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Brake System

GENERAL ABS (ANTI-LOCK BRAKE SYSTEM)


ANTI-LOCK BRAKING SYSTEM CONTROL
MODULE
BRAKE SYSTEM FRONT WHEEL SPEED SENSOR
BRAKE BOOSTER REAR WHEEL SPEED SENSOR
BRAKE LINE
BRAKE PEDAL
FRONT DISC BRAKE EBD (ELECTRONIC BRAKE-FORCE DIS-
MASTER CYLINDER TRIBUTION)
PROPORTIONING VALVE
REAR DISC BRAKE ESP(ELECTRONIC STABILITY PROGRAM)
REAR DRUM BRAKE
SYSTEM
YAW-RATE SENSOR AND G-SENSOR
PARKING BRAKE SYSTEM MASTER CYLINDER PRESSURE SENSOR
PARKING BRAKE ESP SWITCH
PARKING BRAKE SWITCH STEERING WHEEL ANGLE SPEED SENSOR
BR -2 BRAKE SYSTEM
GENERAL BR -3

GENERAL
SPECIFICATIONS EB7F495C

Item Specification
Master cylinder
Type Tandem type
I.D. 22.22 mm (0.875 in)
Piston stroke 29 ~ 31 mm
Fluid level warning sensor Provided
Proportioning valve(CBS)
Cut-in pressure(Split point) 35 kg/㎠ (3.43 MPa, 497.8 psi)
Decompression ratio 0.27 : 1
Brake booster
Type Vacuum
Effective diameter 254 mm(10 in)
Boosting ratio 7 : 1
Front brake(Disc)
Type Floating type with ventilated disc
Disc O.D. 256 mm(10 in)
Disc thickness 22 mm(0.87 in)
Pad thickness 11 mm(0.43 in)
Cylinder type Single piston
Cylinder I.D. Ø54 mm(2.12 in)
Rear brake(Disc)
Type Floating type with solid disc
Disc O.D. 262 mm (10.3 in)
Disc thickness 10 mm (0.39 in)
Pad thickness 10 mm (0.39 in)
Cylinder type Single piston
Cylinder I.D. 31 mm (1.22 in)
Rear brake(Drum)
Type Leading trailing
Drum I.D 203.2 mm (8 in)
Brake lining thickness 4.3 mm(0.17 in)
Clearance adjustment Automatic
Parking brake
Actuation Mechanical brake acting on rear wheels
Type Lever
Drum I.D. 168 mm(6.61 in)

NOTE
ABS : Anti-lock Brake System
CBS : Conventional Brake System
BR -4 BRAKE SYSTEM

SPECIFICATION(ABS) EDA60E0F

Part Item Standard value Remark


4 Channel 4 Sensor
System
(Solenoid)
Type ABS + EBD
HECU Operating Voltage 10 ~ 16 V
Operating Temperature -40 ~ 110 ℃
Motor power 180 W
Min. Operating Voltage 1.2 V
Warning lamp
Max. Current consumption 120 mA
Supply voltage DC 4.5 ~ 20 V
Operating Temperature -40 ~ 150 ℃
Output current low 5.9 ~ 8.4 mA Typ. 7 mA
Active Wheel speed Output current high 11.8 ~ 16.8 mA Typ. 14 mA
sensor (ABS) Output range 1 ~ 2500 Hz
Tone wheel 48 teeth
Air gap 0.4 ~ 1.5 mm
Output duty 30 ~ 70 %
GENERAL BR -5

SPECIFICATION(ESP)

Part Item Standard value Remark


4 Channel 4 Sensor
System
(Solenoid)
Motor, valve relay
Type
intergrated type Total control
HECU
Operating Voltage 10 ~ 16 V (ABS, EBD, TCS, ESP)

Operating Temperature -40 ~ 110 ℃


Motor power 180 W
Min. Operating Voltage 1.2 V
Warning lamp
Max. Current consumption 120 mA
Supply voltage DC 4.5 ~ 20 V
Operating Temperature -40 ~ 150 ℃
Output current low 5.9 ~ 8.4 mA Typ. 7 mA
Active Wheel speed Output current high 11.8 ~ 16.8 mA Typ. 14 mA
sensor (ABS) Output range 1 ~ 2500 Hz
Tone wheel 48 teeth
Air gap 0.4 ~ 1.5 mm
Output duty 30 ~ 70 %
Operating Voltage 9 ~ 16 V
Operating Temperature -30 ~ 75 ℃
Steering Wheel Angle
Sensor Current Consumption Max. 100 mA
Output Current Max. 10 mA
Operating Angular velocity Max. 1500 /sec
Operating Voltage 4.75 ~ 5.25 V
Current Consumption Max. 65 mA
Output voltage 0.5 ~ 4.5 V
Yaw rate & Operating Temperature -40 ~ 85 ℃
Lateral G sensor
Yaw rate sensor
± 75 /sec
measurement range
Lateral G sensor
± 1.5 g
measurement range
BR -6 BRAKE SYSTEM

SERVICE STANDARD EFE66F10

Item Standard value


Standard value
Brake pedal height 164.8 mm (6.49 in)
Brake pedal stroke 125 mm (4.92 in)
Stop lamp switch outer case to pedal stopper clearance 0.5~1.0 mm (0.02~0.04 in)
Brake pedal free play 3~8 mm (0.11~0.31 in)
Booster push rod to master cylinder piston clearance 0 (at 500 mmHg vacuum)
Parking brake lever stroke when lever assembly is pulled 6~ 8 clicks
with 196N (20Kg, 44lb force)
Front disc brake pad thickness 11 mm (0.43 in)
Front disc thickness 22 mm (0.87 in)
Rear drum brake lining thickness 4.3 mm (0.17 in)
Rear drum brake drum I.D. 203.2 mm (8 in)
Rear disc brake pad thickness 10 mm (0.4 in)
Rear disc brake disc thickness 10 mm (0.4 in)

TIGHTENING TORQUE

Item Nm kgf.m lb-ft


Master cylinder to booster mounting nut 7.9 ~ 11.8 0.8 ~ 1.2 5.79 ~ 8.68
Brake booster mounting nut 12.74 ~ 15.68 1.3 ~ 1.6 9.4 ~ 11.57
Bleeder screw 5.88 ~ 9.8 0.6 ~ 1.0 4.34 ~ 7.23
Brake tube nut, brake hose 12.74 ~ 16.64 1.3 ~ 1.7 9.4 ~ 12.3
Caliper guide rod bolt 21.56 ~ 31.36 2.2 ~ 3.2 15.91 ~ 23.14
Caliper mounting bolt 83.36 ~ 93.16 8.5 ~ 9.5 61.48 ~ 68.71
Brake pedal member assembly bracket
7.9 ~ 11.8 0.8 ~ 1.2 5.79 ~ 8.68
mounting bolt
Brake pedal mounting nut 24.51 ~ 34.32 2.5 ~ 3.5 18.08 ~ 25.31
Stop lamp switch mounting nut 7.9 ~ 9.8 0.8 ~ 1.0 5.79 ~ 7.23
Rear drum brake bleeder screw 5.88 ~ 8.82 0.6 ~ 0.9 4.34 ~ 6.51
Wheel speed sensor mounting bolt 8.04 ~ 9.51 0.82 ~ 0.97 5.93 ~ 7.02
HECU mounting bracket bolt 7.9 ~ 9.8 0.8 ~ 1.0 5.79 ~ 7.23
HECU union screw 11.76 ~ 15.68 1.2 ~ 1.6 8.68 ~ 11.57
Rear drum backing plate mounting bolt 9.8 ~ 12.74 1 ~ 1.3 7.23 ~ 9.4
Proportioning valve to master cylinder 34.3 ~ 44.1 3.5 ~ 4.5 25.31~32.55

Yaw rate & Lateral G sensor mounting nut 7.9 ~ 10.79 0.8 ~ 1.1 5.79 ~ 7.95
Master cylinder pressure sensor 22.56 ~ 26.48 2.3 ~ 2.7 16.64 ~ 19.53
GENERAL BR -7

LUBRICANT

Item Recommended lubricant Quantity


Brake fluid DOT 3 or DOT 4 As required
Brake pedal bushing and brake pedal bolt Chassis grease As required
Caliper guide rod bolt and boot AI -11(P) grease 1.0 ~ 1.8 g
Parking brake shoe and backing plate contact surfaces Bearing grease As required

SPECIAL TOOLS EBE980DB

Tool (Number and Name) Illustration Use

09581 - 11000 Pushing back of the front disc and


Piston expander rear disc brake piston

ARJE504I
BR -8 BRAKE SYSTEM

TROUBLESHOOTING EEA006CA

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the prob-
lem. The numbers indicate the priority of the like cause of
the problem. Check each part in order. If necessary, re-
place these parts.

Symptom Suspect Area Remedy


Lower pedal or 1. Brake system (Fluid leaks) Repair
spongy pedal 2. Brake system (Air in) Air bleeding
3. Piston seals (Worn or damaged) Replace
4. Master cylinder (Faulty) Adjust
Brake drag 1. Brake pedal free play (Minimum) Adjust
2. Parking brake lever travel (Out of adjustment) Adjust
3. Parking brake wire (Sticking) Repair
4. Pad or lining (Cracked or distorted) Replace
5. Piston (Stuck) Replace
6. Piston (Frozen) Replace
7. Return spring (Faulty) Replace
8. Booster system (Vacuum leaks) Repair
9. Master cylinder (Faulty) Replace
Brake pull 1. Piston (sticking) Replace
2. Pad or lining (Oily) Replace
3. Piston (Frozen) Replace
4. Disc (Scored) Replace
5. Pad or lining (Cracked or distorted) Replace
Hard pedal but brake 1. Brake system (Fluid leaks) Repair
inefficient 2. Brake system (Air in) Air bleeding
3. Pad or lining (Worn) Replace
4. Pad or lining (Cracked or distorted) Replace
5. Pad or lining (Oily) Replace
6. Pad or lining (Oily) Adjust
7. Pad or lining (Glazed) Replace
8. Disc (Scored) Replace
9. Booster system (Vacuum leaks) Repair
Noise from brake 1. Pad or lining (Cracked or distorted) Replace
2. Installation bolt (Loosen) Retighten
3. Disc (Scored) Replace
4. Pad retainers (Loosen) Retighten
5. Sliding pin (Worn) Replace
6. Pad or lining (Dirty) Clean
7. Pad or lining (Glazed) Replace
8. Return spring (Faulty) Replace
9. Brake pad shim (Damage) Replace
10. Shoe hold-down spring (Damage) Replace
Brake fades 1. Master cylinder Replace
GENERAL BR -9

Symptom Suspect Area Remedy


Brake vibration, 1. Brake booster Replace
pulsation 2. Pedal free play Adjust
3. Master cylinder Replace
4. Caliper Replace
5. Master cylinder cap seal Replace
6. Damaged brake lines Replace
Brake chatter Brake chatter is usually caused by loose or worn components, or
glazed or burnt linings. Rotors with hard spots can also contribute
to brake chatter. Additional causes of chatter are out-of-tolerance
rotors, brake lining not securely attached to the shoes, loose
wheel bearings and contaminated brake lining.
BR -10 BRAKE SYSTEM

BRAKE SYSTEM
OPERATION AND LEAKAGE
CHECK E8ADB1AE

CHECK ALL OF THE FOLLOWING ITEMS:

Component Procedure
Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes
do not work properly, check the brake booster. Replace the brake booster 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.
Wheel cylinder piston cup Check brake operation by applying the brakes.
and dust cover (E) 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, replace the wheel cylinder.

This illustration is shown the LHD type.


RHD type is symmetrical.
D/E
A
B

E C

D/E

LJJF503W
BRAKE SYSTEM BR -11

BRAKE BOOSTER OPERATING TEST 3. With the engine running, step on the brake pedal and
then stop the engine. Hold the pedal depressed for
For simple checking of the brake booster operation, carry 30 seconds. If the pedal height does not change, the
out the following tests : booster is in good condition, if the pedal rises, the
booster is defective. If the above three tests are okay,
1. Run the engine for one or two minutes, and then stop the booster performance can be determined as good.
it. If the pedal depresses fully the first time but grad- Even if one of the above three tests is not okay, check
ually becomes higher when depressed succeeding the check valve, vacuum hose and booster for defect.
times, the booster is operating properly, if the pedal
height remains unchanged, the booster is defective.

Good No good

3rd
2nd
1st
EGGE700C

EJRF500B

2. With the engine stopped, step on the brake pedal sev-


eral times. Then step on the brake pedal and start
the engine. If the pedal moves downward slightly, the
booster is in good condition. If there is no change, the
booster is defective.

When engine is stopped When engine is started

EGGB700B
BR -12 BRAKE SYSTEM

VACUUM HOSE (CHECK VALVE) BRAKE PEDAL BRAKE SWITCH ADJUSTMENT

INSPECTION PEDAL HEIGHT


1. Disconnect the brake booster vacuum hose (check 1. Disconnect the brake switch connector, loosen the
valve built in) (A) at the booster . brake switch locknut (A), and brake off the brake
switch (B) until it is no longer touching the brake
2. Start the engine and let it idle. There should be vac-
pedal.
uum available. If no vacuum is available, the check
valve is not working properly. Replace the brake
2. Lift up the carpet. At the insulator cutout, measure
booster vacuum hose and check valve and retest.
the pedal height (C) from the middle of the left-side
A
center of the pedal pad (D).

Standard pedal height (with carpet removed) :


164.8 mm (6.49 in)

AJJF501A C

EJKE001A

3. Loosen the pushrod locknut (A), and screw the


pushrod in or out with pliers until the standard pedal
height from the floor is reached. After adjustment,
tighten the locknut firmly. Do not adjust the pedal
height with the pushrod depressed.

Lower the pedal

Raise
the pedal

A
2.4 ~ 3.5 kgf.m
(23.54 ~ 34.32 Nm, 17.36 ~ 25.32 lb-ft)

LJJF500A
BRAKE SYSTEM BR -13

BRAKE SWITCH CLEARANCE PEDAL FREE PLAY

Screw in the brake switch until its plunger is fully de- 1. With the engine stopped, depress the brake pedal
pressed (threded end (A) touching the pad (B) on the two or three times. After eliminating the vacuum in
pedal arm) then brake off the switch 3/4 turn to make the power brake booster, press the pedal(B) down by
0.5~1.0 mm(0.0197~0.0394 in.) of clearance between the hand, and confirm that the amount of movement(A)
brake switch connector. Make sure that the brake lights before resistance is met (the free play) is within the
go off when the pedal is released. standard value.

Standard value : 3 ~ 8 mm (0.117 - 0.312 in.)

A C

B
B

0.5 ~ 1.0mm

AJJF600J
A

EJKE001D

2. If free play does not reach the standard value, check


that clearance between the outer case of stop light
switch(C) and brake pedal is within the standard
value. If free play exceeds the standard value, it is
probably due to excessive clearance between the
clevis pin and brake pedal arm. Check for excessive
clearance and replace faulty parts as required.

3. Start the engine, depress the brake pedal with approx-


imately 120kg(1176.8N, 264.5 lb) of force, and check
for oil leakage in the master cylinder, brake line and
each connecting part. Repair the faulty parts as re-
quired.
BR -14 BRAKE SYSTEM

INSPECTION OF FRONT DISC BRAKE PAD INSPECTION OF REAR DISC BRAKE PAD

1. Check the brake pad thickness through the caliper 1. Check the brake pad thickness through the caliper
body inspection hole. body inspection hole.

Pad thickness Pad thickness


Standard value : 11.0 mm (0.43 in.) Standard value : 10.0 mm (0.39 in.)
Service limit : 2.0 mm (0.0787 in.) Service limit : 2.0 mm (0.0787 in.)

AJJF502A AJJF503A

CAUTION CAUTION
- If the pad lining thickness is out of specifica- - If the pad thickness is out of specification, left
tion, left and right pads must be replaced as and right pads must be replaced as a com-
a complete set. plete set.
- When the thickness difference between the - When the thickness difference between the
left pad and right pad is large, check the slid- left pad and right pad is large, check the slid-
ing condition of the piston and the guide rod. ing condition of the piston and the guide rod.
BRAKE SYSTEM BR -15

BRAKE BOOSTER

COMPONENTS(1) E3FEFE85

This illustration is shown the LHD type.


RHD type is similar.

4
1 2

1.3 ~ 1.6
5 (12.74 ~ 15.68,
9.45 ~ 11.63)

2.4 ~ 3.5
6 (23.54 ~ 34.3, 17.36 ~ 25.45)
7

0.8 ~ 1.2
(7.84 ~ 11.76, 5.82 ~ 8.72)

TORQUE : kgf.m (Nm, lb-ft)


1. Vacuum hose 5. Clevis pin
2. Check valve 6. Brake booster
3. Snap pin 7. Mater cylinder
4. Seal 8. Washer
LJJF500B
BR -16 BRAKE SYSTEM

COMPONENTS(2)

Proportioning valve

<CBS Type <ABS Type>

Pressure
Sensor

GSL TYPE
<ESP Type
DSL TYPE

<Diesel engine Type> <Gasoline engine Type>

LJJF500C
BRAKE SYSTEM BR -17

REMOVAL ECEC42CE 5. Remove the brake booster (A) from the engine com-
partment.
1. Remove the master cylinder.( Refer to BR-32)

2. Disconnect the vacuum hose (B) from the brake A


booster (A).

ARJE500H

AJJF600M

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

A
B

C
1.3 ~ 1.6 kgf.m
(12.74 ~ 15.68 Nm, 9.45 ~ 11.63 lb-ft)

LJJF501W

4. Remove the four booster mounting nuts (C).


BR -18 BRAKE SYSTEM

INSTALLATION E4A72DD8 4. Install the master cylinder, then install the brake tubes
to the master cylinder.
1. Adjust push rod length of the booster, and then install
the seal on the booster assembly. 5. Connect the vacuum hose to the brake booster.

Standard length(A) : 116.3 ± 0.5 mm (4.58 ± 0.019 in) 6. After filling the brake reservoir with brake fluid, bleed
the system.

7. Check for fluid leakage.

8. Check and adjust the brake pedal for proper opera-


tion.

ARJE500I

2. Insert the booster and tighten the nuts (C).

A
B

C
1.3 ~ 1.6 kgf.m
(12.74 ~ 15.68 Nm, 9.45 ~ 11.63 lb-ft)

LJJF501X

3. Connect the booster push rod and brake pedal with a


clevis pin (A) and install a snap pin (B) to the clevis
pin (A).

CAUTION
Grease the pin before installing the snap pin.
Always use a new snap pin.
BRAKE SYSTEM BR -19

BRAKE LINE

COMPONENTS EBBA9697

This illustration is shown the LHD type.


RHD type is symmetrical.
Master cylinder to brake line
1.3 ~ 1.7 (12.74 ~ 16.66, 9.45 ~ 12.36)

Brake line to brake hose


1.3 ~ 1.7
Brake line to brake hose (12.74 ~ 16.66, 9.45 ~ 12.36)
1.3 ~ 1.7 (12.74 ~ 16.66, 9.45 ~ 12.36)

Brake hose
to caliper
2.5 ~ 3
(24.5 ~ 29.4,
18.18 ~ 21.81)

Proportioning valve
to brake line
13 ~ 17 Bleed screw
(12.74 ~ 16.66, 0.7 ~ 1.3
9.45 ~ 12.36) (6.86 ~ 12.74, 5.09 ~ 9.45)

Disc brake:
Brake hose to caliper 2.5 ~ 3 (24.5 ~ 29.4, 18.18 ~ 21.81)
Bleed screw 0.7 ~ 1.3 (6.86 ~12.74, 5.09 ~ 9.45)
Drum brake:
Brake line to wheel cylinder 1.3 ~ 1.7 (12.74 ~16.66, 9.45 ~ 12.36)
Bleed screw 0.7~1.3 (6.86 ~12.74, 5.09 ~ 9.45)

TORQUE : kgf.m (Nm, lb-ft)


LJJF500D
BR -20 BRAKE SYSTEM

REMOVAL EFDD23DE INSTALLATION E626ADF9

1. Disconnect the brake hose(C) from the brake line(A) 1. Install a brake hose(A) on the caliper with tightening
using a flare-nut wrench(B). brake hose bolt(C) and washer(B).

B C
A A

AJJF505A AJJF600Q

2. Remove the brake hose clip(A), and then remove the 2. Install the brake hose clip(C) to the brake hose
brake hose(B). bracket(B), then install the brake hose(A).

A
A
B B

AJJF600P AJJF600R

3. Remove the connector bolt from the caliper, and dis- 3. Connect the brake hose to the brake line.
connect the brake hose from the caliper.
4. After installing the brake hose, bleed the brake
system.

CAUTION
- Check the brake hoses for interference and
twisting.
- Check the brake hose and line joint for leaks,
and tighten if necessary.
BRAKE SYSTEM BR -21

INSPECTION E3FF54EC

1. Check the brake tubes for cracks, crimps and corro-


sion.

2. Check the brake hoses for cracks, damaged and oil Front Right Rear Right
leakage.

3. Check the brake tube flare nuts for damage and oil
leakage.

BRAKE SYSTEM BLEEDING EB2B9B45

Front Left Rear Left


NOTE
- Do not reuse the drained fluid.
- Always use Genuine DOT 3 or DOT 4 Brake
Fluid. Using a non-Genuine DOT3 or DOT 4
brake fluid can cause corrosion and decrease
the life of the system. EJKE003B
- Make sure no dirt of other foreign matter is al-
lowed to contaminate the brake fluid. FRONT DISC BRAKE :
- Do not spill brake fluid on the vehicle, it may dam-
0.7 ~ 1.3 kgf.m
age the paint; if brake fluid does contact the paint, (6.86 ~ 12.74 Nm,
wash it off immediately with water. 5.09 ~ 9.45 lb-ft)
- The reservoir on the master cylinder must be at
the MAX (upper) level mark at the start of bleed-
ing procedure and checked after bleeding each
brake caliper. Add fluid as required.

1. Make sure the brake fluid level in the reservoir is at


the MAX (upper) level line.

2. Have someone slowly pump the brake pedal several


times, and then apply steady pressure.

3. Loosen the right-rear brake bleed screw to allow air


to escape from the system. Then tighten the bleed LJJF500E
screw securely.
REAR DISC BRAKE :
4. Repeat the procedure for each wheel in the sequence
0.7 ~ 1.3 kgf.m(6.86 ~ 12.74 Nm, 5.09 ~ 9.45 lb-ft)
shown below until air bubbles no longer appear in the
fluid.

5. Refill the master cylinder reservoir to the MAX (upper)


level line.

LJJF500F
BR -22 BRAKE SYSTEM

BRAKE PEDAL

COMPONENTS(1) EA5956F8

[LHD]
0.8 ~ 1.0 (7.84 ~ 9.8, 5.82 ~ 7.27)

2.5 ~ 3.5
(24.5 ~ 34.3,
18.18 ~ 25.45)

0.8 ~ 1.0 (7.84 ~ 9.8, 3


5.82 ~ 7.27) 2

4 6

TORQUE : kgf.m (Nm, lb-ft)


1. Member assembly bracket 4. Return spring
2. Pedal bushing 5. Stop lamp switch
3. Spring washer 6. Brake pedal
7. Pedal pad

LJJF500G
BRAKE SYSTEM BR -23

COMPONENTS(2)

[RHD]

9
4

3
11 5

10
8
1

(M/T)
(A/T)

1. Brake pedal arm 7. Stop lamp switch


2. Pedal pedal 8. Return spring
3. Pipe 9. Mounting bracket
4. Bush 10. Bushing
5. Washer 11. Support bracket
6. Pedal support bracket
LJJF503X
BR -24 BRAKE SYSTEM

REMOVAL E1A2ACB9 INSPECTION E391CCB2

1. Remove the lower crash pad.(Refer to BD-“ crash 1. Check the bushing for wear.
pad” )
2. Check the brake pedal for bending or twisting
2. Loosen the brake member assembly bracket two up-
per nuts and 4 lower nuts. 3. Check all parts for crack and wear.

3. Remove the stop lamp switch connector (A). 4. Check the stop lamp switch.

nut 1) Connect a circuit tester to the connector (1-2 ter-


A
minals) 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 re-
leased.

2) The stop lamp switch is in good condition if there


is no continuity when the plunger is pushed.

nut

LJJF500H

4. Remove the shift lock cable (A/T).


no continuity (3 mm (0.12 in))
5. Remove the clevis pin and snap pin. A
continuity (4 mm (0.16 in))
6. Remove the brake pedal member assembly mounting
nuts and then remove the brake pedal assembly. EJRF500O
BRAKE SYSTEM BR -25

INSTALLATION E0F0CE0B

1. Installation is the reverse of removal.

CAUTION
Coat the inner surface of the bushings with the
specified grease.

2. Before inserting the pin, apply the specified grease to


the joint pin.

ARJE500U

3. Adjust the brake pedal height and free play.(See page


BR-13)

4. Install the stop lamp switch.


BR -26 BRAKE SYSTEM

FRONT DISC BRAKE

COMPONENTS(1) E2CE9A2B

2.2 ~ 3.2
(21.56 ~ 31.36, 15.99 ~ 23.26)

5
6

TORQUE : kgf.m (Nm, lb-ft)


1. Brake caliper 5. Indicator
2. Brake disc 6. Brake pad
3. Pad retainer 7. Brake pad shim
4. Guide rod bolt
LJJF500I
BRAKE SYSTEM BR -27

COMPONENTS(2)

2.2 ~ 3.2 (21.56 ~ 31.36, 15.99 ~ 23.26)


1
3
4
8 ~ 10
(78.4 ~ 98, 58.2 ~ 71.7)
2

5
6

10
0.7 ~ 1.3
(6.86 ~ 12.74,
5.09 ~ 9.45)

9
8
11

13

14
12

13

TORQUE : kgf.m (Nm, lb-ft)


1. Guide rod bolt 6. Washer 11. Piston boot
2. Bleeder screw 7. Caliper bracket 12. Brake pad
3. Guide rod 8. Caliper body 13. Pad retainer
4. Boot 9. Piston seal 14. Shim
5. Caliper mounting bolt 10. Piston

LJJF500J
BR -28 BRAKE SYSTEM

REMOVAL EDFFC96C INSPECTION EB6A90F5

CAUTION
FRONT BRAKE DISC THICKNESS CHECK

Frequent inhalation of brake pad dust, regardless 1. Remove all rust and contamination from the disc sur-
of material composition, could be hazardous to face, and then measure the disc thickness at 4 posi-
your health. tions at least.
• Avoid breathing dust particles.
• Never use on air hose or brush to clean brake Front brake disc thickness
assemblies. Standard value : 22.0 mm (0.87 in)
Limit : 20.0 mm ( 0.79 in)
1. Remove guide rod bolt(B) and raise the caliper
(A).Check the hoses and pin boots for damage and
2. Thickness variation should not exceed 0.005
deterioration.
mm(0.0002 in) (circumference) and 0.05 mm(0.0020
in) (radius) at any directions.

3. If wear exceeds the limit, replace the discs and pad


assemblies for left and right of the vehicle.

5 mm (0.2 in) (measurement position)

A
B
2.2 ~ 3.2 kgf.m
(21.56 ~ 31.36 Nm, 15.99 ~ 23.26 lb-ft)

LJJF500K

2. Remove the pad shims (A), pad retainers (B) and


pads (C).

LJJF500L

C
LJJF503V
BRAKE SYSTEM BR -29

FRONT BRAKE PAD CHECK SEIZE OF FRONT BRAKE DISC

1. Check the pad wear. Measure the pad thickness. re- 1. Remove the brake disc from hub using M8 screw(A)
place it if it is less than the specified value. if the brake disc has been seized with the hub due to
corrosion or overheat.
Pad thickness
Standard value : 11.0 mm (0.43 in) NOTE
Service limit : 2.0 mm (0.0787 in)
Be careful not to use the hammer. The disc can be
damaged if you remove the disc from the hub by ham-
mer.

ARJE501R

2. Check that grease is applied, to sliding contact points AJJF600W


and the pad and backing metal for damage.

FRONT BRAKE DISC RUN OUT CHECK

1. Place a dial gauge about 5mm (0.2 in) from the outer
circumference of the brake disc, and measure the run
out of the disc.

Brake disc run out


Limit : 0.03mm (0.0012 in) or less

2. If the run out of the brake disc exceeds the limit spec-
ification, replace the disc, and then measure the run
out again.

3. If the run out does not exceed the limit specification,


install the brake disc after turning it 180 and then
check the run out of the brake disc again.

4. If the run out cannot be corrected by changing the


position of the brake disc, replace the brake disc.
BR -30 BRAKE SYSTEM

INSTALLATION E33C4CCA

1. Install the pad retainers (A) to the caliper.

09581-11000

AJJF600Y
A
5. Pivot the caliper down into position. Being careful not
to damage the pin boot(A) , install the guide rod bolt
ARJE501M
(B) and tighten it to the specified torque.

B
2. Check the foreign material at the pad shims (D) and 22~32 Nm(2.2~3.2 kgf.m,
the back of the pads (B). 16.2~23.6 lb-ft)
Contaminated brake discs or pads reduce stopping
A
ability. Keep grease off the discs and pads.

3. Install the brake pads (B) and pad shims (D) on the
pad retainer correctly. Install the pad with the wear
indicator (C) on the inside. If you are reusing the
pads, always reinstall the brake pads in their original
positions to prevent a momentary loss of braking effi-
ciency.

LJJF503S

6. If caliper assembly was removed, install the brake


hose to the caliper.

B 7. Refill the master cylinder reservoir to the MAX line.

8. Bleed the brake system.

A 9. Depress the brake pedal several times to make sure


the brakes work, then test-drive.
C

NOTE
C
Engagement of the brake may require a greater pedal
LJJF503Y stroke immediately after the brake pads have been
replaced as a set. Several applications of the brake
4. Push in the piston (A) using the SST(09581-11000) will restore the normal pedal stroke.
so that the caliper will fit over the pads. Make sure
that the piston boot is in position to prevent damaging 10. After installation, check for leaks at hose and line
it when pivoting the caliper down. joints or connections, and retighten if necessary.
BRAKE SYSTEM BR -31

MASTER CYLINDER

COMPONENTS EF483DAD

4
8

[ABS]

10
[CBS]

3.5 ~ 4.5
(34.3 ~ 44.1,
25.45 ~ 32.72)

TORQUE : kgf.m (Nm, lb-ft)


1. Reservoir cap 6. Retainer
2. Brake fluid filter 7. Primary piston assembly
3. Reservoir 8. Secondary piston assembly
4. Grommet 9. Master cylinder body
5. Cylinder pin 10. Proportioning valve

LJJF500M
BR -32 BRAKE SYSTEM

REMOVAL EFB687E0 4. Disconnect the brake lines (A) from the master cylin-
der. To prevent spills, cover the hose joints with rags
NOTE or shop towels.

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.

1. Remove air cleaner mounting bolts (B) from the air


cleaner mounting bracket and air cleaner body (A).

A
C
A
1.3 ~ 1.7 kgf.m
(12.74 ~ 16.66 Nm,
9.45 ~ 12.36 lb-ft) B
0.8 ~ 1.2 kgf.m
(7.84 ~ 11.76 Nm,
5.82 ~ 8.72 lb-ft)

LJJF500N

5. Remove the master cylinder mounting nuts (B) and


washers.

6. Remove the master cylinder(C) from the brake


booster . Be careful not to bend or damage the brake
B
lines when removing the master cylinder.
AJJF509A

2. Disconnect the brake fluid level switch connector (A), INSTALLTION E11FF80D

and remove the reservoir cap (B).


1. Install the master cylinder to the brake booster.
B
C 2. Connect the brake tubes(A) and brake level switch
A connector(B) to the master cylinder.

AJJF510A

3. Remove the brake fluid from the master cylinder


A
reservoir (C) with a syringe.
AJJF602P

3. After refill the master cylinder reservoir to the Max line


, bleed the brake system.
BRAKE SYSTEM BR -33

DISASSEMBLY E6BECAD4 5. Remove the retainer ring by using the snap ring pliers.

1. Remove the reservoir cap and drain the brake fluid


into a suitable container.

2. Remove the fluid level sensor.

3. Remove the reservoir(B) from the master cylinder af-


ter remove the mounting screw (A).

B
LJJF503Z

6. Remove the pin with the primary piston pushed com-


pletely using a screwdriver. Remove the primary pis-
ton assembly.
A
7. Remove the pin(A) with the secondary piston pushed
completely using a screwdriver. Remove the sec-
ondary piston assembly.

AJJF511A

4. Remove the proportioning valves .( Conventional


brake system)
A

ARJE501C
A

NOTE
Do not disassemble the primary and secondary piston
AJJF601C assembly.
BR -34 BRAKE SYSTEM

INSPECTION EE7BC2AE 4. Press the piston with a screwdriver and install the re-
tainer ring.
1. Check the master cylinder bore for rust or scratch.

2. Check the master cylinder for wear or damage. If


necessary, clean or replace the cylinder.

CAUTION
- If the cylinder bore is damaged, replace the
master cylinder assembly.
- Wash the contaminated parts in alcohol.

REASSEMBLY EFCF70D2

1. Apply genuine brake fluid to the rubber parts of the


cylinder kit and grommets.
ARJE501F
2. Carefully insert the springs and pistons in the proper
direction. 5. Install the proportioning valves.(In case of CBS)

6. Mount two grommets.

7. Install the reservoir on the cylinder.

ARJE501D

3. Press the piston with a screwdriver and install the


cylinder pin.

ARJE501E
BRAKE SYSTEM BR -35

PROPORTIONING VALVE 4. Reconnect the brake lines in their original positions


and bleed the brake system.

DESCRIPTION EFADC65E
NOTE
Do not disassemble the proportioning valve. The propor- This table shows characteristics of the proportioning
tioning valve makes the ideal distribution of fluid pressure valve as the pressure increases.
to the front and rear brakes to prevent the brakes from skid-
ding in the event of rear wheel lock up and to obtain higher Rear
Front
brake efficiency within the range of service brake applica- (Output of proportioning
(Output of master cylinder)
tion. valve)

A : 35 ㎏/㎠ A’ : 35 ㎏/㎠
INSPECTION E6EC99E9 (3.43 MPa, 497 psi) (3.43 MPa, 497 psi)

1. Remove the front brake tube (B) and rear brake tube B’ : 44.5 ± 3.5 ㎏/㎠
B : 70 ㎏/㎠
(C) from the master cylinder (A). (4.36 ± 0.34 MPa,
(6.86 MPa, 996 psi)
633 ± 50 psi)
2. Connect two pressure gauges (D); one to the output
valve of the front (B) and rear (C) brake.
Output pressure (kg/cm2)

C
B’
D
A’
A
B
2
0 A B Input pressure (kg/cm )

LJJF500O

AJJF601D

NOTE
Be sure to bleed the system after connecting the pres-
sure gauges.

3. With the brake applied, measure the front pressure


and the rear pressure. If the measured pressures are
within the specified range as illustrated, the propor-
tioning valve is good.
BR -36 BRAKE SYSTEM

REAR DISC BRAKE

COMPONENTS E2BA80EE

0.6 ~ 1.0 (5.88 ~ 9.8, 4.36 ~ 7.27)


8.5 ~ 9.5 (83.3 ~ 93.1, 61.8 ~ 69.1)

1
2

3
4
5

6 9

7 10
8

11

3 12
2.2 ~ 3.2
(21.56 ~ 31.36, 15.99 ~ 23.26) 4

13

14
8

15

TORQUE : kgf.m (Nm, lb-ft)


1. Bleeder screw 9. Caliper mounting bolt
2. Caliper body 10. Washer
3. Guide rod 11. Guide rod bolt
4. Boot 12. Inner shim
5. Piston 13. Brake Pad
6. Piston seal 14. Outer shim
7. Piston boot 15. Caliper bracket
8. Pad retainer

LJJF500P
BRAKE SYSTEM BR -37

REMOVAL E09D14D6 INSPECTION E85CF784

1. Raise the rear of the vehicle and make sure it is se- REAR BRAKE DISC THICKNESS CHECK
curely supported. Remove the rear wheel.
1. Remove all rust and contamination from the disc sur-
2. Release the parking brake. face, and then measure the disc thickness at 8 posi-
tions at least.
3. Remove the guide rod bolt(A). After raise the caliper
assembly(B) , support it with a wire. Rear brake disc thickness
Standard value : 10.0 mm ( 0.39 in)
Limit : 8.0 mm (0.315 in)
21.56 ~ 31.36 Nm
(2.2 ~ 3.2 kg.m)
A
2. Thickness variation should not exceed
0.005mm(0.0002 in) (circumference) and
0.01mm(0.0004 in) (radius) at any directions.

3. If wear exceeds the limit, replace the discs and pad


assembly for left and right of the vehicle.

B 5 mm (measurement position)

AJJF601E

4. Remove the pad shim(A) and pad assembly(B) .

A
LJJF500Q

EJKE600B
BR -38 BRAKE SYSTEM

REAR BRAKE PAD CHECK 2. If the run out of the brake disc exceeds the limit spec-
ification, replace the disc, and then measure the run
1. Check the pad wear. Measure the pad thickness and out again.
replace it, if it is less than the specified value.
3. If the run out does not exceed the limit specification,
Pad thickness install the brake disc after turning it 180 and then
Standard value : 10.0 mm (0.39 in) check the run out of the brake disc again.
Service limit : 2.0 mm (0.0787 in)
4. If the run out cannot be corrected by changing the
position of the brake disc, replace the brake disc.

SEIZE OF REAR BRAKE DISC

1. Remove the brake disc from hub using M8 screw(A)


if the brake disc has been seized with the hub due to
corrosion or overheat.

NOTE
Be careful not to use the hammer. The disc can be
damaged if you remove the disc from the hub by ham-
mer.

ARJE501R

2. Check that grease is applied, and the pad and backing


metal for damage.

REAR BRAKE DISC RUN OUT CHECK

1. Place a dial gauge(A) about 5mm (0.2 in) from the


outer circumference of the brake disc, and measure
the run out of the disc.

A
Brake disc run out
Limit : 0.03mm (0.0012 in) or less
AJJF601F

A
5 mm

AJJF602R
BRAKE SYSTEM BR -39

INSTALLATION E03660C4 6. Pivot caliper down into position. Being careful not to
damage the pin boot, install the guide rod bolt (A) and
1. Install the pad retainers(A) to the caliper (B). tighten it to the specified torque.

21.56 ~ 31.36 Nm
(2.2 ~ 3.2 kgf.m)
A

AJJF602S
B
7. Install the brake caliper .
EJKE600D

8. After installation, check for leaks at hose and line


2. Check the foreign material at the pad shim (A) and the
joints and connections, and retighten if necessary.
back of the pads (B).
9. Depress the brake pedal several times to make sure
the brakes work, then test-drive.

NOTE
Engagement of the brake may require a greater pedal
stroke immediately after the brake pads have been
replaced as a set. Several applications of the brake
pedal will restore the normal pedal stroke.
A

AJGE019D

3. Contaminated brake discs or pads reduce stopping


ability. Keep grease off the discs and pads.

4. Install the brake pads (B) and pad shim (A) on the
caliper bracket.

5. If you are reusing the pads, always reinstall the brake


pads in their original positions to prevent a momentary
loss of braking efficiency. Push in the piston using
SST(09581-11000) so that the caliper will fit over the
pads. Make sure that the piston boot is in position to
prevent damaging it when pivoting the caliper down.
BR -40 BRAKE SYSTEM

REAR DRUM BRAKE

COMPONENTS EDCBECAA

2 4

6
1

5 7

LJJF500R
BRAKE SYSTEM BR -41

REMOVAL EA43F67D 7. Remove the bolt (C) and the wheel cylinder(B) from
the backing plate(D).
CAUTION
- Frequent inhalation of brake pad dust, re-
gardless of material composition, could be
hazardous to your health.
- Avoid breathing dust particles A
- Never use an air hose or brush to clean brake 1.3 ~ 1.7 kgf.m
D (12.74 ~ 16.66 Nm,
assemblies. 9.45 ~ 12.36 lb-ft)

1. Remove the shoe hold spring and shoe hold pin (B).

2. Remove the upper return spring (A).


C

A B

LJJF501Y
B

AJJF603K

3. Lower the brake shoe assembly (A), and remove the


lower return spring (B). Make sure not to damage the
dust cover on the wheel cylinder.

A A

AJJF601G

4. Disconnect the parking brake cable from the parking


brake lever.

5. Remove the brake shoe assembly.

6. Disconnect brake tubes(A) from the wheel cylin-


der(B).
BR -42 BRAKE SYSTEM

INSPECTION EC8DF780 8. Measure the inside diameter of the brake drum with
inside vernier calipers.
CAUTION
Drum inside diameter
Frequent inhalation of brake pad dust, regardless Standard : 203.2 mm (8.0 in)
of material composition, could be hazardous to Drum roundness
your health. Service limit : 0.06 mm(0.00236 in)
- Avoid breathing dust particles.
- Never use an air hose or brush to clean brake
assemblies.

NOTE
- Contaminated brake linings or drums reduce
stopping ability.
- Block the front wheels before jacking up the rear
of the vehicle.

1. Raise the rear of the vehicle, and make sure it is se-


curely supported.

2. Release the parking brake, and remove the rear brake


drum.

3. Check the wheel cylinder (A) for leakage.

EJKE800B

9. If the inside diameter of the brake drum is more than


the service limit, replace the brake drum.

10. Check the brake drum for scoring, grooves, and


cracks.

11. Inspect the brake lining and drum for proper contact.
C
12. Inspect the wheel cylinder outside for excessive wear
B and damage.

AJJF603N 13. Inspect the backing plate for wear or damage.

4. Check the brake linings (B) for cracking, glazing, wear,


and contamination.

5. Measure the brake lining thickness (C).


Measurement does not include brake shoe thickness.

Brake lining thickness


Standard : 3.9 ~ 4.5 mm (0.15 ~ 0.177 in.)
Service limit : 1.0 mm (0.039 in.)

6. If the brake lining thickness is less than the service


limit, replace the brake shoes as a set.

7. Check the bearings in the hub unit for smooth opera-


tion. If it requires servicing, replace it.
BRAKE SYSTEM BR -43

INSTALLATION E287DD5D 5. Hook the shoe adjuster lever, then install it to the
brake shoe.
NOTE
6. Install the adjuster assembly and upper return spring
- Do not spill brake fluid on the vehicle: it may dam- (D) as right direction. Be careful not to damage the
age the paint; if brake fluid does contact the paint. wheel cylinder dust covers.
Wash it off immediately with water.
- To prevent spills, cover the hose joints with rags 7. Install the lower return spring (E).
or shop towels.
- Use only a genuine wheel cylinder special bolt. 8. Apply brake cylinder grease or equivalent rubber
grease to the sliding surfaces shown. Don’t get
1. Apply sealant (C) between the wheel cylinder (A) and grease on the brake linings.
backing plate (B), and install the wheel cylinder.
Sliding surface

D
B 1.3 ~ 1.7 kgf.m
(12.74 ~ 16.66 Nm,
9.45 ~ 12.36 lb-ft)

A
LJJF501Z

LJJF500S
9. Apply brake cylinder grease or equivalent rubber
2. Connect the brake tubes (D) to the wheel cylinder. grease to the brake shoe ends and opposite edges
of the shoes shown. Don’t get grease on the brake
3. Connect the parking brake cable to the parking brake linings.
lever.

4. Clean the threaded portions of adjuster sleeve (A) and


push rod female (B). Coat the threads of the adjuster
assembly with grease. To shorten the clevises, turn
the adjuster bolt (C).

C
B

D
LJJF502A

10. Install the brake shoes (A) onto the backing plate. Be
careful not to damage the wheel cylinder dust covers.

E
AJJF603E
BR -44 BRAKE SYSTEM

11. Install the shoe hole down pins (B) and the shoe hole
down springs.

B
A

AJJF602V

12. Install the brake drum.

13. If the wheel cylinder has been removed, bleed the


brake system.

14. Depress the brake pedal several times to set the self-
adjusting brake.

15. Adjust the parking brake.


PARKING BRAKE SYSTEM BR -45

PARKING BRAKE SYSTEM


PARKING BRAKE

COMPONENTS EC7B78AA

5 6 7

10

15 11
14 12
13

1. Rear brake caliper 6. Strut spring 11. Adjuster


2. Parking brake lever 7. Strut 12 .Cup washer
3. Parking brake switch 8. Shoe & lining 13. Shoe hold down spring
4. Parking brake cable 9. Shoe guide 14. Return spring
5. Backing plate 10. Return spring 15. Shoe hold down pin
LJJF500T
BR -46 BRAKE SYSTEM

INSPECTION E0C21CF5 ADJUSTMENT E037206C

1. Pull the parking brake lever (A) with 196 N (20 kg, NOTE
44lbf) force to fully apply the parking brake. The park-
ing brake lever should be locked within the specified After rear brake caliper servicing, loosen the park-
number of clicks (B). ing brake adjusting nut, start the engine and depress
the brake pedal several times to set the self-adjusting
Lever locked clicks: 8~9 clicks brake before adjusting the parking brake.

1. Block the front wheels, then raise the rear of the vehi-
Pulled up with 196 N (20 kgf, 44 lb) cle and make sure it is securely supported.

2. Pull the parking brake lever up one click.


A

LJJF503U

2. Adjust the parking brake if the lever clicks are out of


specification.
ARJE502R

3. Remove the console.(Refer to the body group -con-


sole)

4. Tighten the adjusting nuts (A) until the parking brakes


drag slightly when the rear wheels are turned.

AJJF513A

5. Release the parking brake lever fully, and check that


parking brakes do not drag when the rear wheels are
turned. Readjust if necessary.

6. Make sure that the parking brakes are fully applied


when the parking brake lever is pulled up fully.

7. Reinstall the console.


PARKING BRAKE SYSTEM BR -47

REMOVAL EBF83E8B 4. Remove the parking brake lever assembly(A) with


loosening the bolts(B).
NOTE
The parking brake cables must not be bent or dis-
torted. This will lead to stiff operation and premature
failure.
B
1. Remove the console.(refer to body group-console)

2. Loosen the adjusting nut (A) and the parking brake


cables.

AJJF515A

5. Remove the wheel and tire.

6. Remove the brake disc(A).

AJJF601I

3. Disconnect the connector(A) of parking brake switch.

A
A

AJJF516A

7. Remove the rear hub unit bearing(A).

AJJF514A

AJJF517A
BR -48 BRAKE SYSTEM

8. Remove the parking brake cable(A) from the brake INSTALLATION E4FB9A84

shoe.
1. Check the parking brake cables for an identification
mark paint and install as appropriate on the left and
right sides.

Identification color
Rear drum brake
Left side : Red
Right side : Yellow
Rear disc brake
Left side : Green
Right side : White

A 2. Install the removed parts in the reverse order of re-


moval.
AJJF518A
3. Apply a coating of the specified grease to each sliding
parts of the ratchet plate or the ratchet pawl.
9. Remove the brake shoe.

10. Remove the parking brake cable retaining ring(B) Specified grease :
from the parking brake cable (A). Multi purpose grease SAE J310, NLGI No.2

4. After installing the cable adjuster, adjust the parking


brake lever stroke (see page BR-46).
B
A

ARJE502W

11. Loosen the parking brake cable clamp , then remove


the parking brake cable assembly.
PARKING BRAKE SYSTEM BR -49

PARKING BRAKE SWITCH

INSPECTION EFDC90BA

1. Remove the floor console .(refer to body group-con-


sole)

2. Remove the connector(B) from the switch(A).

AJJF601J

3. Inspect the continuity between (-) terminal and the


ground.
• When the brake lever is pulled, there should be
the continuity between them.
• When the brake lever is released, there should
be no continuity between them.
BR -50 BRAKE SYSTEM

ABS (ANTI-LOCK BRAKE


SYSTEM)
COMPONENTS EB2E466E

This illustration is shown the LHD type.


RHD type is symmetrical.

1 2 3

7
6

1. Cluster (ABS/EBD warning lamp) 4. Front right wheel speed sensor


2. Front left wheel speed sensor 5. Hydrauric line
3. ABS control module (HECU) 6. Rear right wheel speed sensor
7. Rear left wheel speed sensor

LJJF500U
ABS (ANTI-LOCK BRAKE SYSTEM) BR -51

DESCRIPTION E5846EFE VOLTAGE LIMITS

This specification applies to HCU(Hydraulic Control Unit) - Overvoltage


and ECU(Electronic Control Unit) of the HECU.(Hydraulic When overvoltage is detected(above 17 ± 0.5 V), the
and Electronic Control Unit) ECU switches off the valve relay and shuts down the
This specification is for the wiring design and installation system.
of ABS/ESP ECU. When voltage is returned to operating range, the sys-
This unit has the functions as follows. tem goes back to the normal condition after the initial-
- Input of signal from Pressure sensor, Steering angle ization phase.
sensor, Yaw & Lateral G sensor,the wheel speed sen- - Undervoltage
sors attached to each wheel. In the event of undervoltage(below 10V), ABS con-
- Control of braking force / traction force / yaw moment. trol shall be inhibited and the warning lamp shall be
- Failsafe function. turned on.
- Self diagnosis function. When voltage is returned to operating range, the
- Interface with the external diagnosis tester. warning lamp is switched off and ECU returns to
normal operating mode.
Installation position : engine compartment
- Brake tube length from Master cylinder port to HECU PUMP MOTOR CHECKING
inlet port should be max. 1m
The ECU performs a pump motor test at a speed of
- The position should not be close to the engine block
12k m/h(7 MPH) once after IGN is switched on.
and not lower than the wheel.
DIAGNOSTIC INTERFACE
OPERATION
Failures detected by the ECU are encoded on the ECU,
The ECU shall be put into operation by switching on the stored in a EEPROM and read out by diagnostic equip-
operating voltage (IGN). ment when the ignition switch is turned on.
On completion of the initialization phase, the ECU shall be The diagnosis interface can also be used for testing the
ready for operation. ECU during production of the ECU and for actuating the
In the operating condition, the ECU shall be ready, within HCU in the test line of manufactories (Air-bleeding line or
the specified limits (voltage and temperature), to process Roll and Brake Test line).
the signals offered by the various sensors and switches in
accordance with the control algorithm defined by the soft-
ware and to control the hydraulic and electrical actuators.

WHEEL SENSOR SIGNAL PROCESSING

The ECU shall receive wheel speed signal from the four
active wheel sensors.
The wheel signals are converted to voltage signal by the
signal conditioning circuit after receiving current signal
from active wheel sensors and given as input to the MCU.

SOLENOID VALVE CONTROL

When one side of the valve coil is connected to the pos-


itive voltage that is provided through the valve relay and
the other side is connected to the ground by the semicon-
ductor circuit, the solenoid valve goes into operation.
The electrical function of the coils are always monitored by
the valve test pulse under normal operation conditions.
BR -52 BRAKE SYSTEM

WARNING LAMP MODULE

Parking brake / EBD


warning lamp ABS warning lamp

LJJF500V

1. ABS Warning Lamp module


The active ABS warning lamp module indicates the
self-test and failure status of the ABS.
The ABS warning lamp shall be on:
- During the initialization phase after IGN ON.
(continuously 3 seconds).
- In the event of inhibition of ABS functions by fail-
ure.
- During diagnostic mode.
- When the ECU Connector is seperated from
ECU.

2. PARKING/EBD warning lamp module


The active EBD warning lamp module indicates the
self-test and failure status of the EBD.
However, in case the Parking Brake Switch is turned
on, the EBD warning lamp is always turned on regard-
less of EBD functions.
The EBD warning lamp shall be on:
- During the initialization phase after IGN ON.
(continuously 3 seconds).
- When the Parking Brake Switch is ON or brake
fluid level is low.
- When the EBD function is out of order.
- During diagnostic mode.
- When the ECU Connector is seperated from
ECU.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -53

ABS CONTROL EFC9BCEA

1. NORMAL BRAKING without ABS

Under the normal braking, voltage is not supplied to solenoid valve, inlet valve is opened and outlet valve is closed.When
the brake is depressed, brake fluid is supplied to the wheel cylinder via solenoid valve to activate the brake.
When the brake is released, brake fluid is back to the master cylinder via inlet valve and check valve.

Pump
Solenoid valve State Valve Passage
motor
Inlet valve (NO) OFF Open Master cylinder ⇔ Wheel cylinder
OFF
Outlet valve (NC) OFF Close Wheel cylinder ⇔ Reservoir

MCS MCP

NO NO NO NO
M

NC NC NC NC

FL RR RL FR
LPA LPA

LJJF500W
BR -54 BRAKE SYSTEM

2. DUMP MODE

Under the emergency braking, if the wheels start to lock up, HECU sends a signal to the solenoid valve
to decrease the brake fluid, then voltage is supplied to each solenoid. At this time inlet valve is closed
and brake fluid is blocked from the master cylinder. Conversely outlet valve is opened and brake fluid
passes through wheel cylinder to reservoir, resulting in pressure decrease.

Pump
Solenoid State Valve Passage
motor
Inlet valve (NO) ON Close Master cylinder ⇔ Wheel cylinder ON

Outlet valve (NC) ON Open Wheel cylinder ⇔ Reservoir

MCS MCP

NO NO NO NO
M

NC NC NC NC

FL RR RL FR
LPA LPA

LJJF500X
ABS (ANTI-LOCK BRAKE SYSTEM) BR -55

3. HOLD MODE

When the brake fluid pressure is maximally decreased in wheel cylinder, HECU sends a signal to solenoid
valve to keep the fluid pressure, voltage is supplied to inlet valve but it is not supplied to outlet valve. At
this time inlet and outlet valves are closed and brake fluid is kept in wheel cylinder.

Pump
Solenoid State Valve Passage
motor
Inlet valve (NO) ON Close Master cylinder ⇔ Wheel cylinder OFF

Outlet valve (NC) OFF Close Wheel cylinder ⇔ Reservoir

MCS MCP

NO NO NO NO
M

NC NC NC NC

FL RR RL FR
LPA LPA
LJJF500Y
BR -56 BRAKE SYSTEM

4. INCREASE MODE

If HECU determines there’s no lock-up in the wheel, HECU cuts voltage to solenoid valve. So voltage is not supplied
to each solenoid valve, brake fluid passes through the inlet valve to wheel cylinder, resulting in pressure increase.

Pump
Solenoid State Valve Passage
motor
Inlet valve (NO) OFF Open Master cylinder ⇔ Wheel cylinder ON

Outlet valve (NC) OFF Close Wheel cylinder ⇔ Reservoir

MCS MCP

NO NO NO NO
M

NC NC NC NC

FL RR RL FR
LPA LPA

LJJF500Z
ABS (ANTI-LOCK BRAKE SYSTEM) BR -57

ABS HECU EXTERNAL DIAGRAM

N
25

A : Inlet valve(FR)
9

D C B A B : Inlet valve(RL)
C : Inlet valve(RR)
D : Inlet valve(FL)
E : Outlet valve(FR)
F : Outlet valve(RL)
H G F E G : Outlet valve(RR)
H : Outlet valve(FL)
M M : Motor(+)
10

N : Motor(Ground)
17
1

LJJF501A
BR -58 BRAKE SYSTEM

HYDRAULIC SYSTEM DIAGRAM

MCS MCP

NO NO NO NO
M

NC NC NC NC

FL RR RL FR
LPA LPA

MCP : Primary master cylinder M : Motor pump


MCS : Secondary master cylinder NO : Normal open valve
LPA : Low pressure accumulator NC : Normal close valve

LJJF501B
BR -59

LJJF501C
HOT IN ON OR START HOT AT ALL TIMES HOT AT ALL TIMES
See Power I/P E/R FUSE &
Distribution JUNCTION RELAY BOX
(Page : SD110-4, BOX
SD110-5) PHOTO 25
ABS-1 ABS-2 INSTRUMENT
ABS STOP LP 40A 40A CLUSTER ECM
10A 15A
See Passenger
Compartment
Fuse Details DATA LINK MULTIPURPOSE
(Page : SD120-9) CONNECTOR CHECK CONNECTOR
1 M33 18 E16 12 M09-3 64 C01
1 10 I/P-F 20 C01-1
PHOTO 25 PHOTO 15 PHOTO
39 PHOTO 27
R
1 E39
W W B/O Br
STOP LAMP
SWITCH
PHOTO PHOTO 25
39 15 EM02 5 EM02 9 EC01
PHOTO PHOTO 27
P 2 E39 R R 39
R/O
R/O W G Br
R/O
See Stop Lamps
(Page : SD927-1)
4 18 9 25 7 16 3 E51
ABS
ON/START Stop Lamp K-Line ABS IND. CONTROL
Input Switch Battery Voltage Control. MODULE
PHOTO 21
Ground
ABS (ANTI-LOCK BRAKE SYSTEM)

Power Signal Power Signal Power Signal Power Signal


1 2 19 20 5 6 23 22 8 24 E51
EAA338FD

B W R L
G O B Y 13 14 11 12 EF01 PHOTO 80
B B
B W R L
ABS CIRCUIT DIAGRAM

1 2 E49 1 2 E50 1 2 F31 1 2 F32


FRONT WHEEL FRONT WHEEL REAR WHEEL REAR WHEEL
SENSOR LH SENSOR RH SENSOR LH SENSOR RH
PHOTO 22 PHOTO 22 PHOTO 54 PHOTO 56
P S P S P S P S G01 G02
PHOTO 48 PHOTO 48
BR -60 BRAKE SYSTEM

ABS CONNECTOR INPUT/OUTPUT

7 6 5 4 3 2 1
9 8
16
25 24
* * * * * *
23 22
* 20 19 18 *
LJJF504A

Connector Terminal
Specification Remark
No Description
Over voltage range: 16.5 ± 0.5 V < V
Operating voltage range: 9.5 ± 0.5 V
< V < 16.5 ± 0.5 V
4 IGNITION1(+) Low voltage range: 7.0 ± 0.5 V <
V < 9.5 ± 0.5 V
Max. current: I < 300 mA

Max leakage current : I < 0.8 mA


25 POS. BATTERY.(SOLENOID) Operating voltage range: 9.5 ± 0.5 V
< V < 16.5 ± 0.5 V
Max current : I < 30 A
Operating voltage range: 9.5 ± 0.5 V
< V < 16.5 ± 0.5 V
Rush current : I < 100 A
9 POS, BATTERY.(MOTOR) Max current :
I < 30 A (lower 250 W motor)
I < 40 A (higher 250 W motor)
Max leakage current : I < 0.2 mA

8 GROUND Rated current : I < 300 mA


Max. current: I < 30 A

24 PUMP MOTOR GROUND Rush current : I < 100 A


Max current : I < 30 A

18 BRAKE LIGHT SWITCH Input voltage low: 0 V ≤ V ≤ 3.0 V


Input voltage High: 7.0 V ≤ V ≤ 16.0 V

16 ABS/EBD W/LAMP DRIVE Max. current: I < 200 mA


Max. output low voltage : V < 1.2 V
1 SENSOR FRONT LEFT POWER
SENSOR FRONT RIGHT
19 - Output voltage : IGN[V] ± 1V
POWER
- Output current : Max 30mA
5 SENSOR REAR LEFT POWER
23 SENSOR REAR RIGHT POWER
2 SENSOR FRONT LEFT SIGNAL
SENSOR FRONT RIGHT - Input current LOW : 5.9 ~8.4 ㎃
20 - Input current HIGH : 11.8 ~ 16.8 ㎃
SIGNAL
- Frequency range : 1 ~ 2000 Hz
6 SENSOR REAR LEFT SIGNAL - Input duty : 50 ± 20 %
22 SENSOR REAR RIGHT SIGNAL
ABS (ANTI-LOCK BRAKE SYSTEM) BR -61

Connector Terminal
Specification Remark
No Description
Input voltage :
VI_L < 0.3 IGN[V]
VI_H > 0.7 IGN[V]
7 DIAGNOSIS INPUT/OUTPUT
Output voltage :
VO_L < 0.2 IGN[V]
VO_H > 0.8 IGN[V]
Maxcurrent : I < 2 mA
SENSOR FRONT RIGHT
3 External pull up resister : 10KΩ < R
OUTPUT
Output duty : 50 ± 20 %
BR -62 BRAKE SYSTEM

HI-SCAN (PRO) CHECK EBB7BD2A

1. Turn the ignition switch OFF.

2. Connector the Hi-scan(pro) to the 16P data link con-


nector located the driver’d side kick panel.

GROUND ABS

* * 6 5 4 3 2 1

* * * 13 12 11 * 9

Memory power

LJJF501D

3. Turn the ignition switch ON.

4. Check for diagnostic trouble using the Hi-scan(pro)

5. After completion trouble of the repair or correction of


the problem, erase the stored fault codes the clear key
on the Hi-scan(pro).

6. Disconnect the Hi-scan(pro) from the 16P data link


connector.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -63

STANDARD FLOW OF DIAGNOSTIC


TROUBLESHOOTING

Gathering information from customer


Reoccurs Does not reoccur

Check diagnostic code Check diagnostic code


No trouble code Trouble code displayed Trouble code No trouble
displayed code
Recheck trouble code(s) then erase

Basic brake system is normal or not Recheck trouble symptom


Abnormal Normal
No trouble
code
Refer to BR-Troubleshooting Check trouble codes
Trouble code displayed

Problem is intermittent or was Inspection chart for diagnostic trouble


repaired and memory was not cleared. codes Intermittent malfunction

* Using the customer problem analysis check sheet for reference, ask the customer as much detail as
possible about the problem.
EJKB055A

NOTES WITH REGARD TO DIAGNOSIS

The phenomena listed in the following table are not abnor-


mal.

Phenomenon Explanation
System check sound When starting the engine, a thudding sound can sometimes
be heard coming from inside the engine compartment. This is
because the system operation check is being performed.
ABS operation sound 1. Sound of the motor inside the ABS hydraulic
unit operation (whine).
2. Sound is generated along with vibration of the
brake pedal (scraping).
3. When ABS operates, sound is generated from the vehicle
chassis due to repeated brake application and release
(Thump : suspension; squeak: tires)
ABS operation (Long braking distance) For road surfaces such as snow-covered and gravel roads, the
braking distance for vehicles with ABS can sometimes be longer
than that for other vehicles. Accordingly, advise the customer to
drive safely on such roads by lowering the vehicle speed.
Diagnosis detection conditions can vary depending on the diagnosis code. When checking the trouble symptom
after the diagnosis code has been erased, ensure that the requirements listed in "Comment" are met.
BR -64 BRAKE SYSTEM

ABS CHECK SHEET

Inspector's
ABS Check Sheet Name

Registration No.

Customer's Name Registration Year

VIN.

Date Vehicle Km
Odometer
Brought In Miles

Date the Problem First Occurred

Frequency of Occurence of Problem Continuous Intermittent ( times a day)

ABS does not operate.

Symptoms ABS does not operate efficiently. Intermittent ( times a day)

ABS Warning
Light Abnormal Remains ON Does not light up

Diagnostic 1st Time Normal Code Malfunction Code (Code )


Trouble Code
Check 2nd Time Normal Code Malfunction Code (Code )

EJDA017A
ABS (ANTI-LOCK BRAKE SYSTEM) BR -65

PROBLEM SYMPTOMS TABLE

If a normal code is displayed during the DTC check but the


problem still occurs, check the circuits for each problem
symptom in the order given in the table below and proceed
to the relevant troubleshooting page.

See
Symptom Suspect Area
page
ABS does not operate. Only when 1. -4. are all normal and the problem
is still occurring, replace the HECU.
1. Check the DTC reconfirming that the normal
code is output. BR - 66
2. Power source circuit.
3. Speed sensor circuit.
4. Check the hydraulic circuit for leakage.
ABS does not operate intermittently. Only when 1. -4. are all normal and the problem is still
occurring, replace the ABS actuator assembly.
1. Check the DTC reconfirming that the normal
code is output. BR - 68
2. Wheel speed sensor circuit.
3. Stop lamp switch circuit.
4. Check the hydraulic circuit for leakage.
Communication with Hi-scan (pro) 1. Power source circuit
is not possible. 2. Diagnosis line
BR - 69
(Communication with any system is
not possible)
Communication with Hi-scan (pro) 1. Power source circuit
is not possible. 2. Diagnosis line BR - 70
(Communication with ABS only is not possible) 3. HECU
When ignition key is turned ON (engine OFF), 1. ABS warning lamp circuit
BR - 72
the ABS warning lamp does not light up. 2. HECU
Even after the engine is started, the ABS 1. ABS warning lamp circuit
BR - 73
warning lamp remains ON. 2. HECU

CAUTION
During ABS operation, the brake pedal may vi-
brate or may not be able to be depressed. Such
phenomena are due to intermittent changes in hy-
draulic pressure inside the brake line to prevent
the wheels from locking and is not an abnormal-
ity.
BR -66 BRAKE SYSTEM

ABS Does Not Operate

DETECTING CONDITION

Trouble Symptoms Possible Cause


Brake operation varies depending on driving conditions - Faulty power source circuit
and road surface conditions, so diagnosis can be - Faulty wheel speed sensor circuit
difficult.However if a normal DTC is displayed, check - Faulty hydraulic circuit for leakage
the following probable cause. When the problem is still - Faulty HECU
occurring, replace the ABS control module.

INSPECTION PROCEDURES CHECK THE POWER SOURCE CIRCUIT.

DTC INSPECTION 1. Disconnect the connector from the ABS control mod-
ule.
1. Connect the Hi-Scan (pro) with the data link connector
and turn the ignition switch ON. 2. Turn the ignition switch ON, measure the voltage be-
tween terminal 4 of the ABS control module harness
2. Verify that the normal code is output. side connector and body ground.
Is the normal code output?
Specification : approximately B+
NO
Is the voltage within specification?
▶ Check the power source circuit.

YES YES

▶ Check the ground circuit.


▶ Erase the DTC and recheck using Hi-Scan (pro).
NO

▶ Check the harness or connector between the fuse


(10A) in the engine compartment junction block and
the ABS control module. Repair if necessary.

ON (+) (-)

7 6 5 44 3 2 1
9 8
16
25 24
* * * * * *
23 22
* 20 19 18 *

LJJF501E
ABS (ANTI-LOCK BRAKE SYSTEM) BR -67

CHECK THE GROUND CIRCUIT. CHECK THE WHEEL SPEED SENSOR CIRCUIT.

1. Disconnect the connector from the ABS control mod- Refer to the DTC troubleshooting procedures.(See page
ule. BR-78)
Is it normal?
2. Check for continuity between terminals 8, 24 of the
ABS control module harness side connector and YES
ground point.
Is there continuity? ▶ Check the hydraulic circuit for leakage.

YES NO

▶ Check the wheel speed sensor circuit. ▶ Repair or replace the wheel speed sensor.

NO CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE.

Refer to the hydraulic lines.


▶ Repair an open in the wire and ground point.
Inspect leakage of the hydraulic lines.
Is it normal?

YES

▶ The problem is still occurring, replace the ABS control


module.

NO

9 8
7 6 5 4 3 2 1 ▶ Repair the hydraulic lines for leakage.
16
25 24
* * * * * *
23 22
* 20 19 18 *

LJJF501F
BR -68 BRAKE SYSTEM

ABS Does Not Operate Intermittently.

DETECTING CONDITION

Trouble Symptoms Possible Cause


Brake operation varies depending on driving conditions - Faulty power source circuit
and road surface conditions, so diagnosis can be difficult. - Faulty wheel speed sensor circuit
However if a normal DTC is displayed, check the following - Faulty hydraulic circuit for leakage
probable cause. When the problem is still occurring, - Faulty HECU
replace the ABS control module.

INSPECTION PROCEDURES ▶ Check the hydraulic circuit for leakage.

DTC INSPECTION NO
1. Connect the Hi-Scan (pro) with the data link connector
▶ Repair the stop lamp switch. Repair an open in the
and turn the ignition switch ON.
wire between the ABS control module and the stop
2. Verify that the normal code is output. lamp switch.
Is the normal code output?
ON
NO (+) (-)

▶ Check the wheel speed sensor circuit.

YES
7 6 5 2 1
▶ Erase the DTC and recheck using Hi-Scan (pro). 9 8 4 3
16
25 24
* * * * * *
23 22
CHECK THE WHEEL SPEED SENSOR CIRCUIT. * 20 19 18 *

Refer to the DTC troubleshooting procedures.(See page


LJJF501G
BR-78)
Is it normal? CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE.
YES Refer to the hydraulic lines.
Inspect leakage of the hydraulic lines.
▶ Check the stop lamp switch circuit. Is it normal?

NO YES

▶ Repair or replace the wheel speed sensor. ▶ The problem is still occurring, replace the ABS control
module.
CHECK THE STOP LAMP SWITCH CIRCUIT.
NO
1. Check that stop lamp lights up when brake pedal is
depressed and turns off when brake pedal is released.
▶ Repair the hydraulic lines for leakage.
2. Measure the voltage between terminal 18 of the ABS
control module harness side connector and body
ground when brake pedal is depressed.

Specification : approximately B+

Is the voltage within specification?

YES
ABS (ANTI-LOCK BRAKE SYSTEM) BR -69

Communication With Hi-Scan (pro) Is Not Possible.


(Communication With Any System Is Not Possible)

DETECTING CONDITION

Trouble Symptoms Possible Cause


Possible defect in the power supply system (including - An open in the wire
ground) for the diagnosis line. - Poor ground
- Faulty power source circuit

INSPECTION PROCEDURES CHECK THE GROUND CIRCUIT FOR THE


DIAGNOSIS
CHECK THE POWER SUPPLY CIRCUIT FOR THE DI-
AGNOSIS Check for continuity between terminal 5 of the data link
Measure the voltage between terminal 9 of the data link connector and body ground.
connector and body ground. Is there continuity?

Specification : approximately B+ NO

▶ Repair an open in the wire between terminal 5 of the


Is voltage within specification?
data link connector and ground point.
YES

▶ Check the ground circuit for the diagnosis.

NO

▶ Repair an open in the wire. Check and replace fuse


(15A) from the engine compartment junction block.
* * 6 5 4 3 2 1

13 12 11 9
* * * *
(-) (+)

LJJF501I

* * 6 5 4 3 2 1

13 12 11 9
* * * *

LJJF501H
BR -70 BRAKE SYSTEM

Communication With Hi-Scan (pro) Is Not Possible.


(Communication With ABS Only Is Not Possible)

DETECTING CONDITION

Trouble Symptoms Possible Cause


When communication with Hi-Scan (pro) is not possible, - An open in the wire
the cause may be probably an open in the HECU power - Faulty HECU
circuit or an open in the diagnosis output circuit. - Faulty power source circuit

INSPECTION PROCEDURES CHECK THE POWER SOURCE OF ABS CONTROL


MODULE
CHECK FOR CONTINUITY IN THE DIAGNOSIS LINE
1. Disconnect the connector from the ABS control mod-
1. Disconnect the connector from the ABS control mod- ule.
ule.
2. Turn the ignition switch ON, measure the voltage be-
2. Check for continuity between terminals 7 of the ABS tween terminal 4 of the ABS control module harness
control module connector and 1 of the data link con- side connector and body ground.
nector.
Is there continuity? Specification : approximately B+

YES
Is voltage within specification?
▶ Check the power source of ABS control module. YES
NO
▶ Check for poor ground.
▶ Repair an open in the wire. NO

▶ Check the harness or connector between the fuse


(10A) in the engine compartment junction block and
the ABS control module.Repair if necessary.

ON (+) (-)

7 6 5 44 3 2 1
9 8
16
25 24
* * * * * *
23 22
* 20 19 18 *

LJJF501E
ABS (ANTI-LOCK BRAKE SYSTEM) BR -71

CHECK FOR POOR GROUND

Check for continuity between terminal 5 of the data link


connector and ground point.

YES

▶ Replace the ABS control module and recheck.

NO

▶ Repair an open in the wire or poor ground.

* * 6 5 4 3 2 1

13 12 11 9
* * * *

LJJF501I
BR -72 BRAKE SYSTEM

When Ignition Key Is Turned ON (Engine OFF), The ABS Warning Lamp Does Not Light Up.

DETECTING CONDITION

Trouble Symptoms Possible Cause


When current flows in the HECU the ABS warning lamp turns - Faulty ABS warning lamp bulb
from ON to OFF as the initial check.Therefore if the lamp does - Blown fuse is related to ABS in the engine
not light up, the cause may be an open in the lamp power supply compartment junction block
circuit, a blown bulb, an open in the both circuits between the - Faulty ABS warning lamp module
ABS warning lamp and the HECU, and the faulty HECU. - Faulty HECU

INSPECTION PROCEDURES ON
(+) (-)
PROBLEM VERIFICATION
Disconnect the connector from the ABS control module
and turn the ignition switch ON.
Does the ABS warning lamp light up?

YES
6 4 3 2 1
* * *
▶ It is normal. Recheck the ABS control module.
* 15 14
* 12 11 10 9
NO
LJJF501J

▶ Check the power source for the ABS warning lamp.


CHECK FOR BLOWN FUSE
CHECK THE POWER SOURCE FOR THE ABS
WARNING LAMP Check continuity of fuse (10A) from the engine compart-
ment junction block.
1. Disconnect the instrument cluster connector and turn Is there continuity?
the ignition switch ON.
YES
2. Measure the voltage between terminal 12 of the clus-
ter harness side connector and body ground. ▶ Repair an open in the wire between ABS fuse and 12
of cluster connector.
Specification : approximately B+
NO
Is voltage within specification?
▶ Replace the blown fuse.
YES

▶ Repair bulb or instrument cluster assembly.

NO

▶ Check for blown fuse.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -73

Even After The Engine Is Started, The ABS Warning Lamp Remains ON.

DETECTING CONDITION

Trouble Symptoms Possible Cause


If the HECU detects trouble, it lights the ABS warning lamp while - An open in the wire
at the same time prohibiting ABS control. At this time, the HECU - Faulty instrument cluster assembly
records a DTC in memory.Even though the normal code is - Faulty ABS warning lamp module
output, the ABS warning lamp remains ON, then the cause may - Faulty HECU
be probably an open or short in the ABS warning lamp circuit.

INSPECTION PROCEDURES

CHECK DTC OUTPUT.

1. Connect the Hi-Scan (pro) to the 16P data link con-


nector located behind the driver’s side kick panel.

2. Check the DTC output using Hi-Scan (pro).


Is DTC output?

NO

▶ Repair circuit indicated by code output.

YES

▶ Check instrument cluster.

CHECK INSTRUMENT CLUSTER

Disconnect the cluster connector and turn the ignition


switch ON.
Does the ABS warning lamp remains ON?

YES

▶ Replace the instrument cluster.

NO

▶ Check for open the wire.

CHECK FOR OPEN IN THE WIRE

Check for continuity in the wire between cluster and ABS


control module.
Is there continuity?

YES

▶ Replace the ABS control module and recheck.

NO

▶ Repair an open in the wire between cluster and ABS


control module.
BR -74 BRAKE SYSTEM

BLEEDING OF BRAKE SYSTEM 5. Select and operate according to the instructions on


the hi-scan (Pro) screen.
This procedure should be followed to ensure adequate
bleeding of air and filling of the ABS unit, brake lines and
CAUTION
master cylinder with brake fluid.
You must obey the maximum operating time of the
1. Remove the reservoir cap and fill the brake reservoir ABS motor with the hi-scan (Pro) to prevent the
with brake fluid. motor pump from burning.

CAUTION 1) Select KIA vehicle diagnosis.

If there is any brake fluid on any painted surface, 2) Select vehicle name.
wash it off immediately.
3) Select Anti-Lock Brake system.
NOTE
4) Select air bleeding mode.
When pressure bleeding, do not depress the brake
pedal. 5) Press "YES" to operate motor pump and solenoid
Recommended fluid........ DOT3 or DOT4 valve.

2. Connect a clear plastic tube to the wheel cylinder 1.6 AIR BLEEDING MODE
bleeder plug and insert the other end of the tube into ABS AIR BLEEDING STATUS
a half filled clear plastic bottle.
01. SOLENOID VALVE STATUS CLOSE
02. MOTOR PUMP STATUS OFF
DO YOU WANT TO START ?
(PRESS [YES] KEY)

EJDA014F

6) Wait 60 sec. before operating the air bleeding.


(If not, you may damage the motor.)

1.6 AIR BLEEDING MODE


ABS AIR BLEEDING STATUS
AJJF508A
01. SOLENOID VALVE STATUS OPEN
3. Bleed the brake system(See page BR-21) 02. MOTOR PUMP STATUS ON
TIME : AUTOMATIC COUNT (1-60 SEC.)
4. Connect the hi-scan (pro) to the data link connector
located underneath the dash panel.

EJDA014G

ARJE503N
ABS (ANTI-LOCK BRAKE SYSTEM) BR -75

6. Pump the brake pedal several times, and then loosen


the bleeder screw until fluid starts to run out without
bubbles. Then close the bleeder screw.

7. Repeat step 5 until there are no more bubbles in the


fluid for each wheel.

Front right Rear right

Front left Rear left

KJKE003B

8. Tighten the bleeder screw.

Bleed screw tightening torque:


6.86~12.74 Nm (0.7 ~1.3 kgf·m, 5.09 ~ 9.45 lb-ft)
BR -76 BRAKE SYSTEM

DIGNOSTIC TROUBLE CODE CHART(DTC)

Warning lamp See


DTC Trouble description Remarks
EBD ABS ESP page

C1101 Battery voltage high ○ ○ ○ BR - 78

C1102 Battery voltage low X/○ ○ ○ BR - 82

C1112 Sensor power voltage X X ○ ESP BR - 84

C1200 Wheel speed sensor front-LH open/short X/○ ○ ○ BR - 87


Wheel speed sensor front-LH range / perfor-
C1201
mance / intermittent X/○ ○ ○ BR - 92

C1202 Wheel speed sensor front-LH invalid/no signal X/○ ○ ○ BR - 96

C1203 Wheel speed sensor front-RH open/short X/○ ○ ○ BR - 87


Wheel speed sensor front-RH range / perfor-
C1204 X/○ ○ ○ BR - 92
mance / intermittent
C1205 Wheel speed sensor front-RH invalid/no signal X/○ ○ ○ BR - 96

C1206 Wheel speed sensor rear-LH open/short X/○ ○ ○ BR - 87


Wheel speed sensor rear-LH range / perfor-
C1207
mance / intermittent X/○ ○ ○ BR - 92

C1208 Wheel speed sensor rear-LH invalid/no signal X/○ ○ ○ BR - 96

C1209 Wheel speed sensor rear-RH open/short X/○ ○ ○ BR - 87


Wheel speed sensor rear-RH range / perfor-
C1210
mance / intermittent X/○ ○ ○ BR - 92

C1211 Wheel speed sensor rear-RH invalid/no signal X/○ ○ ○ BR - 96

C1235 Primary pressure sensor - electrical X X ○ ESP BR - 99

C1237 Primary pressure sensor - signal X X ○ ESP BR - 103

C1259 Steering sensor - electrical X X ○ ESP BR - 105

C1260 Steering sensor circuit - signal X X ○ ESP BR - 110

C1282 Yaw rate & lateral G sensor - electrical X X ○ ESP BR - 113

C1283 Yaw rate & lateral G sensor - signal X X ○ ESP BR - 118

C1503 ESP switch error X X ○ ESP BR - 121

C1513 Brake switch error X X ○ ESP BR - 124

C1604 ECU hardware error ○ ○ ○ BR - 127

C1605 CAN hardware error X X ○ ESP BR - 129

C1611 CAN time-out EMS X X ○ ESP BR - 131

C1612 CAN time-out TCU X X ○ ESP BR - 132

C1613 CAN wrong message X X ○ ESP BR - 133

C1616 CAN bus off X X ○ ESP BR - 135

C2112 Valve relay error ○ ○ ○ BR - 137


ABS (ANTI-LOCK BRAKE SYSTEM) BR -77

Warning lamp See


DTC Trouble description Remarks
EBD ABS ESP page

C2227 Excessive temperature of brake disc X X ○ ESP BR - 141

C2380 ABS/TCS/ESP valve error ○ ○ ○ BR - 143

C2402 Motor electrical X ○ ○ BR - 145


BR -78 BRAKE SYSTEM

DTC C1101 BATTERY VOLTAGE HIGH

COMPONENT LOCATION E86F046F

AJJF601M

GENERAL DESCRIPTION E64B6E20

The ABS ECU(Electronic Control Unit) checks the battery voltage to determine, as a safety issue, whether the ABS system
can operate normally or not. The normal battery voltage range is essential for controlling the ABS system as intended.

DTC DESCRIPTION E0A0EAF2

The ABS ECU monitors battery voltage by reading the value of voltage. When the voltage is higher than the expected
normal value, this code is set, and the ABS/EBD/TCS/ESP functions are prohibited. If the voltage recovers, to within
normal operating ranges, then the controller returns to normal operation as well.

DTC DETECTING CONDITION EADC4DFA

Item Detecting Condition Possible cause


DTC Strategy • Battery Voltage Monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode • Inside the ABS control cycle
• Diagnosis mode • Poor connection in
• Failure mode power supply circuit
• When V_IGN > 17 ± 0.5 V is continued for 500msec. (IGN+)
Enable • Faulty Alternator
Conditions • If V_IGN is recovered to normal operating voltage,
the controller is reset. • Faulty HECU

• System down. The ABS/EBD/TCS/ESP functions are inhibited.


- The valve relay and all solenoids are prevented
Fail Safe
from being switched on.
• The ABS/EBD/ESP warning lamps are activated.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -79

TERMINAL AND CONNECTOR INSPECTION E9C0ABDC

1. Many malfunctions in the electrical system are caused by poor harness(es) and terminals. Faults can also be caused
by interference from other electrical systems, and mechanical or chemical damage.

2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or
damage.

3. Has a problem been found?

YES

▶ Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

NO

▶ Go to next step.

ALTERNATOR OUTPUT VOLTAGE INSPECTION E5BEA0DA

1. Engine "ON".

2. Measure voltage between the battery terminal(+) and the battery terminal(-).

Specification : 10 < V < 16 V

V
1. Battery terminal (+)
2. Battery terminal (-)

Battery

LJJF502E

3. Is the measured voltage within specifications?

YES

▶ Go to "Power Circuit Inspection" procedure.

NO

▶ Check for damaged harness and poor connection between alternator and battery. If OK repair or replace alternator
and then go to "Verification of vehicle Repair" procedure.
BR -80 BRAKE SYSTEM

POWER CIRCUIT INSPECTION E6CC30A0

1. Engine "ON".

2. Measure voltage between the battery terminal(+) and terminal "4" of the HECU harness connector.

Specification : Approx. below 0.2 V

7 6 5 4 3 2 1 <ABS, ESP>
9 8 4. IGNITION (+)
16 * * * * * *
25 24 23 22
* 20 19 18 *

Battery

LJJF502F

3. Is the measured voltage within specifications?

YES

▶ Go to "Ground Circuit Inspection" procedure.

NO

▶ Check for damaged harness and poor connection between the battery terminal(+) and terminal "4" of the HECU
harness connector. Repair as necessary and then go to "Verification of vehicle Repair" procedure.

GROUND CIRCUIT INSPECTION E5E30846

1. Ignition "OFF".

2. Disconnect HECU connector.

3. Measure resistance between terminal "8, 24(ESP : 16, 47)" of the HECU harness connector and chassis ground.

Specification : Approx. below 1Ω

<ABS>
9 8 7 6 5 4 3 2 1 8. GROUND
24. GROUND
16 * * * * * *
25 24 23 22 <ESP>
* 20 19 18 * 16. GROUND
47. GROUND

Ω Ω

LJJF502G
ABS (ANTI-LOCK BRAKE SYSTEM) BR -81

4. Is the measured resistance within specifications?

YES

▶ Go to "Component Inspection" procedure.

NO

▶ Check for damaged harness and poor connection between terminal " 8, 24( ESP : 16, 47)" of the HECU harness
connector and chassis ground. Repair as necessary and then go to "Verification of vehicle Repair" procedure.

COMPONENT INSPECTION EDDCDB1D

1. Ignition "OFF".

2. Engine "ON".

3. Does warning lamp remain On?

YES

▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.

NO

▶ Fault is intermittent caused by poor connection in power harness (IGN+), faulty Alternator and/or faulty HECU or
was repaired and HECU memory was not cleared. Go to the applicable troubleshooting procedure.

VERIFICATION OF VEHICLE REPAIR E63D688F

After a repair, it is essential to verify that the fault has been corrected.

1. Connect scantool and select "Diagnostic Trouble Codes(DTCs)" mode.

2. Using a scantool, Clear DTC.

3. Operate the vehicle within DTC Detecting Condition in General Information.

4. Are any DTCs present ?

YES

▶ Go to the applicable troubleshooting procedure.

NO

▶ System performing to specification at this time.


BR -82 BRAKE SYSTEM

DTC C1102 BATTERY VOLTAGE LOW

COMPONENT LOCATION E629A9A7

Refer to DTC C1101.

GENERAL DESCRIPTION EABCC08E

The ABS ECU(Electronic Control Unit) checks the battery voltage to determine, as a safety issue, whether the ABS system
can operate normally or not. The normal battery voltage range is essential for controlling the ABS system as instended.

DTC DESCRIPTION E91CADBA

The ABS ECU monitors the battery voltage by reading the value of voltage. When the voltage is lower than the expected
normal value, this code is set. The ABS/TCS/ESP functions are prohibited and the EBD function is allowed on LOW
VOLTAGE CONDITION, the ABS/EBD/TCS/ESP functions are prohibited on UNDER VOLTAGE CONDITION. If the volt-
age recovers, to within normal operating ranges, then the controller returns to normal operations as well.

DTC DETECTING CONDITION E0986C0F

Item Detecting Condition Possible cause


DTC Strategy • Battery Voltage Monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode • Inside the ABS control cycle
• Diagnosis mode
• Failure mode

• When Vign < 9.5 V ± 0.5 V is continued for 500


Enable msec during Vref >= 7 Km/h.
Condi- • When Vign < 8.5 V ± 0.5 V is continued for 500msec during
tions Vref < 7 Km/h or ABS/TCS/ESP control.
- If IGN voltage is recovered to normal operating voltage,
the system recovers to normal state.
• Outside the ABS control cycle : inhibit the ABS/TCS/ESP
Case1 control of front wheels and allow the ABS/TCS/ESP control of • Poor connection
(Low rear wheels, deactivating the motor and the ABS/ESP warning in power supply
voltage) lamps are directly switched on. When the voltage recovers circuit (IGN+)
the normal operating range, enable ABS/ESP functions and • Faulty HECU
Fail Safe warning lamps are switched off and erase the error code.
• Inside the ABS control cycle : inhibit the ABS/TCS/ESP
control of front wheels and allow the ABS/TCS/ESP control
of rear wheels, deactivating the motor. The ABS/ESP
warning lamps are directly switched on and the state keeps
continuously. The error code is always stored.
Enable • When Vign < 7.2 V ± 0.5 V is continued for 56 msec.
Condi- - If IGN voltage is recovered to normal operating voltage,
Case2 tions the system recovers to normal state.
(Under Fail Safe • System down. The ABS/EBD/TCS/ESP functions are inhibited.
voltage) - The valve relay and all solenoids are prevented
from being switched on.
• The ABS/EBD/ESP warning lamps are activated.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -83

TERMINAL AND CONNECTOR INSPECTION E42A2729

Refer to DTC C1101.

POWER CIRCUIT INSPECTION EC6A8DF8

1. Ignition "OFF"

2. Disconnect HECU connector.

3. Ignition "ON" & Engine "OFF".

4. Measure voltage between terminal "4" of the HECU harness connector and chassis ground.

Specification : Approx. B+

7 6 5 4 3 2 1 <ABS, ESP>
9 8 4. IGNITION (+)
16 * * * * * *
25 24 23 22
* 20 19 18 *

LJJF502H

5. Is the measured voltage within specifications?

YES

▶ Go to "Ground Circuit Inspection" procedure.

NO

▶ Check for damaged harness and poor connection between the battery terminal(+) and terminal "4" of the HECU
harness connector. Check for open or blown 10A ABS fuse. Repair as necessary and then go to "Verification of
vehicle Repair" procedure.

GROUND CIRCUIT INSPECTION EBB7C44C

Refer to DTC C1101.

COMPONENT INSPECTION E8DECCCC

Refer to DTC C1101.

VERIFICATION OF VEHICLE REPAIR E5AC65FB

Refer to DTC C1101.


BR -84 BRAKE SYSTEM

DTC C1112 SENSOR POWER VOLTAGE

COMPONENT LOCATION E4206C1B

AJJF530A

GENERAL DESCRIPTION E3A5B345

The HECU supplies operating voltage with pressure sensor in master cylinder & lateral G sensor . The HECU monitors
supply voltage of each sensor for normal ESP control. If supply voltage is out of specified range ESP warning lamps are
turned on and TCS/ESP controls are inhibited.

DTC DESCRIPTION E3963D6D

A failure is detected if the external sensor supply voltage is out of the specified range for more than the specified min.
fault duration.

DTC DETECTING CONDITION EC67A8EB

Item Detecting Condition Possible cause


DTC Strategy • Voltage monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode • Inside the ABS control cycle
• Diagnosis mode
• Failure mode
• During sensor power ON, If the voltage of sensor power is
out of the range of 5 ± 0.5 V for 500 ms. • Faulty HECU
Enable • During sensor power OFF, If the voltage of sensor power is
Conditions out of the range of 0.5 ± 0.1 V for 500 ms.
• If the YAW or lateral sensor signal pin has a short
circuit to a battery.
• Inhibit the TCS/ESP control and allow the ABS/EBD control.
Meanwhile, stop checking the ESP switch failure
Fail Safe
under the TCS/ESP control.
• The ESP warning lamp is activated.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -85

TERMINAL AND CONNECTOR INSPECTION EEF3C7E7

Refer to DTC C1101.

POWER CIRCUIT INSPECTION E44CA8B3

1. Ignition "ON" & Engine "OFF".

2. Measure voltage between terminal "3" of the Yaw Rate & Lateral G sensor harness connector and chassis ground.

Specification : Approx. 5 V

1. YAW sensor signal


3 2 1 2. Lateral G sensor signal
3. Power Supply (B+)
6 4
* 4. Ground
6. Self Test

LJJF502J

3. Is the measured voltage within specifications?

YES

▶ Go to number 4 (Power Circuit Inspection procedure of pressure sensor).

NO

▶ Check for short to GND or short to B+ in the Yaw Rate & Lateral G sensor harness between terminal "3" of the Yaw
Rate & Lateral G sensor harness connector and terminal "36" of the HECU harness connector. Repair as necessary
and then go to "Verification of vehicle Repair" procedure. If OK, go to "Component Inspection" procedure.

4. Measure voltage between terminal "2" of the pressure sensor harness connector and chassis ground.

Specification : Approx. 5 V
BR -86 BRAKE SYSTEM

COMPONENT INSPECTION E7ACA997

1. Ignition "OFF".

2. Engine "ON".

3. Does warning lamp remain On?

YES

▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.

NO

▶ Fault is intermittent caused by faulty HECU or was repaired and HECU memory was not cleared. Go to the appli-
cable troubleshooting procedure.

VERIFICATION OF VEHICLE REPAIR EA01D7B1

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -87

DTC C1200 WHEEL SPEED SENSOR FRONT-LH OPEN/SHORT


DTC C1203 WHEEL SPEED SENSOR FRONT-RH OPEN/SHORT
DTC C1206 WHEEL SPEED SENSOR REAR-LH OPEN/SHORT
DTC C1209 WHEEL SPEED SENSOR REAR-RH OPEN/SHORT

COMPONENT LOCATION E7E508E9

Front wheel sensor Rear wheel sensor


LJJF502L

GENERAL DESCRIPTION E11BBCFA

The wheel speed sensor is the essential component the ABS ECU uses to calculate vehicle speed and to determine
whether wheel lock occurs. For example, rear wheel speed signal is used as a referecnce value, for vehicle speed, in
front wheel drive vehicles, and if a difference between front and rear wheel speed occurs, then ABS control is performed.
Wheel speed sensor is active hall-sensor type and good at temperature and noise tolerance. Digital wave is produced as
tone wheel rotate according as hall sensor principle. Frequency of duty wave is changed in proportion to rotation of tone
wheel and HECU calculate vehicle speed by this frequency.

DTC DESCRIPTION EAB8EAE6

The ABS ECU monitors the wheel speed sensor circuit continuously. If the sensor signal current is continuously out of
the specified range for 140 msec, then the HECU determines that the circuit is open/short, and sets this code. Warning
lamp is turned OFF if the detected fault is not more than when the IG KEY is turned to ON again, and wheel speeds are
more than 10 Km/h.
BR -88 BRAKE SYSTEM

DTC DETECTING CONDITION E9F91CAF

Item Detecting Condition Possible cause


DTC Strategy • Current Monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode • Inside the ABS control cycle
• Diagnosis mode
• Failure mode
Enable • When the sensor signal current is continuously out of the
Conditions specified range of 4 mA ± 10% ~ 22 mA ± 10% for 140msec.
• Sensor failure outside of the ABS control cycle
1) Only one wheel failure : Only the ABS/TCS/ESP functions
are inhibited. The ABS/ESP warning lamps are activated
and the EBD warning lamp is not activated.
2) More than two wheels failure : System down. The
ABS/EBD/TCS/ESP functions are inhibited. The valve relay
and all solenoids are prevented from being switched on. • Open or short of Wheel
The ABS/EBD/ESP warning lamps are activated. speed sensor circuit
• Faulty Wheel speed
• Sensor failure inside the ABS control cycle sensor
1) One front wheel failure : Inhibit the ABS/TCS/ESP control • Faulty HECU
of the failed-wheel and maintain the ABS/TCS/ESP
control of normal wheel. After the ABS/TCS/ESP
Fail Safe
control, the ABS/TCS/ESP functions are inhibited.
The ABS/ESP warning lamps are activated and the
EBD warning lamp is not activated.
2) Failure at one rear wheel : ABS/TCS/ESP control of both
front wheels are inhibited and the pressure of both rear
wheels are decreased. After the controller completes
the ABS/TCS/ESP control, the ABS/TCS/ESP functions
are inhibited. The ABS/ESP warning lamps are activated
and the EBD warning lamp is not activated.
3) More than 2 wheels failure : System down. The
ABS/EBD/TCS/ESP functions are inhibited. The valve relay
and all solenoids are prevented from being switched on.
The ABS/EBD/ESP warning lamps are activated.

TERMINAL AND CONNECTOR INSPECTION E592AA81

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -89

POWER CIRCUIT INSPECTION EDCC40EE

1. Ignition "ON" & Engine "OFF".

2. Measure voltage between terminal "1" of the wheel speed sensor harness connector and chassis ground.

Specification : Approx. B+

1. Wheel speed sensor(power)


2. Wheel speed sensor(signal)

2 1

LJJF502M

3. Is the measured voltage within specifications?

YES

▶ Go to "Signal Circuit Inspection" procedure.

NO

▶ Check for open or short to GND in wheel speed sensor harness between terminal 1 of the wheel speed sensor
harness connector and terminal of the HECU harness connector. Repair as necessary and then go to "Verification
of vehicle Repair" procedure.
▶ If OK, go to "Component Inspection" procedure.

DTC HECU connector harness terminal


DTC C1200 1(ESP : 46) - FL
DTC C1203 19(ESP : 45) - FR
DTC C1206 5(ESP : 44) - RL
DTC C1209 23(ESP : 43) - RR
BR -90 BRAKE SYSTEM

SIGNAL CIRCUIT INSPECTION E82017AE

1. Ignition "ON" & Engine "OFF".

2. Turn the wheel slowly with hand.

3. Measure voltage between terminal "2, 20, 6, 22(ESP : 15, 30, 14, 29)" of the HECU harness connector and chassis
ground.

Specification : Approx. High : 1.18 ~ 1.68 V , Low : 0.59 ~ 0.84 V

DTC HECU connector harness terminal


DTC C1200 2(ESP : 15) - FL
DTC C1203 20(ESP : 30) - FR
DTC C1206 6(ESP : 14) - RL
DTC C1209 22(ESP : 29) - RR

FR CH A 0.2 V 5.0 mS CH B 0.5 V

9 8 7 6 5 4 3 2 1
16 * * * * * *
25 24 23 22
* 20 19 18 *

<ABS> HOLD ZOOM CURS MEMO RECD MENU

LJJF502N

4. Is the measured voltage within specifications?

YES

▶ Go to "Component Inspection" procedure.

NO

▶ Check for open or short to GND in wheel speed sensor harness between terminal "2" of the wheel speed sensor
harness connector and terminal "2, 20, 6, 22(ESP : 15, 30, 14, 29)" of the HECU harness connector. Repair as
necessary and then go to "Verification of vehicle Repair" procedure.
▶ If OK, substitute with a known-good Wheel speed sensor and check for proper operation. If problem is corrected,
replace Wheel speed sensor and then go to "Verification of Vehicle Repair" procedure.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -91

COMPONENT INSPECTION E14FF72B

1. Ignition "OFF".

2. Engine "ON".

3. Start and drive vehicle in gear and maintain vehicle speed is approx. 10km/h or more(6mph or more).

4. Does warning lamp remain On?

YES

▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.

NO

▶ Fault is intermittent caused by open or short of wheel speed sensor harness, faulty wheel speed sensor and/or
faulty HECU or was repaired and HECU memory was not cleared. Go to the applicable troubleshooting procedure.

VERIFICATION OF VEHICLE REPAIR E33D2EB4

After a repair, it is essential to verify that the fault has been corrected.

1. Connect Scantool and select "Diagnostic Trouble Codes(DTCs)" mode.

2. Using a Scantool, Clear DTC.

3. Operate the vehicle within DTC Detecting Condition in General Information. (Start and drive vehicle in gear and
maintain vehicle speed is approx. 10km/h or more(6mph or more))

4. Are any DTCs present ?

YES

▶ Go to the applicable troubleshooting procedure.

NO

▶ System performing to specification at this time.


BR -92 BRAKE SYSTEM

DTC C1201 WHEEL SPEED SENSOR FRONT-LH RANGE /


PERFORMANCE / INTERMITTENT
DTC C1204 WHEEL SPEED SENSOR FRONT-RH RANGE /
PERFORMANCE / INTERMITTENT
DTC C1207 WHEEL SPEED SENSOR REAR-LH RANGE /
PERFORMANCE / INTERMITTENT
DTC C1210 WHEEL SPEED SENSOR REAR-RH RANGE /
PERFORMANCE / INTERMITTENT

COMPONENT LOCATION EA110FAD

Refer to DTC C1200.

GENERAL DESCRIPTION EFFFA124

Refer to DTC C1200.

DTC DESCRIPTION E4D74D24

The ABS ECU monitors the wheel speed sensor signal continuously. This code is set if an abnormal speed change ratio
is detected while the vehicle speed is more than 2Km/h . Warning lamp is turned OFF if the detected fault is not more
than when the IG KEY is turned to ON again, and wheel speeds are more than 10 Km/h.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -93

DTC DETECTING CONDITION E9A7DDC6

Item Detecting Condition Possible cause


DTC Strategy • Signal monitoring
• Outside the ABS control cycle
• Inside the ABS control cycle
Detect Mode
• Diagnosis mode
• Failure mode
• Max. wheel velocity exceeds 20km/h and the wheel velocity is 40%
Case1
of max. wheel velocity. if this condition is lasted for 2 minutes.
(Wrong
• Max. wheel velocity exceeds 40km/h and the wheel velocity is 60%
Exciter)
of max. wheel velocity. if this condition is lasted for 2 minutes.
• Controller counts the number of the wheel acceleration of
100 g[(25 km/h) for 7 ms]. When the numbers at one wheel
exceed 56 times, or When the numbers at more two wheels
exceed 5 times, controller recognize the failure.
• Controller counts the number of the wheel acceleration of 40
g[(17.5 km/h) for 7 ms]. When the numbers at one wheel
exceed 126 times, or When the numbers at more two wheels
Enable exceed 20 times, controller recognize the failure.
Conditions • Controller counts the number of the wheel deceleration of
Case2 -100 g[(-25 km/h) for 7 ms]. When the numbers at each wheel
(Speed exceed 56 times, controller recognize the failure.
• Improper
Jump) • The wheel deceleration of -100 g[(-25 km/h) for 7 ms] causes
installation
the controller to start monitoring this failure and to compare
of wheel
the wheel velocity with the vehicle velocity from next cycle.
speed
When its difference of -100 g is continued for more than 140
sensor
msec, controller recognize the failure.
• Abnormal
• n case that any sensor failure at other wheel was already
Rotor and
detected, When the numbers of 100 g at each wheel exceed
wheel
5 times, or When the numbers of 40 g at each wheel exceed
bearing
20 times, controller recognize the failure.
• Faulty
- The counter of speed jump is cleared every 30 min.
Wheel
• Sensor failure outside of the ABS control cycle speed
1) Only one wheel failure : Only the ABS/TCS/ESP functions sensor
are inhibited. The ABS/ESP warning lamps are activated • Faulty
and the EBD warning lamp is not activated HECU
2) More than two wheels failure : System down. The
ABS/EBD/TCS/ESP functions are inhibited. The valve relay
and all solenoids are prevented from being switched on. The
ABS/EBD/ESP warning lamps are activated.

• Sensor failure inside the ABS control cycle


1) One front wheel failure : Inhibit the ABS/TCS/ESP control of the
failed-wheel and maintain the ABS/TCS/ESP control of normal
Fail Safe wheel. After the ABS/TCS/ESP control, the ABS/TCS/ESP
functions are inhibited. The ABS/ESP warning lamps are
activated and the EBD warning lamp is not activated.
2) Failure at one rear wheel : ABS/TCS/ESP control of both
front wheels are inhibited and the pressure of both rear
wheels are decreased. After the controller completes the
ABS/TCS/ESP control, the ABS/TCS/ESP functions are
inhibited. The ABS/ESP warning lamps are activated and
the EBD warning lamp is not activated.
3) More than 2 wheels failure : System down. The
ABS/EBD/TCS/ESP functions are inhibited. The valve relay
and all solenoids are prevented from being switched on. The
ABS/EBD/ESP warning lamps are activated.
BR -94 BRAKE SYSTEM

MONITOR SCANTOOL DATA E7E642DB

1. Connect scantool to Data Link Connector(DLC)

2. Engine "ON".

3. Start and drive vehicle in gear and maintain vehicle speed is approx. 40 km/h or more(24 mph or more)

4. Monitor the "Wheel speed sensor" parameter on the Scantool.

Specification : Approx. 40 km/h or more(24 mph or more)

5. Is parameter displayed within specifications?

YES

▶ Fault is intermittent caused by faulty wheel speed sensor and/or faulty HECU or was repaired and HECU memory
was not cleared. Repair or replace as necessary and then go to "Component Inspection" procedure.

NO

▶ Check for improper installation of wheel speed sensor. If NG, repair as necessary and then go to "Verification of
vehicle Repair" procedure.
▶ Check for damage of rotor teeth or wheel bearing. If NG, repair as necessary and then go to "Verification of vehicle
Repair" procedure.
▶ Substitute with a known-good Wheel speed sensor and check for proper operation. If problem is corrected, replace
Wheel speed sensor and then go to "Verification of Vehicle Repair" procedure.
▶ If OK, Go to "Component Inspection" procedure.

COMPONENT INSPECTION EC5CC323

1. Ignition "OFF".

2. Engine "ON".

3. Start and drive vehicle in gear and maintain vehicle speed is approx. 40 km/h or more(24 mph or more).

4. Does warning lamp remain On?

YES

▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.

NO

▶ Fault is intermittent caused by faulty wheel speed sensor and/or faulty HECU or was repaired and HECU memory
was not cleared. Go to the applicable troubleshooting procedure.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -95

VERIFICATION OF VEHICLE REPAIR E71B34F7

After a repair, it is essential to verify that the fault has been corrected.

1. Connect scantool and select "Diagnostic Trouble Codes(DTCs)" mode.

2. Using a scantool, Clear DTC.

3. Operate the vehicle within DTC Detecting Condition in General Information. (Start and drive vehicle in gear and
maintain vehicle speed is approx. 40 km/h or more(24 mph or more))

4. Are any DTCs present ?

YES

▶ Go to the applicable troubleshooting procedure.

NO

▶ System performing to specification at this time.


BR -96 BRAKE SYSTEM

DTC C1202 WHEEL SPEED SENSOR FRONT-LH INVALID/NO SIGNAL


DTC C1205 WHEEL SPEED SENSOR FRONT-RH INVALID/NO SIGNAL
DTC C1208 WHEEL SPEED SENSOR REAR-LH INVALID/NO SIGNAL
DTC C1211 WHEEL SPEED SENSOR REAR-RH INVALID/NO SIGNAL

COMPONENT LOCATION EACCCDF0

Refer to DTC C1200.

GENERAL DESCRIPTION E28ED6F1

Refer to DTC C1200.

DTC DESCRIPTION E0EBBEF9

The ABS ECU monitors the wheel speed sensor signal continuously. This code is set when the sensor air gap is out of
specified range or when the ABS control cycle is continued abnormally. The HECU checks for air gap malfunctioning by
monitoring the sensor signal at speeds between 2 Km/h to 10 Km/h. Warning lamp is turned OFF if the detected fault is
not more than when the IG KEY is turned to ON again, and wheel speeds are more than 10 Km/h.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -97

DTC DETECTING CONDITION E92AEAE2

Possible
Item Detecting Condition
cause
DTC Strategy • Signal monitoring
• Outside the ABS control cycle
Detect Mode • Diagnosis mode
• Failure mode
• When the minimum wheel velocity is 2 km/h and the velocity of
other wheels exceed 10 km/h with the acceleration of < 0.4g
, the controller start comparing the velocity of other wheels
except the min. wheel. if their difference below 4 km/h is
Case1 continued for 140 msec, Otherwise, if their difference beyond
(Large 4 km/h or > 0.4 g is continued for 2 minutes.
Air-gap) • In < 0.4 g, when the velocity of more two wheels is 2 km/h and the
Enable
max. wheel velocity exceeds 10 km/h, the condition is continued
Conditions
for 20 sec. Otherwise, In >0.4 g, the condition is 2 minutes.
• After velocity of 4 wheel exceeds 10km/h, when velocity of 1 wheel
or 2 wheel is 2 km/h and difference of other 2 wheel velocity
is less than 4 km/h under that those velocity is more than 10
km/h, if that conditions are continued for 12 seconds. • Improper
- This monitoring is performed for the period that the minimum installa-
velocity rises from 2 km/h to 10 km/h. tion of
Detect Mode • Inside the ABS control cycle wheel
Case2
speed
(long • During the ABS control cycle, if the wheel velocity of 2
Enable sensor
term ABS km/h is lasted for more than 12 sec.
Conditions • Abnormal
mode) • If the ABS control cycle is continued for more than 36 sec. Rotor and
• Sensor failure outside of the ABS control cycle wheel
1) Only one wheel failure : Only the ABS/TCS/ESP functions bearing
are inhibited. The ABS/ESP warning lamps are activated • Faulty
and the EBD warning lamp is not activated Wheel
2) More than two wheels failure : System down. The speed
ABS/EBD/TCS/ESP functions are inhibited. The valve relay sensor
and all solenoids are prevented from being switched on. • Faulty
The ABS/EBD/ESP warning lamps are activated. HECU

• Sensor failure inside the ABS control cycle


1) One front wheel failure : Inhibit the ABS/TCS/ESP control
of the failed-wheel and maintain the ABS/TCS/ESP control
Fail Safe of normal wheel. After the ABS/TCS/ESP control, the
ABS/TCS/ESP functions are inhibited. The ABS/ESP warning
lamps are activated and the EBD warning lamp is not activated.
2) Failure at one rear wheel : ABS/TCS/ESP control of both
front wheels are inhibited and the pressure of both rear
wheels are decreased. After the controller completes the
ABS/TCS/ESP control, the ABS/TCS/ESP functions are
inhibited. The ABS/ESP warning lamps are activated and
the EBD warning lamp is not activated.
3) More than 2 wheels failure : System down. The
ABS/EBD/TCS/ESP functions are inhibited. The valve relay
and all solenoids are prevented from being switched on.
The ABS/EBD/ESP warning lamps are activated.
BR -98 BRAKE SYSTEM

MONITOR SCANTOOL DATA E8AEBAB8

1. Connect scantool to Data Link Connector(DLC)

2. Engine "ON".

3. Start and drive vehicle in gear and maintain vehicle speed is approx. 10 km/h or more(6mph or more)

4. Monitor the "Wheel speed sensor" parameter on the Scantool.

Specification : Approx. 10km/h or more(6mph or more)

5. Is parameter displayed within specifications?

YES

▶ Fault is intermittent caused by faulty wheel speed sensor and/or faulty HECU or was repaired and HECU memory
was not cleared. Repair or replace as necessary and then go to "Component Inspection" procedure.

NO

▶ Check for improper installation of wheel speed sensor. If NG, repair as necessary and then go to "Verification of
vehicle Repair" procedure.
▶ Check for damage of rotor teeth or wheel bearing. If NG, repair as necessary and then go to "Verification of vehicle
Repair" procedure.
▶ Substitute with a known-good Wheel speed sensor and check for proper operation. If problem is corrected, replace
Wheel speed sensor and then go to "Verification of Vehicle Repair" procedure.
▶ If OK, Go to "Component Inspection" procedure.

COMPONENT INSPECTION EBD79849

Refer to DTC C1200.

VERIFICATION OF VEHICLE REPAIR E1D06A23

Refer to DTC C1200.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -99

DTC C1235 PRESSURE SENSOR(PRIMARY) - ELECTRICAL

COMPONENT LOCATION ED5B2E14

Pressure sensor

LJJF502O

GENERAL DESCRIPTION ED74D4A0

The one pressure sensor ,installed in the master cylinder, sense the brake oil pressure to judge driver’s brake intention
when ESP is operating. If pressure of master cylinder is applied to pressure sensor, the strain of the piezo element
is changed and then the resistance of bridge circuit is changed according to changed strain. Therefore this changed
resistance changes output voltage of bridge circuit and output voltage changes linearly. The sensor output is a analog
signal in proportion to supply voltage, and the HECU recognizes a pressure value according to signal ratio about supply
voltage.

DTC DESCRIPTION E11BE39E

Each unfiltered input signal voltage is monitored to be in the range of 0.2V ± 0.1V < input signal voltage < 4.8V ± 0.1V.
A failure is detected if the output signal value is out of specified range for more than 1s or pressure sensor self test form
is against to specification during self test.
BR -100 BRAKE SYSTEM

DTC DETECTING CONDITION EB39369F

Item Detecting Condition Possible cause


DTC Strategy • Voltage Monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode • Inside the ABS control cycle
Case1 • Diagnosis mode
• Failure mode
Enable • Vmcp > 4.8 ± 0.1 V or Vmcp < 0.2 ± 0.1 V continue 1 sec.
Conditions - The monitoring starts 1sec after power up.
Detect Mode • Initial Check
• Open or short of
Case2 Enable • When sensor self test form is against to sensor specification. pressure sensor
Conditions - The monitoring starts 1sec after power up. circuit
• Outside the ABS control cycle • Faulty pressure
• Inside the ABS control cycle sensor
Detect Mode • Faulty HECU
• Diagnosis mode
• Failure mode
Case3
• While the vehicle is stopped affter driving over 40kph for 3
Enable times, If predefined value of pressure signal is not detected,
Conditions ECU detect the failure after sensor self test.
- The monitoring starts 1sec after power up.
• Inhibit the TCS/ESP control and allow the ABS/EBD
control. Meanwhile, stop checking the ESP switch
Fail Safe
failure under the TCS/ESP control.
• The ESP warning lamp is activated.

TERMINAL AND CONNECTOR INSPECTION EECFDFE9

Refer to DTC C1101.

POWER CIRCUIT INSPECTION EED704C0

1. Ignition "ON" & Engine "OFF".

2. Measure voltage between terminal "2" of the pressure sensor harness connector and chassis ground.

Specification : Approx. 5 V

1 1. Pressure Sensor Signal


2. Pressure Sensor Power Supply
3 2 3. Pressure Sensor Ground

LJJF502P
ABS (ANTI-LOCK BRAKE SYSTEM) BR -101

3. Is the measured voltage within specifications?

YES

▶ Go to "Ground Circuit Inspection" procedure.

NO

▶ Check for open or short to GND in pressure sensor harness between terminal "2" of the pressure sensor harness
connector and terminal "37" of the ESP HECU harness connector. Repair as necessary and then go to "Verification
of vehicle Repair" procedure. If OK, go to "Component Inspection" precedure.

GROUND CIRCUIT INSPECTION EF116A70

1. Ignition "OFF".

2. Disconnect pressure sensor connector.

3. Measure resistance between terminal "3" of the pressure sensor harness connector and chassis ground.

Specification : Approx. below 1Ω

1 1. Pressure Sensor Signal


2. Pressure Sensor Power Supply
3 2 3. Pressure Sensor Ground

LJJF502Q

4. Is the measured resistance within specifications?

YES

▶ Go to "Signal Circuit Inspection" procedure.

NO

▶ Check for open or short in pressure sensor harness between terminal "3" of the pressure sensor harness connector
and terminal "28" of the ESP HECU harness connector. Repair as necessary and then go to "Verification of vehicle
Repair" procedure.

SIGNAL CIRCUIT INSPECTION ECFE7C32

1. Ignition "ON" & Engine "OFF".

2. Measure voltage between terminal "1" of the pressure sensor harness connector and chassis ground.

Specification : 0.2 ± 0.1 V ~ 4.8 ± 0.1 V


BR -102 BRAKE SYSTEM

1 1. Pressure Sensor Signal


2. Pressure Sensor Power Supply
3 2 3. Pressure Sensor Ground

LJJF502R

3. Is the measured resistance within specifications?

YES

▶ Go to "Component Inspection" procedure.

NO

▶ Check for open or short in pressure sensor harness between terminal "1" of the pressure sensor harness connector
and terminal "12" of the HECU harness connector. Repair as necessary and then go to "Verification of vehicle Repair"
procedure.
▶ If OK, substitute with a known-good pressure sensor and check for proper operation. If problem is corrected,
replace pressure sensor and then go to "Verification of Vehicle Repair" procedure.

COMPONENT INSPECTION EDDEACF8

1. Ignition "OFF".

2. Engine "ON".

3. Start and drive vehicle in gear and maintain vehicle speed is approx. 40 km/h or more(24 mph or more) and then put
on the brake three times.

4. Does warning lamp remain On?

YES

▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.

NO

▶ Fault is intermittent caused by open or short of pressure sensor harness, faulty pressure sensor and/or faulty
HECU or was repaired and HECU memory was not cleared. Go to the applicable troubleshooting procedure.

VERIFICATION OF VEHICLE REPAIR E3519CEC

Refer to DTC C1201.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -103

DTC C1237 PRESSURE SENSOR - OTHER

COMPONENT LOCATION EBA1CAB9

Refer to DTC C1235.

GENERAL DESCRIPTION EFB4F1DC

Refer to DTC C1235.

DTC DESCRIPTION EA0B5882

The failure is detected if the pressure sensor signal noise is out of normal range, or the pressure sensor signal is changed
abnormally, or In spite of no brake switch signal, master cyclinder pressure exceeds 20 bar when brake switch is normal.

DTC DETECTING CONDITION E49E374A

Item Detecting Condition Possible cause


DTC Strategy • Voltage Monitoring
• Outside the ABS control cycle
Detect Mode • Diagnosis mode
• Failure mode
• If input signal is noisy, Which the gradient of the sensor signal is • Open or short of
larger than 15 bar over 25 times in 2 sec, ECU detect the failure. pressure sensor circuit
Enable
• Outside an ABS/TCS/ESP control,And after normal operation • Faulty pressure sensor
Conditions
of BLS, If the pressure sensor signal is higher than 20 bar • Faulty HECU
and BLS is low for 3 sec, ECU detects the failure.
• Inhibit the TCS/ESP control and allow the ABS/EBD control.
Meanwhile, stop checking the ESP switch failure
Fail Safe
under the TCS/ESP control.
• The ESP warning lamp is activated.

TERMINAL AND CONNECTOR INSPECTION E7F748EE

Refer to DTC C1101.


BR -104 BRAKE SYSTEM

SIGNAL CIRCUIT INSPECTION E8D3D17A

1. Ignition "ON" & Engine "OFF".

2. Press the brake pedal.

3. Measure voltage between terminal "1" of the pressure sensor harness connector and chassis ground by using the
oscilloscope.

Specification : 0.2 ± 0.1 V ~ 4.8 ± 0.1 V

1 1. Pressure Sensor Signal


2. Pressure Sensor Power Supply
3 2 3. Pressure Sensor Ground

LJJF502S

4. Is the measured voltage within specifications?

YES

▶ Go to "Component Inspection" procedure.

NO

▶ Check for damaged harness and poor connection in pressure sensor harness between terminal "1" of the pressure
sensor harness connector and terminal "12" of the HECU harness connector. Repair as necessary and then go to
"Verification of vehicle Repair" procedure.
▶ If OK, substitute with a known-good pressure sensor and check for proper operation. If problem is corrected,
replace pressure sensor and then go to "Verification of Vehicle Repair" procedure.

COMPONENT INSPECTION EABDECFA

Refer to DTC C1101.

VERIFICATION OF VEHICLE REPAIR EFF7010E

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -105

DTC C1259 STEERING ANGLE SENSOR - ELECTRICAL

COMPONENT LOCATION EFDEAE17

S R S
AIRBAG

S
SR
BAG
AIR

LJJF502T

GENERAL DESCRIPTION ECCC1E98

The Steering wheel angle sensor uses two sensors ( A-sensor and B-sensor ) to determine the direction of the rotation.
The main components of each sensor are LED, photo transistor and slit plate.The slit plate, which has 45 holes, is installed
between LED and photo transistor, and generates signals if slit plate rotates according to the steering wheel rotation.The
sensor signals are generated by photo transistor which is driven whenever the light passes through the holes. The HECU
detects operating speed and direction of the steering wheel by this input signal, and the signal is used to input signal for
anti-roll control.

DTC DESCRIPTION EF9B02E6

If some signal voltage stays in abnormal voltage range, the time is counted separately. And if the monitored time exceeds
the specified min. fault duration, failure is detected. The monitoring starts 1sec after Power Up.

DTC DETECTING CONDITION E98AEFE9

Item Detecting Condition Possible cause


DTC Strategy • Voltage Monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode • Inside the ABS control cycle
• Diagnosis mode • Open or short of
• Failure mode steering wheel sensor
circuit
Enable • When Vsas > 4.2 ± 0.1 V or Vsas < 1.2 ± 0.1 V • Faulty steering wheel
Conditions or 2.1 ± 0.1 V < Vsas < 2.9 ± 0.1 V continue 1 sec. sensor
- The monitoring starts 1 sec after Power Up. • Faulty HECU
• Inhibit the TCS/ESP control and allow the ABS/EBD
control. Meanwhile, stop checking the ESP switch
Fail Safe
failure under the TCS/ESP control.
• The ESP warning lamps are activated.
BR -106 BRAKE SYSTEM

TERMINAL AND CONNECTOR INSPECTION E343554D

Refer to DTC C1101.

POWER CIRCUIT INSPECTION EF6A40C1

1. Ignition "ON" & Engine "OFF".

2. Measure voltage between terminal "6" of the steering wheel angle sensor harness connector and chassis ground.

Specification : Approx. B+

2. Ground
3. ST1 Signal
4. ST2 Signal
6 5 4 3 2 5. STN Signal
* 6. Power Supply (IG1)

LJJF502U

3. Is the measured voltage within specifications?

YES

▶ Go to "Ground Circuit Inspection" procedure.

NO

▶ Check for open or blown 10 A fuse. Repair as necessary and then go to "Verification of vehicle Repair" procedure.
▶ If OK, check for open or short to GND in steering wheel angle sensor harness between the battery terminal(+) and
terminal "2" of the steering wheel angle sensor harness connector. Repair as necessary and then go to "Verification
of vehicle Repair" procedure.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -107

GROUND CIRCUIT INSPECTION E2587253

1. Ignition "OFF".

2. Disconnect steering wheel angle sensor connector.

3. Measure resistance between terminal "2" of the steering wheel angle sensor harness connector and chassis ground.

Specification : Approx. below 1 Ω

2. Ground
3. ST1 Signal
4. ST2 Signal
6 5 4 3 2 5. STN Signal
* 6. Power Supply (IG1)

LJJF502V

4. Is the measured resistance within specifications?

YES

▶ Go to "Signal Circuit Inspection" procedure.

NO

▶ Check for open or short in steering wheel angle sensor harness between terminal "2" of the steering wheel angle
sensor harness connector and terminal "31" of the HECU harness connector. Repair as necessary and then go to
"Verification of vehicle Repair" procedure.

SIGNAL CIRCUIT INSPECTION EBAF5FE2

1. Ignition "ON" & Engine "ON".

2. Turn the steering wheel to the left or right.

3. Measure signal waveform between terminal "3, 4, 5" of the steering wheel angle sensor harness connector and
chassis ground.

Specification :
HIGH : 2.9 ± 0.1 V ~ 4.4 ± 0.1 V
LOW : 1.2 ± 0.1 V ~ 2.1 ± 0.1 V
BR -108 BRAKE SYSTEM

FR CH A 1.0 V 10 mS CH B 1.0 V FR CH A 1.0 V 10 mS CH B 1.0 V

ST1 STN

ST2

HOLD TIME VOLT GND CHNL MENU HOLD TIME VOLT GND CHNL MENU
Fig1 Fig2

Fig 1) Test Condition : Ignition "ON" & Engine "ON".


Normal data ( Approx. High : 3.5 V , Low : 1.5 V )
Fig 2) Test Condition : Ignition "ON" & Engine "ON".
Normal data ( Approx. High : 3.5 V , Low : 1.5 V )
LJJF502W

2. Ground
3. ST1 Signal
4. ST2 Signal
6 5 4 3 2 5. STN Signal
* 6. Power Supply (IG1)

LJJF502X

4. Is the measured signal waveform within specifications?

YES

▶ Go to "Component Inspection" procedure.

NO

▶ Check for open or short in steering wheel angle sensor harness between terminal "3, 4, 5" of the steering wheel
angle sensorr harness connector and terminal "8, 40, 39" of the HECU harness connector. Repair as necessary and
then go to "Verification of vehicle Repair" procedure.
▶ If OK, substitute with a known-good steering wheel angle sensor and check for proper operation. If problem is
corrected, replace steering wheel angle sensor and then go to "Verification of Vehicle Repair" procedure.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -109

COMPONENT INSPECTION EDD8EF37

Refer to DTC C1101.

VERIFICATION OF VEHICLE REPAIR E8ECAAEC

Refer to DTC C1101.


BR -110 BRAKE SYSTEM

DTC C1260 STEERING ANGLE SENSOR - SIGNAL

COMPONENT LOCATION EF20506F

Refer to DTC C1259.

GENERAL DESCRIPTION E00D4B37

Refer to DTC C1259.

DTC DESCRIPTION E0B1F5B8

This monitoring function monitors the changing point of N-signal with measured steering angle from ST1 and ST2. If
N-signal changing point differs more than predefined degree, the failure is detected. If there is no variation of the steering
wheel angle for predefined time ECU detect the failure.

DTC DETECTING CONDITION E54AE65B

Item Detecting Condition Possible cause


DTC Strategy • Signal Monitoring
• Outside the ABS control cycle
Detect Mode • Inside the ABS control cycle
• Diagnosis mode
• The STN is low more than ± 20 degrees for 70 msec.
• When the steering wheel is turned more than 370 ± 5 degrees,
if center is not detected, ECU detects the failure.
• When the steering wheel angle is higher than 700
degrees ECU detects the failure.
• During straight driving, if the steering wheel angle is larger
than 55 ± 5 degree ECU detects the failure.
• When the curve is detected after driving straight, if • Faulty steering wheel
Enable there is no variation of the steering wheel angle for sensor
Conditions 3 sec, ECU detect the failure. • Faulty HECU
• While the vehicle drive 60 ± 5 degree ↔ -60 ± 5 degree, if
STN is not detected low, ECU detect the failure.
• While steering angle sensor wheel through center, of
steering angle sensor is against specification three
times, ECU detect the failure.
• When the curve is detected after driving straight, if
estimated valve and measured value of the sensor indicate
in the opposite direction for 2 times.
• Inhibit the TCS/ESP control and allow the ABS/EBD
control. Meanwhile, stop checking the ESP switch
Fail Safe
failure under the TCS/ESP control.
• The ESP warning lamps are activated.

TERMINAL AND CONNECTOR INSPECTION E2D107FC

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -111

SIGNAL CIRCUIT INSPECTION EEBE1731

1. Ignition "ON" & Engine "ON".

2. Turn the steering wheel to the left or right.

3. Measure signal waveform between terminal "1, 4, 5" of the steering wheel angle sensor harness connector and
chassis ground.

Specification :
HIGH : 2.9 ± 0.1 V ~ 4.4 ± 0.1 V
LOW : 1.2 ± 0.1 V ~ 2.1 ± 0.1 V

FR CH A 1.0 V 10 mS CH B 1.0 V FR CH A 1.0 V 10 mS CH B 1.0 V

ST1 STN

ST2

HOLD TIME VOLT GND CHNL MENU HOLD TIME VOLT GND CHNL MENU
Fig1 Fig2

Fig 1) Test Condition : Ignition "ON" & Engine "ON".


Normal data ( Approx. High : 3.5 V , Low : 1.5 V )
Fig 2) Test Condition : Ignition "ON" & Engine "ON".
Normal data ( Approx. High : 3.5 V , Low : 1.5 V )
LJJF502Y

2. Ground
3. ST1 Signal
4. ST2 Signal
6 5 4 3 2 5. STN Signal
* 6. Power Supply (IG1)

LJJF502Z
BR -112 BRAKE SYSTEM

4. Is the measured signal waveform within specifications?

YES

▶ Go to "Component Inspection" procedure.

NO

▶ Check for open or short in steering wheel angle sensor harness between terminal "1, 4, 5" of the steering wheel
angle sensorr harness connector and terminal "39, 40, 8" of the HECU harness connector. Repair as necessary and
then go to "Verification of vehicle Repair" procedure.
▶ If STN signal is LOW when the steering wheel is in center position, Check for improper installation of steering
angle sensor. Repair as necessary and then go to "Verification of vehicle Repair" procedure.
▶ If OK, substitute with a known-good steering wheel angle sensor and check for proper operation. If problem is
corrected, replace steering wheel angle sensor and then go to "Verification of Vehicle Repair" procedure.

COMPONENT INSPECTION E6DFD15D

Refer to DTC C1101.

VERIFICATION OF VEHICLE REPAIR E1A8ECD4

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -113

DTC C1282 YAW RATE AND LATERAL G SENSOR - ELECTRICAL

COMPONENT LOCATION E69AFBD4

LJJF503A

GENERAL DESCRIPTION E783901F

When the vehicle is turning with respect to a vertical axis the yaw rate sensor detects the yaw rate electronically by the
vibration change of plate fork inside the yaw rate sensor. If yaw velocity reaches the specific velocity after it detects the
vehicle’ yawing, the ESP control is reactivated. The lateral G sensor senses vehicle’s lateral G. A small element inside
the sensor is attached to a deflectable leverarm by lateral G. Direction and magnitude of lateral G loaded to vehicle can
be known with electrostatic capacity changing according to lateral G. The output voltage of the lateral G sensor is 2.5V
when the vehicle is at a standstill. Only with lateral G sensor, the ESP can not be reactivated.

DTC DESCRIPTION EDE32EB7

A failure is detected if the lateral acceleration sensor or yaw rate sensor signal stays in the fault range longer than the
specified failure detection time. The Monitoring starts 1sec after Power Up.
BR -114 BRAKE SYSTEM

DTC DETECTING CONDITION EADB0C9F

Item Detecting Condition Possible cause


DTC Strategy • Lateral G sensor monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode • Inside the ABS control cycle
Case1 • Diagnosis mode
• Failure mode

Enable • When V_LG > 4.90 ± 0.05 V or V_LG < 0.10 ±


Conditions 0.05 V continue 1 sec,
- The monitoring starts 1 sec after power up.
DTC Strategy • YAW rate Sensor monitoring
• Initial Check • Faulty Yaw
• Outside the ABS control cycle Rate &
Detect Mode • Inside the ABS control cycle Lateral G
Case2 • Diagnosis mode sensor
• Failure mode • Open or short
Enable • When V_YAW > 4.90 ± 0.05 V of Yaw Rate
Conditions or V_YAW < 0.10 ± 0.05 V continue 1sec, & Lateral G
- The monitoring starts 1sec after power up. sensor
• Faulty HECU
DTC Strategy • CBIT(Commended built in test) monitoring
Detect Mode • Initial Check

• When CBIT is high ( > 3.6 V ), YAW signal voltage don’t increase


Case3
Enable 0.1 ~ 1.2 V than case of low state of CBIT pin .
Conditions • Lateral G signal voltage is smaller than 4.1 ± 0.1 V
when CBIT is high(> 3.6 V ).
• When GND of yaw rate sensor and lateral G sensor are open.
• Inhibit the TCS/ESP control and allow the ABS/EBD
control. Meanwhile, stop checking the ESP switch failure
Fail Safe
under the TCS/ESP control.
• The ESP warning lamp is activated.

TERMINAL AND CONNECTOR INSPECTION E9BA7B5D

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -115

POWER CIRCUIT INSPECTION E550ADAB

1. Ignition "ON" & Engine "OFF".

2. Measure voltage between terminal "3" of the Yaw Rate & Lateral G sensor harness connector and chassis ground.

Specification : Approx. 5 V

1. YAW sensor signal


3 2 1 2. Lateral G sensor signal
3. Power Supply (B+)
6 4
* 4. Ground
6. Self Test

LJJF503B

3. Is the measured voltage within specifications?

YES

▶ Go to "Ground Circuit Inspection" procedure.

NO

▶ Check for open or short to GND in the Yaw Rate & Lateral G sensor harness between terminal "3" of the Yaw Rate
& Lateral G sensor harness connector and terminal "36" of the HECU harness connector. Repair as necessary and
then go to "Verification of vehicle Repair" procedure. If OK, go to "Component Inspection" procedure.

GROUND CIRCUIT INSPECTION EB2A763D

1. Ignition "OFF".

2. Disconnect Yaw Rate & Lateral G sensor connector.

3. Measure resistance between terminal "4" of the Yaw Rate & Lateral G sensor harness connector and chassis ground.

Specification : Approx. below 1Ω

1. YAW sensor signal


3 2 1 2. Lateral G sensor signal
3. Power Supply (B+)
6 4
* 4. Ground
6. Self Test

LJJF503C
BR -116 BRAKE SYSTEM

4. Is the measured resistance within specifications?

YES

▶ Go to next procedure.

NO

▶ Check for open or short in the Yaw Rate & Lateral G sensor harness between terminal "4" of the Yaw Rate &
Lateral G sensor harness connector and terminal "23" of the HECU harness connector. Repair as necessary and
then go to "Verification of vehicle Repair" procedure.

SIGNAL CIRCUIT INSPECTION EA556B67

1. Ignition "ON" & Engine "OFF".

2. Measure voltage between terminal "1, 2" of the Yaw Rate & Lateral G sensor harness connector and chassis ground.

Specification : Approx. 2.5 V

1. YAW sensor signal


3 2 1 2. Lateral G sensor signal
3. Power Supply (B+)
6 4
* 4. Ground
6. Self Test

LJJF503D

3. Is the measured resistance within specifications?

YES

▶ Go to "Component Inspection" procedure.

NO

▶ Check for open or short in the Yaw Rate & Lateral G sensor harness between terminal "1, 2" of the Yaw Rate &
Lateral G sensor harness connector and terminal "41, 9" of the HECU harness connector. Repair as necessary and
then go to "Verification of Vehicle Repair" procedure. If OK, go to "Component Inspection" procedure.
▶ If OK, Substitute with a known-good Yaw Rate & Lateral G sensor and check for proper operation. If problem is
corrected, replace Yaw Rate & Lateral G sensor and then go to "Verification of Vehicle Repair" procedure.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -117

COMPONENT INSPECTION EBA4A1AF

1. Ignition "OFF".

2. Engine "ON".

3. Does warning lamp remain On?

YES

▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.

NO

▶ Fault is intermittent caused by open or short of Yaw Rate & Lateral G sensor harness and/or faulty Yaw Rate
& Lateral G sensor or was repaired and HECU memory was not cleared. Go to the applicable troubleshooting
procedure.

VERIFICATION OF VEHICLE REPAIR EAAD4BFF

Refer to DTC C1101.


BR -118 BRAKE SYSTEM

DTC C1283 YAW RATE AND LATERAL G SENSOR - SIGNAL

COMPONENT LOCATION E98ACA48

Refer to DTC C1282.

GENERAL DESCRIPTION E9FF780E

Refer to DTC C1282.

DTC DESCRIPTION E65AF5BC

A lateral acceleration reference signal is calculated from the wheel speeds, the steering angle and the yaw rate signals
to observe the lateral acceleration sensor signal. The difference between the reference signal and the sensor signal is
evaluated for failure detection. A yaw rate reference signal is calculated from the wheel speeds, the steering angle and
the lateral acceleration signals to observe the yaw rate sensor signal. The difference between the reference signal and
the sensor signal, and the gradient of the measured sensor signal is evaluated for the failure detection. If the difference
between estimated value and measured value of the sensor is larger than predefined value for predefined time, the failure
is recognized.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -119

DTC DETECTING CONDITION E56FE750

Item Detecting Condition Possible cause


DTC Strategy • Signal monitoring
Detect Mode • Initial Check
• During standstill if lateral G value is larger than 7 g,
Case1 Enable and continue 2 sec.
Conditions • During standstill if yaw rate value is larger than 7 deg/s,
and continue 2 sec.
• Initial Check
Detect Mode • Outside the ABS control cycle
• Diagnosis mode
• If noise of input signal is happened 429 times in 5 sec , Which
Case2 the amplitude of the sensor signal is larger than predefined
Enable value(standstill : 0.3 g , driving:0.5 g~ 1.0 g).
Conditions • If noise of input signal is happened 429 times in 5 sec , Which
the amplitude of the sensor signal is larger than predefined
value(standstill : 8 deg/s , driving:15 deg/s~ 30 deg/s).
• Faulty Yaw Rate
• Outside the ABS control cycle & Lateral G
Detect Mode • Inside the ABS control cycle sensor
• Diagnosis mode • Open or short
• When the difference between estimated value and of Yaw Rate &
measured value of the sensor is lager than 0.3 g, the Lateral G sensor
Case3 difference value add and subtract. When sum Total • Faulty HECU
Enable value is larger than predefined value.
Conditions • When the difference between estimated value and
measured value of the sensor is lager than 7 deg/s,
the difference value add and subtract. When sum Total
value is larger than predefined value
• Outside the ABS control cycle
• Inside the ABS control cycle
Detect Mode
• Diagnosis mode
Case4 • Failure mode
Enable
• When GND of yaw rate sensor and lateral G sensor are open.
Conditions
• Inhibit the TCS/ESP control and allow the ABS/EBD
control. Meanwhile, stop checking the ESP switch
Fail Safe
failure under the TCS/ESP control.
• The ESP warning lamp is activated.

TERMINAL AND CONNECTOR INSPECTION EEC56762

Refer to DTC C1101.


BR -120 BRAKE SYSTEM

POWER CIRCUIT INSPECTION E9BCBBD5

1. Ignition "ON" & Engine "OFF".

2. Measure voltage between terminal "1, 2" of the Yaw Rate & Lateral G sensor harness connector and chassis ground.

Specification : Approx. 2.5 V

1. YAW sensor signal


3 2 1 2. Lateral G sensor signal
3. Power Supply (B+)
6 4
* 4. Ground
6. Self Test

LJJF503E

3. Is the measured voltage within specifications?

YES

▶ Go to "Ground Circuit Inspection" procedure.

NO

▶ Check for open or short in the Yaw Rate & Lateral G sensor harness between terminal "1, 2" of the Yaw Rate &
Lateral G sensor harness connector and terminal "41, 9" of the HECU harness connector. Repair as necessary and
then go to "Verification of Vehicle Repair" procedure. If OK, go to "Component Inspection" procedure.
▶ If OK, Substitute with a known-good Yaw Rate & Lateral G sensor and check for proper operation. If problem is
corrected, replace Yaw Rate & Lateral G sensor and then go to "Verification of Vehicle Repair" procedure.

GROUND CIRCUIT INSPECTION E53EE55F

Refer to DTC C1282.

COMPONENT INSPECTION EBFCB6EA

Refer to DTC C1282.

VERIFICATION OF VEHICLE REPAIR E83A58ED

Refer to DTC C1201.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -121

DTC C1503 ESP SWITCH ERROR

COMPONENT LOCATION E3CD9CDF

LJJF503G

GENERAL DESCRIPTION E21B45BD

Driver can inhibit the ESP control by ESP switch. When switch signal send into HECU, ESP warning lamp goes ON and
ESP control is stopped and if next switch signal is inputted again, ESP control is ready. This function is used for sporty
driving or vehicle inspection.

DTC DESCRIPTION E9A1CA8C

Trouble code is set when the condition that the level of ESP switch is high is continued for 60sec. When the ESP switch
failure is set there is no signal in the warning lamp and HECU inhibits the ESP control and allows the ABS/EBD control.

DTC DETECTING CONDITION EF68EA70

Item Detecting Condition Possible cause


DTC Strategy • Short circuit monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode • Inside the ABS control cycle
• Diagnosis mode
• Failure mode • Open or short ESP
Enable switch
• When the ESP switch is ON for 60 sec.
Conditions
• Inhibit the TCS/ESP control and allow the ABS/EBD
control. Meanwhile, stop checking the ESP switch
Fail Safe
failure under the TCS/ESP control.
• The ESP warning lamps are activated.

TERMINAL AND CONNECTOR INSPECTION E011BF8D

Refer to DTC C1101.


BR -122 BRAKE SYSTEM

SIGNAL CIRCUIT INSPECTION EDD7CCBC

1. Ignition "ON" & Engine "OFF" & ESP Switch "ON".

2. Measure voltage between terminal "27" of the HECU harness connector and chassis ground.

Specification : Approx B+

<ESP>
16 15 14
31 30 29 * 28 12 27 * * 9 24 8 23 7 22 6 21 5 4 19 * 18 * 1
27. ESP switch
* * * *
47 46 45 44 43
* 41 40 39 * 37 36 35 34 * 32

LJJF503H

3. Is the measured signal waveform within specifications?

YES

▶ Fault is intermittent caused by open or short in ESP switch line, faulty ESP switch or was repaired and HECU
memory was not cleared. Go to the applicable troubleshooting procedure.

NO

▶ Check for damaged harness and poor connection in the power harness between the battery terminal(+) and the
terminal "27" of the HECU harness connector . Check for open or blown 10 A fuse referring to "Circuit Diagram" .
Repair as necessary and then go to "Verification of vehicle Repair" procedure.
▶ If OK, go to "Component Inspection" procedure.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -123

COMPONENT INSPECTION E984E174

1. Ignition "OFF".

2. Disconnect ESP switch connector.

3. Press the ESP switch.

4. Measure resistance between terminal "1" of the ESP switch harness connector and terminal "4" of the ESP switch
harness connector

Specification : Approx. below 1 Ω

1. POWER SUPPLY
1 2 4. SIGNAL

* 4
* 6

LJJF503I

5. Is the measured resistance within specifications?

YES

▶ Fault is intermittent caused by faulty ESP switch or was repaired and HECU memory was not cleared. Go to the
applicable troubleshooting procedure.

NO

▶ Substitute with a known-good ESP switch and check for proper operation. If problem is corrected, replace ESP
switch and then go to "Verification of Vehicle Repair" procedure.

VERIFICATION OF VEHICLE REPAIR EA9AF6A6

Refer to DTC C1101.


BR -124 BRAKE SYSTEM

DTC C1513 BRAKE SWITCH ERROR

COMPONENT LOCATION EEAAFA2B

LJJF503J

GENERAL DESCRIPTION E70CC3A5

The brake light switch indicates brake pedal status to the ABS control unit. The switch is turned on when brake is de-
pressed. The brake light switch is a normally-open contact which runs to battery voltage when active (brake depressed).
When passive (brake not depressed), the cable is grounded via the break light bulbs.

DTC DESCRIPTION E3F3BA54

The brake light signal is a reference to judge driver’s will for braking. ABS ECU monitor open circuit of brake light switch
for normal ABS control. HECU set the warning lamp if either BLS or BS is fault.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -125

DTC DETECTING CONDITION EA7C1E54

Item Detecting Condition Possible cause


DTC Strategy • Open circuit monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode • Inside the ABS control cycle
• Diagnosis mode
• Failure mode
• If both BLS and BS have a same state for predetermined • Open circuit in brake
time, The failure is recognized. switch line
• Outside an ABS/TCS/ESP control, And after normal • Faulty brake light
operation of MCP, If the pressure sensor. switch
Enable
• The signal is higher than 20 bar and BLS is low for 3 sec, • Faulty input stage
Conditions
ECU detect the failureIf the BLS/BS changed more than in HECU
40 times for 5 sec, ECU detect the failure.
• While Vref > 10 KPH, TPS > 5 %, MCP < 7 bar, if BLS
is high over 1 minute, ECU detect the failure.
• Inhibit the TCS/ESP control and allow the ABS/EBD
control. Meanwhile, stop checking the ESP switch
Fail Safe
failure under the TCS/ESP control.
• The ESP warning lamps are activated.

TERMINAL AND CONNECTOR INSPECTION EBC51CC1

Refer to DTC C1101.

SIGNAL CIRCUIT INSPECTION EDBE8C0F

1. Ignition "ON" & Engine "OFF".

2. Press the brake pedal.

3. Measure voltage between the terminal "5, 21" of the HECU harness connector and chassis ground.

Specification :
Brake Light Switch - Approx. B+
Brake Switch - Approx. 0 V

16 15 14
31 30 29 * 28 12 27 * * 9 24 8 23 7 22 6 21 5 4 19 * 18 * 1
<ESP>
* * * * 5. Brake Light Switch
47 46 45 44 43
* 41 40 39 * 37 36 35 34 * 32
21. Brake Switch

V V

LJJF503K
BR -126 BRAKE SYSTEM

4. Is the measured signal waveform within specifications?

YES

▶ Fault is intermittent caused by open harness in brake light switch and brake switch line, faulty brake light switch or
was repaired and HECU memory was not cleared. Go to the applicable troubleshooting procedure.

NO

▶ Check for damaged harness and poor connection in the power harness between the battery terminal(+) and the
terminal "5, 21" of the HECU harness connector . Check for open or blown 15 A stop fuse. Repair as necessary and
then go to "Verification of vehicle Repair" procedure.
▶ If OK, Go to "Component Inspection" procedure.

COMPONENT INSPECTION E1F47329

1. Connect a ohmmeter to the connector of brake light switch, and check whether or not there is continuity when the
plunger of the brake light switch is pushed in and when it is released.
The switch is in good condition if there is no continuity when the plunger is pushed.

2. Is there no continuity when the plunger is pushed?

YES

▶ Fault is intermittent caused by open harness in brake light switch line, faulty brake light switch or was repaired and
HECU memory was not cleared. Go to the applicable troubleshooting procedure.

NO

▶ Substitute with a known-good brake light switch and check for proper operation. If problem is corrected, replace
brake light switch and then go to "Verification of Vehicle Repair" procedure.

VERIFICATION OF VEHICLE REPAIR EE8BF7AF

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -127

DTC C1604 ECU HARDWARE ERROR

COMPONENT LOCATION EB2E9D41

Refer to DTC C1112.

GENERAL DESCRIPTION ECCC0525

The HECU is composed of an ECU (Electronic Control Unit ) and a HCU( Hydraulic Control Unit) , so the HECU hardware
includes all solenoid valves inside the unit as well as the ECU.

DTC DESCRIPTION E7ED66CB

The HECU monitors the operation of the IC components such as memory, register, A/D converter and so on. The HECU
sets this code when the EEPROM data read by the master processor is different from prior data written, or when the
master/slave processor detects abnormal operation in RAM, Status Register, Interrupt, Timer, A/D converter or cycle
time.

DTC DETECTING CONDITION E66CC98E

Item Detecting Condition Possible cause


DTC Strategy • Internal monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode • Inside the ABS control cycle
• Diagnosis mode
• Failure mode

• When the MCU can’ t erase or write a data of the EEPROM. • Faulty HECU
Enable • When the master/slave processor detects abnormal
Conditions operation in RAM, ROM, INTERRUPT, TIMER, A/D
CONVERTER, CYCLE TIME.
• System down. The ABS/EBD/TCS/ESP functions are inhibited.
- The valve relay and all solenoids are prevented
Fail Safe
from being switched on.
• The ABS/EBD/ESP warning lamps are activated.
BR -128 BRAKE SYSTEM

COMPONENT INSPECTION EA811336

1. Ignition "OFF".

2. Engine "ON".

3. Does warning lamp remain On?

YES

▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.

NO

▶ Fault is intermittent caused by faulty HECU or was repaired and HECU memory was not cleared. Go to the appli-
cable troubleshooting procedure.

VERIFICATION OF VEHICLE REPAIR E0467F6A

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -129

DTC C1605 CAN HARDWARE ERROR

COMPONENT LOCATION E5FDEFE7

Refer to DTC C1112.

GENERAL DESCRIPTION E97AF3F3

CAN communication is applied just for ESP( Electronic Stability Program) installed in the vehicle for sending requirement
data, such as torque reduction, the number of fuel cut cylinders, and TCS control requests, to the Engine ECM & TCU. The
Engine ECM performs fuel cut functions according to requests from the ABS ECU and retards ignition timing by torque
reduction requests. The TCU maintains current gear positions during TCS/ESP control time, by not increasing power
which causes a kickdown shift.

DTC DESCRIPTION E72D0C86

The HECU checks the CAN RAM for normal TCS/ESP control, and sets this code if a CAN RAM malfunction is detected.

DTC DETECTING CONDITION EF086471

Item Detecting Condition Possible cause


DTC Strategy • CAN RAM monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode • Inside the ABS control cycle
• Diagnosis mode
• Failure mode
• Faulty HECU
Enable
• CAN Hardware failure.
Conditions
• Inhibit the TCS/ESP control and allow the ABS/EBD
control. Meanwhile, stop checking the ESP switch
Fail Safe
failure under the TCS/ESP control.
• The ESP warning lamp is activated.
BR -130 BRAKE SYSTEM

COMPONENT INSPECTION EE3CEEA0

1. Ignition "OFF".

2. Ignition "ON"

3. Does warning lamp remain On?

YES

▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.

NO

▶ Fault is intermittent caused by short harness in CAN line and/or faulty HECU or was repaired and HECU memory
was not cleared. Go to the applicable troubleshooting procedure.

VERIFICATION OF VEHICLE REPAIR E5BEAD44

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -131

DTC C1611 CAN TIME-OUT EMS

COMPONENT LOCATION EFE0FD95

Refer to DTC C1112.

GENERAL DESCRIPTION E10CCCB2

Refer to DTC C1605.

DTC DESCRIPTION EB9B196A

The HECU checks the CAN communication lines for normal TCS/ESP control, and sets this code if an ECM message is
not received within 500ms. The HECU does not detect this code until 2 seconds after the IG KEY is turned to ON.

DTC DETECTING CONDITION ECA8BF44

Item Detecting Condition Possible cause


DTC Strategy • CAN message monitoring
• Outside the ABS control cycle
• Inside the ABS control cycle
Detect Mode
• Diagnosis mode
• Failure mode
• In case that EMS1 or EMS2 message was not received for • Faulty ECM
Enable • Faulty HECU
more than 500ms within normal voltage condition.
Conditions
- The Monitoring starts 2s after power up.
• Inhibit the TCS/ESP control and allow the ABS/EBD
control. Meanwhile, stop checking the ESP switch
Fail Safe
failure under the TCS/ESP control.
• The ESP warning lamp is activated.

COMPONENT INSPECTION E6539CBF

1. Ignition "OFF".

2. Ignition "ON"

3. Does warning lamp remain On?

YES

▶ Substitute with a known-good ECM and check for proper operation. If problem is corrected, replace ECM and then
go to "Verification of Vehicle Repair" procedure. If NG, replace HECU and then go to "Verification of Vehicle Repair"
procedure.

NO

▶ Fault is intermittent caused by faulty ECM and/or faulty HECU or was repaired and HECU memory was not cleared.
Go to the applicable troubleshooting procedure.

VERIFICATION OF VEHICLE REPAIR E4CF0C2B

Refer to DTC C1101.


BR -132 BRAKE SYSTEM

DTC C1612 CAN TIME-OUT TCU

COMPONENT LOCATION EB6F117B

Refer to DTC C1112.

GENERAL DESCRIPTION EE0A8696

Refer to DTC C1605.

DTC DESCRIPTION EB0FFE43

The HECU checks the CAN communication lines for normal TCS/ESP control, and sets this code if an TCU message is
not received within 500ms. The HECU does not detect this code until 3 seconds after the IG KEY is turned to ON.

DTC DETECTING CONDITION EAF7F0D3

Item Detecting Condition Possible cause


DTC Strategy • CAN message monitoring
• Outside the ABS control cycle
• Inside the ABS control cycle
Detect Mode
• Diagnosis mode
• Failure mode
• In case that TCU message was not received for more than • Faulty TCU
Enable • Faulty HECU
500ms within normal voltage condition.
Conditions
- The Monitoring starts 2s after power up.
• Inhibit the TCS/ESP control and allow the ABS/EBD
control. Meanwhile, stop checking the ESP switch
Fail Safe
failure under the TCS/ESP control.
• The ESP warning lamp is activated.

COMPONENT INSPECTION EBF665A2

1. Ignition "OFF".

2. Ignition "ON"

3. Does warning lamp remain On?

YES

▶ Substitute with a known-good TCU and check for proper operation. If problem is corrected, replace TCU and then
go to "Verification of Vehicle Repair" procedure. If NG, replace HECU and then go to "Verification of Vehicle Repair"
procedure.

NO

▶ Fault is intermittent caused by faulty TCU and/or faulty HECU or was repaired and HECU memory was not cleared.
Go to the applicable troubleshooting procedure.

VERIFICATION OF VEHICLE REPAIR E750A40A

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -133

DTC C1613 CAN WRONG MESSAGE

COMPONENT LOCATION E4ED0EAF

Refer to DTC C1112.

GENERAL DESCRIPTION E036BE9D

Refer to DTC C1605.

DTC DESCRIPTION E5ADA5BB

The HECU checks the CAN communication lines for normal TCS/ESP control, and sets this code if the data received
between the EMS2 and TCU is not the same. The HECU will not detect this code until 2 seconds after the IG KEY is
turned ON.

DTC DETECTING CONDITION E325EEA0

Item Detecting Condition Possible cause


DTC Strategy • CAN message monitoring
• Outside the ABS control cycle
• Inside the ABS control cycle
Detect Mode
• Diagnosis mode
• Failure mode
• In case that TCU message was not received for more than • Faulty ECM
Enable • Faulty HECU
500ms within normal voltage condition.
Conditions
- The Monitoring starts 2s after power up.
• Inhibit the TCS/ESP control and allow the ABS/EBD
control. Meanwhile, stop checking the ESP switch
Fail Safe
failure under the TCS/ESP control.
• The ESP warning lamp is activated.
BR -134 BRAKE SYSTEM

COMPONENT INSPECTION EF552E8B

1. Ignition "OFF".

2. Ignition "ON"

3. Does warning lamp remain On?

YES

▶ Substitute with a known-good ECM and check for proper operation. If problem is corrected, replace TCU and then
go to "Verification of Vehicle Repair" procedure. If NG, replace HECU and then go to "Verification of Vehicle Repair"
procedure.

NO

▶ Fault is intermittent caused by faulty ECM and/or faulty HECU or was repaired and HECU memory was not cleared.
Go to the applicable troubleshooting procedure.

VERIFICATION OF VEHICLE REPAIR EF4F3C6B

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -135

DTC C1616 CAN BUS OFF

COMPONENT LOCATION E1EC7CB1

Refer to DTC C1112.

GENERAL DESCRIPTION E7BC00A6

Refer to DTC C1605.

DTC DESCRIPTION EE354B34

The HECU checks the CAN communication lines for normal TCS/ESP control, and sets this code if CAN BUS OFF status
is detected for more than 100 ms.

DTC DETECTING CONDITION E6FA986F

Item Detecting Condition Possible cause


DTC Strategy • Open or short circuit monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode • Inside the ABS control cycle
• Diagnosis mode
• Failure mode • Open or short circuit
Enable in CAN line
• In case CAN BUS off state continued for more than 100 ms.
Conditions
• Inhibit the TCS/ESP control and allow the ABS/EBD
control. Meanwhile, stop checking the ESP switch
Fail Safe
failure under the TCS/ESP control.
• The ESP warning lamp is activated.

TERMINAL AND CONNECTOR INSPECTION EBDC7C4E

Refer to DTC C1101.


BR -136 BRAKE SYSTEM

SIGNAL CIRCUIT INSPECTION E08FE0DF

1. Ignition "OFF".

2. Measure resistance between terminal "22" of the HECU harness connector and terminal "7" of the HECU harness
connector.

Specification : Approx. 60 Ω

16 15 14
<ESP>
31 30 29 * 28 12 27 * * 9 24 8 23 7 22 6 21 5 4 19 * 18 * 1
7. CAN (HIGH)
* * * *
22. CAN (LOW)
47 46 45 44 43
* 41 40 39 * 37 36 35 34 * 32

LJJF503L

3. Is the measured resistance within specifications?

YES

▶ Fault is intermittent caused by open or short in CAN signal harnessor was repaired and HECU memory was not
cleared. Go to the applicable troubleshooting procedure.

NO

▶ Check for open or short in CAN signal harness between terminal "22" of the HECU harness connector and terminal
"7" of the HECU harness connector. Repair as necessary and then go to "Verification of vehicle Repair" procedure.

VERIFICATION OF VEHICLE REPAIR E84AFAEF

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -137

DTC C2112 VALVE RELAY ERROR

COMPONENT LOCATION EBFE3A37

Refer to DTC C1112.

GENERAL DESCRIPTION EF6ACBFF

The ABS ECU supplies battery power to all solonid valves by way of a valve relay which is controlled by the Electronic
Control UNIT(ECU). The valve relay and all solenoid valves are installed inside the HECU ( Hydraulic and Electronic
Control Unit ).

DTC DESCRIPTION E7AF19B1

ABS ECU monitors voltage of the valve relay to check if ABS ECU can perform ABS control normally. When the valve
relay is switched to ON, the HECU will set this code if the solenoid drive voltage is below permissible voltage ranges for
a period of time. When the valve relay is switched to OFF, the HECU sets this code if the solenoid drive voltage is over
the permissible voltage range for a period of time.

DTC DETECTING CONDITION E70C37ED

Item Detecting Condition Possible cause


DTC Strategy • Battery Voltage Monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode
• Inside the ABS control cycle
Case1 • Diagnosis mode
(Open)
• If the valve relay is switched on and the reference
Enable
voltage of valve relay < 5 ± 0.5 V continuously
Conditions
for 56 ms, the failure is detected. • Open or short
• Initial Check of power supply
Detect Mode circuit (ABS1)
Case2 • Failure mode
• Faulty HECU
(Short or • If the valve relay is switched off and Vvr > 6 ±
Leakage) Enable
Conditions 0.5 V or Vvr < 2.5 ± 0.5 V continuously for 56
ms, the failure is detected.
• System down. The ABS/EBD/TCS/ESP
functions are inhibited.
Fail Safe - The valve relay and all solenoids are prevented
from being switched on.
• The ABS/EBD/ESP warning lamps are activated.
BR -138 BRAKE SYSTEM

MONITOR ACTUATION TEST E90AEF84

1. Connect scantool to Data Link Connector(DLC)

2. Ignition "ON" & Engine "OFF".

3. Select the "Actuation Test" mode on the scantool.

4. Inspect opearating status of all valves with Actuation Test.

Specification : It’s normal if operating sound is heard.

1.5 ACTUATION TEST 02/15

FRONT LEFT VALVE( IN)

DURATION 2 SECONDS

METHOD ACTIVATION

CONDITION IG. KEY ON


ENGINE OFF

PRESS [STRT], IF YOU ARE READY !

STRT
Fig1

Fig 1) Test Condition : Ignition "ON" & Engine "OFF".


Ex) Actuation Test on Front left valve(in)

LJJF503M

5. Do all valves operate normally?

YES

▶ Fault is intermittent caused by poor connection in power harness (ABS1) and/or HECU’s connector or was re-
paired and HECU memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending,
corrosion, contamination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.

NO

▶ Go to next step.

TERMINAL AND CONNECTOR INSPECTION E75919CA

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -139

POWER CIRCUIT INSPECTION E61B7B57

1. Ignition "OFF"

2. Disconnect HECU connector.

3. Ignition "ON" & Engine "OFF".

4. Measure voltage between terminal "25(ESP : 32)" of the HECU harness connector and chassis ground.

Specification : Approx. B+

7 6 5 4 3 2 1 <ABS>
9 8 25. Battery (ABS1)
16 * * * * * *
25 24 23 22 <ESP>
* 20 19 18 * 32. Battery (ABS1)

LJJF503N

5. Is the measured voltage within specifications?

YES

▶ Go to "Ground Circuit Inspection" procedure.

NO

▶ Check for open or short in power harness between battery terminal(+) and terminal "25(ESP : 32) " of the HECU
harness connector. Check for open or blown 40 A ABS1 fuse referring to "Circuit Diagram". Repair as necessary
and then go to "Verification of vehicle Repair" procedure.
BR -140 BRAKE SYSTEM

GROUND CIRCUIT INSPECTION E6CACDD8

1. Ignition "OFF".

2. Disconnect HECU connector.

3. Measure resistance between terminal "8, 24(ESP : 16, 47) " of the HECU harness connector and chassis ground.

Specification : Approx. below 1Ω

<ABS>
9 8 7 6 5 4 3 2 1 8. Ground
16 * * * * * * 24. Ground
25 24 23 22
* 20 19 18 * <ESP>
16. Ground
47. Ground

Ω Ω

LJJF503O

4. Is the measured resistance within specifications?

YES

▶ Go to "Component Inspection" procedure.

NO

▶ Check for damaged harness and poor connection between terminal "8, 24(ESP : 16, 47)" of the HECU harness
connector and chassis ground. Repair as necessary and then go to "Verification of vehicle Repair" procedure.

COMPONENT INSPECTION EDBA6B9D

Refer to DTC C1101.

VERIFICATION OF VEHICLE REPAIR EB5ADFCD

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -141

DTC C2227 EXCESSIVE TEMPERATURE OF BRAKE DISC

COMPONENT LOCATION ED0AC921

Refer to DTC C1101.

GENERAL DESCRIPTION E9FB6CF4

BTCS ( Brake Traction Control System ) is operated when the value ( Wheel acceleration value + speed difference value )
exceeds the specified value when vehicle speed is lower than the 50 Km/h. The BTCS intalled HECU calculates the disc
temperature logically, which is an assumed value, by using the value of Wheel speed, vehicle speed change, CONTROL
MODE and BLS SIGNAL. Assumed disc temperature is used to protect DISC overheating, caused by long-time operation,
which may cause a decrease in brake efficiency.

DTC DESCRIPTION EAEBCECB

If the HECU decides that the disc is over-heated ( above 500 ℃ ), then it turns the ESP lamp ON and inhibits BTCS
operation to protect overheating of the disc. If the calculated temperature becomes lower than specified value ( aprrox.
250 ℃ ), then the HECU turns the ESP lamp OFF and operates the BTCS again.

DTC DETECTING CONDITION ECBB59D5

Item Detecting Condition Possible cause


DTC Strategy • Internal monitoring
• Initial Check
Detect Mode • Outside the ABS control cycle
• Inside the ABS control cycle

• When the calculated temperature of disc is higher than 500 ℃.


Enable • If the calculated temperature drops below 300 ℃, the
controller recovers to normal state. • Faulty HECU
Conditions
• When IGN switched OFF, ECU calculate temperature of disc until
calculated temperature drops below 80 ℃ by BATT1 power.
• Inhibit the TCS/ESP control and allow the ABS/EBD
control. Meanwhile, stop checking the ESP switch
Fail Safe
failure under the TCS/ESP control.
• The ESP warning lamp is activated.
BR -142 BRAKE SYSTEM

COMPONENT INSPECTION E098927E

1. Ignition "OFF".

2. Ignition "ON"

3. Does warning lamp remain On?

YES

▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.

NO

▶ Fault is caused by Faulty HECU or was repaired and HECU memory was not cleared.
▶ The DTC code can be set by excessive TCS/ESP control in normal system status. Go to "Verification of Vehicle
Repair" procedure.

VERIFICATION OF VEHICLE REPAIR E215391C

Refer to DTC C1101.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -143

DTC C2380 ABS/TCS/ESP VALVE ERROR

COMPONENT LOCATION E6BDFBCE

Refer to DTC C1112.

GENERAL DESCRIPTION E3774D8A

The ABS HECU is composed of an ECU (Electronic Control Unit ) and a HCU( Hydraulic Control Unit), so the HECU
hardware includes all solenoid valves inside the unit as well as the ECU. Solenoid valves are switched to ON, OFF by
HECU when the ABS is activated. Solenoid valves function is to increase, decrease or maintain the hydrualic pressure
supplied to a wheel cylinder.

DTC DESCRIPTION EED5BE4F

The HECU monitors the operation of the valves by checking the drive circuit of the solenoid valves, and then sets this
code when the unexpcted drive voltage is detected. For example, the HECU sets the DTC if an unexpected high drive
voltage is detected when the valve relay is switched to OFF. (or unexpected low voltage is detected when the solenoid
valve drive TR is switched to ON).

DTC DETECTING CONDITION E30DDC3D

Item Detecting Condition Possible cause


DTC Strategy • Internal monitoring
• Initial Check
• Outside the ABS control cycle
Detect Mode
• Inside the ABS control cycle
• Diagnosis mode
• If the valve relay is switched ON and corresponding solenoid
driver OFF and the voltage of solenoid < 3.5 ± 0.5 V
Enable continuously for 56 ms, the failure is detected. • Faulty HECU
Conditions • If the valve relay is switched ON and corresponding solenoid
driver ON and the voltage of solenoid > 1.5 ± 0.5 V
continuously for 56 ms, the failure is detected.
• System down. The ABS/EBD/TCS/ESP functions are inhibited.
- The valve relay and all solenoids are prevented
Fail Safe
from being switched on.
• The ABS/EBD/ESP warning lamps are activated.
BR -144 BRAKE SYSTEM

COMPONENT INSPECTION ED7A83D3

1. Ignition "OFF".

2. Ignition "ON"

3. Start and drive vehicle in gear and maintain vehicle speed is approx. 12 km/h or more(7 mph or more)

4. Does warning lamp remain On?

YES

▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.

NO

▶ Fault is intermittent caused by faulty HECU or was repaired and HECU memory was not cleared. Go to the appli-
cable troubleshooting procedure.

VERIFICATION OF VEHICLE REPAIR EFBFE90D

After a repair, it is essential to verify that the fault has been corrected.

1. Connect scantool and select "Diagnostic Trouble Codes(DTCs)" mode.

2. Using a scantool, Clear DTC.

3. Operate the vehicle within DTC Detecting Condition in General Information. (Start and drive vehicle in gear and
maintain vehicle speed is approx. 12 km/h or more(7 mph or more))

4. Are any DTCs present ?

YES

▶ Go to the applicable troubleshooting procedure.

NO

▶ System performing to specification at this time.


ABS (ANTI-LOCK BRAKE SYSTEM) BR -145

DTC C2402 MOTOR - ELECTRICAL

COMPONENT LOCATION EEAF69C1

Refer to DTC C1112.

GENERAL DESCRIPTION E0F8B2D5

The ABS ECU supplies battery power to the electric motor by way of a motor relay which is controlled by the Electronic
Control Unit(ECU). The electric motor pump supplies hydraulic pressure to all wheel brake calipers by operating the piston
inside the pump.

DTC DESCRIPTION EFBA030A

The ABS ECU monitors the pump motor relay or fuse open, open or short in motor or motor lock and then sets this code
if a malfunction is detected.
BR -146 BRAKE SYSTEM

DTC DETECTING CONDITION E17D2E59

Item Detecting Condition Possible cause


DTC Strategy • Battery Voltage Monitoring
Case1 • Outside the ABS control cycle
(Motor Detect Mode • Inside the ABS control cycle
Relay • Diagnosis mode
Open
orMotor Enable • If the motor relay is switched ON and motor voltage < (IGN
Short to Conditions voltage - 4 ± 0.5 V) continued for 56 msec, the failure is detected.
GND)
• Initial Check
Case2 • Outside the ABS control cycle
(Motor Detect Mode
• Diagnosis mode
Open, • Failure mode
Motor
Short to • After 1.8 sec from the time that motor relay is switched
Enable
BATT) OFF, the motor voltage > 4 ± 0.5 V continued for
Conditions
1.8 sec, the failure is detected.
• Open or short
Detect Mode • Outside the ABS control cycle
of power
Case3 • After motor relay is switched OFF, motor voltage is measured. supply circuit
(Motor If the time which motor voltage > 1 ± 0.1 V is less than (ABS2)
Enable
Lock) evaluation time, recheck is performed again for a maximum of • Faulty HECU
Conditions
three times. When the motor voltage is not normal even on
the third recheck, the controller recognizes it as failure.
• Initial Check
Case4 • Outside the ABS control cycle
Detect Mode
(Motor • Diagnosis mode
Fuse • Failure mode
Open) Enable • If the motor relay is switched OFF and motor power supply
Conditions voltage < 4 ± 0.5 V continued for 1 sec, the failure is detected.
• The ABS/TCS/ESP functions are inhibited.
• The ABS/ESP warning lamps are activated and the
EBD warning lamp is not activated.
Fail Safe • Motor failure during the ABS control cycle (Case 1, 4)
:Inhibit the ABS/TCS/ESP control of front wheels, allow the
ABS/TCS/ESP control of rear wheels, and ABS/ESP warning
lamps are switched on at the end of ABS control.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -147

MONITOR ACTUATION TEST E878E3EB

1. Connect scantool to Data Link Connector(DLC)

2. Ignition "ON" & Engine "OFF".

3. Select the "Actuation Test" mode on the scantool.

4. Inspect opearating status of all valves with Actuation Test.

Specification : It’s normal if operating sound is heard.

1.5 ACTUATION TEST 01/15

MOTOR

DURATION 2 SECONDS

METHOD ACTIVATION

CONDITION IG. KEY ON


ENGINE OFF

PRESS [STRT], IF YOU ARE READY !

STRT
Fig1

Fig 1) Test Condition : Ignition "ON" & Engine "OFF".


Ex) Actuation Test on Motor

LJJF503P

5. Does the motor operate normally?

YES

▶ Fault is intermittent caused by poor connection in power harness (ABS1) and/or HECU’s connector or was re-
paired and HECU memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending,
corrosion, contamination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.

NO

▶ Go to "W/Harness Inspection" procedure.

TERMINAL AND CONNECTOR INSPECTION E7F49312

Refer to DTC C1101.


BR -148 BRAKE SYSTEM

POWER CIRCUIT INSPECTION E4702A3D

1. Ignition "OFF"

2. Disconnect HECU connector.

3. Ignition "ON" & Engine "OFF".

4. Measure voltage between terminal "9(ESP : 1)" of the HECU harness connector and chassis ground.

Specification : Approx. B+

7 6 5 4 3 2 1 <ABS>
9 8 9. Battery Voltage (ABS2)
16 * * * * * *
25 24 23 22 <ESP>
* 20 19 18 * 1. Battery Voltage (ABS2)

LJJF503Q

5. Is the measured voltage within specifications?

YES

▶ Go to "Ground Circuit Inspection" procedure.

NO

▶ Check for open or short in power harness between battery terminal(+) and terminal "9(ESP : 1)" of the HECU
harness connector. Check for open or blown 40 A ABS2 fuse referring to "Circuit Diagram". Repair as necessary
and then go to "Verification of vehicle Repair" procedure

GROUND CIRCUIT INSPECTION E1A49E88

1. Ignition "OFF".

2. Check for open or short in power harness between battery terminal(+) and terminal "9(ESP :1)" of the HECU harness
connector. Check for open or blown 40A ABS2 fuse referring to "Circuit Diagram". Repair as necessary and then go
to "Verification of vehicle Repair" procedure.

Specification : Approx. below 1Ω


ABS (ANTI-LOCK BRAKE SYSTEM) BR -149

<ABS>
9 8 7 6 5 4 3 2 1 8. Ground
16 * * * * * * 24. Ground
25 24 23 22
* 20 19 18 * <ESP>
16. Ground
47. Ground

Ω Ω

LJJF503R

3. Is the measured resistance within specifications?

YES

▶ Go to "Component Inspection" procedure.

NO

▶ Check for damaged harness and poor connection between terminal "8, 24(ESP : 16, 47)" of the HECU harness
connector and chassis ground. Repair as necessary and then go to "Verification of vehicle Repair" procedure.

COMPONENT INSPECTION EACFBADB

1. Ignition "OFF".

2. Engine "ON".

3. Start and drive vehicle in gear and maintain vehicle speed is approx. 12 km/h or more(7 mph or more)

4. Does warning lamp remain On?

YES

▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.

NO

▶ Fault is intermittent caused by open or short of power harness (ABS2) and/or faulty HECU or was repaired and
HECU memory was not cleared. Go to the applicable troubleshooting procedure.

VERIFICATION OF VEHICLE REPAIR EDBE8E7B

Refer to DTC C1200.


BR -150 BRAKE SYSTEM

ANTI-LOCK BRAKING SYSTEM


CONTROL MODULE

COMPONENTS EEB9DF59

10

4 6
5
3 2
1

1. Front-right tube 6. MC1


2. Rear-left tube 7. ABS control module connector (25P)
3. Rear-right tube 8. ABS control module(HECU)
4. Front-left tube 9. Damper screw
5. MC2 10. Bracket
LJJF501K
ABS (ANTI-LOCK BRAKE SYSTEM) BR -151

REMOVAL EED88E12 4. Loosen the 3 ABS HECU bracket bolts (A) and 1
nut(B) , then remove HECU and bracket.
1. Turn the ignition switch OFF.
A
2. Pull up the lock(A) of the ABS control unit 25P con-
nector , then disconnect the connector.

A B

AJJF529A

CAUTION
AJJF519A 1. Never attempt to disassemble the HECU.
2. The HECU must be transported and stored in.
3. Disconnect the brake tubes from the HECU by unlock- 3. Never shock to the HECU.
ing the nuts counterclockwise with a spanner.
5. Remove the 3 damper screws and washer , then re-
1.22 ~ 1.63 kgf.m
(11.96 ~ 15.98 Nm, move the bracket.
8.82 ~ 11.79 lb-ft)

INSTALLATION E195F15A

1. Installation is the reverse of removal.

2. Tighten the HECU mounting bolts and brake tube nuts


to the specified torque.

Tightening torque
HECU damper screw :
10.98 ~ 14.02 Nm (1.12 ~ 1.43 kgf.m, 8.1 ~ 10.34 Ib-ft)
HECU bracket mounting bolt, nut :
7.85 ~ 9.8 Nm (0.8 ~ 1.0 kgf.m, 5.79 ~ 7.23 Ib-ft)
LJJF502B
BR -152 BRAKE SYSTEM

FRONT WHEEL SPEED SENSOR

COMPONENTS E7C754E6

1. Front wheel speed sensor connector


2. Front wheel speed sensor

LJJF501L
ABS (ANTI-LOCK BRAKE SYSTEM) BR -153

REMOVAL E26A6E4D 4. Disconnect the front wheel speed sensor connector


(A) , then remove the front wheel speed sensor.
1. Remove the front wheel speed sensor mounting
bolt(A).

A
A

AJJF523A

AJJF532A

2. Remove the front wheel speed sensor bracket(A).

AJJF521A

3. Remove the front wheel guard .

AJJF522A
BR -154 BRAKE SYSTEM

INSPECTION EB1D3836

1. Measure the output voltage between the terminal of


the wheel speed sensor and the body ground.

CAUTION
In order to protect the wheel speed sensor, when
measuring output voltage, a 100 Ω resister must
be used as shown.

Power

DC 12V Ground
Wheel sensor
Vin
Vout

R(100Ω)

Tone wheel

Oscilloscope
Airgap : 0.4 ~ 1.5 mm

LJJF501M

2. Compare the change of the output voltage of the


wheel speed sensor to the normal change of the
output voltage as shown below.

Vhigh

Vlow

0V
t

ARJE503Z

V_low : 0.59 V ~ 0.84 V


V_high : 1.18 V ~ 1.68 V
Frequency range : 1 ~ 2,500 Hz
ABS (ANTI-LOCK BRAKE SYSTEM) BR -155

REAR WHEEL SPEED SENSOR

COMPONENTS EA4ECF1C

1. Rear wheel speed sensor connector


2. Rear wheel speed sensor
LJJF501N
BR -156 BRAKE SYSTEM

REMOVAL E44D6BB4

1. Remove the rear wheel speed sensor connector (A).

AJJF524A

2. Remove the rear seat assembly.(Refer to BD-"rear


seat")

3. Remove the rear wheel speed house trim and rear pil-
lar trim.Disconnect the rear wheel speed sensor con-
nector.
EBD (ELECTRONIC BRAKE-FORCE DISTRIBUTION) BR -157

EBD (ELECTRONIC The proportioning valve, because of a mechanical device,


has limitations to achieve an ideal brake force distribu-
BRAKE-FORCE tion tothe rear wheels as well as to carry out the flexible
DISTRIBUTION) brake force distribution proportioning to the vehicle load
or weight increasing. And in the event of malfunctioning,
driver cannot notice whether it fails or not.
EBD (ELECTRONIC BRAKE-FORCE
DISTRIBUTION) OPERATION E1D47EAC EBD controlled by the ABS Control Module, calculates the
slip ratio of each wheel at all times and controls the brake
The EBD system (Electronic Brake force Distribution) as pressure of the rear wheels not to exceed that of the front
a sub-system of the ABS system is to control the effective wheels.
adhesion utilization by the rear wheels.
If the EBD fails, the EBD warning lamp (Parking brake
It further utilizes the efficiency of highly developed ABS lamp) lights up.
equipment by controlling the slip of the rear wheels in the ADVANTAGES
partial braking range.
- Function improvement of the base-brake system.
The brake force is moved even closer to the optimum and - Compensation for the different friction coefficients.
controlled electronically, thus dispensing with the need for - Elimination of the proportioning valve.
the proportioning valve. - Failure recognition by the warning lamp.

COMPARISON BETWEEN PROPORTIONING VALVE AND EBD

[With P-Valve] [With EBD]


Rear pressure
Rear pressure

Fixed distribution

Ideal distribution Ideal distribution

Cut-in point EBD starting point

Front pressure Front pressure

EJA0032A
BR -158 BRAKE SYSTEM

ESP(ELECTRONIC ESP essentially consists of three assemblies : the sen-


STABILITY PROGRAM) sors, the electronic control unit and the actuators.
SYSTEM The electronic control unit incorporates the technological
experience accumulated in connection with the MGH 25
DESCRIPTION OF ESP E4383D92 system, but has been substantially expanded in terms of
capacity and monitoring concept in order to permit the ad-
Optimum driving safety now has a name : ESP, the Elec- ditional sensor signals and arithmetic operations to be pro-
tronic Stability Program. cessed and converted into corresponding valve, pump and
engine control commands. Two 16-bit processors and one
ESP is based on the MGH 25 ABS Hydraulic System. ESP 8-bit processor, which monitor each other, cooperate to
recognizes critical driving conditions, such as panic reac- handle these requirements.
tions in dangerous situations, and stabilizes the vehicle
by wheel-individual braking and engine control interven- Of course, the stability control feature works under all driv-
tion with no need for actuating the brake or the gas pedal. ing and operating conditions. Under certain driving condi-
tions, the ABS/TCS function can be activated simultane-
ESP adds a further function known as Active Yaw Control ously with the ESP function in response to a command by
(AYC) to the ABS, TCS, EBD and EDC functions. Whereas the driver.
the ABS/TCS function controls wheel slip during braking
and acceleration and, thus, mainly intervenes in the longi- In the event of a failure of the stability control function, the
tudinal dynamics of the vehicle, active yaw control stabi- basic safety function, ABS, is still maintained.
lizes the vehicle about its vertical axis.

This is achieved by wheel individual brake intervention and


adaptation of the momentary engine torque with no need
for any action to be taken by the driver.

Driving force control

E E
ESP ESP
S S
Drift-out Yaw-moment
P P
Control Control

Brake force control

LJCD201A
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -159

DESCRIPTION OF ESP CONTROL


AYC function prevents unstable maneuver of the vehicle.
ESP system includes ABS/EBD, TCS and AYC function. To determine the vehicle maneuver, AYC function uses the
maneuver sensor signals(Yaw Rate Sensor, Lateral Accel-
ABS/EBD function The ECU changes the active sensor eration Sensor, Steering Wheel Angle Sensor).If vehicle
signal (current shift) coming from the four wheel sensors maneuver is unstable (Over Steer or Under Steer), AYC
to the square wave.By using the input of above signals, function applies the brake pressure on certain wheel, and
the ECU calculates the vehicle speed and the acceleration send engine torque reduction signal by CAN.
& deceleration of the four wheels.And, the ECU judges
whether the ABS/EBD should be actuated or not. After the key-on, the ECU continually diagnoses the
system failure. (self-diagnosis)If the system failure is
TCS function prevents the wheel slip of drive direction by detected, the ECU informs driver of the system failure
adding the brake pressure and engine torque reduction via through the BRAKE/ABS/ESP warning lamp. (fail-safe
CANcommunication.TCS function uses the wheel speed warning)
sensor signal to determine the wheel slip as far as ABS
function.

Master cylinder
Pressure sensor
Steering wheel
Angle sensor
Master
cylinder

ESP Yaw-rate &


Wheel speed HECU Wheel speed
lateral acceleration
sensor sensor
sensor

EJQE005M
BR -160 BRAKE SYSTEM

INPUT AND OUTPUT DIAGRAM

Input ESP HECU Output


Active Wheel
speed sensor Hydraulic unit
(FL) -Intergrated with HECU
Active Wheel
speed sensor
(FR)

Active Wheel
ESP Control
speed sensor
Warning Lamp
(RL)
(ABS, EBD, ESP)
Active Wheel
speed sensor
(RR)
ABS Control
Steering Wheel Diagnosis
Angle sensor K-Line

Yaw-rate & Lateral TCS Control


Function Lamp
Acceleration sensor
(ESP)

Master cylinder
pressure sensor
Primary
Secondary Wheel speed
sensor output

Brake switch

CAN ECU
ESP OFF switch
TCU

LJJF501O
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -161

COMPONENTS EEC776A9

5
6

1. Pressure Sensor 4. Front wheel speed sensor


2. Steering angle sensor 5. Yaw rate & Lateral G sensor
3. HECU module 6. Rear Wheel Speed Sensor

LJJF502C
BR -162 BRAKE SYSTEM

ESP OPERATION MODE E4255DB9

ESP HYDRAULIC SYSTEM DIAGRAM

ABS
ESP

MCS MCP

FL RR RL FR

LJJF501P

1. ESP Non-operation : Normal braking.

Solenoid valve Continuity Valve Motor pump TC Valve


IN (NO) OFF OPEN
OFF OFF
OUT (NC) OFF CLOSE

2. ESP operation

Solenoid valve Continuity Valve Motor pump TC Valve


Understeering IN(NO) OFF OPEN
(Only inside of
rear wheel) OUT(NC) OFF CLOSE
ON ON
Oversteering IN(NO) OFF OPEN
(Only outside
of front wheel) OUT(NC) OFF CLOSE
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -163

ESP FUNCTION LAMP (ESP SYSTEM)

The ESP function lamp indicates the self-test and operat-


ing status of the ESP.
The ESP Function lamp operates under the following con-
ESP function ditions :
lamp - During the initialization phase after IGN ON. (contin-
uously 3 seconds).
- When the ESP control is operating. (Blinking - 2Hz)
Parking brake / EBD ABS warning lamp
warning lamp ESP ON/OFF SWITCH (ESP SYSTEM)
ESP OFF warning lamp
The ESP On/Off Switch shall be used to toggle the ESP
LJJF501Q
function between On/Off states based upon driver input.
ABS WARNING LAMP MODULE The On/Off switch shall be a normally open, momentary
contact switch.Closed contacts switch the circuit to igni-
The active ABS warning lamp module indicates the self- tion.
test and failure status of the ABS .The ABS warning lamp Initial status of the ESP function is on and switch toggle
shall be on: the state.
- During the initialization phase after IGN ON. (contin-
uously 3 seconds).
- In the event of inhibition of ABS functions by failure.
- During diagnostic mode.
- When the ECU Connector is seperated from ECU.

EBD/PARKING BRAKE WARNING LAMP MODULE

The active EBD warning lamp module indicates the self-


test and failure status of the EBD. However, in case the
Parking Brake Switch is turned on, the EBD warning lamp
is always turned on regardless of EBD functions. The EBD
warning lamp shallbe on:
- During the initialization phase after IGN ON. (contin-
uously 3 seconds).
- When the Parking Brake Switch is ON or brake fluid
level is low.
- When the EBD function is out of order .
- During diagnostic mode.
- When the ECU Connector is seperated from ECU.

ESP WARNING LAMP (ESP SYSTEM)

The ESP warning lamp indicates the self-test and failure


status of the ESP.
The ESP warning lamp is turned on under the following
conditions :
- During the initialization phase after IGN ON. (contin-
uously 3 seconds).
- In the event of inhibition of ESP functions by failure.
- When driver trun off the ESP function by on/off switch.
- During diagnostic mode.
LJJF501R
BRAKE SYSTEM

HOT IN ON OR START HOT AT ALL TIMES HOT AT ALL TIMES


See Power I/P E/R FUSE &
Distribution JUNCTION RELAY BOX
(Page : SD110-4, BOX
SD110-5) PHOTO 25
ABS-1 ABS-2
ABS STOP LP 40A 40A
10A 15A
See Passenger
Compartment
Fuse Details
(Page : SD120-9)
4 I/P-H 1 10 I/P-F
See Illuminations
(Page : SD941-1)
R
Y P P
1 E39
2 3 M13 6 M41 STOP
ESP STEERING SWITCH
SWITCH ON/START Input
OFF ANGLE PHOTO
ILL. PHOTO 52 SENSOR 39
ESP Control Module
ON PHOTO 56
P 2 E39 W W
5 6 M13 3 5 4 2 M41
R/O
B/O W/B L/B Gr Br/B P/B
2 EM01 6 9 7 10 EM02 R/O R/O
See Illuminations
(Page : SD941-1) PHOTO 52 PHOTO 52
W/B L/B Gr Br/B P/B See Stop Lamps
(Page : SD927-1)
27 8 39 40 31 4 5 1 32 E17
ESP
ESP Switch ST1 STN ST2 Ground ON/START Stop Lamp CONTROL
"ON" Input Switch Battery Voltage MODULE
Steering Angle Sensor
PHOTO 21
Ground
EC8B231B

Power Signal Power Signal Power Signal Power Signal


46 15 45 30 44 14 43 29 16 47 E17
B W R L
CIRCUIT DIAGRAM - ESP(1)

G O B Y 13 14 11 12 EF01
PHOTO 80 B B
B W R L
1 2 E49 1 2 E50 1 2 F31 1 2 F32
FRONT WHEEL FRONT WHEEL REAR WHEEL REAR WHEEL
SENSOR LH SENSOR RH SENSOR LH SENSOR RH
PHOTO 22 PHOTO 22 PHOTO 54 PHOTO 56
P S P S P S P S G01 G02
PHOTO 48 PHOTO 48
BR -164
BR -165

LJJF501S
HOT IN ON OR START HOT WITH MAIN RELAY ON
See Power I/P See Power I/P
Distribution JUNCTION Distribution JUNCTION
(Page : SD110-5) BOX (Page : SD110-2) BOX
CLUSTER PHOTO SNSR PHOTO
10A 62 10A 62
See Passenger
Compartment
Fuse Details
(Page : SD120-1)
ECM
11 I/P-G
MULTIPURPOSE PHOTO
DATA LINK CHECK 62
P CONNECTOR CONNECTOR See Stop Lamps
11 M09-1 1 M33 18 E16 64 C01(M/T) (Page : SD927-1)
PHOTO 25 PHOTO 15 20 C01-1(A/T) W
INSTRUMENT
CLUSTER
PHOTO 55 R
ESP
ABS ESP OFF W W Br
3 1 E39
( ABS ) ESP ESP
OFF STOP LAMP
SWITCH
15 EM02 9 EC01 PHOTO 52
PHOTO 25
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM

PHOTO 27
12 M09-3 1 2 M09-1 4 2 E39
PHOTO
B/O 62 Y/B P/O R/O
W Br
5 EM02 19 17 EM01 R/O
PHOTO PHOTO 55 See Stop Lamps
G 62 Y/B P/O (Page : SD927-1)
18 35 34 19 6 21 E17
ESP
K-Line Vehicle Stop Lamp CONTROL
Speed Input Switch MODLUE
ESP IND. Control
PHOTO
YAW Sensor LG YAW Sensor YAW Sensor 6
Signal Sensor Power Ground CBIT Signal Power Ground CAN Low CAN High
41 9 36 23 24 12 37 28 22 7 E17
Gr/B P/B R/O B/O G/O
4 2 5 6 3 EF01 L R B L R
CIRCUIT DIAGRAM - ESP(2)

PHOTO 81
Gr/B Y/B R/O B/O G/O
1 2 3 4 6 F10 1 2 3 E31
G-YAW PRESSURE
YAW LAR.G VCC GND SELF SENSOR VOUT VCC GND SENSOR
RATE TEST
PHOTO PHOTO See Data Link Details
61 61 (Page : SD200-1)
BR -166 BRAKE SYSTEM

ESP CONNECTOR INPUT/OUTPUT E7E349BA

Connector Terminal
Specification Remark
No Description
4 IGNITION1(+)
32 POS.BATTERY.(SOLENOID) Max leakage current : I < 0.8 mA
Operating voltage range:
9.5 ± 0.5 V < V < 16.5 ± 0.5 V
1 POS.BATTERY.(MOTOR) Rush current : I < 100 A
Max current : I < 30 A
Max leakage current : I < 0.2 mA

16 GROUND Rated current : I <300 mA


Max. current: I < 30 A

47 PUMP MOTOR GROUND Rush current : I < 100 A


Max current : I < 30 A
YAW &amp;amp; LATERAL G
23 Rated current : I <65 mA
SENSOR GROUND
MASTER PRESSURE SENSOR
28 Rated current : I <10 mA
GROUND
STEERING ANGLE SENSOR
31 Rated current : I <100 mA
GROUND

37
MASTER PRESSURE SENSOR Max Output current : I < 10 mA
POWER Max Output voltage : 4.9 V ≤ V ≤ 5.1 V

36 YAW SENSOR POWER Max Output current : I < 65mA


Max Output voltage : 4.9V ≤ V ≤ 5.1V
5 BRAKE LIGHT SWITCH Input voltage low: 0 V ≤ V ≤ 3.0 V
21 BRAKE SWITCH Input voltage High: 7.0 V ≤ V ≤ 16.0 V

SENSOR FRONT RIGHT Max current : I < 2 mA


6 External pull up resistance :10 KΩ < R
OUTPUT
Output duty :50 ± 20 %
18 ABS/EBD W/LAMP DRIVE
34 ESP W/LAMP DRIVE Max. current: I < 200 mA
Max. output low voltage: V < 1.2 V
35 ESP F/LAMP DRIVE

Input voltage low:0 V ≤ V ≤ 3.0 V


27 ESP ON/OFF SWITCH Input voltage High: 7.0 V ≤ V ≤ 16.0 V
Max input current:I <10 mA
22 CAN BUS LINE(LOW)
Max. current : I < 10 mA
7 CAN BUS LINE(HIGH)
46 SENSOR FRONT LEFT POWER
SENSOR FRONT RIGHT
45 Output voltage : IGN (V) ± 1 V
POWER
Output current : Max 30 mA
44 SENSOR REAR LEFT POWER
43 SENSOR REAR RIGHT POWER
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -167

Connector Terminal
Specification Remark
No Description
15 SENSOR FRONT LEFT SIGNAL
SENSOR FRONT RIGHT Input current LOW : 5.9 ~ 8.4 ㎃
30 Input current HIGH :11.8 ~ 16.8 ㎃
SIGNAL
Frequency range :1 ~ 2000 Hz
14 SENSOR REAR LEFT SIGNAL Input duty : 50 ± 20 %
29 SENSOR REAR RIGHT SIGNAL
STEERING ANGLE SENSOR
8
PHASE 1 Input duty (ST1, ST2): 50 ± 10
Phase difference (ST1, ST2):
STEERING ANGLE SENSOR
40 2 ± 0.6 deg
PHASE 2
High voltage: 3.0 V < V < 4.1 V
STEERING ANGLE SENSOR Low voltage: 1.3 V < V < 2.0 V
39
PHASE N

MASTER PRESSURE SENSOR Sensor Input Voltage : 0 V ≤ V ≤ 5.0 V


12 Zero offset Voltage : 0.5 V ± 0.15 V
SIGNAL
Input current :Max 2 mA

9 LATERAL G SENSOR SIGNAL Sensor Input Voltage :0 V ≤ V ≤ 5.0 V


Zero offset Voltage : 2.5 ± 0.1 V

41 YAW SENSOR SIGNAL Sensor Input Voltage :0 V ≤ V ≤ 5.0 V


Zero offset Voltage : 2.5 ±0.1 V
Input voltage
IL(V) < 0.3 IGN (V)
IH(V) > 0.7 IGN (V)
19 DIAGNOSIS INPUT/OUTPUT
Output voltage
OL(V) < 0.2 IGN (V)
OH(V) > 0.8 IGN (V)
BR -168 BRAKE SYSTEM

FAILURE DIAGNOSIS EC4A44FB COUNTERMEASURES IN FAIL

1. In principle, ESP and TCS controls are prohibited in 1. Turn the system down and perform the following ac-
case of ABS failure. tions and wait for HECU power OFF.

2. When ESP or TCS fails, only the failed system control 2. Turn the valve relay off.
is prohibited.
3. Stop the control during the operation and do not exe-
3. However, when the solenoid valve relay should be cute any until the normal condition recovers.
turned off in case of ESP failure, refer to the ABS
WARNING LAMP ON
fail-safe.
1. ABS warning lamp turns on when ABS is fail.
4. Information on ABS fail-safe is identical to the fail-safe
in systems where ESP is not installed. 2. ESP operation lamp turns on and ESP OFF warning
MEMORY OF FAIL CODE lamp blinks when ESP is fail.

1. It keeps the code as far as the backup lamp power is When power voltage and valve relay voltage are abnormal,
connected. (O) input/output related failure judgment is not made.

2. It keeps the code as far as the HCU power is on. (X)

FAILURE CHECKUP

1. Initial checkup is performed immediately after the


HECU power on.

2. Valve relay checkup is performed immediately after


the IG2 ON.

3. It executes the checkup all the time while the IG2


power is on.

4. Initial checkup is made in the following cases.

1) When the failure is not detected now

2) When ABS and ESP are not in control.

3) Initial checkup is not made after ECU power on.

4) If the vehicle speed is over 5 mph(8 km/h) when


the brake lamp switch is off.

5) When the vehicle speed is over 24.8 mph(40


km/h).

5. Though, it keeps on checkup even if the brake lamp


switch is on.

6. When performing ABS or ESP control before the ini-


tial checkup, stop the initial checkup and wait for the
HECU power input again.

7. Judge failure in the following cases.

1) When the power is normal.

2) From the point in which the vehicle speed


reaches 4.9 mph(8 km/h) after HECU power on.
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -169

YAW-RATE SENSOR AND


G-SENSOR

DESCRIPTION E73B8D8C

1. The yaw-rate & lateral G sensor is applied for the


ESP system.

2. The yaw-rate is the angular velocity, when a vehicle


turns a corner, and the lateral G is the acceleration to
move a vehicle out of the way when cornering.

3. The sensor is located in the front passenger seat


lower floor on vehicle.
AJJF520A

SPECIFICATIONS

Description Specification Remarks


Operating voltage 4.75 ~ 5.25 V
Current consumption Max. 65 mA
Output voltage range 0.5 ~ 4.5 V
Operating temperature -40 ~ 85 C
Measurement range -75 ~ 75 /sec
Output voltage range 0.5 ~ 4.5 V
Yaw-rate sensor Sensitivity 26.67 mV ( /sec.)
Zero rate output 2.5 V
Frequency response 10 Hz
Measurement range -1.5 ~ 1.5 g
Output voltage range 0.5 ~ 4.5 V
Lateral G sensor Sensitivity 1.33 V/g
Zero rate output 2.5 V
Frequency response 50 Hz
BR -170 BRAKE SYSTEM

OUTPUT CHARACTERISTIC

[Yaw-rate]
Vcc=5 (V)
5

4.525

4
Zerorate = 2.5 (V
Sensitivity= 27 (mV/deg/s)

3
Output(V)

2.5

0.475

-75 -50 -25 0 25 50 75

Yaw-rate (deg/s)

EJQE206A

[Lateral G.]
Vcc = 5 (V)
5

4.54

Zerorate = 2.5 (V)


Sensitivity = 1.33 (V/G)
Output(V)

2.5

out 2

0.46

-2 -1.7 -1.5 -1 -0.5 0 0.5 1 1.5 1.7 2

Lateral G. (G)

LJJF502D
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -171

EXTERNAL DIAGRAM

Yaw-rate 1 41

3 2 1 Lateral G. 2 9

6 4
* Sensor Power 3 36

GND 4 23

Self-test 6 24

[Yaw-rate & Lateral G sensor's connector]


Yaw-rate & ESP HECU

Lateral G. sensor

LJIF502C

REPLACEMENT E73B8D9C

1. Remove the passenger seat. (refer to BD- "seat")

2. Remove the floor console. (refer to BD- "console")

3. Remove the center pillar upper trim.(refer to BD-"inte-


rior trim")

4. Remove the front , rear lower scuff trim(refer to


BD-"interior trim")

5. Clerar away the floor mat.

6. Disconnect the yaw rate & lateral G sensor connector.

7. Remove the mounting bolts(A).

LJJF538K
BR -172 BRAKE SYSTEM

MASTER CYLINDER PRESSURE


SENSOR

DESCRIPTION EE2AC6B4

The pressure sensor(A) is connected to the master cylin-


der, when ESP is on operation, detecting the brake pres-
sure in order to sense the user’s will to brake a vehicle.The
pressure sensor(A) consists of two ceramic discs, one is
fixed and the other movable, so that changes the distance A
of the two discs.(Max. measurable pressure is 200bar.)

LJJF501T

SPECIFICATIONS

Item Specification Remark


Supply voltage 4.75 V ~ 5.25 V
Supply current less than 15 mA
Operating temperature -40 C ~ 125 C
Measurement pressure range 0 ~ 200 bar
Max. pressure limit 350 bar
Zero rate output 0.5 V
Output range 0.5 ~ 4.4 V

CIRCUIT DIAGRAM

Sensor Signal 1 12
Power 2 37
GND 3 28
[Pressure sensor] [ESP HECU]
1
3 2

[Pressure sensor's connector]

LJIF502D
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -173

OUTPUT CHARACTERISTIC

Vcc=5 (V)
5

4.4
4
Zero rate = 2.5 (V)
Sensitivity = 23 (mV/bar)
Output(V)

0.5
0
0 1 50 100 150 171
Pressure(bar)
EJQE206C

REPLACEMENT E74B8D8C

1. Remove air cleaner mounting bolts (B) from the air


cleaner mounting bracket and air cleaner body(A).

LJJF501T

AJJF509A

2. Disconnect the pressure sensor(A).


BR -174 BRAKE SYSTEM

ESP SWITCH

DESCRIPTION E3CFAAC7

1. The ESP OFF switch is for the user to turn off the ESP
system.

2. The ESP OFF lamp is on when ESP OFF switch is


engaged.

INSPECTION E9929FC0

1. Remove the ESP OFF switch from the switch panel


on the center cover of the floor console assembly.

LJJF501U

2. Check the continuity between the switch terminals as


the ESP OFF switch is engaged.

Terminal
2 5 6 3
Function

ON

OFF

LJJF504B
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -175

STEERING WHEEL ANGLE calculates the steering angle by the pulse from the steering
SPEED SENSOR angle sensor.

DESCRIPTION E7AAC47B

The steering angle speed sensor detects the angle of


the steering wheel in order to which direction a user
chooses.The sensor is detached on the MPS(Mutil-Func-
tion Switch) under the steering wheel.

MEASUREING PRINCIPLE

The split of the steering angle sensor detects a steering


angle of the steering wheel by a ON/OFF pulse caused
by whether or not the LED lights go through the hole of
the split, rotating as the steering wheel revolves. There
are three LEDs, two(ST1, ST2) for detecting a steering
direction, and the other for the neutral position.The HECU LJJF501V

SPECIFICATION

Description Specification
Operating voltage 9 ~ 16 V
Operating temperature -30 ~ 75 ℃
Current consumption Max.100 mA
Steering angle velocity Max. ± 1500 /sec
Voltage(high) 3.0 V ~ 4.1 V
Voltage(low) 1.3 V ~ 2.0 V
Pulse duty 40 ~ 60 %

CIRCUIT DIAGRAM( STEERING WHEEL SPEED


ANGLE SENSOR)

Steering angle sensor ESP HECU

12V IG 6

STN 5 39
1.2KΩ
ST1 3 8

ST2 4 40

GND 2 31

6 5 4 3 2
*

LJJF504C
BR -176 BRAKE SYSTEM

OUTPUT CHARACTERISTIC

H
ST 1
L

H
ST 2
L

H
ST N
L

ARCD204A
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -177

No. INPUT OUTPUT Steering direction Remark


ST1 L L
Right
ST2 L H
1
ST1 L H
Left
ST2 L L
ST1 L L
Left
ST1 H L
2
ST1 L H
Right
ST2 H H
ST1 H H
Left
ST2 L H
3
ST1 H L
Right
ST2 L L
ST1 H H
Right
ST2 H L
4
ST1 H L
Left
ST2 H H

REPLACEMENT E75B8D8C 4. Remove the steering angle sensor from the clock
spring.
1. Remove the driver airbag.(Refer to RT group )

2. Remove the steering wheel and steering wheel col-


umn cover(Refer to ST group ).

3. Disconnect the clock spring and horn connector, then


remove the clock spring.

LJJF501V

ARJF102F