Hyundai Ioniq: Brake System / Repair procedures

Hyundai Ioniq (AE) 2017-2024 Service Manual / Brake System / Brake System / Repair procedures

Operation and Leakage Check

Check all of the following items :

Component	Procedure
Integrated Brake Actuation Unit (IBAU) (A) and Pressure Source Unit (PSU) (B)	Check brake operation by applying the brakes during a test drive. If the brakes do not work properly, check the IBAU and PSU. Replace IBAU and PSU as an assembly if it does not work properly or if there are signs of leakage.
Piston cup and pressure cup inspection (B)	Check brake operation by applying the brakes. Look for damage or signs of fluid leakage. Replace the IBAU as an assembly if the pedal does not work properly or if there is damage or signs of fluid leakage.
Brake hoses (C)	Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it is damaged or leaking.
Caliper piston seal and piston boots (D)	Check brake operation by applying the brakes. Look for damage or signs of fluid leakage. If the pedal does not work properly, the brakes drag, or there is damage or signs of fluid leakage, disassemble and inspect the brake caliper. Replace the boots and seals with new ones whenever the brake caliper is disassembled.

Bleeding of Brake System

Air Bleeding Tool Installation Procedure

•	To prevent the brake fluid reservoir tank from beingdamaged and ensure the safety of worker, set thepressure of the gauge to the standard value beforeinstalling the SST.

Before installing the SST on the vehicle, close the airshut-off valve (A) to adjust the pressure gauge to thestandard value.

•	For safety of worker and correct pressure setting,make sure that the plug (B) is installed correctly.

After connecting an air hose and opening the airshut-off valve (A), adjust the pressure gauge (B) to the standard value.

Standard pressure value :

0.3 - 0.35 MPa (43.5 - 50.7 psi)

Close the air shut off valve (A) and remove the plug(B).

•	For safety of worker, make sure that the air shut offvalve is closed and remove the plug.

4.	Remove the brake reservoir tank cap.

5.	Install the cap (A) of SST (0k585-E8100) on the reservoir tank.

6.	Make sure the check valve is closed and connect SST (09580-3D100) (A) to the adapter (B).

Air Bleeding Tool Removal Procedure

1.	To remove the SST (09580-3D100) from the vehicle, close the air shut-off valve (A).

Remove SST (09580-3D100) (A) and the cap of SST (0k585-E8100) (B) on the reservoir tank.

•	To prevent backflow of brake fluid, be sure to open the air shut-off valve slowly then bleed air in the reservoir tank.

3.	Install the brake reservoir tank cap.

Brake System (Judder Inspection)

Bleeding of Brake System

•	Do not reuse the drained fluid.

•	Always use genuine DOT3/DOT4 brake Fluid.

•	Using a non-genuine DOT3/DOT4 brake fluid can cause corrosion and decrease the life of the system.

•	Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.

•	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.

•	The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure and checked after bleeding each brake caliper. Add fluid as required.

1.	Make sure the brake fluid in the reservoir is at the MAX (upper) level line.

2.	Have someone slowly pump the brake pedal several times, and then apply pressure.

3.	Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw securely. [Front] [Rear]

4.	Repeat the procedure for wheel in the sequence shown below until air bubbles no longer appear in the fluid.

5.	Refill the master cylinder reservoir to MAX (upper) level line.

Brake System

Brake Line. Components and components location

C..

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