Kia Optima Hybrid: AHB(Active Hydraulic Boost) System / Pressure Source Unit Repair procedures

Removal
1.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
2.
Remove the air duct (A).

3.
Remove air cleaner assembly (B).

4.
Disconnect the brake fluid level switch connector (A), and remove the reservoir cap.

   
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.
5.
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.
6.
Remove the IBAU (Refer to the AHB system - Intergrated Brake Actuation Unit (IBAU))
7.
Disconnect the connector (A) and after removing a mounting clip, disconnect the reservoir hose(B).

8.
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 TF HEV.

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

9.
After disconnecting a connecter, 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)

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 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 zeroing adjustment is required when installed for the first time.After replacing the PSU (you cannot change only the sensor), the calibration must be performed.
Calibration procedure
1.
Connect the GDS. (CAN line or OBD connector)
2.
Turn ignition switch on.
3.
Press calibration button of the pressure sensor.
4.
Pressure sensor calibration procedure is performed. (Calibration records, DTC codes erasure)

5.
Turn ignition switch off and on after calibration procedure.
6.
Confirm success of calibration.
Pressure Source Unit Components and Components Location

Components     PSU must not be disassembled. 1. Motor connecter2. Bracket3. Block4. Accumulator5. Damper6. Motor ...

Brake Line Components and Components Location

Components ...

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