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Home >> Hyundai >> 2017 >> Sonata Plug-In Hybrid >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> AHB (Active Hydraulic Boost) System (PHEV) >> Brake Actuation Unit >> Repair Procedures >> Removal

Repair Procedures: Removal

  1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
  2. Remove the air duct (A) and air cleaner assembly (B).
    Fig 1: Locating Air Cleaner Assembly
    G11668933Courtesy of HYUNDAI MOTOR AMERICA
  3. Disconnect the brake fluid level switch connector (A), and remove the reservoir cap.
    Fig 2: Disconnecting Brake Fluid Level Switch Connector
    G11668934Courtesy of HYUNDAI MOTOR AMERICA
    NOTE: Be sure to completely remove foreign substances from around brake fluid reservoir and cap before opening the reservoir cap. If not, it may cause contamination of brake fluid and deterioration in braking performance.
  4. Remove the brake fluid from the reservoir with a syringe.
    NOTE: 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.
  5. Disconnect reservoir hose (A) from the reservoir and IBAU connector (B).
    Fig 3: Disconnecting Reservoir Hose From Reservoir And IBAU Connector
    G11668935Courtesy of HYUNDAI MOTOR AMERICA
  6. Disconnect the brake tube from the IBAU (Integrated Brake Actuation Unit) by loosening the tube flare nut.

    Tightening torque: 

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

    Fig 4: Disconnecting Brake Tube From IBAU (Integrated Brake Actuation Unit) Tube Flare Nut
    G11668936Courtesy of HYUNDAI MOTOR AMERICA
    CAUTION: 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 to LF HEV.
  7. Disconnect the brake tube from the IBAU (Integrated Brake Actuation Unit).

    Tighten torque: 

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

    Fig 5: Disconnecting Brake Tube From IBAU (Integrated Brake Actuation Unit)
    G11668937Courtesy of HYUNDAI MOTOR AMERICA
  8. Remove the wiring fixed clip from the IBAU (Integrated Brake Actuation Unit) bracket.
    Fig 6: Removing Wiring Fixed Clip From IBAU (Integrated Brake Actuation Unit) Bracket
    G11668938Courtesy of HYUNDAI MOTOR AMERICA
  9. Remove the snap pin (A) and clevis pin (B).
    Fig 7: Removing Snap Pin And Clevis Pin
    G11668939Courtesy of HYUNDAI MOTOR AMERICA
  10. Remove the brake pedal member assembly mounting nuts and then remove the brake pedal assembly.

    Tightening torque: 

    9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)

    Fig 8: Removing Brake Pedal Member Assembly Mounting Nuts
    G11668940Courtesy of HYUNDAI MOTOR AMERICA
    NOTE: Be careful not to damage the brake tube when removing the IBAU (Integrated Brake Actuation Unit).