Kia Soul: Brake Pedal Repair procedures - AHB(Active Hydraulic Boost) System - Brake SystemKia Soul: Brake Pedal Repair procedures

Kia Soul EV (PS EV) 2015-2020 Service Manual / Brake System / AHB(Active Hydraulic Boost) System / Brake Pedal Repair procedures

Removal
1.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
2.
Remove the crash pad lower panel and reinforcing panel. (Refer to the Body group - crash pad)
3.
Remove the lower duct (A).

4.
Pull down steering column shaft after removing bolts and nuts. (Refer to the steering group - Steering columm & shaft)
5.
Disconnect the stop lamp switch connector (A) and the brake pedal stroke sensor connector (B).

6.
Remove the brake pedal member mounting nut (A).

7.
Remove the snap pin (A) and clevis pin (B).

8.
Remove the brake pedal member assembly mounting nuts (A) and then remove the brake pedal assembly.

Tightening torque:10.8 ~ 12.7 N.m (1.1 ~ 1.3 kgf.m, 8.0 ~ 9.4 lb-ft)

Installation
1.
Install in the reverse order of removal.
2.
Check the brake pedal operation.
3.
Conduct calibration after removing the brake pedal assembly.
Brake pedal sensor Calibration
The brake pedal sensor calculates the pedal full stroke according to the preset zero. Therefore, zeroing adjustment is necessary when first installed.
Calibration must be performed in the following cases:
After changing the brake pedal assembly (you cannot change only the sensor)
After changing the BAU (Brake Actuation Unit)
When error codes C1380 (calibration) or C1379 (signal error) are detected.
After bleeding IBAU & PSU lines.
Calibration procedure
The calibration must be done while the vehicle is parked without stepping on the brake pedal and while there is no vibration on the vehicle.
1.
Connect the GDS. (CAN line or OBD connector)
2.
Turn ignition switch ON.
3.
Select calibration of the brake pedal sensor.
4.
Follow prompts displayed on the GDS screen to complete brake pedal sensor calibration.

5.
Turn ignition switch off after calibration procedure.
6.
Confirm success or failure of calibration.
Stop lamp switch clearance adjustment
Removal
1.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
2.
Remove the crash pad lower panel and reinforcing panel. (Refer to the Body group - crash pad)
3.
Remove the lower duct (A).

4.
Pull down steering column shaft after removing bolts and nuts. (Refer to the steering group - Steering columm & shaft)
5.
Disconnect the stop lamp switch connector (A) and the brake pedal stroke sensor connector (B).

6.
Pull the locking plate (A) as indicated by the arrow.

7.
Turn brake switch 45° counterclockwise and remove it.

Inspection
1.
Check the stop lamp switch.
(1)
Connect a circuit tester to the connector of stop lamp switch, and check whether or not there is continuity when the plunger of the stop lamp switch is pushed in and when it is released.
(2)
The stop lamp switch is in good condition if there is no continuity when plunger is pushed.

Installation
1.
With brake pedal fully released, insert the brake switch fully in contact with brake pedal arm.

2.
After inserting, turn the brake switch 45° clockwise, and then push in the locking plate to assemble.

3.
Confirm the gap between brake switch and bracket.

Brake clearance (A):
1.0 ~ 2.0 mm (0.04 ~ 0.08 in.)

4.
Connect the brake switch connector (A).

Adjustment
Brake switch clearance adjustment
If the gap between brake switch and bracket does not fall between 1.0 ~ 2.0mm (0.04~ 0.08in), conform to the following:
1.
Disconnect the brake switch connector (A).

2.
Pull the locking plate (A) as indicated by the arrow.

3.
Turn brake switch 45° counterclockwise and remove it.

4.
With brake pedal fully released, insert the brake switch fully in contact with brake pedal arm.

5.
After inserting, turn the brake switch 45° clockwise, and then push in the locking place to assemble.

6.
Confirm the gap between brake switch and bracket.

Brake clearance (A):
1.0 ~ 2.0 mm (0.04 ~ 0.08 in.)

7.
Connect the brake switch connector (A).

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