2013 > G 2.

4 HEV > Brake System > Brake System > Repair procedures

Operation and Leakage Check

Check all of the following items:
Component Procedure
Brake Actuation Unit (A) Check brake operation by applying the brakes during a test drive. If the brakes
do not work properly, check the brake actuation unit. Replace the brake
actuation unit as an assembly if it does not work properly or if there are signs of
leakage.
Hydraulic Power Unit (E) Check brake operation by applying the brakes during a test drive. If the brakes
do not work properly, check the hydraulic power unit. Replace the hydraulic
power unit as an assembly if it does not work properly or if there are signs of
leakage.
Piston cup and pressure ● Check brake operation by applying the brakes. Look for damage or signs of
cup inspection (B) fluid leakage. Replace the master cylinder as an assembly if the pedal does
not work properly or if there is damage or signs of fluid leakage.
● Check for a difference in brake pedal stroke between quick and slow brake
applications. Replace the master cylinder if there is a difference in pedal
stroke.
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 Check brake operation by applying the brakes.
piston boots (D) 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.

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2013 > G 2.4 HEV > Brake System > Brake System > Repair procedures

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.
● When bleeding air, make sure the brake fluid is above 10mm starting from the “MIN” line.

● Toremove the reservoir tank cap to refill the brake fluid, always close the air shut-off valve of the
SST.

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 2013 > G 2.4 HEV > Brake System > Brake System > Repair procedures

1. Before changing brake lines or related parts, perform the air bleeding procedure mentioned below.
(1) BAU and reservoir replacement: AHB brake system air bleeding.
(2) HPU and HPU brake line replacement: HPU & BAU line air bleeding.
But if the brake fluid level is below “MIN” perform the AHB brake system air bleeding.
(3) ESC or ESC brake line replacement: ESC brake line and brake wheel air bleeding.
(4) Brake caliper assembly and brake wheel line replacement: Brake wheel line air bleeding.
Air Bleeding Tool Installation Procedure

To prevent the brake fluid reservoir tank from being damaged and ensure the safety of worker, set
the pressure of the gauge to the standard value before installing the SST.

1. Before installing the SST on the vehicle, close the air shut-off valve (A) to adjust the pressure gauge to
the standard value.

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

2. After connecting an air hose and opening the air shut-off valve (A), adjust the pressure gauge (B) with
the pressure adjuster (C) to the standard value.

Standard pressure value:

0.3 ~ 0.35MPa (43.5 ~ 50.7psi)

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2013 > G 2.4 HEV > Brake System > Brake System > Repair procedures

3. Remove the brake reservoir tank cap.

4. Install the cap (A) of SST (09580-3D100) on the reservoir tank.

Before using the SST adapter, fill up the reservoirtank with brake fluid.

5. Fix the adapter to the master cylinder with a SST adapter wire (A).

6. Make sure the check valve (A) is closed, remove the plug from the SST hose and connect it to the
adapter (B).

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 2013 > G 2.4 HEV > Brake System > Brake System > Repair procedures

Air Bleeding Tool Removal Procedure

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

2. After disconnecting the air hose (B), bleed air in the reservoir tank by opening the air shut-off valve (A)
slowly.

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

3. Remove the SST hose (B) from the adapter (A).

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 2013 > G 2.4 HEV > Brake System > Brake System > Repair procedures

4. Remove the SST adapter wire (B) unscrewing the wing nut (A).

5. Remove the cap of SST (09580-3D100) on the reservoir tank.

AHB Brake System Bleeding procedure

HPU is supplied with the accumulator empty. (But HPU inner circuit is completely filled.)
Air bleeding must be conducted when changing the HPU (Hydraulic Power Unit) or the BAU (Brake
Actuation Unit).
Also, air bleeding must be conducted when changing the hose or tube between HPU and BAU.

- Use theair bleeding tool (SST : 09589-3D100), or a tool that can provide pressure inside the
reservoir than when air bleeding the HPU and BAU. Air bleeding only by pressing the brake pedal

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 2013 > G 2.4 HEV > Brake System > Brake System > Repair procedures

will not completely extract air and might cause noise or abnormal operation.
- When bleeding air, make sure the brake fluid is above 10mm starting from the “MIN” line.
- To remove the reservoir tank cap to refill the brake fluid, always close the air shut-off valve of the
SST.
- Turn on the engine when depressing the brake pedal with the negative (-) battery terminal
connected. If the brake pedal is excessively depressed without the engine running, the 12V
battery can be discharged.

1. Disconnect the negative (-) battery terminal to turn HPU ECU off.
2. Set the air bleeding tool (SST: 09580-3D100) to reservoir tank and operate HPU & BAU line bleeding.
3. Connect the negative (-) battery terminal to turn the HPU ECU ON. And then operate the HPU and BAU
line bleeding again.
4. Operate the ESC and Wheel line bleeding under the same conditions.
5. Perform brake pedal sensor calibration.
(Brake System - "Brake pedal")
Brake Wheel Line Bleeding Procedure

The 12V battery can be discharged if the brake pedal is excessively depressed without the engine

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2013 > G 2.4 HEV > Brake System > Brake System > Repair procedures

running.

1. Make sure the brake fluid in the reservoir is at the MAX(upper) level line.
2. Use the air bleeding tool (SST: 09580-3D100) and feed oil pressure 0.3 ~ 0.35MPa (43.5 ~ 50.7psi) into
the reservoir.
3. Loosen the bleed screw (A) on the wheel and initiate air bleeding on all the wheels.
[Front]

[Rear]

When bleeding air, make sure the brake fluid leveldoes not go below the “MIN” line.

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

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 2013 > G 2.4 HEV > Brake System > Brake System > Repair procedures

5. Tighten the bleeder screw.

Tightening torque:
6.9 ~ 12.7 N.m (0.7 ~ 1.3 kgf.m, 5.1 ~ 9.4 lb-ft)

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

ESC Control Module bleeding procedure
This procedure should be followed to ensure adequate bleeding of air and filling of the ESC unit, brake
lines and master cylinder with brake fluid.
1. Remove the reservoir cap and fill the brake reservoir with brake fluid.

If there is any brake fluid on any painted surface, wash it off immediately.

When pressure bleeding, do not depress the brake pedal.

Recommended fluid........ DOT3 or DOT4

2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a
half filled clear plastic bottle.
3. Connect the GDS to the data link connector located underneath the dash panel.
Select and operate according to the instructions on the GDS screen.

You must obey the maximum operating time of the ABS motor with the GDS to prevent the motor
pump from burning.
4.
(1) Select vehicle name.
(2) Select Anti-Lock Brake system.
(3) Select HCU air bleeding mode.

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2013 > G 2.4 HEV > Brake System > Brake System > Repair procedures

(4) Press "OK" to operate motor pump and solenoid valve.

(5) Wait 60 sec. before operating the air bleeding.(If not, you may damage the motor.)

(6) Perform the air bleeding.

5. Use the air bleeding tool (SST: 09580-3D100) and feed oil pressure (0.3 ~ 0.35MPa (43.5 ~ 50.7psi)) into
the reservoir.
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2013 > G 2.4 HEV > Brake System > Brake System > Repair procedures

6. Loosen the bleed screw (A) on the wheel and initiate air bleeding on all the wheels.
[Front]

[Rear]

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

8. Tighten the bleeder screw.

Bleed screw tightening torque:

6.9 ~ 12.7 N.m (0.7 ~ 1.3 kgf.m, 5.1 ~ 9.4 lb-ft)

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

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 2013 > G 2.4 HEV > Brake System > Brake System > Repair procedures
HPU & BAU line bleeding procedure
1. HPU & BAU Line Filling
(1) Disconnect the negative (-) battery terminal to turn HPU ECU off.
(2) Pressurize the pressure (0.3 ~ 0.35MPa (43.5 ~ 50.7psi)) to reservoir using air bleeding tool (SST:
09580-3D100).
(3) Remove all of the air by opening the bleed screw (A) and then close again.

When bleeding air, make sure the brake fluid is above 10mm starting from the “MIN” line.

(4) Open the bleeder screw (B) and let fluid flow until all the air is removed.

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2013 > G 2.4 HEV > Brake System > Brake System > Repair procedures

When bleeding air, make sure the brake fluid is above 10mm starting from the “MIN” line.

HPU & BAU Line Filling

(1) Connect the negative (-) battery terminal to turn HPU ECU on.
(2) Pressurize the pressure (0.3 ~ 0.35MPa (43.5 ~ 50.7psi)) to reservoir using air bleeding tool (SST:
09580-3D100).
(3) Press the brake pedal 20~40mm (0.79 ~ 1.57 in) while opening the bleed screw (A) and hold for 10
seconds.
Try these operations 2~3 times to each wheel until the air does not come out from brake fluid.And
then close the bleed screw.

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2.

● Be careful that bleed screw hose does not break away.

● Fill the brake fluid if it is necessary.

(4) Press the brake pedal fully while removing all of the brake fluid by opening the bleed screw (B) of
wheel side, and then close the bleed screw and release the brake pedal. Try these operations 3~5
times to each wheels until the air does not come out from brake fluid.

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2013 > G 2.4 HEV > Brake System > Brake System > Repair procedures

● Be careful that bleed screw hose does not break away.

● Fill the brake fluid if it is necessary.

(5) Open the bleeder screw (A). Then slowly press the brake pedal. Then close the bleed screw and
release the brake pedal.
Repeat this procedure 3~5 times until no air bubbles are observed.

(6) Remove the air bleeding tool (SST: 09580-3D100) from reservoir. With the reservoir cap off, slowly
press the brake pedal 5~10 times.

● Be careful not to overflow the Brake Fluid.

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(7) If accumulator does not charge and motor operate continuously, start the bleeding process over
again.
(8) If air bubbles are not be observed rising in the reservoir, the bleed process is complete cap the
reservoir.
3. Perform brake pedal sensor calibration.
(Brake System - "Brake pedal")

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