KIA Niro: Air Bleeding Tool Removal Procedure

1. Close the air shut-off valve (A) first, after disconnecting the air hose (B), bleed air in the reservoir tank by opening the air shut-off valve (A) slowly.

Warning

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

2. Remove SST (09580-3D100) (B) and the cap of SST(0K585-E8100) (A) on the reservoir tank.

3. Install the brake reservoir tank cap (A).

AHB Brake System Bleeding

Warning

The iBAU consists of total 3 brake fluid lines (Low/High pressure and pedal simulator section), Air bleeding for iBAU system should be carried out sequentially following the procedure below.

AHB Brake System Bleeding Step 1 (IBAU ECU OFF)- Air bleeding for low pressure & simulator fluid lines

Warning

IBAU filled with brake oil should be used for bleeding

1. Disconnect the IBAU connector(A) to turn off iBAU ECU.

2. Set the air bleeding tool (SST: 09580-3D100) and the cap of SST (0k585-E8100)to reservoir tank and make pressure (0.3-0.5MPa (43.5 - 72.5psi)) to it.

3. Initiate air bleeding screws of iBAU (2EA ports) → 4 Calipers (1port per each caliper) in the following sequences. until air bubbles no longer appear in the fluid.

Bleeding sequence : iBAU → Caliper

(1) Bleeding method (iBAU 2EA ports) 1) Drain brake fluid by opening each bleed screw for 30seconds and then close it.

2) Main worker opens bleed screw and assistant depresses the brake pedal strongly and quickly 10~20 times to drain brake fluid and close the bleed screw again. (Working with buddy system)

(2) Bleeding method (1port per each caliper) 1) Drain brake fluid by opening each bleed screw for 30seconds and then close it again.

2) Main worker opens bleed screw and assistant depresses the brake pedal strongly and quickly 10~20 times to drain brake fluid and close the bleed screws again. (Working with buddy system) - Caliper bleed screw sequence : Rear RH → Rear LH → Front RH → Fornt LH

Warning

• Be careful not to open the bleed screw excessively. Otherwise, air may enter the brake fluid line.
• Repeat it until air bubbles no longer appear in the fluid.

AHB Brake System Bleeding Step2 (iBAU ECU ON) - Air bleeding for high pressure brake fluid line

Warning

Always remember to monitor & refill the iBAU reservoir as necessary. Do not allow the reservoir to go empty, or you will need to restart the bleeding procedure again, FROM THE BEGINNING.

1. Connect the IBAU connector to proceed with the bleeding high pressure brake fluid line by turning ON the system.
2. Entering air bleeding mode (Important)

If you fail to implement the air bleeding mode, air bleeding for high pressure brake fluid line will not be made as the system is OFF.

(1) With ignition switch ON, set the front wheels straight forward and place the shift lever in 'P' range.

(2) While pressing & holding the ESC OFF switch (over 5 seconds), repeat pressing and releasing the brake pedal for 10 times, with a full stroke. (Press the ESC OFF switch continuously.)

(3) While continuing to press & hold the ESC OFF switch, turn the ignition switch OFF and then turn ON again.

(4) If 3 warnig lamps on the instrument cluster turn ON simultaneously, entering air bleeding mode is completed.

(5) The step 1) ~ 3) must be carried out within 30 seconds.

(6) If 3 warning lamps do not turn ON, repeat the 1)~3)

Warning

Cases when air bleeding mode is deactivated :

• When ignition switch is OFF or shift lever is placed in D/R/N range.
• When defect is detected.
• Brake fluid is under the min level.
• When ESC OFF is deactivated.

3. Conduct air bleeding of Calipers by opening the caliper bleed screws(1port per each caliper)

(1) Assistant: Press brake pedal with the stroke of 30~40mm and then send 'stand by' signal.

(2) Main worker : Drain brake fluid by opening the caliper bleed screws for 3 seconds and then close the bleed screws again. (Repeat this step 10~20 times until no air bubbles appear).

• Caliper bleed screw sequence : Rear RH → Rear LH → Front RH → Fornt LH

(3) Be careful not to deactivate the self bleeding mode during air bleeding.

(4) If opening the bleed screw excessively, air may enter the fluid line, so, open the bleed screw a quarter of 1 revolution and then close it again.

Warning

CASE OF EPB VEHICLE

1) Assistant: Activate/deactivate EPB by operating the EPB switch, simultaneously depressing/releasing the brake pedal.

2) Main worker : Strike the caliper body with a rubber hammer, simultaneously opening/closing the caliper bleed screws.

4. When air bleeding is completed, release the self bleeding mode by turning the ignition switch to OFF position or pressing the ESC OFF switch.

AHB Brake System Bleeding Step3 (iBAU ECU ON) - Fluid Circulation Mode by KDS

1. Remove the SST (0K585-E8100) and fill the brake fluid until it reaches Max line in reservoir tank.
2. Start up the engine and then conduct the 'Fluid Circulation Mode' by KDS. (For about 20minutes)

3. After finishing the 'Fluid Circulation Mode', check the brake operating condition/brake pedal feeling, and DTC's.

Warning

• Be sure to conduct the 'Fluid Circulation Mode' whie engine is running. Otherwise, battery can be discharged.
• After finishing the air bleeding, if brake pedal exhibits spongy pedal symptom or braking response is slow. redo the air bleeding from 1st step of air bleeding.
• If braking performance/brake pedal feeling is good but noise is generated, redo the 'Fluid Circulation Mode'.

Specifications

Warning

O.D.: Outer Diameter

I.D: Inner Diameter

Specification (ESC)

Service Standard

Tightening Torques

Lubricants

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