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Home >> Hyundai >> 2017 >> Sonata Plug-In Hybrid >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> AHB (Active Hydraulic Boost) System (PHEV) >> Hydraulic Power 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 Duct And Air Cleaner Assembly
    G11668946Courtesy 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
    G11668947Courtesy 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 the TCM connector (A).
    Fig 3: Locating TCM Connector
    G11668948Courtesy of HYUNDAI MOTOR AMERICA
  6. Remove the ECM wiring after loosening the wiring bolts and nut.

    Tightening torque: 

    9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

    Fig 4: Removing ECM Wiring Bolts And Nut
    G11668949Courtesy of HYUNDAI MOTOR AMERICA
  7. Remove the hybrid motor cable at the bracket.
    Fig 5: Removing Hybrid Motor Cable Bracket
    G11668950Courtesy of HYUNDAI MOTOR AMERICA
  8. Remove the brake tube at the PSU bracket.
    Fig 6: Removing Brake Tube PSU Bracket
    G11668951Courtesy of HYUNDAI MOTOR AMERICA
  9. Disconnect the brake hose after removing a mounting clip.
    Fig 7: Disconnecting Brake Hose Mounting Clip
    G11668952Courtesy of HYUNDAI MOTOR AMERICA
  10. Disconnect the brake tube from the PSU by loosening the flare nut (A).

    Tighten torque: 

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

    Fig 8: Disconnecting Brake Tube From PSU Flare Nut
    G11668953Courtesy of HYUNDAI MOTOR AMERICA
    CAUTION: 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 LF HEV.
  11. After disconnecting a connector, Loosen the PSU bracket bolts and remove the PSU.

    Tighten torque: 

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

    Fig 9: Loosening PSU Bracket Bolts
    G11668954Courtesy of HYUNDAI MOTOR AMERICA