Hyundai Kona: Brake System / Brake Line Repair procedures

Removal
Brake Tube [VDC Control unit ↔ Master cylinder]
1.
Turn ignition switch OFF and disconnect the battery negative (-) cable.
2.
Disconnect the brake fluid level switch connector (A)

3.
Remove the brake fluid from the master cylinder 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.
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
4.
Loosen the flare nuts and then separate the brake tube (A) from the master cylinder.
Tightening torque :
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m. 13.7 - 16.6 lb-ft)

5.
Separate the intercooler inlet hose (A) from the turbocharger and then remove the inter cooler inlet pipe (B). [Gasoline 1.6 T-GDI]
Tightening torque
Clamp : 4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)
Mounting bolt : 18.6 - 23.5 N.m (1.9 - 2.4kgf.m, 13.7 - 17.4 lb-ft)

6.
Loosen the flare nuts (A) from the VDC control module (HECU) and remove the brake tube.
Tightening torque :
18.6 - 22.5 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)

Brake Tube [VDC Control unit ↔ Rear Brake hose]
1.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
2.
Disconnect the brake fluid level switch connector (A).

3.
Remove the brake fluid from the master cylinder reservior 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.
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
4.
Separate the intercooler inlet hose (A) from the turbocharger and then remove the inter cooler inlet pipe (B). [Gasoline 1.6 T-GDI]
Tightening torque
Clamp : 4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)
Mounting bolt : 18.6 - 23.5 N.m (1.9 - 2.4kgf.m, 13.7 - 17.4 lb-ft)

5.
Loosen the flar nuts (A) from the VDC control module (HECU).
Tightening torque :
12.7 - 16.7 N.m (1.3 - 1.7kgf.m, 9.4 - 12.3 lb-ft)

6.
Remove the air cleaner.
(Refer to Engine Mechanical System - "Air Cleaner")
7.
Remove the battery.
(Refer to Engine Electrical System - "Battery")
8.
Remove the ECM.
(Refer to Engine Control System - "ECM")
9.
Loosen the nuts (A) and then remove the brake tube.
Tightening torque :
12.7 - 16.7 N.m (1.3 - 1.7kgf.m, 9.4 - 12.3 lb-ft)

10.
Loosen the rear wheel nuts and then remove the wheel and tire (A) from the rear hub.
Tightening torque :
107.8 - 127.4 N.m (11.0 - 13.0kgf.m, 79.5 - 94.0 lb-ft)
  
Be careful not to damage the hub bolts when removing the front wheel and tire (A).

11.
Remove the flare nut (A) and then rear brake hose.
Tightening torque :
12.7 - 16.7 N.m (1.3 - 1.7kgf.m, 9.4 - 12.3 lb-ft)

12.
Remove the fuel tank.
(Refer to Engine Control Fuel System "Fuel Tank")
13.
Remove the fuel and brake line protector (A).

14.
Separate the fixing clip (A) from the brake line using a driver.

15.
Remove the brake line from the bottom of the vehicle to prevent damage.
Brake Hose
1.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
2.
Disconnect the brake fluid level switch connector (A).

3.
Remove the brake fluid from the reservoir tank with a syringe after remove the reservoir cap.
  
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.
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
4.
Remove the front wheel and tire (A) from front hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)
  
Be careful not to damage the hub bolts when removing the wheel and tire (A).
[Front]

[Rear]

5.
Remove the brake hose cilp (A).
6.
Separate the brake tube after loosening the brake tube flare nut (B).
Tightening torque :
12.7 - 16.7 N.m (1.3 - 1.7 kgf.m, 9.4 - 12.3 lb-ft)
[Front]

[Rear]

7.
Remove the brake hose bracket bolt (A).
Tightening torque :
8.82 - 13.7 N.m (1.3 - 1.7 kgf.m, 6.5 - 10.1 lb-ft)

8.
Loosen the brake hose mounting bolt (A) from the caliper and then remove the brake hose.
Tightening torque :
24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)
[Front]

[Rear]

Inspection
1.
Check the brake tubes for cracks, crimps and corrosion.
2.
Check the brake tube flare nuts for damage and fluid leakage.
Installation
1.
To install, reverse the removal procedure.
  
Use a new washer (A) whenever installing.

2.
After installing, bleed the brake system.
(Refer to Brake System - "Brake System Bleeding")
(Refer to Brake System - "ABS System Bleeding")
(Refer to Brake System - "ESP System Bleeding")
Brake Line Components and components location
Components ...

Brake Pedal Components and components location
Components 1. Stop lamp switch 2. Brake pedal arm assembly 3. Brake member assembly 4. Return spring ...

Other information:

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