.
1.
Connect the diagnostic instrument to the self-diagnostic connector (16-pin) beneath the crash pad on the side of driver's seat, and then turn on the ignition to activate the diagnostic instrument.
2.
In the GDS Vehicle Type Selection menu, select "Vehicle Type" and "ABS/ESC" System, and then opt for "OK."
[Brake Pedal Sensor Calibration]

[Pressure Sensor Calibration]

[Auto Detected Configuration Reset]

[Longitidinal G Sensor Clibration]

3.
Turn ignition switch off and on after calibration procedure.
4.
Confirm success of calibration.

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