GENERAL ‘SPECIFICATIONS SPECIAL TOOLS: TOUBLESHOOTING OPERATION AND LEAKAGE CHECK” BRAKE SYSTEM BRAKE BOOSTER COMPONENTS TESTS REMOVAL INSTALLATION BRAKE LINE COMPONENTS INSPECTION REMOVAL INSTALLATION « BRAKE SYSTEM BLEEDING BRAKE PEDAL COMPONENTS ADJUSTMENT INSPECTION REMOVAL INSTALLATION MASTER CYLINDER ‘COMPONENTS REMOVAL... INSTALLATION DISASSEMBLY INSPECTION REASSEMBLY PROPORTIONING VALVE DESCRIPTION INSPECTION FRONT DISC BRAKE COMPONENTS INSPECTION OF BRAKE PAD REMOVAL INSTALLATION s.. INSPECTION OF BRAKE DISC REAR DISC BRAKE COMPONENTS INSPECTION OF BRAKE PAD REMOVAL INSTALLATION. INSPECTION OF BRAKE DISC REAR DRUM BRAKE COMPONENTS -..-. INSPECTION OF BRAKE PAD REMOVAL INSTALLATION INSPECTION OF BRAKE DISC PARKING BRAKE SYSTEM COMPONENTS ‘ADJUSTMENT PARKING BRAKE REMOVAL INSTALLATION rake System BR-2 BR-6 BR-7 BR-8 BR-9 BR-10 BR-12 BR-13 BR-14 BR-15 “BR -15 BR-15 BR-16 8R-18 “BR -19 BR-21 BR -21 BR -22 BR -23 “BR -24 BR -25 BR -25, BR -26 BR-27 BR 28 BR 28 BR-29 BR 31 BR-3t BR -32 BR 34 BR -38 BR 37 BR-37 BR -38 BR -39 BR 41 BR -42 BR -43 BR -45 BR-A7 BR -48 BR -49 BR-51 BR-52 PARKING BRAKE SWITCH INSPECTION ABS (ANTI-LOCK BRAKE SYSTEM) DESCRIPTION (OPERATION COMPONENTS HYDRAULIC SYSTEM DIAGRAM CIRCUIT DIAGRAM TROUBLESHOOTING BLEEDING OF BRAKE SYSTEM ANTI-LOCK BRAKING SYSTEM CONTROL MODULE ‘COMPONENTS HECU EXTERNAL DIAGRAM CIRCUIT DIAGRAM. HECU CONNECTOR INPUT/OUTPUT REMOVAL INSTALLATION ANT-LOCK BRAKING SYSTEM WHEEL ‘SPEED SENSOR ‘COMPONENTS DESCRIPTION ‘SPECIFICATIONS. REMOVAL INSPECTION G- SENSOR COMPONENTS INSPECTION BR-53 BR -54 BR -54 BR -665 BR -67 BR -68, 8R-70 BR-134 BR-136 “BRST BR-138 BR-140 BR142 BR-142 BR-143 CBRad BR-144 BR-145 BR-146 BR-147 BR-148 ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM COMPONENTS HECU EXTERNAL DIAGRAM DESCRIPTION OPERATION CIRCUIT DIAGRAM HECU CIRCUIT DIAGRAM... HECU CONNECTOR INPUTIOUTPUT TROUBLESHOOTING STEERING WHEEL ANGLE SPEED SENSOR DESCRIPTION SPECIFICATIONS... CIRCUTT DIAGRAM ‘OUTPUT CHARACTERISTIC. ‘YAW-RATE SENSOR. DESCRIPTION... ‘SPECIFICATIONS. ‘OUTPUT CHARACTERISTIC EXTERNAL DIAGRAM MASTER CYLINDER PRESSURE SENSOR DESCRIPTION SPECIFICATIONS. CIRCUIT DIAGRAM OUTPUT CHARACTERISTIC ESP SWITCH DESCRIPTION INSPECTION 1 BR149 R-150 BRIS BR-154 BR-157 "I BR-159 BR-160 “ BR-162 'BR-168 R16 “BR-166 BR-167 BR-168 “BRo168 BR-169 R170 BRAT BRA71 BRAT BR-172 BR-173 BR-173Bi BRAKE SYSTEM GENERAL SPECIFICATIONS — caasvace ~ tem ee Specification | Master oylinder | | Type Tandem type 1.D. mmtin)(CBS/ABS) 22.22(0.875) Piston stroke mmtin) 3.1(1.22) Output port(CBS/ABS) 4port2port Fluid level waring sensor Provided Proportioning valve ct Shen prebuetSpt ron) sro ~ Decompression ratio Caney Brake booster - Type Vacuum Effective dia. mm(in.) 849 in Boosting ratio. st Front brake(Disc) Disc thickness Pad thickness Cylinder type Cylinder LD. Rear brake(Drum) Type Drum 1D, Brake lining thickness Clearance adjustment Floating type with ventilated disc, 280 mm 472 mm (6.77 in.) 26 mm 141 mm single piston {60 mm (2,36 in.) Leading trailing drum 228.6 mm (9.0 in.) 45mm (0.17 in.) Automatic Rear brake(Disc) Type Floating type with solid disc Disc 0.0, (2wo/4WD) 262/284 mm (10.34/11.18 in.) Disc thickness 40 mm (0.39 in.) Pad thickness 40 mm (0.39 in.) | Cylinder type single piston | Oylinder 1.0 | 34mm (1.34 in.) Parking brake Type V type Actuation Mechanical brake acting on rear wheels Cable arrangement 0. 1=Outer Diameter L.D=Inner Diameter W note CBS : Conventional Brake System LeverGENERAL BR3 SPECIFICATION (ABS & TCS) PART Tew ~ STANDARD VALVE REWARK 4 channel 4 sensor System Paes a 7 Slay | ABS system: ABS & EBD control Type Roam FTCS system: ABS & EBD control I ar pe (Both Brake and Engine control) Operating voltage 10V~16V(06) Operating temperature | -40~110°C(-40-230°F) | Motor power 180W = | Hecu nr — Ghateut PUMP orice 0.5mmn(0.0197 in.) = cand | Accumul | ipa MCS: 2.5ee/MCP2,5cc LPA; Low pressure accumulator Electroni | ator semis Control | capacity [HPA 0.1306 HPA‘High pressure accumulator bad Font. 2 0.71mm Inlet valve | (0.0280in.) (NO) Rear: 9 0.315mm_ NO valve: 4 va (0.0124 in.) | — Font @ 0.56mm Outlet vaive | (0.0220 in.) (no) Rear. 0 0.355mm NC valve: 4 : (0.0140 in.) . Traction Control valve it raliot preseure 4120bar with TCS z ‘ABS WIL: ABS failure | Waring | Operating voltage 12v Brake WIL: Parking, brake lamp oil, EBD failure Current consumption TCS WIL: TCS failure Internal reistance 198541100 2345°C whee! | Output range 16-2000H2 Sees. Min: Vottage peak See) Max.air gay sensor ge peal 200mVp p{1000HZ) gap (CBS) . | airgap 0.2~1.3mm | Supply voltage : Operating temperature |-40~120°C | Active Return spring Bushing | Brake pedal TORQUE : Nm (Kgf-cm, Ibf-ft)BRAKE SYSTEM BR. BRAKE PEDAL BRAKE SWITCH ADJUSTMENT PI 1 EBCAIca0 EDAL HIGET Disconnect the brake swithch connector, loosen the brake switch locknut (A), and bake off the brake swi- tch (B) unil itis no longer touching the brake pedal. Life up the carpet. At the insulator cutout, measure the pedal heigh (C) from the middle of the lefe-side center of the pedal pad (D). Standard pedal height( with carpet removed): 163mm(6. tin) Loosen the pushrod locknut (A), and screw the push- rod in or out with pliers unti 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 (160-220 kgtem, 11.8-162 tt)BR, BRAKE SYSTEM 10 BRAKE SWITCH CLEARANCE PEDAL FREE PLAY ‘Screw in the brake switch untl its plunger is fully depressed {threded end (A) touching the pad (B) on the pedal arm) then brake off the switch 3/4 turn to make 0.5~1.0mm(0.0- ae 197-0.0394 in.) of clearance between the brake switch connector. Make sure that the brake lights go off when the Free Play: 38mm (0.10.31 in.) pedal is released. 1. With the engine of, inspect the pedal free play (A) ‘on the pedal pad (B) by pushing the pedal by hand 2. Ifthe pedal free play is out of specification, adjust the brake switch (C). If the pedal free play is insufficient, it may result in brake drag.BRAKE SYSTEM BR.21 INSPECTION EECBEDOA Check the blushing for wear. Check the brake pedal for bending or twisting Check the brake pedal return spring for damage, Check the stop lamp switch 4) Connect a circuit tester to the connector (1-2ter- 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 itis re- leased 2) The stop lamp switch is in good condition if there is no continuity when plunger is pushed. eceaz00 REMOVAL, - E1B4F FAS Remove the lower crash pad.(reference to BD-"cras- hped’) Pull down steering culum shafe after removing 4 bo- Its Remove the stop lamp switch connector (A). Remove the shift lock cable (A/T). Remove the pin and snap pin. Remove the brake pedal member assembly mounting nuts and then remove the brake pedal assembly.BR.22 BRAKE SYSTEM INSTALLATION o;226a3 41, Installation is the reverse of removal. & caution Coat the inner surface of the bushings with the specit- ied grease. 2. Before inserting the pin, apply the specified grease to the joint pin. 3, Install the nuts with speacified torque, when installing the brake pedal. TORQUE Nin(kgf-om.lbfft); 13~16(1.3~1.6, 9.6~11.8) 4, Adjust the brake pedal height and free play. 5, Install the stop lamp switch.BRAKE SYSTEM BR-23 MASTER CYLINDER COMPONENTS — exzescae GS Brake fluid fiter Reservoir Ores Primary piston assembly Grommet Oyfinder pin ass} Master cylinder body (cas) Proportioning valve, 35 ~ 55 (850-550, 26-40) TORQUE : Nm (Kgf-cm, Ibf-ft)BR24 REMOVAL esico1es W nore Do not spil 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) and air cleaner body (A) from the air cleaner mounting bracket. BRAKE SYSTEM Disconnect the brake fluid level switch connectors (A), and remove the reservoir cap (B). Remove the brake fluid from the master cylinder res- ervoir (C) with a syringe. Disconnect the brake lines (A) from the master cylin- der. To prevent spills, cover the hose joints with rags or shop towels. Rh (130-170 kgttm 8 86-1255 Ibfft)8~12Nm (0-120 kgf-tm 59-8.91bt) Remove the master cylinder mounting nuts (B) and washers, Remove the master cylinder(C) from the brake boos- ter (D). Be careful not to bend or damage the brake lines when removing the master cylinder.BRAKE SYSTEM BR.25 nen INSTALLATION earoasac DISASSEMBLY e7e3c030 1. Install the master cylineder on the brake booster with 1. Remove the reservoir cap and drain the brake fluid 2 nuts. into a suitable container. 2. Connect 2 brake tubes and the brake fluid level sen- 2. Remove the fluid level sensor. sor connector. 3. Remove the reservoir from the master cylinder after ‘mounting screw (A). 3, Filthe brake reservoir with the brake fluid and bleed excereo the brake system.BR 6 BRAKE SYSTEM 4, Remove the proportioning valves (A) - CBS only. 5. Remove the retainer ring by using the snap ring pliers then remove the primary piston assembly. 6. Remove the pin with the secondary piston pushed ‘completely using a screwdriver. Remove the second- ary piston assembly -ABS/TCS/ESP. i Nore Do not disassemble the primary and' secondary piston assembly. INSPECTION czcaoccr 4. Check the master cylinder bore for rust or scratch. 2. Check the master cylinder for wear or damage. If ne- cessary, clean or replace the cylinder. Q caution + Ifthe cylinder bore is damaged, replace the ma- ster cylinder assembly. + Wash the contaminated parts in alcoholBRAKE SYSTEM BR27 REASSEMBLY cxesiaas 4 Press the piston with a screwdriver and install the re~ tainer ring, 1, Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets, Carefully insert the springs and pistons in the proper direction, 5. Mount two grommets. 6. Install the reservoir on the cylinder. Tightening torque : 1.5~3.0 N-m(15~30kg'om, 1.22.1 3. Press the piston with a screwdriver and install the cy- IDFR) linder pin,BRAKE SYSTEM BR-28 3. With he brake applied, measure the front pressure PROPORTIONING VALVE ih ne broke appt DESCRIPTION If the measured pressures are within the specified EATEAFD2 range as illustrated, the proportioning valve is good Do not disassemble the proportioning valve. The proporti- ning valve makes the ideal distribution of fluid pressure to the front and rear brakes to prevent the brakes from skid- ding in the event of rear whee! lock up and to obtain a hig- her brake efficiency within the range of service brake app- lication. 2 5 INSPECTION — oossoo0 hi ge 41. Remove the front brake tube (B) and rear brake tube 33 (C) from the master cylinder (A), i 2” 3 2. Connect two pressure gauges (D); one to the output valve of the front (B) and rear (C) brake 0 a B Output of master conlndar(kofem*) 4. Reconnect the brake lines in their original positions and bleed the system, © nore This table shows characteristics of the proportioning valve as the pressure increases. Rear Front | inder (Output of proportioning (Output of master cylinder ave) | A 26 kgiom? A 26 kglem? oe (2.55MPa, 370psi) (2.58MPa, 370psi) W nore B: 80 kglom* B: 40.623 kgicm* (7.84MPa, 1137psi) (982 03MPe,§77 Be sure to bleed the system after connecting the pres- ia ‘sure gauges.BRAKE SYSTEM BR-29 FRONT DISC BRAKE COMPONENTS easaeces Brake caliper Guide rod bolt Brake disc (220-320, 16.2-23.6) oC es NX Indicator \& ; Brake pads Brake pad shims TORQUE: N-m (kgf-cm, Ibf-ft)BR-30 BRAKE SYSTEM Guide rod bolt 22-82 (220-320, 16.2-23.68) Guide rod Bleeder screw Caliper mounting bott 65-75 (650-750, 48-55) Caliper bracket Inner shim Brake pad ‘Outer shim Pad retainer TORQUE : Nm (kgf-cm, Ibf-ft)BRAKE SYSTEM INSPECTION OF FRONT DISC BRAKE 41, Check the brake pad thickness throgh the caliper body inspection hole Pad thickness ‘Standard value : 11.0 mm (0.43 in.) Service limit : 2.0 mm (0.0787 in.) & caution + Ifthe pad lining thickness is out of specification, left and right pads must be replaced as a comp- lete set, + When the thickness difference between the left pad right pad is large, check the sliding condition Of the pistion and the guide rod. BR31 REMOVAL cosere79 PAD EEAQS170 : Raise the rear of the vehicle and make sure itis sec- urely supported. Remove the rear wheel, Release the parking brake. Remove the two guide rod bolt (B) and support the caliper assembly with a piece of wire so that it does not hang from the brake hose.BRAKE SYSTEM nena Rec ae ‘4 Remove the pad shims (A), pad retainers(@), and pads INSTALLATION. eracrosi (©). 1. Install the pad retainers (A) on the caliper bracket(B) e008 2. Check the foreign material at the pad st the back of the pads (B). : Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.BRAKE SYSTEM BR-33 3 Install the brake pads (B) and pad shims (A) correct- ly. Install the pad with the wear indicator (C) on the inside, Ifyou 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 (A) 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 dow- n. Pivot the caliper down into position. Being careful not to damage the pin boot, install the guide rod bolt (B) and torque it to proper specification. 8 22.92 Nm (220-920kg-em, 162-236 16) W nore Insert the piston in the cylinder using the special tool (09581-11000) 6. Depress the brake pedal several times to make sure the brakes work, then test-drive, W nore Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been re- placed as a set. Several applications of the brake will restore the normal pedal stroke. 7. After installation, check for leaks at hose and line jo- ints or connections, and retighten if necessary.BR34 BRAKE SYSTEM On INSPECTION exo7ears FRONT BRAKE DISC THICKNESS CHECK 4, Remove all rust and contramination from the surface, and measure the disc thicness at 8points, at least, of seme disance (Smm) front the brake disc outer ci- ‘le. Front brake disc thickness Standard valve : 26.0mm(1.024 in.) Limit : 24.4mm(0.961 in.) 2. Thickness variation should not exceed 0.005mm (0.- (0004 in.) (circumference) and 0.01mm ( in.)(radius) at any directions. 3. If wear exceeds the limit, replace the disce and pad assembly left and right of the vehicle. FRONT BRAKE PAD CHECK 1. Check the pad wear. Measure the pad thickness and replace it, fit is less than the specified value. Pad thickness Standard value : 9.0 mm (0.35 in.) Service limit : 2.0 mm (0.0787 in.) 2. Check that grease is applied, and the pad and back- ing metal for damage.BRAKE SYSTEM FRONT BRAKE DISC RUN OUT CHECK 4. Place a dial gauge about Smm (0.2 in.) from the outer circumference of the brake disc, and measure the run out of the disc. Brake disc run out Limit : 0.03 mm (0.0012 in.) or less 2. Ifthe run out of the brake disc exceeds the limit spe~ ification, repiace the disc, and then measure the run out again, 3. Ifthe run out does not exceed the limit specification, install the brake disc after turning it 180° and then ccheck the run out of the brake disc again. 4, Ifthe run out cannot be corrected by changing the position of the brake disc, replace the brake disc. (0.03 mm (0.0042 in) . evget056Bi REAR DISC BRAKE BRAKE SYSTEM COMPONENTS | ¢roracro Bleeder screw 7-19 (70-190,5.2-8.8) Caliper body Pad retainer Caliper mounting bolt ‘80-100 (800~1,000,59-74) Washer Guide rod bolt 22-82 (220-320, 16.2-23.6) Inner shim Guide rod Boot Brake pad Pad retainer Caliper bracket TORQUE : Nm (kgf-cm, Ibt-ft)BRAKE SYSTEM BR-37 INSPECTION OF REAR DISC BRAKE REMOVAL cosssors PAD eosaears 1. Raise the rear of the vehicle and make sure it is sec- 1. Check the rear disk brake pad thickness through the urely supported. Remove the rear wheel. caliper body inspection hole, 2. Release the parking brake. Ped thickness 3, Remove the two guide rod bolt (B) and support the ‘Standard value : 10.0 mm (0.39 in.) caliper assembly with a piece of wire so that it does ‘Service limit : 2.0 mm (0.0787 in.) not hang from the brake hose. & caution + Ifthe pad thickness is out of specification, left and right pads must be replaced as a complete set. + When the thickness difference between the left pad and right pad is large, check the sliding con- dition ofthe piston and the guide rodBR-38 BRAKE SYSTEM 4. Remove the pad shims (A), pad retainers(B), and pads 2. Check the foreign material at the pad shim (A) and ©), the back of the pads (B), INSTALLATION cecsap00 3. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs ang pads. 41, Install the pad springs(A) to the carrier(B) @ nore Insert the piston in the cylinder using the special tool(- (09581-11000).BRAKE SYSTEM 10. 22-32N'm 162-236 1b-f) Install the brake pads (B) and pad shim (A) on the capliper braket Install the inner pad with its wear indicator (C) facing down ward. Ityou are reusing the pads, always reinstall the brake pads in their original positions to prevent a momtary loss of braking efficiency. Rotate the caliper piston (A) clockwise into the cylin- der, the align the cutout (B) in the piston with the tab (C) on the inner pad by turning the piston back. Lubricate the boot with rubber grease to avoid twisting the piston boot Ifthe piston boot is twisted, back it out so itis positio- ned properly Install the brake caliper (D). Install and torque the guide rods (E) to proper speci- fication Install the brake hose (F) onto the suspension arm with the brake hose clip (G). After installation, check for leaks at hose and line jo- ints and connections, and retighten if necessary. Depress the brake pedal several times to make sure the brakes work, then test-drive, BR-39 W Nore Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been re- placed as a set. Several applications of the brake pedal will restore the nosmal pedal stroke INSPECTION eorcrsoa REAR BRAKE DISC THICKNESS CHECK 1, Remove all rust and contamination from the disc su- rface, and then measure the disc thickness at 8 poin- ts, atleast.of the same distance (5mm) from the brake disk outer circle. Rear brake disc thickness ‘Standard value : 10.0 mm ( 0.39 in.) Limit : 8.0 mm (0.318 in.) 2. Thickness variation should not exceed 0.005mm(0.0- 002 in.) (circumference) and 0.01mm(0.0020 in.) (ra~ dius) at any directions. 3. Ifwear exceeds the limit, replace the discs and pad assembly for left and right of the vehicle.BR-40 REAR BRAKE PAD CHECK 1. Check the pad wear. Measure the pad thickness and replace it, ifit is less than the specified value. Pad thickness Standard value : 10.0 mm ( 0.38in.) Service limit 2.0 mm (0.0787 in.) BRAKE SYSTEM REAR 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 it: 0.03 mm (0.0012 in.) or less 2. Check that grease is applied, and the pad and back- ing metal for damage. 2. Ifthe run out of the brake disc exceeds the limit spe- ification, replace the disc, and then measure the run ‘out again. 3. Ifthe 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. Ifthe run out cannot be corrected by changing the position of the brake disc, replace the brake disc.BRAKE SYSTEM BR-41 REAR DRUM BRAKE COMPONENTS © exessosc Bol, 5~11 (50-110,3.7-8.1) ‘Shoe hold down pin Bleeder screw T18 (70~180,5.2-9.6) hoe & lining assembl Wheel cylinder . rama! Shoe hold down spring Rear hub Upper shoe | ear brake backing plate “@gretur spring Lower shoe return spring TORQUE : Nm (Kgf-cm, Ibf-ft)BR-A2 BRAKE SYSTEM INSPECTION — eaccaazc & caution Frequent inhalation of brake pad dust, regardless of ‘material composition, could be hazardous to your hea- tt, + Avoid breathing dust particles. + Never use an air hose or brush to clean brake assemblies. @ sore + Contaminated brake linings or drums reduce st- opping abit + Block the front wheels before jacking up the rear of the vehicle. 1, Raise the rear of the vehicle, and make sure itis se- curely supported, 2. Release the parking brake, and remove the rear brake drum. 3. Check the wheel cylinder (A) for leakage. 4, Check the brake linings (B) for cracking, glazing, we- ar, and contamination. 5. Measure the brake lining thickness (C), Measurement does not include brake shoe thicknes- s. Brake lining thickness. Standard : 4.5 mm (0.177 in.) Service limit : 1.0 mm (0.039 in.) 6. Ifthe 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. Ifit requires servicing, replace itBRAKE SYSTEM BR-A3 oe NTO 8, Measure the inside diameter of the brake drum with REMOVAL cesiseao inside vernier calipers. & caution Frequent inhalation of brake pad dust, regardless of ‘material composition, could be hazardous to your hea~ Drum inside diameter: Standard : 228.6 mm (9 in.) Service limit : 230.6 mm (8.078in.) ith Drum roundness Service limit : 230.6mm (0.0024in.) * Avoid breathing dust particles. tae + Never use an air hose or brush to clean brake assemblies 1, Remove the shoe hold down pins (B) by pushing the shoe hold cup washer (C) and turning them. 2. Disengage the upper return spring (A) 9. Ifthe inside diameter of the brake drum is more than the service limit, replace the brake drum. 410. Check the brake drum for scoring, grooves, and cra- ks. caerBR44 3. Remove the lower shoe retur spring (B) as removing the brake shoe assembly(A). Make sure not to dam- age the dust cover on the wheel cylinder. ragso4e 4. Disconnect the parking brake cable from the parking brake lever. 5. Remove the brake shoe assembly. 6. Remove the upper return spring (C), shoe adjuster lever (D), and separate the brake shoes. 7. Disconnect the brake line (A) from the wheel cylinder ©). BRAKE SYSTEM 8 Remove the bolt (C) and the wheel cylinder from the backing plate(O). "(of (60-40 kg-em, 37-81 Ib)BRAKE SYSTEM BR45 INSTALLATION eyrstsce @ note + Do not spill brake fluid on the vehicle: it may da- ‘mage the paint; if brake fluid does contact the paint. Wash it off immediately with water. + To prevent spills, cover the hose joints with rags or shop towels. + Use only a genuine wheel cylinder special bolt 4. Apply sealant (C) between the wheel cylinder (A) and backing plate (B), and install the wheel cylinder. . 317m (130-170 kg-em, 95-125 10K) 2. Connect the brake tubes (D) to the wheel cylinder. 3. Connéct the parking brake cable to the parking brake lever. Clean the threaded portions of adjuster sleeve (A) ‘and push rod female (B). Grease the threads of the adjuster assembly, tur the adjuster bolt (C), adjusting the length of the shoe ajuster assembly Hook the shoe adjuster spring (D} to the adjuster lever first, then to the brake shoe. Install the shoe adjuster assembly and upper return ‘spring (E), noting the instalation direction. Be careful not to damage the wheel cylinder dust covers. Install the lower return spring (F).BRAG BRAKE SYSTEM 8. Grease brake cylinder to the sliding surfaces as shown below. Wipe off any excess. Don't get grease on the brake linings. ‘> Sliding surtace 9. Grease brake cylinder to the brake shoe ends and ‘opposite edges of the as shoes as shown below. Wipe off any excess. Don't get grease on the brake linings. ‘= Opposite edge ofthe shoe © Brake shoe ends (shoe side ends and backing Plate contact surtace) 10. Grease brake shoes (A) onto the backing plate. Be careful not to damage the wheel cylinder dust cover- s. 1 12. 13, 14, 15, 16. Install the shoe hold down pins (B) and the shoe hold down washers (C). Install the upper return spring (D). Install the brake drum. . Bleed the brake systematter refiling the brake fluid Depress the brake pedal several times to set the se- tfadjusting brake ‘Adjust the parking brake.BRAKE SYSTEM INSPECTION csosccas 1. Inspect the brake lining and drum for proper contact. 2. Inspect the wheel cylinder outside for excessive wear and damage. 3. Inspect the backing plate for wear or damage. BR-47BR48 BRAKE SYSTEM PARKING BRAKE SYSTEM COMPONENTS coacoiie Parking brake lever Rear brake caliper ‘Shoes & linings Backing plato Shoe guide Return spring ‘Shoe hold down springPARKING BRAKE SYSTEM BR49 PARKING BRAKE CHECK AND ‘ADJUSTMENT ADJUSTMENT pena oe INSPECTION After rear brake caliper servicing, loosen the parking brake adjusting nut, start the engine and depress the 1. Pull the parking brake lever (A) with 196 N (20 kg, brake pedal several times to set the self-adjusting brake ‘dlbf) force to fully apply the parking brake. The par- before adjusting the parking brake. king brake lever should be locked within the specified number of clicks (B). 3. Block the front wheels, then raise the rear of the veh- icle and make sure itis securely supported. 4, Pull the parking brake lever up one click. Pulled up with 196 N (20 ko, 44 Ib) 2. Adjust the parking brake ifthe lever clicks are out of © Remove the floor console, specification.BR-50 BRAKE SYSTEM 6. Tighten the adjusting nut (A) until the parking brakes are dragged slightly when the rear wheels are turne- 7. Release the parking brake lever completely, and ch- ‘eck if parking brakes are not dragged when the rear wheels are turned, Readjust if necessary. 8. Make sure that the parking brakes are fully applied ‘when the parking brake lever is pulled up completly. 9. Reinstall the floor console,PARKING BRAKE SYSTEM PARKING BRAKE REMOVAL execyeae W nore The parking brake cables must not be bent or distorte- a. This wil lead to stiff operation and premature failure. 4. Remove the floor console. 2. Loosen the adjusting nut (A) and the parking brake cables. BR.51 3. Disconnect the connector(A) of the parking brake sw- iten, 4, Remove the 4 bolts and parking brake lever assemb- IA). . 5. Remove the wheel and tire. 6. Remove the brake drum and the brake shoe (Refer to the rear drum brake).BRAKE SYSTEM 7. Remove the parking brake cable(A) from the brake INSTALLATION ersiaces shoe. 1. Install the removed parts in the reverse order of rem- oval 2. Apply the specified grease to each siiding parts of the ratchet plate or the ratchet paw! Specified grease Multi purpose grease SAE J310, NLGI No.2 3. After installing the parking brake cable adjuster, adj- ust the parking brake lever stroke (Refer to the park- ing brake check and adjustment). 8 Remove the parking brake cable retaining ring (B), from the parking brake cable (A).PARKING BRAKE SYSTEM. BR-53 PARKING BRAKE SWITCH INSPECTION essosaso 4. Remove the floor console and the switch (B) from the ‘connector (A). 2. Inspect the continuty between (-) termanal 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.BR54 BRAKE SYSTEM ABS (ANTI-LOCK BRAKE SYSTEM) DESCRIPTION — cxsesroc ‘This specification applies to HCU(Hydraulic Contro! Unit) and ECU(Electronic Control Unit) of the HECU.(Hydraulic and Electronic Control Unit) lation of ‘This specification is for the wiring design and ins ABS/TCSIESP ECU ‘This unit has the functions as follows. = Input of signal from Pressure sensor, Steering angle sensor, Yaw & Lateral G sensor,the wheel speed se- nsors attached to each wheel = Control of braking force / traction force/ yaw momen- t ~ Failsafe function. ~ Self diagnosis function = Interface with the external diagnosis tester. Installation position : engine room ~ Brake Pipe length from Master cylinder port to HECU inlet port should be max. im ~The position should not be close to the engine block ‘and not lower than the wheel. OPERATION ‘The ECU shall be put into operation by switching on the operating voltage (IGN). ‘On completion of the initialization phase, the ECU shall be ready for operation, In the operating condition, the ECU shall be ready, within the specified limits (voltage and temperature), to process the signals offered by the various sensors and switches in accordance with the control algorithm defined by the software and to control the hydraulic and electrical actua- tors. 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 positive voltage that is provided through the valve relay and the other side is connected to the ground by the semiconduc- tor 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, VOLTAGE LIMITS = Ovenvoltage When overvoltage is detected(above 16V), the ECU switches off the valve relay and shuts down the sys- tem. ‘When voltage is returned to operating range. the sy- stem goes back to the normal condition after the init ialization phase. - — Undervottage In the event of undervoltage(below 10V), ABS control shall be inhibited and the warning lamnp shall be turned on ‘When voltage is returned to operating range, the wa- ming lamp is switched off and ECU returns to normal operating mode. PUMP MOTOR CHECKING ‘The ECU performs a pump motor test at a speed of 12km/h once after IGN is switched on. DIAGNOSTIC INTERFACE Failures detected by the ECU are encoded on the ECU, stored in a EEPROM and read out by diagnostic equipment when the ignition switch is turned on, ‘The diagnosis interface can also be used for testing the ECU during production of the ECU and for actuating the HCU in the test line of manufactories (Air-bleeding line or Rall and Brake Test line).ABS (ANTI-LOCK BRAKE SYSTEM) Parking brake/EBD warning lamp A88Waminglamp [Ts OFF Warning lame TOS Function lamp ABS WARNING LAMP MODULE ‘The active ABS warning lamp module indicates the self-- est and failure status of the ABS. ‘The ABS warning lamp shall be on: ~ During the initialization phase after IGN ON. (contin ously 3 seconds), = _ Inthe event of inhibition of ABS functions by failure = During diagnostic mode. - When the ECU Connector is seperated from ECU. EBD WARNING LAMP MODULE. ‘The active EBD warning lamp module indicates the self-t- est 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 shall be on = During the initialization phase after IGN ON. (contin- ously 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. BR-55, ‘TCS WARNING LAMP (TCS SYSTEM) The TCS warning lamp indicates the self-test and failure status of the TCS, The TCS warning lamp is tured on under the following conditions. = During the initialization phase after IGN ON. (contin uuously 3 seconds), = Inthe event of inhibition of TCS functions by failure When driver trun off the TCS function by on/off switc- h = During diagnostic mode. ‘TCS FUNCTION LAMP (TCS SYSTEM) ‘The TCS function lamp indicates the self-test and operat- ing status of the TCS ‘The TCS Function lamp operates under the folowing con- ditions = During the initialization phase after IGN ON. (contin- uuously 3 seconds). - When the TCS control is operating. (Blinking - 2Hz) ‘TCS ON/OFF SWITCH (TCS SYSTEM) ‘The TCS On/Off Switch shall be used to toggle the TCS function between On/Off states based upon driver input. ‘The On/Off switch shall be a normally open, momentary contact switch, Closed contacts switch the circuit to ignition. Initial status of the TCS function is on and switch toggle the stateBR.56 BRAKE SYSTEM. HI-SCAN (PRO) CHECK 1, Tum the ignition switch OFF. 2. Connector the Hi-scan (pro) to the 16P data link con- nector located the driverd side kick panel. emoasra Turn the ignition switch ON. Check for diagnostic trouble using the Hi-s pro) ‘After completion trouble of the repair or correction of the probim, erase the stored fault codes the clear key on the Hi-scan(pro). Disconnect the Hi-scan (pro) from the 16P date link connector.ABS (ANTI-LOCK BRAKE SYSTEM} ABS CONTROL csarsere 4. NORMAL BRAKING without ABS Pump Solenoid valve State Valve Passage beth Inlet valve (NO) OFF OPEN Master cylinder © Wheel cyinde| ‘Outlet valve (NC) OFF “CLOSE Wheel cylinder & Reservoir When braking, the hydraulic pressure in the TMC is increased. The pressure reaches the wheel brake Via the current less open inlet valve IV. The current less closed outlet vaive OV is closed. For the sake of simplicity the diagram is limited to only the solenoid valve pair of one brake circuit. The wheel speed is reduced as the brake pressure increases, in the ext- reme case unti the whee! locks.BR-58 BRAKE SYSTEM. 2 with ABS 1) DUMP MODE “soso | State Vale Passage Pump | Inlet valve (NO) | ON CLOSE Master cylinder <> Wheel cylinde| on | cute vive (6) “oN OREN | Wheel ovinder © Reservoir | If the wheel speed decreases, there is still a ten- dency to lock; the brake pressure on the corres- ponding wheel must be reduced accordingly. For this, the outlet valve OV is opened, the inlet valve IV remains closed. ‘The brake pressure to the low-pressure accumu- lator is reduced. The wheel in danger of locking gains speed again. ‘AccumulatorABS (ANTI-LOCK BRAKE SYSTEM) 2) HOLD MODE BR.59 ] Pump Solenoid State valve Passage ave Inlet vaive (NO) oN CLOSE Master cylinder © Wheel cylinde] | ‘Outlet vaive (NC) OFF CLOSE Wheel cylinder & Reservoir When a wheel (or several) tends to lock the inlet valve IV's first closed to avoid a further increase in brake pressure. The outlet valve OV remains closed: the brake pressure is kept constantBR-60 BRAKE SYSTEM ——— EE SYSTEM 3) INCREASE MODE | = Pump Solenoid State | Valve Passage ae Inlet valve (NO) | OFF | OPEN Master cylinder ¢ Wheel cylinde) Cuttet valve (NC) OFF [close Wheel cylinder © Reservoir For optimum brake from the certain wheel acce- leration a brake pressure increase is necessary. For this, the inlet valve IV is opened and the ou- tlet valve OV is closed. The pump of the unit sta- 'ts to run and aspirates the necessary quantity of fluid from the Lowpressure accumulator, in order to produce the necessary brake pressure for the pressure increase phase in seconds. With an increase in the brake pressure the wheel speed is reduced. These control phases are rep- ated until the ABS control unit no longer detects any tendency of the wheels to lock. @ nore During ABS control function, the brake pedal only ‘moves in accordance with the volume requirem- ent of the wheels. Because of a sudden change in friction coefficient this pedal movement may increase slightly. 3. Fall Safe Funtion If there is a problem with the ABS system, the Failsafe function operates, turing off the relay which supplies the power to the solenoid valve, stoping the output of the control signal, and turning on the ABS warning lamp in order to warn the user of malfunction of the ABS system. Conventional brake system operates under the circu- stance,ABS (ANTI-LOCK BRAKE SYSTEM) TRACTION CONTROL SYSTEM (TCS) FUNCTION 1 Main performance ‘Traction: Lower vibration and higher launchabilty, acceleration and climbabilty by slip control Comering and passing: Stable comering and pas- sing, Steering stability: Control traction force traverse vector prior to provide easy turning when turning the steering wheel General TCS features Improved drivability. Minor operation of accelerat- ion is not necessary in launching and acceleration (on slippery road, More stable cornering by stable acceleration on normal road condition TCS system will compare vehicle speed received from rear wheel speed sensor and driving wheel speed from front wheel speed sensor on slippery road condition, and provide optimum slipping rate of driving wheels. TYPE BR61 FULL TRACTION CONTROL SYSTEM (FTCS) 4, The TCS control module (HECU) controls TCS cont- rol. It includes ABS control module. 2, HECU will compare signals from front (driving) and rear wheel speed sensors to detect driving wheels slip, 3. Upon detecting driving wheels slip, HECU will perform ‘TCS control. The TCS control will include brake TCS. (8TCS) control 4, HECU will transmit engine torque reduction request, fuel cut cylinder number, and TCS control request signals in accordance with slip level to engine ECM and TCM through BUS line which will provide CAN ‘communication for TCS control 5. Engine ECM will perform fuel cut as requested by HECU and retard ignition timing as per engine torque reduction request signal. 6. TCM will hold shift position by TCS control time acc- ording to TCS operation signal. Then enhanced acc- eleration by kick-down will not ogeur. Engine torque Engine rpm Trrotlle angle Current shit range Engine type [a Enaine type | CAN oe BUS Tes “Requested en sine torque TCS operation signal Requested engine tor TCS operation ENGINE signal ECM Engine torque Engine wpm Throttle angle Engine type TCS operation signal Tou <—____| Current shift range| BRAKE TRACTION CONTROL SYSTEM (BTCS) 1 ‘On TCS control, only brake contro! will be performed, (engine and TCM control will not happen) 2. Controlled by motor pump output pressure,BR62 BRAKE SYSTEM On TRACTION CONTROL SYSTEM (TCS) 4, NORMAL MODE - - oe Solenoid valve ‘State Vane Motor pump ~_TCvaive Inlet (NO) F OPEN eae) oA OFF OFF Outlet (NC) OFF CLOSE : + Inthe normal driving condition, TC valve (normally ‘open) is the passage between the master cylinder and the each wheel cylinder. + When brake pedal is applied, brake pressure is delivered to the wheel cylinders via NO-TC valve and all solenoid valves inside the hydraulic unit are deactivated. + Incase of TCS malfunction, it does not affect brake operation.ABS (ANTI-LOCK BRAKE SYSTEM) 2._ PRESSURE INCREASE MODE as Solenoid valve State [ Valve Motor pump "Te valve FRONT: OFF FRONT: OPEN | Inlet (NO) (No) REAR: ON REAR: CLOSE on on Outlet (NC) OFF “CLOSE + Ifa front wheel spin is detected, TCS begins a br- ake control to decrease a whee! spin + Hydraulic shuttle valve (HSV) is opened. Brake fluid is supplied from the master cylinder by motor operation to the spin wheel via HSV. + TC valve is closed (ON). Brake pressure generated from motor pump is de- livered only to the front wheel. + Inlet valve remains open to deliver the brake pres- sure generated from motor pump to the spinning wheels. LLeotzonBR.64 BRAKE SYSTEM One en rere enna 3._PRESSURE DUMP MODE {_Sotenoid valve State I Valve Motor pump TC valve { Infet (NO) ON | CLOSE ie FRONT: ON FRONT : OPEN ON ON lb) REAR : OFF REAR : CLOSE + When the wheel deceleration is under the threshold and the wheel spin is reduced under a slip thresh- ld, applied brake pressure is reduced to get an ‘optimum traction force. + Outlet valve is open to release the brake pressure and inlet valve is closed to block the pressure inc- rease from the motor pump. + Hydraulic shuttle valve (HSV) remains opened, TC valve is ON. + Motor is ON, to dump the brake fluid being released from the lock-up wheel.ABS (ANTI-LOCK BRAKE SYSTEM) 4. PRESSURE HOLD MODE BR65 Some vane [State Vane tor pump Te vane Inlet (NO) ON | close on on OFF l CLOSE Outlet (t HiBR66 BRAKE SYSTEM COMPONENTS — cicreaso Cluster ‘ABS Warning lamp EBD/Parking brake warning lamp |ABS control module (HECU) Front left wheel speed sensor Front right wheel speed sensor Rear left whee! speed sensor Hydraulic tine Rear right wheel speed sensorABS (ANTI-LOCK BRAKE SYSTEM) BR67 HYDRAULIC SYSTEM DIAGRAM cas3oa00 UPA FR AL AR FL TCS :Traction Control System M: Motor Pump MCP : Master Cylinder Primary HSV : Hydraulic Shuttle Valve MCS : Master Cylinder Secondary TC : Traction Control valve HPA : High Pressure Accumulator NO : Normal Open valve LPA: Low Pressure Accumulator NC : Normal Close valveee CIRCUIT DIAGRAM egazcoe1 CIRCUIT DIARAM(1) ul &BR-69 ABS (ANTI-LOCK BRAKE SYSTEM) CIRCUIT DIAGRAM(2)BR-70 BRAKE SYSTEM OT TROUBLESHOOTING ‘STANDARD FLOW OF DIAGNSTIC TROUBLESHOOTING easvaces Gathering information from customer I Does not reoccur I Reoccurs| Cheat depres cose | Check diagnostic code No trouble code ‘Trouble code displayed Trouble code | No trouble displayed code Recheck trouble code(s) then erase y Basic brake system is normal or not Recheck trouble symptom Yacrormal Normal Nore Y code Refer to BR-Troubleshooting Check trouble codes Trouble code displayed y : Problem is intermittent or was Inspection char for agnostic trouble repaired and memory was not cleared. odes Intermittent malfunction * Using the customer problem analysis check sheet for reference, ask the customer es much detail as possible about the problem. NOTES WITH REGARD TO DIAGNOSIS ‘The phenomena listed in the following table are not abno- mal. Phenomenon, Explanation | ‘System check sound ‘ABS operation sound | ABS operation (Long braking | distance) For road surfaces such as snow-covered and gravel roads, the braking 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 | 4. 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) 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.ABS (ANTI-LOCK BRAKE SYSTEM) BR-71 ABS CHECK SHEET Inspector's ABS Check Sheet een Registration No. Customer's Name Registration Year 7. / VIN. Date Vehicle Km Brought In / / Odometer Miles Date the Problem First Occurred / / Frequency of Occurence of Problem |) Continuous Intermittent ("times a dey) (ABS does not operate. Symptoms G_ABS does not operate efficianty. C1 Intermittent (times a day) Light Abmortel eos © Does not light up Diagnostic Ast Time CO Normal Gode Cl Malfunction Code (Code) Trouble Code A cemaas 2nd Time Cl Normal Code Malfunction Code (Code 7BR-72 BRAKE SYSTEM. PROBLEM SYMPTOMS TABLE ta 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. ‘Symptom [ Suspect Area ‘See pag Only when 1. -4, are all normal and the problem is still occurring, | replace the HECU ‘Check the DTC reconfirming that the normal code is output. : ABS does not operate fe Checks De een BR-75 3. Speed sensor circuit 4, Check the hydraulic circuit for leakage Only when 1. ~4. are allnormal and the problem is stil occurring, replace the ABS actuator assembly. | ABS does not operate 4. Check the OTC reconfirming that the normal code is output ce | intermitent 2. Wheel speed sensor eeu, 3. Stop lamp switch circuit | 4, Check the hydraulic circuit for leakage | ‘Communication with Hrsean ~ | (pro) is not possible. 4, Power source circuit os (Communication with any 2. Diagnosis ine - system is not possible) - Communication with Hi-scan (pro) not possible, 4. Power source circuit (Communication with ABS only | 2. Diagnosis ine BR- 80 {Snot possible) 3. HECU ‘When ignition key is turned ON es eran ee, et Rae rary. 1. ABS wamng amp creat ea amp does not ight up. Even afier the engine is started, the ABS waming lamp remains | 1+ ABS warming lamp circuit BR -82 2. HECU ON. 1. Brake oil level sensor eee 2. Parking brake switch BR-83 3. Brake waming lamp circut & caution During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is not an abnormality.ABS (ANTI-LOCK BRAKE SYSTEM) DIAGNOSTIC TROUBLE CODE CHART Follow an inspection procedure of a detected DTC in the chart below. © nore EBD A - waming lamp "ON’; in case of errors on more than 2 wheels. Tore | orsmnoy RANE O Tre Ta er ne | ‘ABS | EBD| TOS] ESP| MEMORY | e101 Battery voltage high O#l no: |s0n|20 ° _ BR-84 1102 Battery voltage low ofolofo iO: BR-87 Wheel speed sensor FR-LH ©1200 Crean o}|o}ojo ° BR-89 Wheel speed sensor FR-LH 61201 | rangelpertormancefintermittent | O | “ | O | © . mee Wheel speed sensor FR-LH cr202 ataive agral o}ajol|o ° | Bros Wheel speed sensor FR-LH - 1203 eaveen | a1 0/0 ° | BRE ‘Wheel speed sensor FR-LH | tee 61204 | range/pertormancefintermittent | 9 | © | 9 | O = ae ‘Wheel speed sensor FR-LH eee invalidino signal Se |e |e 2 oe ‘Whee! speed sensor FR-LH C1208 pare ©) 4] 0 \20 ° BR89 Wheel speed sensor FR-LH | ©1207 | rangelpertormancefintermittent | O | ® | O | © © ae - “| Wheel speed sensor FR-LH 2 ow invalidino signal Clee |e c ae Wheel speed sensor FR-LH 1209 oven o}a}ojo ° BR-89 Wheel speed sensor FR-LH | C1210 | rangelperformancefintermittent | O | ® | O | O ° BRO Wheel speed sensorRR-RH | | a crait fee hg O|a ° ° BR-95 | c1604 ECU hardware error ° Oreo BR-98 o2i2 Valve relay error ° ° } BR-89 ©2380 | ABS/TOSIESP vaive error ° } 3 BR-101 2402 Motor - electrical ° ° ° BR-103 | c1274 G sensor - electrical ° ol] o 4WD BR-106 C1275 G sensor- signal ° ° ° 4wo | BR-108 | c1503 | TCS switch error x ° ° BR-110 C1605 CAN harware error x Ca BRA13 [_crent CAN time-out EMS x ° ° BR-114BR-74 BRAKE SYSTEM ‘ore DESCRIPTION WARNING LAMP "ON" | OTC | | remark | SEE PAGE | ABS | EBD| Tcs| Esp | MEMORY 1612 | __ CANtime-out TCU x|x[olo ° BR115 cieta CAN wrong message et ee 0 [e0. ° BR-116 C1616 CAN bus off x[Lx[o|o ° Excessive temperature of brake |. | c2227 pe jo|o ° nia ‘Sensor source voliage eee | 0a | sO: ° = | ee Pressure sensor(priman)- | , | x | x cies electrical | . . | Pressure sensor(seconday)- |, | x | x | o | c1237 arian | ° ° ©1269 | Steering angle sensor-electrical | x | x ° ° BR-124 [61260 | Steering angle sensor- signal |x | x 3 © BR-126 ch ch Oe Ee Yawrate &lateralGsensor- |, | x | x | 1282 & lateral ¢ | ° o. | BR-128 Yew rate & lateral G sensor - y T | cr283 el x | x ° | BR-130 crs Brake switch error Sees lho ome ~) BRaa2ABS (ANTI-LOCK BRAKE SYSTEM) BR-75 eee ABS Does Not Operate 1. CHECK THE DTC RECONFIRMING THAT THE NORMAL CODE IS OUTPUT. 1, Connect the Hi-Scan (pro) with the data link connector and tur the ignition ewitch ON. 2. Verify that the normal code is output. Is the normal code output? Yea No | Erase the DTC and recheck using Hi-Scan (pro). 2. CHECK THE POWER SOURCE CIRCUIT. 1. Disconnect the connector from the ABS control module. 2. Turn the ignition switch ON, measure the voltage between terminal 4 of the ABS control module hares side connector (E37) and body ground. + Specification: approximately B+ Is the voltage within specification? So ae SSIS TT SST TORTS Yes No compartment junction block and the ABS control module. sarees 3. CHECK THE GROUND CIRCUIT. A 5 er cern r@Qr 2. Check for continuity between terminals 8,24 of the ABS control module harness side connector (E37) and ground point (G17. Is there continuity? . Ad No | Repair an open in the wire and ground point (G17), 4, CHECK THE WHEEL SPEED SENSOR CIRCUIT. Refer to the DTC troubleshooting procedures.(see page BR- 75) ba Na __| Repair or replace the wheel speed sensor.BR-76 BRAKE SYSTEM ESTE 5. CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE. Refer to the hydraulic lines. (see page BR. 44) [oc] [se Trent trae ‘The problem is stil occurring, replace the ABS control module.ABS (ANTI-LOCK BRAKE SYSTEM) ABS Does Not Operate intermittently enor 1. CHECK THE DTC RECONFIRMING THAT THE NORMAL CODE IS OUTPUT. 1. Connect the Hi-Scan (pro) tothe data link connector and turn the Ignition switch ON, 2. Verity thatthe normal code is output. Is the normal code output? vee No | Erase the DTC and recheck using Hi-Scan (pro) 2. CHECK THE WHEEL SPEED SENSOR CIRCUIT. Reter to the DTC troubleshooting procedures. (see page BR- 75) as NG | Repair or replace the wheel speed sensor. 3. CHECK THE STOP LAMP SWITCH CIRCUIT. 1. Check that stop lamp lights up when brake pedal is depressed and turns off when brake pedal s released. 2, Measure the voltage betwoon terminal 18 of the ABS control module harness side connector (E87) and body ground when brake pedal is depressed. + Specification: approximately B+ Is the voltage within specification? Repair the stop lamp switch. Yes No | Repair an open in the wire between the ABS control module and the stop lamp switch, exonsBR78 BRAKE SYSTEM 4, CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE. | Retr to the hydraulic tines, (see page BR: 44) ‘The problem is stil occurring, replace the ABS control module.ABS (ANTI-LOCK BRAKE SYSTEM) BR-79 ‘Communication With Hi-Scan (pro) Is Not Possible. (Communication With Any System Is Not Possible) 1. CHECK THE POWER SUPPLY CIRCUIT FOR THE DIAGNOSIS ‘Measure the voltage between terminal 9 ofthe data link connector (MO7) and body ground. ‘+ Specification: approximately B+ Is voltage within specification? Yes No | Repair an open in the wire. Check and replace fuse (154) from the passenger compartment junction block. 2. CHECK THE GROUND CIRCUIT FOR THE DIAGNOSIS Check for continuity between terminal § of the data link connector (M07) and body ground, Is there continuity? Repair an open in the wire between terminal 5 of the data link connector No | (M07) and ground point (14),BR-80 BRAKE SYSTEM ‘Communication With Hi-Scan (pro) Is Not Possible. (Communication With ABS Only Is Not Possible) 1. CHECK FOR CONTINUITY INTHE DIAGNOSIS LINE 1. Disconnect the connector from the ABS control module. 2. Check for continuity between terminals 7 of the ABS control module ‘connector (E37) and 1 of the data link connector (MO7). {s there continuity? Vou No | Repair an open in the wire. 2, CHECK THE POWER SOURCE OF ABS CONTROL MODULE 1. Disconnect the connector from the ABS control module. 2. Turn the ignition switch ON, measure the voltage between terminal 4 of the ABS control module harness side connector (E37) and body ground. + Specification: approximately B+ Is voltage within specification? a ‘Check the hamness or connector between the No.11 fuse (TOA) in the passenger fos No | compartment junction block and the ABS control module. Repair if necessary. 3. CHECK FOR POOR GROUND ‘Check for continuity between terminal 5 of the data link connector (M07) land ground point (G14). Is there continuity? (J No | Repair an open in the wire or poor ground. Replace the ABS control module and recheck.ABS (ANTI-LOCK BRAKE SYSTEM) BR.81 eee When Ignition Key Is Turned ON (Engine OFF), The ABS Warning Lamp Does Not Light Up. 1, PROBLEM VERIFICATION Disconnect the connector from the ABS control module and turn the ignition switch ON. Does the ABS warning lamp light up? 2. CHECK THE POWER SOURCE FOR THE ABS WARNING LAMP 1. Disconnect the instrument cluster connector (M10-1) and turn the ignition switch ON. 2. Measure the voltage between terminal 3 ofthe cluster harness side ‘connector (M10-1) and body ground. + Specification: approximately B+ Is voltage within specification? (ee) [sm Pri stn rey 3. CHECK FOR BLOWN FUSE ‘Check continuity of No.2 fuse (10A) from the passenger compartment junction block (A). Is there continuity? Yes No | Replace the blown fuse. Repair an open in the wire between terminals 12 of I/P-H connector and 3 of cluster connector (M10-1),BR-82 BRAKE SYSTEM OE a en en nena Even After The Engine Is Started, The ABS Warning Lamp Remains ON. 1, CHECK DTC OUTPUT. 4, Connect the Hi-Scan (pro) to the 16P data link connector located behind the driver's side kick panel. 2. Check the DTC output using Hi-Scan (pro}. Is DTC output? WL 2. CHECK INSTRUMENT CLUSTER Repair circuit indicated by code output. Disconnect the cluster connector (M10-1) and turn the ignition switch ON. Does the ABS warning lamp remains ON? . 3. CHECK FOR OPEN INTHE WIRE (Check for continuity in the wire betwoen cluster and ABS control module. Is there continuity? Replace the ABS control module and recheck.ABS (ANTI-LOCK BRAKE SYSTEM) BR83 Brake Warning Lamp Is Abnormal 1. CHECK PARKING BRAKE SWITCH CIRCUIT oK NG | Repair or replace parking brake switch circuit. 2. CHECK BRAKE OIL LEVEL WARNING SWITCH CIRCUIT oK NG | Repair or replace brake cil evel warming switch circuit 3. CHECK BRAKE WARNING LAMP CIRCUIT IN CLUSTER : oK NG | Repair or replace the instrument cluster. 4, CHECK FOR OPEN OR SHORT CIRCUIT IN HARNESS AND CONNECTOR bad NG | Repair or replace the harness and connector. Replace the ABS control module and recheck.BR.84 BRAKE SYSTEM DTC C1101 [BATTERY VOLTAGE OUT OF RANGE (OVER-VOLTAGE FAULT) This code shows in case that the power source for the HECU drops lower than or rises higher than the specified value. If the power source returns within the specified value, this code will not show any longer. & caution Before carrying out the following inspection, check and recharge, if necessary, the battery. | DTCNo| Condition ___| Possible Cause 4. When Vign more than 16%0.5V is continued for 500msec. 2. When Vign more than 1920.5V is continued for 49msec. 3. if the voltage recover normal operating range, the controller is reset C1101 | Low Voltage | (High | 4. When Vign more than 1620.5V is continued for 500msec. Voltage) | 2. When Vign more than 1940.5V is continued for 49msec. > Open/short in power supply C1102 | 3. if the voltage recover normal operating range, the controller is circuit : Low | reset ~ Faulty power source { ~ Faulty HECU Voltage) | 1. When Vign less than 9.5V40.5V is continued for 500msec during Vref more than or equal to 7Km/h 2. When Vign less than 8 5V#0.5V is continued for 500msec during Vref less than or equal to 7Kmih or ABS, TCS(ESP) control 3. When Vigh less than 7.2V+0.5V is continued for 28msec, 4. IFIGN voltage is recovered to normal operating voltage, the system recovers to normal state ‘The system stops. the ABS, TCS(ESP) and the EBD functions are inhibited. The ABS, TCS(ESP) and the EBD warning lamps are ON. The valve relay and all solenoids are OFF. Low voltage : 1, Without the ABS control : inhibit the ABS, TCS(ESP) control of front wheels and allow the ABS control of rear whee- Is, deactivating the motor, and the ABS, TCS(ESP) warning lamps are switched on. When the voltage recover to the normal operating range, enable ABS function and ABS, TCS(ESP) warning lamps are switched off and erase the error code 2. With the ABS control : inhibit ABS control of the front wheels and allow ABS control of the rear wheels, deactivating the motor. the ABS, TCS(ESP) warning lamps are directly switched on and the state keeps continuously. the error code is always stored,ABS (ANTI-LOCK BRAKE SYSTEM) INSPECTION PROCEDURE =0r0e107 1. CHECK POWER BETWEEN TERMINAL OF HECU CONNECTOR. 41) Disconnect the connector from the ABS control module, and then turn the ignition switch ON. 2) Measure the voltage between terminals 4(+) and 8(-) or 24(-) of the HECU connector. Specification: 9.4~17V Is the voltage within the specification? YES, > Check the HECU connector If no error is founded, replace the HECU and recheck > Check battery 2. CHECK BATTERY. ‘Measure the voltage between positive(+) and negative(-) terminals of the battery. Is the voltage below 9.4V? ey Check and replace the battery > Check circuit for contingtinuty between bettery and HECU. 3. CHECK CIRCUIT FOR CONTINUITY BETWEEN BATTERY AND HECU Check the resistance between terminal 4(+) of the HECU connector and battery positive(+) terminal Is the resistance below 197 Repair harness or connector. } Check circuit for continuity between the HECU and body ground,BR-86 BRAKE SYSTEM. 4, CHECK CIRCUIT FOR CONTINUITY BETWEEN THE HECU AND BODY GROUND. ‘Measure the resistance between terminals 8(-), 24(-) of the HECU connector and the body ground. Is the resistance below 107 > Check and readjust the installing of the body groud. YES > Check voltage beween the HECU connector. 5. CHECK VOLTAGE BETWEEN THE HECU CONNECTOR. 1) Tum the ignition switch ON. 2) Measure the voltage between terminals 4(+) and 8(-), 24(-) of the HECU connector. exoesu0n Is the voltage above 17V? > Repair and replace, if necessary, the charging system, > Repeat the inspection procedure.ABS (ANTI-LOCK BRAKE SYSTEM) BR-87 IBATTERY VOLTAGE OUT OF RANGE (UNDER-VOLTAGE FAULT) [Dtc C1102 1. CHECK POWER BETWEEN TERMINAL OF HECU CONNECTOR. 1) Disconnect the connector from the ABS control module, and then turn the ignition switch ON, 2) Measure the voltage between terminals 4(+) and 8(-) or 24(-) of the HECU connector. ‘Specification: 9.4~17V Is the voltage within the specification? > Check the HECU connector If no error is founded, replace the HECU and recheck. > Check battery 2. CHECK BATTERY. Measure the voltage between positive(+) and negative(-) terminals of the battery. Is the voltage below 9.4V? > Check and replace the battery. > Check circuit for continuity between bettery and HECU, 3. CHECK CIRCUIT FOR CONTINUITY BETWEEN BATTERY AND HECU. Check the resistance between terminal 4(+) of the HECU connector and battery positive(+) terminal, Is the resistance below 107 } Repair hamess or connector. Te > Check circuit for continuity between the HECU and body ground,BR88 BRAKE SYSTEM 4, CHECK CIRCUIT FOR CONTINUITY BETWEEN THE HECU AND BODY GROUND. ‘Measure the resistance between terminals 8|-), 24(-) of the HECU connector and the body ground. Is the resistance below 10? > Check and readjust the installing ofthe body groud. YES > Check voltage beween the HECU connector. CHECK VOLTAGE BETWEEN THE HECU CONNECTOR. 4) Tum the ignition switch ON. 2) Measure the voltage between terminals 4(+) and 8(-), 24(-) of the HECU connector. . on Is the voltage above 17? > Repair and replace, ifnecessary, the charging system. > Repeat the inspection procedure.ABS (ANTI OCK BRAKE SYSTEM) BR.89 DTC C1200 |FRONT LEFT WHEEL SPEED SENSOR OPEN OR SHORT TO GROUND ‘The HECU receives wheel speed signals from the four wheel speed sensors. ‘The wheel signals are converted to voltage signals by the signal converting circuit and given as input to the HECU, ‘The HECU checks an open or short in the circuit of the wheel speed sensor. If more than one wheel speed sensor malfunctions, the system stops. DTC No [Condition : Possible Cause ©1200 (FL) E4203 (FR) Ifthe sensor signal current is continuously out of the = Openishort in circuit of wheel 61206 (RL) specified range of 4 mA 210% ~ 22 mA #10% for speed sensor 1208 (RR) 1140msec, the failure is detected. ~ Faulty wheel speedsensor : Faulty HECU ‘Sensor malfunction without ABS control : = One wheel sensor matfuntion Only the ABS, TCS(ESP) functions are inhibited. the ABS, TCS(ESP) warning lamps are ON, but the EBD warning lamp is OFF. ~ More than two wheels malfunction ‘The system stops. the ABS, TCS(ESP) and the EBD functions are inhibited. the ABS, TCS(ESP) and the EBD warning lamps are ON. The valve relay and all solenoids are OFF. ‘Sensor matfunction with ABS control : ~ One front wheel matfunction Inhibit the ABS control of a wheel with a malfunctioning sensor and maintain the ABS control of other wheels. ‘After the ABS control has completed, the ABS, TCS(ESP) functions are inhibited. The ABS, TCS(ESP) warning lamps are ON but the EBD waming lamp is OFF. = One rear wheel malfunction Inhibit ABS control of both front wheels and the pressure of both rear wheels is decreased. After the controller comple- tes the ABS control, Only the ABS, TCS(ESP) functions are inhibited. The ABS, TCS(ESP) warning lamps are ON but the EBD warning lamp is OFF. ~ More than two wheels malfunction ‘The system stops. the ABS, TCS(ESP) and the EBD functions are inhibited. The ABS, TCS(ESP) and the EBD warning lamps are ON. The valve relay and all solenoids are OFF.BRAKE SYSTEM INSPECTION PROCEDURE 4. CHECK POWER FOR WHEEL SPEED SENSOR Measure the voltage between an appropriate wheel sensor(+) terminal and the body ground (see the table below, DTC _ 2 Terminal ©1200 (Font-ieft) 1 ©1203 (Font-ight) 19 C1206 (Rear-right) 5 1208 (Rear-right) 23 Specification: Battery positive(+) Is the voltage within the specification? Repair short to power in the (+) circuit between the HECU and the appropriate wheel sensor. > Check output of the wheel speed sensor 2. CHECK OUTPUT OF THE WHEEL SPEED SENSOR Check the volrange between terminals (see the table below)of the HECU and the body ground. : DTC : Terminal ©1200 (Fontleft) 2 ©1203 (Font-ight) on C1206 (Rear-right) . 61208 (Rear-right) Specification:0.4~2.2V Is the voltage within the specification? > Replace the wheel sensor and recheck. Repair the wire between the HECU and the wheel speed sensor.ABS (ANTI-LOCK BRAKE SYSTEM) DTC C1201 [FRONT LEFT WHEEL SPEED SENSOR SIGNAL ERROR This code shows in case that a speed signal from any of the 4 wheel speed sensors does not match to the others at any speed, DTC No Condition _ Possible Cause | ‘Speed Jump This monitoring is performed for the period that the velocity of each wheel exceeds 2km/h, = Controller counts the number of the wheel acceleration of 100gI(26km/h) for ‘7ms]. 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 40g{(10km/h) for ‘7ms}. When the numbers at one wheel exceed 126 times, or When the numbers at more two wheels exceed 20 times, controller recognize the failure. = Controller counts the number of the wheel deceleration of -1009{(-25kmih) for 7ms]. When the numbers at each wheel exceed 66 times, controller recognize the failure, = The wheel deceleration of ~100g{(-25kmih) for 7ms] causes the controler to start monitoring this failure and to compare the wheel velocity with the vehicle velocity from next cycle. When its difference of -100g is continued for more than 140msec, controller recognize the failure. ~ In case that any sensor failure at other wheel was already detected, When the numbers of 100g at each wheel exceed 5 times, or When the numbers of 1201 440g at each wheel exceed 20 times, controller recognize the failure. = Openishort in ctiady | The counter of speed jump is cleared every 30min circuit of wheel (FR). | Wrong Exciter speed sensor GER), | ="Controter counts the number of the wheel acceleration of 1009I(25kmvn) for__|~ Faulty whee! speed (kL). | 7s]. When the numbers at one wheel exceed 56 times, or When the numbers | Sensor ff, | at more two wheels exceed 5 times, controller recognize the failure. ~ Faully rotor or (RR) |= Controller counts the number of the wheel acceleration of 40g{(10km/h) for wheel bearing ‘7ms]. When the numbers at one wheel exceed 126 times, or When the ~ Faulty HECU numbers at more two wheels exceed 20 times, controller recognize the failure. = Controller counts the number of the wheel deceleration of -100g{(-25kmih) for 7ms}. When the numbers at each wheel exceed 56 times, controller recognize the failure ~The wheel deceleration of -100g[(-25kmih) for 7ms] causes the controller to start monitoring this failure and to compare the wheel velocity with the vehicle velocity from next cycle. When its difference of -100g is continued for more | than 140msec, controller recognize the failure. = In case that any sensor failure at other wheel was already detected, When | the numbers of 100g at each wheel exceed 5 times, or When the numbers of | 40g at each wheel exceed 20 times, controller recognize the failure. - The counter of speed jump is cleared every 30min, | - Max. wheel velocity exceeds 20km/n and the wheel velocity is 40% of max. wheel velocity. if this condition is lasted for 2 minutes. | - Max. wheel velocity exceeds 40km/n and the wheel velocity is 60% of max. ‘wheel velocity. if this condition is lasted for 2 minutes. - Faulty installing of wheel speed sensorBR-92 BRAKE SYSTEM aie ‘Sensor matfunction without ABS control : = One wheel sensor maffuntion Only the ABS, TCS(ESP) functions are inhibited. the ABS, TCS(ESP) warming lamps are ON, but the EBD warning lamp is OFF. More than two wheels malfunction ‘The system stops. the ABS, TCS(ESP) and the EBD functions are inhibited. the ABS, TCS(ESP) and the EBD warning lamps are ON. The valve relay and all solenoids are OFF. ‘Sensor matfunction with ABS control: One front wheel matfunction Inhibit the ABS control of a wheel with @ malfunctioning sensor and maintain the ABS control of other wheels. After the ABS control has completed, the ABS, TCS(ESP) functions are inhibited. The ABS, TCS(ESP) warning lamps are ON and the EBD warning lamp is OFF. ~ One rear wheel malfunction Inhibit ABS control of both front wheels and the pressure of both rear wheels is decreased. . After the controller completes the ABS control, Only the ABS, TCS(ESP) functions are inhibited. THie ABS, TCS(ESP) warning lamps are ON and the EBD warning lamp is OFF. = More than two wheels malfunction. ‘The system stops. the ABS, TCS(ESP) and the EBD functions are inhibited. The ABS, TCS(ESP) and the EBD waming lamps are ON. The valve relay and all solenoids are OFF.ABS (AN’ 1, CHECK AIR GAP BETWEEN WHEEL SPEED SENSOR AND TONE WHEEL, Visually check the installing of wheel speed sensors and rotors(see the table below) Specification : 0.5~1.5mm OCK BRAKE SYSTEM) Y Uy r 0K Ne prc ‘Appropriate wheel sensor C1201 Front - left wheel sensor C1204 Front right wheel sensor 1207 Rear- left wheel sensor | 1210 Rear- right wheel sensor @ nore The mounting bolt shall be tightened property and there is no clearance is allowed between the sensor and front ste- tering knuckle or rear axle carrier. Is the air gap within the specification? > Reinstall or replace, if neccessary, wheel speed sensors in trouble, D Check sensor rotor and sensor tip.BRAKE SYSTEM BR-94 2. CHECK SENSOR ROTOR AND SENSOR TIP Check visually the sensor rotor and the sensor tip have scratches, missing teeth or foreign objects. Is itnormal? nT 1) Remove foreign objects form the sensor rotor and tip. 2) Replace the sensor rotor or the sheel speed sensor. ces After clearing the DTC and driving the vehicle at 40kmih speed or more, ifthe TCS(ESP) lamp is ON and the same DTC shows again, replace the HECU and recheck, .ABS (ANTI-LOCK BRAKE SYSTEM} BR.95 [DTC C1202 |WHEEL SPEED SENSOR FR-LH INVALID/NO SIGNAL. DESCRIPTION © /e70#86 DTC DETECTING Con Condition PossibleCause Large AirGap ‘This monitoring is performed for the period that the minimum velocity rises from 2km/h to 10kmih, = When the minimum wheel velocity is 2km/h and the velocity of other wheels exceed 10kmih with the less than acceleration of 0.49, the controller start comparing the velocity of other wheels except the min. wheel, if their difference below 4km/h is continued for 140msec, Otherwise, if their difference beyond 4km/h or more than 0.4g is continued for 2 minutes. - In<0.4g, when the velocity of more than two wheels is 2km/h and the max. wheel velocity exceeds 10kmih, the condition is continued for 20 sec. Otherwise, In more than 0.4g, the condition is 2 minutes. ~ After velocity of 4 wheel exceeds 10kmv/h, when velocity of 1 wheel or 2 wheel is 2km/h and difference of other 2 wheel velocity is less than 4km/h under that those velocity is more than 10kmih, if that conditions are continued for 12 seconds. [DTC No C1202 (FL) C1205 (FR) = Faulty installing of wheel speed sensor = Openishort'n circuit of whee! C1208 (RL) C1211 (RR) Long Term ABS mode = When the minimum wheel velocity is 2km/h and the velocity of other wheels exceed 10kmih with the less than acceleration of 0.49, the controller start comparing the velocity of other wheels except the min. wheel. if their difference below 4kmn/h is continued for 140msec, Otherwise, if their difference beyond 4kmy/h or more ian 0.4g is continued for 2 minutes, In< 0.4g, when the velocity of more than two wheels is 2km/h and | the max. wheel velocity exceeds 10km/h, the condition is continued for 20 sec. Otherwise, In more than 0.4g, the condition is 2 minutes. ~ After velocity of 4 wheel exceeds 10km/h, when velocity of 1 wheel or 2 wheel is 2km/h and difference of other 2 wheel velocity is less than 4km/h under that those velocity is more than 10km/h, if that conditions are continued for 12 seconds. = During the ABS control cycle, if the wheel velocity of 2km/h is lasted for more than 12sec. ~ If the ABS control cycle is continued for more than 36sec. speed sensor ~ Faulty wheel speed sensor - Faulty rotor or wheel bearing - Faulty HECU - One wheel sensor malfuntion Only the ABS, TCS(ESP) functions are inhibited. the ABS, TCS(ESP) warning lamps are ON, but the EBD warning lamp is OFF. = More than two wheels malfunction ‘The system stops. the ABS, TCS(ESP) and the EBD functions are inhibited. the ABS, TCS(ESP) and the EBD wamingBR-96 BRAKE SYSTEM lamps are ON. The valve relay and all solenoids are OFF. ‘Sensor matfunction with ABS control : - One front wheel matfunction Inhibit the ABS control of @ wheel with a malfunctioning sensor and maintain the ABS control of other wheels. ‘After the ABS control has completed, the ABS, TCS(ESP) functions are inhibited. The ABS, TCS(ESP) warning lamps are ON and the EBD warning lamp is OFF. ~ One rear wheel malfunction Inhibit ABS control of both front wheels and the pressure of both rear wheels is decreased. After the controller completes the ABS control, Only the ABS, TCS(ESP) functions are inhibited. The ABS, TCS(ESP) ‘warning lamps are ON and the EBD warning lamp is OFF. - More than two wheels matfunction, ‘The system stops. the ABS, TCS(ESP) and the EBD functions are inhibited. The ABS, TCS(ESP) and the EBD waming lamps are ON. The valve relay and all solenoids are OFF. 1. CHECK AIR GAP BETWEEN WHEEL SPEED SENSOR AND TONE WHEEL. . Visually check the installing of wheel speed sensors and rotors(see the table below), Specification : 0.5~1.5mm. 4 SN Sle OK NG cana. Dre ‘Appropriate wheel sensor ‘c1202 Front - eft wheel sensor | C1205 Front - right wheel sensor C1208 Rear- left wheel sensor crit Rear- right wheel sensor @ Nore The mounting bolt shall be tightened property and there is no clearance is allowed between the sensor and front ste- ering knuckle or rear axle carver Is the air gap within the specification?ABS (ANTI-LOCK BRAKE SYSTEM) BR.97, > Reinstall or replacece if neccessary, wheel speed sensors in trouble. eS > Check resistance between terminals of wheel speed sensor. 2. CHECK RESISTANCE BETWEEN TERMINALS OF WHEEL SPEED SENSOR. 41) Disconnect the HECU connector. 2) Measure the resistance between wheel speed sensors(+) and (-) circuit terminals(see the table below), Tt ae ERMINAL _ side ©1202 (Front - left) 1 ©1208 (Front - right) 19 ©1208 (Rear - left) 5 | ©1211 (Rear - right) | 23 Is the resistance within less than 10? YES 4)There is @ short in the circuit between the HECU and the wheel speed sensor. 2)Replace the wheel speed sensor. Check speed of each wheel 3. CHECK SPEED OF EACH WHEEL ‘ Check if the speed of each of four wheel properly represents the speed of a vehicle, increasing the speed of the ve- hicle till 6Oknvh. Is the speed of each wheel the same as that of the vehicle? 1) Check any foreign objects on the rotor of the whee! in trouble. 2) Check if the exitoris genuine, eS ‘After cleaning the DTC and driving the vehicle at 40 kmh speed or more, ifthe ABS warning lamp is ON and the same DTC shows again, replace the HECU and recheck.BR.98 BRAKE SYSTEM [DTc c1604 |ECU HARDWARE ERROR TEN Sonaen Posse Cass ~ Wen he MGU can erase or wie dala ofthe EEPROM creo | he mestenlave proceso dtets aonomal operation n Raw, |” EEPROM Falla of HECU status register, interrupt, timer, A/D converter and cycle time. | ee coerce The system stops. the ABS, TCS(ESP) and the EBD functions are inhibited. The ABS, TCS(ESP) and the EBD warning lamps are ON. The valve relay and all solenoids are OFF. 1, CHECK CIRCUIT FOR CONTINUITY BETWEEN THE HECU AND BODY GROUND. Measure the resistance between terminals 8(-), 24(-) of the HECU connector and the body ground. Is the resistance below 107 nw > Check and readjust the installing of the body groud. eS Afr cleaning the DTC and driving the vehicle at 40 km/h speed or more, if he ABS warning lamp is ON and the same DTC shows again, replace the HECU and recheck.ABS (ANTI-LOCK BRAKE SYSTEM) (DTC C2112 [VALVE RELAY ERROR DESCRIPTION | «cosi0e ‘The HECU makes the valve relay OFF, when the ignition switch is turned ON, but ON during its initial check, The HECU checks the valve relay by checking the voltage of the valve power monitoring wire and comparing the signals from the valve relay. The HECU also checks continuity of the valve power monitoring wire. DTC DESRIPTION” Sanwa = This code shows in case that there is no continuity of the valve power monitoring wire, DTC DETECTING CONDITION =1s0c7A9 OFONe onion [Posse Gause |- tn vay stat on ann reerence oop ane | relay, lass than 540.5V_ continuously for 56ms, the failure is, detected, = Ifthe valve relay is switched off and the reference voltage of valve | - Open/shortin the value regal relay, more than 6£0.5V continuously for Sms, the failure is circuit detected ~ Faulty HECU, - Ifthe valve relay is switched off and all solenoid drivers are : switched off and reference voltage of valve relay, less than 2.540.5V continuously for S6ms, , the failure is detected. 2112 FAILSAFE FUNCTION ‘The system stops. the ABS, TCS(ESP) and the EBD functions are inhibited. The ABS, TCS(ESP) and the EBD warning lamps are ON. The valve relay and all solenoids are OFF. INSPECTION PROCEDURE © sta 1. CHECK POWER SOURCE OF MOTOR, 1) Disconnect the connector from the HECU. 2) Measure the voltage between the terminals 9(+) and (-), 24(-) of the HECU connector, Specification: Battery positive(+) 25: 7 ‘ecesoor Is the voltage within the specification?BR-100 BRAKE SYSTEM Is the voltage within the specification? 41) Check ABS fuse (10A) and fusible link (304). 2) Check and repair harness or connector. > Check circuit for conyinuty to ground 2. CHECK CIRCUIT FOR CONTINUITY TO GROUND. 1) Disconnect the connector from the HECU. 2) Measure the resistance between terminals 8(-), 24(-) of the HECU connector and the body ground, Is the resistance below 197 > Check and readjust the installing of the body ground, = > Test motor actuation by using hi-scan (pro) 3. TEST MOTOR ACTUATION BY USING HI-SCAN (PRO), Is the sound of motor operating heard? aS > Check repair, if necessary, hamess and connector. B:8 > Replace the HECU then reckeckABS (ANTI-LOCK BRAKE SYSTEM) BR-101 DTC C2380 |ABS/TCS/ESP VALVE ERROR ‘The HECU monitors the solenoid valve operating circuit. If there is no continuity of the solenoid valve, when the HECU switches the solenoid valve ON, it is @ cause an open or short in the circuit of the solenoid coil or harness. ee Possible Cause ~ If the valve relay is switched ON and corresponding solenoid driver OFF and the voltage of solenoid, less than 3.520.5V 2380 _| continuously for 56ms, the fallure is detected. ace = Ifthe valve relay is switched ON and corresponding solenoid acc driver ON and the voltage of solenoid, more than 1.50.5V_ ulty ‘continuously for 56ms, the failur detected The system stops. the ABS, TCS(ESP) and the EBD functions are inhibited. The ABS, TCS(ESP) and the EBD warning lamps are ON. The valve relay and all solenoids are OFF. 4. CHECK THE DTC 1) Clear the DTC using the Hi-Scan(pro). 2) Tum the ignition wsitch OFF. 3) Tum the ignition switch ON, and check if the same DTC is stored in the memory. Is the same DTC output? Problem is intermittent and the HECU memory was not cleared, Check power source of valve relayBi 02 BRAKE SYSTEM 2. CHECK POWER SOURCE OF VALVE RELAY 1) Disconnect the connector from the HECU. 2) Measure the voltage between the terminals 25 and 8, 24 of the HECU connector. Specification: Battery positive(B+) ora 25: Is the voltage within the specification? 3) Check and replace fuse (10A) and fusible link (0A). 4) Check and repair hamess or connector. . YES > Check circuit for continuity to ground. 3. CHECK CIRCUIT FOR CONTINUITY TO GROUND. 1) Disconnect the connector from the HECU. 2) Measure the resistance between terminals 8(-), 24(-) of the HECU connector and the body ground. Is the resistance below 19? > Check and readjust the installing of the body ground. Replace the HECU then reckeck.ABS (ANTI-LOCK BRAKE SYSTEM) (DTC C2402 [MOTOR-ELECTRICAL ‘This code shows in case that there is no signal to the motor monitering wire or an error on the motor power. & caution Keep a vehicle ioling because the compulsive operating of the motor shall cause the discharge ofthe battery, when testing the actuator. Condition ___| Possible Cause = Ifthe motor relay is switched ON and motor voltage is 4V less than IGN voltage continued for 56ms, the failure is detected, ~ After 1.8sec from motor relay is switched OFF, the motor voltage is more than 4V continued for 1.8sec, the failure is detected. . = After motor relay is switched OFF, motor voltage is measured. If | - Openishortin motor regal or ©2402 _| the time which motor voltage less than 1V/is less than evaluation | motor circuit. time, the motor is reactivated for 500msec and the above check is. | - Motor lock performed again for a maximum of two times. When the motor | + Faulty HECU voltage is not normal even on the second recheck, the controller recognizes it as failure. ifthe motor relay is swithched OFF and motor power supply voltage < 4V continued for 200ms, the failure is detected 4, Motor error without the ABS control : only the ABS, TCS(ESP) functions are inhibited. The ABS,TCS(ESP) warning lamps are ON, but the EBD warning lamp OFF. 2. Motor error with the ABS control: inhibit the ABS control of front wheels, allow ABS control of the rear wheels. After the ABS contro! has completed, the ABS,TCS(ESP) warning lamps are ON.BRAKE SYSTEM 1. CHECK POWER SOURCE OF MOTOR. 4) Disconnect the connector from the HECU. 2) Measure the voltage between the terminals 9(+) and 8(-), 24() ofthe HECU connector. Specification: Battery positive(+) 24 esse Is the voltage within the specification? 3) Check ABS fuse (10A) and fusible link (30A). 4) Check and repair hamess or connector. D Check circuit for conyinuty to ground.ABS (ANTI-LOCK BRAKE SYSTEM) BR-105 CHECK CIRCUIT FOR CONTINUITY TO GROUND. 1) Disconnect the connector from the HECU. 2) Measure the resistance between terminals &(-), 24(-) of the HECU connector and the body ground. 2 a below 107 > Check and readjust the instaling of the body ground, YES > Test motor actuation by using hi-scan (pro) 3, TEST MOTOR ACTUATION BY USING HI-SCAN (PRO). Is the sound of motor operating heard? a. YES > Check repair, if necessary, hamess and connector. > Replace the HECU then reckeck.BR-106 BRAKE SYSTEM DTC C1274|G SENSOR-ELECTRICAL [BTC No Conalion Possible Caese| | When the voltage of Gsensor signal is more than 4.5V or less than | ~ Oper’short in G-sensorcircutt cr27a | ~ Faulty G-sensor (0.8V for 250) seheelier eltea ~ Faulty installing of G-sensor | | ~ Faulty HECU FAILSAFE FUNCTION a Only the ABS, TCS(ESP) functions are inhibited. The ABS,TCS(ESP) waming lamps are ON, but the EBD warning lamp OFF. 1, CHECK SHORT IN CIRCUIT TO BATTERY(+), 41) Disconnect the connector from the HECU. 2) Tum the ignition switch ON. 3) Measure the voltage between terminal 13 of the HECU connector and the body ground, Is the voltage above 4.5V? D> Repair short in the circuit to battery(+) between the G-sensor and the HECU. D Check short in circuit to ground, 2. CHECK SHORT IN CIRCUIT TO GROUND. 1) Disconnect the connector from the HECU. 2) Measure the resistance between terminal 13 of the HECU connector and the body ground. Is the resistance below 107 D> Repair short in the circuit to the body ground between the G-sensor and the HECU. > Check output in HECU connector 3, CHECK OUTPUT IN HECU CONNECTOR. 4) Disconnect the connector from the HECU and tur the ignition switch ON. 2) Measure the voltage between terminals 13(+) and 15(-) of the HECU connector. Is the voltage within 0.6V ~ 4.5V? YES > Check the HECU hamess or connector. i) > If necessary, replace the HECU then recheckABS (ANTI-LOCK BRAKE SYSTEM) BR-107 4, CHECK OUTPUT IN G-SENSOR CONNECTOR, 1) Tum the ignition switch ON. 2) Measure the voltage between terminals 2(+) and 3(-) of the G-sensor connector. Specification: approximately 8 5V Is the voltage within the specification? > Replace the G-sensor. > Replace the HECU then recheck.BR-108 BRAKE SYSTEM [DTC C1275 |G SENSOR-SIGNAL DTC DETECTING CONDITION — e0aesert [DTC No Condition T “Possible Caese = When vehicle speed is more thantOkmih and the brake light | - Open/short in G-sensor circuit. 1275 switch is off, \G|> 0.56’ for 20sec continuously. ~ Faulty G-sensor = When’ |min. wheel speed| dt 20.2G and [G| $0.16 for 60sec | - Faulty instaling of G-sensor continuousty ~ Faulty HECU FAILSAFE FUNCTION) Sse a Only the ABS, TCS(ESP) functions are inhibited. The ABS,TCS(ESP) warning lamps are ON, but the EBD warning lamp OFF. 4. CHECK OPEN/SHORT IN CIRCUIT OF G-SENSOR. 4) Tum the ignition switch ON. 2) Measure the output voltage between terminals 2(+) and 3(-) of the G-sensor connector. Is the voltage within 0.6V ~ 4.5V? > Repair an open or short in the circuit between the G-sensor and the HECU. Check installing of G-sensor 2. CHECK INSTALLING OF G-SENSOR Visually check for the intalling of the G-sensor. Be sure to install the G-sensor with the arrow mark to be facing forward direction. Is it installed correctly? > Reinstall the G-sensor and recheck. > Check output voltage in G-sensor connectorABS (ANTI-LOCK BRAKE SYSTEM) 3, CHECK OUTPUT VOLTAGE IN G-SENSOR CONNECTOR. Turn the ignition switch ON. Measure the voltage between terminals 2(+) and 3(-) of the G-sensor connector. Specification : approximately 2.5V Incline the G-sensor to 90 degrees angle then measure the voltage between terminals 2(+) and 3(-) of the G-sensor connector. Specification : approximately 3.5V Is the voltage within the specification? > Replace the G-sensor. > Replace the HECU then recheck.BR-110 BRAKE SYSTEM DTC C1503 |TCS SWITCH ERROR The TCS(ESP) OFF switch is for ON/OFF of TCS(ESP) function When the TCS(ESP) OFF switch is pushed, the TCS(ESP) system stops and the TCS(ESP) OFF lamp is ON. Condition Possible Cause = Openishort in TCSIESP switch 103. | When the TCS/ESP switch is ON for 1 min. circuit. - Faulty TCS/ESP switch - Faulty HECU ‘The TCS/ESP function is inhibited, while the ABS and EBD controls allowed. The TCS/ESP warning lamp is ON, but the ABS and EBD warning lamps OFF.ABS (ANTI-LOCK BRAKE SYSTEM) Bi 1. CHECK TCS(ESP) OFF SWITCH 1) Remove the TCS(ESP) OFF switch from the panel of the driver’s side crashpad. 2) Check for the continuity between the TCS(ESP) OFF switch terminals, when the TCS(ESP) OFF switch is ON. Is there continuity between terminals 3 and 4 of the TCS (ESP) switch connector? Temninal Funeton ow [oto we ue > Replace with a new TCS(ESP) OFF switch. } Check short in circuit of TCS/ESP SwitchBR-112 BRAKE SYSTEM 2, CHECK SHORT IN CIRCUIT OF TCS/ESP SWITCH 1) Remove the TCS(ESP) OFF switch from the panel of the driver's side crashpad. 2) After the ignition switch is ON, measure the voltage between terminal 3 of the TCS(ESP) OFF switch connec- tor and the body ground, Specification : Battery positive (B+) Is the voltage within the specification? (1) Check and replace fuse(10A). (2) Check and repair harness and connector. YES > Check open/short in circuit between TCS(ESP) OFF switch and the HECU. 3, CHECK OPEN/SHORT IN CIRCUIT BETWEEN TCS(ESP) OFF SWITCH AND THE HECU ‘Check an open or short in the circuit between terminal 3 of TCS(ESP) OFF switch connector and terminal 14 (ES- P:27) of the HECU connector. 1s the circuit normal? > Check and repair the circuit between the switch and the HECU. : > After clearing the DTC and driving the vehicle at 40Knv/h speed or more, ifthe TCS(ESP) lamp is ON and the same DTC shows again, replace the HECU and recheck.ABS (ANTI-LOCK BRAKE SYSTEM) DTC C1605 |CAN HARDWARE ERROR: DTC No Condition Possible Cause C1605 | In case that CAN has hardware failure, - Faulty CAN bus ‘The TCS/ESP function is inhibited, while the ABS and EBD controls allowed. ‘The TCS/ESP warming lamp is ON, but the ABS and EBD waming lamps OFF.BR-114 BRAKE SYSTEM a Enea” [DTC C1617 [CAN TIME-OUT EMS ‘The CAN is for sending and recelving the information for TCS(ESP) control, between the HECU and EMS/TCU. ‘This code shows in case that there is no signal to the CAN from EMS. [DTC No Condition Possible Cause | 4. In case that EMS1 or EMS2 message was not received for more | - Open/short in CAN bus circuit. | C1611 | than 500ms within normal voltage condition. ~ Faulty CAN bus | | 2. The monitoring starts 2000 ms after power up. - Faulty EMS | | ~ Faulty HECU | ‘The TCS/ESP function is inhibited, while the ABS and EBD controls allowed. ‘The TCS/ESP warning lamp is ON, but the ABS and EBD warning lamps OFF. 4. CHECK DTC DETECTED IN HI-SCAN 1) Clear the DTC related to the CAN, from the EMS or TCU by using the HI-SCAN. 2). Check if any DTC related to the CAN is detected again, when the ignition switch ON. Is any DTC related to the CAN, detected again? > Problem is intermittent and the HECU memory was not cleared. > Check open/short in sircuit of the CAN 2. CHECK OPEN/SHORT IN CIRCUIT OF THE CAN 1) Check an open or short in the circuit between terminal 10 of the HECU connector and terminal 4 of PCM con- nector. 2) Check an open or short in the circult between terminal 11 of the HECU connector and terminal 7 of PCM con- nector. Is the circuit normal? NO. > Check and repair harness and connector. } Check the PCM (refer to EE or TR group).OCK BRAKE SYSTEM) BR. ABS (ANTI. DTC C1612 |CAN TIME-OUT TCU The CAN is for sending and receiving the information for TCS(ESP) control, between the HECU and EMS/TCU. This code shows in case that there is no signal to the CAN from TCU. [ DTC No Condition Possible Cause | | 1. Incase that TCU message was not received for more than = Openvshort in CAN bus circuit ©1612. | 500ms within normal voltage condition 2. The monitoring starts = Faulty CAN bus | 2000 ms after power up, - Faulty TCU | | - Faulty HECU ‘The TCS/ESP function is inhibited, while the ABS and EBD controls allowed. ‘The TCS/ESP warning lamp is ON, but the ABS and EBD warning lamps OFF. 1. CHECK DTC DETECTED IN HI-SCAN 1) Clear the DTC related to the CAN, from the EMS or TCU by using the HI-SCAN. 2) Check if any DTC related to the CAN is detected again, when the ignition switch ON. Is any DTC related to the CAN, detected again? > Problem is intermittent and the HECU memory was not cleared. > Check openishort in circuit of the CAN 2. CHECK OPENISHORT IN CIRCUIT OF THE CAN 1) Check an open or short in the circuit between terminal 10 of the HECU connector and terminal 4 of PCM con- nector. 2) Check an open or short in the circuit between terminal 11 of the HECU connector and terminal 7 of PCM con- rector. Is the circuit normal? > Check and repair hamess and connector. > Check the PCM (refer to EE or TR group).BRAKE SYSTEM. CAN WRONG MESSAGE The CAN is for sending and receiving the information for TCS(ESP) control, between the HECU and EMSITCU. This code shows in case that EMS misunderstands a vehicle with A/T to with M/T. In this case check if itis correct the information received from EMS by using the HI-SCAN. DTC No i Condition = Possible Cause 7. In case that the information about transmission is different in the 1613. | EMS2 and TCU within normal voltage condition.2. The monitoring | - Faulty CAN bus starts 2000 ms after power up. = Faulty EMS or TCM ‘The TCS/ESP function is inhibited, while the ABS and EBD controls allowed. ‘The TCS/ESP warning lamp is ON, but the ABS and EBD waming lamps OFF.ABS (ANTI-LOCK BRAKE SYSTEM) BR-117 [DTC C1616 [CAN BUS OFF OTENe cna Bossbie Cause = Open/short in CAN bus circuit. C1846 | ncose CAN BUS of state continue for more than 100ms. = Openisont nC © Feuly HecU | ‘The TCS/ESP function is inhibited, while the ABS and EBD controls allowed. ‘The TCS/ESP warning lamp is ON, but the ABS and EBD waming lamps OFF. 1. CHECK OPEN/SHORT IN CIRCUIT OF THE CAN 1) Check an open or short in the circuit between terminal 10 of the HECU connector and terminal 4 of PCM con- nector. 2) Check an open or short inthe circuit between terminal 11 of the HECU connector and terminal 7 of PCM con- rector. Is the circuit normal? > Check and repair harness and connector. Check the POM (refer to EE or TR)BR-118 BRAKE SYSTEM DTC ©2227 |EXCESSIVE TEMPERATURE OF BRAKE DISC ‘The TCS controls the brake by using the motor pump. When the TCS operates, The TCS detects overheating of the brake disk. DTC No_| Condition Possible Cause ‘When the calculated temperature of disc is higher than 500°C 2.If the calculated temperature drops below 300°C, the controller 62227 | recovers to normal state. 3.When IGN switched OFF, ECU calculate temperature of disc until calculated temperature drops below 80°C by BATT1 power. ~ Brake disc over working ‘The TCSIESP function is inhibited, while the ABS and EBD controls allowed. ‘The TCS/ESP warning lamp is ON, but the ABS and EBD warning lamps OFF.ABS (ANTI-LOCK BRAKE SYSTEM) BR-119 [DTC C1112 [SENSOR SOURCE VOLTAGE DTC No Condition Possible Cause C1112 _| Ifthe voltage of sensor power is out ofthe range of SV0.8V for 0.8sec, the fail I - Faulty Sensor Power 20, the failure is recognized. teen cena ‘The ESP function is inhibited, while the ABS and EBD controls allowed, ‘The ESP warning lamp is ON, but the ABS and EBD warning lamps OFF.BR-120 BRAKE SYSTEM DTC C1235 |PRESSURE SENSOR(PRIMARY)-ELECTRICAL ing. [DTC No. | Detecting Condition Possible Cause | _ “ = Open/Short in the pressure C1235. | 1. When VMCP > 4.8V or VMCP < 0.2V continue 1second, eene cecum 2. The Monitoring starts 1 sec after Power Up. ~ Faulty the pressure sensor ~ Faulty instaling of the pressure sensor ~ Faulty HECU The ESP function is inhibited, while the ABS and EBD controls allowed. ‘The ESP warning lamp is ON, but the ABS and EBD warning lamps OFF. 1. CHECK INSTALLING OF PRESSURE SENSOR 1) Check if the pressure sensor is property installed on the master cylinder. Is the pressure sensor installed properly? > Reinstall the pressure sensor properly, > Check power of pressure sensor 2. CHECK POWER OF PRESSURE SENSOR 4) Disconnect the pressure sensor connector, and measure the voltage between terminals 1(-) and 3(+) of the pressure sensor connector. Specification : 4.8~5. Is the voltage within the specification? D> Check hamess and connector between the HECU and the pressure sensor. ra, output voltage of pressure sensorABS (ANTI-LOCK BRAKE SYSTEM) 3, CHECK OUTPUT VOLTAGE OF PRESSURE SENSOR 1) Measure the voltage between terminal 2 of the pressure sensor connector and the body ground. “Specification : 0.5~4.5V Is the output voltage within the specification? > Check harness and connector of the pressure sensor. Ifno error on the hamess and the connector, replace the pressure sensor and recheck. = > Check output voltage of HECU connector 4, CHECK OUTPUT VOLTAGE OF HECU CONNECTOR 1) Measure the voltage between terminal 12 of the HECU connector and the body ground. Specification : 0.5~4.5V Is the voltage within the specification? > Repair hamess and connector between the HECU and the pressure sensor. 3 : > Alter clearing the DTC and driving the vehicle at 40Kmw/h speed or more, ithe ESP lary DTC shows again, replace the HECU and recheck. ON and the sameBRAKE SYSTEM DTC C1237 [PRESSURE SENSOR-SIGNAL DTC No. Detecting Condition 1. If input signal is noisy, which the gradient of the sensor signal is larger than predefined value, the failure is recognized, 2. Outside an ABSIBTCS control, correlation of the vehicle deceleration and the pressure sensor signal is evaluated, ifit is not ©1237 | reasonable ECU detect the failure. 3. When the vehicle speed is higher than predefined value and pressure signal is higher than predefined value, if there is no Variation of the pressure sensor signal for predefined time ECU detect the failure. = Open/Short in the pressure | sensor circuit | Faulty the pressure sensor Faulty installing of the pressure sensor | - Faulty HECU ‘The ESP function is inhibited, while the ABS and EBD controls allowed. The ESP waming lamp is ON, but the ABS and EBD waming lamps OFF.1 CHECK INSTALLING OF PRESSURE SENSOR Check if the pressure sensor is properly installed on the master cylinder. Is the installing proper ? > Reinstall the pressure sensor properly. > Check power of pressure sensor. CHECK POWER OF PRESSURE SENSOR Disconnect the pressure sensor connector, and measure the voltage between terminals 1 and 3 of the pressure se- ‘asor connector. Specification : 4.8~5.2 V Is the power voltage within the specification? Check harness and connector between the HECU and the pressure sensor. > Check output voltage of pressure sensor (CHECK OUTPUT VOLTAGE OF PRESSURE SENSOR : Measure the output voltage between terminal 2 of the pressure sensor connector and the body ground. Specification : 0.5~4.5V Is the output voltage within the specification? > Check hamess and connector of the pressure sensor. Ifno error on the harness and the connector, replace the pressure sensor and recheck Alter clearing the DTC and driving the vehicle at 40Km/h speed or more, if the ESP lamp is ON and the same DTC shows again, replace the HECU and recheckBR-124 BRAKE SYSTEM DTC C1259 [STEERING ANGLE SENSOR-ELECTRICAL Steering angle sensor is a plate between the photo-controller LED and the photo transistor. As the plate rotates with steering wheel rotation, electrical signal will be generated depending on whether the LED light passes through the plate to the photo-transistor or not. The signal is the steering wheel operation angular velocity and used to detect the steering wheel tuming direction, ‘DIC DESCRIPTION = etrsiroo ‘This code shows in case that there is an open or short in the circuit of the steering angle sensor. [DTC No. Detecting Condition Possible Cause 4.When Vsas > 4.4 or Vsas < 1.1 oF 2.3V Reinstall the steering angle sensor property 75 > Check power of steering angle sensor 2, CHECK POWER OF STEERING ANGLE SENSOR Disconnect the steering angle sensor connector, and measure the voltage between terminals 2 and 3 of the steering angle sensor connector. Specification : 9~16 V Is the voltage within the specification? > Check harness and connector between the HECU and the steering angle sensor. Check output voltage of steering angle sensorABS (ANTI-LOCK BRAKE SYSTEM) BR-125 3. CHECK OUTPUT VOLTAGE OF STEERING ANGLE SENSOR Measure the voltage between terminal 1,4, and 6 of the steering angle sensor connector and the body ground. Specification : High : 3.0~4.1V Low : 1.3~2,0V Is the voltage within the specification? > Check hamess and connector of the steering angle sensor. If no error on the harness and the connector, replace the steering angle sensor and recheck. YES } Check output of HECU connector 4, CHECK OUTPUT OF HECU CONNECTOR Measure the voltage between terminal 8,40, and 39 of the HECU connector and the body ground. Specification : High : 3.0~4.1V Low : 1.3~2.0V Is the voltage within the specification? > Repair hamess and connector between the HECU and the steering angle sensor. : > After clearing the DTC and driving the vehicle at 40Knvh speed or more, if the ESP lamp is ON and the same DTC shows again, replace the HECU and recheck.BR-126 BRAKE SYSTEM DTC C1260 [STEERING ANGLE SENSOR-SIGNAL Steering angle sensor is a plate between the photo-controller LED and the photo transistor. As the plate rotates with steering wheel rotation, electrical signal will be generated depending on whether the LED light passes through the plate to the photo-transistor or not. The signal is the steering wheel operation angular velocity and used to detect the steering wheel turning direction. (DTC DESCRIPTION Detecting Condition Possible Cause | 1. When the steering wheel is turned more than 36 degrees, i neutral signals maintained ECU detects the failure 2. When the steering wheel s turned more than 364 degrees, if neutral signal is not detected, ECU detects the failure 3.When the steering wheel angle is lager than 700 degrees ECU | rake genon nu or stenting detec the failure : : C2 cacti ivng, ie steeng hee anlage than |” Fa ting angle sonsor predefined degree ECU detects the failure a 8. When the vehicle speed is higher than 15km/H and reference | * Faulty HECU steering wheel angle i larger than #18 degrees, if there is no Variation ofthe steering whee! angle for predefined time ECU detect the failure. ‘The ESP function is inhibited, while the ABS and EBD controls allowed. ‘The ESP waming lamp is ON, but the ABS and EBD warning lamps OFF. 1. CHECK INSTALLING OF STEERING ANGLE SENSOR Check ifthe steering angle sensor is properly installed. Is the installing proper? > Reinstall the steering angle sensor propery > Check power of steering angle sensorABS (AN’ OCK BRAKE SYSTEM) 2, CHECK POWER OF STEERING ANGLE SENSOR, Disconnect the steering angle sensor connector, and measure the voltage between terminal 2 and 3 of the steering angle sensor connector. eV Specification Is the voltage within the specification? > Check harness and connector between the HECU and the steering angle sensor. > Check output signal of steering angle sensor 3. CHECK OUTPUT SIGNAL OF STEERING ANGLE SENSOR 1) Check if both ST1 and ST2 alterate High and Low signal, rotating the wheel 2) Check if STN has Low signal, rotating the wheel at 360 degree in one direction. Is the signal of the steering angle sensor normal? > Check harness and connector of the steering angle sensor. If no error on the harness and the connector, replace the steering angle sensor and recheck. aa Afr clearing the DTC and driving the vehicle at 40Knvh speed or more, if the ESP lamp’is ON and the same DTC shows again, replace the HECU and recheck :BR-128 BRAKE SYSTEM DTC C1282 [YAW RATE & LATERAL G SENSOR-ELECTRICAL ‘The yaw-rate & Lateral G sensor's for the stability of a vehicle. The yaw-rate is to measure angular velocity while the Lateral G is to measure the force that makes a vehicle away from the center, when a vehicle comering. ‘DTC DESCRIPTION © ‘This code shows in case that there is an open or short in the circuit of the yaw-rate & lateral G sensor. DTC No. Detecting Condition Possible Cause [Yaw Rate Sensor Open, short to GND, B+] 1) When Vyaw > 4.85V or Vyaw < 0.15V continue 1sec, ~ Yaw Rate & Lateral G Sensor 2) The Monitoring starts 1 s after Power Up Open, short to GND ©1282 | 1 ateral G Sensor Open, Short to GND, B+] ~ Faulty Yaw Rate & Lateral G 4) When Vig > 4.85V or Vig < 0.15V continue 1sec, Sensor 2) The Monitoring starts 1 § after Power Up = Faulty HECU ‘The ESP function is inhibited, while the ABS and EBD controls allowed. ‘The ESP warning lamp is ON, but the ABS and EBD warming lamps OFF. 1. CHECK POWER OF YAW-RATE & LATERAL G SENSOR Disconnect the connector from the yaw-rate& Lateral G sensor, and measure the voltage between terminals 3 and 4 of the yaw-rate& Lateral G sensor. Specification : 4.75~5.25 V = : Is the voltage within the specification? > Check harness and connector between the HECU and the yaw-rate & lateral G sensor. > Check output of yaw-rate & lateral G sensorABS (ANTI-LOCK BRAKE SYSTEM) 29 2, CHECK OUTPUT OF YAW-RATE & LATERAL G SENSOR 1) When the ignition switch is OFF, measure the voltage between terminal 1 of the yaw-rate sensor connector and the body ground. 2) When the ignition switch is OFF, measure the voltage between terminal 2 of the lateral G sensor connector and the body ground, Specification : 2.252.75V Is the voltage within the specification? > Check hamess and connector of the yaw-rate & lateral G sensor. If no error on harness and connector, replace and recheck the yaw-rate & lateral G sensor. YES > Check output voltage of HECU connector for yaw-rate & lateral G sensor 3. CHECK OUTPUT VOLTAGE OF HECU CONNECTOR FOR YAW-RATE&LATERAL G SENSOR 1) When the ignition switch is OFF, measure the output voltage between terminal 41 of the HECU connector and the ground. 2) When the ignition switch is OFF, measure the output voltage between terminal 9 of the HECU connector and the ground, ‘Specification : 2.25~2.75V Is the output voltage within the specification? > Repair hamess and connector between the HECU and the yaw-rate & lateral G sensor. After clearing the DTC and driving the vehicle at 40Knvh speed or more, ifthe ESP lamp is ON and the same DTC shows again, replace the HECU and recheck.BR-130 BRAKE SYSTEM DTC C1283 [YAW RATE & LATERNAL G SENSOR-SIGNAL ‘The yaw-rate & Lateral G sensor is for the stability of a vehicle. The yaw-rate is to measure angular velocity while the Lateral G is to measure the force that makes a vehicle away from the center, when a vehicle comering SSS See DTC No. Detecting Condition Possible Cause [Yaw Rate Sensor offset error, noisy signal, stick] 4) During standstil if yaw rate value is larger than predefined value, the failure is recognized | 2)if input signal is noisy, which the gradient of the sensor signal is larger than predefined value, the failure is recognized. | If the difference between estimated value and measured value of + Yaw Rate & Lateral G Sensor the sensor is larger than predefined value for predefined time, the | Open, short to GND ©1283 | failure is recognized. = Faulty Yaw Rate & Lateral | [Lateral G Sensor offset error, noisy signal, slick) Sensor 7 | 4)if input signal is noisy, which the gradient ofthe sensor signal is. | - Faulty HECU . larger than predefined value, the failure is recognized. 2) Ifthe difference between estimated value and measured value of the sensor is larger than predefined value for predefined time, the I failure is recognized. ‘The ESP function is inhibited, while the ABS and EBD controls allowed. The ESP warning lamp is ON, but the ABS and EBD warning lamps OFF. 4. CHECK POWER OF YAW-RATE & LATERAL G SENSOR Disconnect the connector from the yaw-rate& Lateral G sensor, and measure the voltage between terminal 3 and 4 of the yaw-rate& Lateral G sensor. Specification : 4.75~5.25 V = Is the voltage within the specification? Check hamess and connector between the HECU and the yaw-rate & lateral G sensor. > Check output of yaw-rate & lateral G sensorABS (ANTI-LOCK BRAKE SYSTEM) BR-131 2. CHECK OUTPUT OF YAW-RATE & LATERAL G SENSOR 41) When the ignition switch is OFF, measure the output voltage between terminal 4 of the yaw-rate sensor conn- ector and the body ground. 2) When the ignition switch is OFF, measure the output voltage between terminal 2 of the lateral G sensor conn- ector and the body ground. Specification : 2.25~2.75V Is the output voltage within the specification? > Check hamess and connector of the yaw-rate & lateral G sensor. If no error on harness and connector, replace and recheck the yaw-rate & lateral G sensor. YES > Check output voltage of HECU connector for yaw-rate & lateral G sensor 3. CHECK OUTPUT VOLTAGE OF HECU CONNECTOR FOR YAW-RATE&LATERAL G SENSOR 1) When the ignition switch is OFF, measure the output voltage between terminal 41 of the HECU connector and the body ground, 2) When the ignition switch is OFF, measure the output voltage between terminal 9 of the HECU connector and the body ground. Specification : 2,2~2.75V Is the output voltage within the specification? > Repair hamess and connector between the HECU and the yaw-rate & lateral G sensor. > Check output of yaw-rate & lateral G sensor when vehicle cornering 4. CHECK OUTPUT OF YAW-RATESLATERAL G SENSOR WHEN VEHICLE CORNERING. Check if any change of the voltage of the yaw-rate & lateral G sensor, when a vehicle is comering Is there any change of the voltage of the sensor? > Replace and recheck the yaw-rate & lateral G sensor. > After clearing the DTC and driving the vehicle at 40Km/h speed or more, if the ESP lamp is ON and the same DTC shows again, replace the HECU and recheckBR-132 [DTC C1513 [BRAKE SWITCH ERROR: DTC No. Detecting Condition Possible Cause If both brake lamp switch and brake switch have a same state for nee ‘switch Open, short to 1813 predetermined time, the failure is recognized. GAD. iid evan ~ Faulty HECU ‘The ESP function is inhibited, while the ABS and EBD controls allowed. - ‘The ESP warning lamp is ON, but the ABS and EBD warming lamps OFF.ABS (ANTI-LOCK BRAKE SYSTEM) BR-133 1. CHECK OPEN/SHORT IN CIRCUIT OF BRAKE SWITCH 1) Disconnect the connector from the HECU, and measure the voltage between terminal 21 of the HECU conne- ctor and the body ground, not pushing the brake pedal. ‘Specification : Battery (B+) 2) Disconnect the connector from the HECU, and measure the voltage between terminal 21 of the HECU conne- ctor and the body ground, pushing the brake pedal Specification : OV Is the voltage within the specification? > Repair hamess and connector ofthe brake switch > Check open/short in circuit of brake lamp switch 2. CHECK OPEN/SHORT IN CIRCUIT OF BRAKE LAMP SWITCH 1) Disconnect the connector from the HEU, and measure the voltage between terminal § ofthe HECU connec- tor and the body ground, not pushing the brake pedal ‘Specification : OV 2) Disconnect the connector from the HECU, and measure the voltage between terminal 21 of the HECU conne- ctor and the body ground, pushing the brake pedal Specification : Battery (B+) Is the voltage within the specification? > Repair harness and connector of the brake lamp switch, > Alter clearing the DTC and driving the vehicle at 40Kmyh speed or more, if the ESP lamp is ON and the same DTC shows again, replace the HECU and recheck.BR-134 BRAKE SYSTEM BLEEDING OF BRAKE SYSTEM — ceeposco «3 Connect the hi-scan (pro) to the data link connector located underneath the dash panel. ‘This procedure should be followed to ensure adequate bleeding of air and filing of the ABS unit, brake lines and master cylinder with brake fluid, 1. Remove the reservoir cap (A) and fil the brake rese- oir with brake fluid. & caution If there is any brake fluid on any painted surface, wash itoff immediately @ nore When pressure bleeding, do not depress the brake pedal. Recommended fluid... OOT3 or DOT4 2, Connect a clear plastic tube to the wheel cylinder bl- soo eeder plug (A) and insert the other end of the tube into a half filled clear plastic bottle.ABS (ANTI-LOCK BRAKE SYSTEM) BR-135 4, Select and operate according to the instructions on the hi-scan (Pro) screen. & caution You must obey the maximum operating time of the ABS motor with the hi-scan (Pro) to prevent the motor ‘pump from burning. 1) Select hyundai vehicle diagnosis. 2) Select vehicle name. 3) Select Anti-Lock Brake system. 4) Select air bleeding mode. 5) Press "YES" to operate motor pump and solenoid valve. 1.6 AIR BLEEDING MODE ABS AIR BLEEDING STATUS 01. SOLENOID VALVE STATUS 02, MOTOR PUMP STATUS DO YOU WANT TO START ? (PRESS [YES] KEY) cLose OFF 6) Walt 60 sec. before operating the air bleeding, (lf not, you may damage the motor.) 1.6 AIR BLEEDING MODE ABS AIR BLEEDING STATUS 01. SOLENOID VALVE STATUS OPEN. 02. MOTOR PUMP STATUS ON TIME : AUTOMATIC COUNT (1-60 SEC.) o Pump the brake pedal several times, and then loosen the bleeder screw unti fluid starts to run out without bubbles. Then close the bleeder screw. 6. Repeat step 5 until there are no more bubbles in the fluid for each whee. @ Front right © Rear right @ Front et @Reariett recom 7. Tighten the bleeder screw. Bleed screw tightening tore 7-13 Nm (70 ~130 kg'cm, 5.1 ~ 95 lb-ft)BR-136 BRAKE SYSTEM ANTI-LOCK BRAKING SYSTEM CONTROL MODULE COMPONENTS — ccoocier Rearlett tube Front-right tube Master cylinder Primary(MCP) tube Nut,12~16(120-160, 8.9-11.8) : Bolt, 17-26(170-260,12.5~19.2) | Far-right tube : : ? [ABS control module connector (25P) I ‘ABS control module (HECU) Bracket Bolt, 8-10(80-100,5.9-7.4) TORQUE : Nm(Kgf-em,lbf-ft)ABS (ANTI-LOCK BRAKE SYSTEM, HECU EXTERNAL DIAGRAM cagsag0a [ABs ECU] INLET VALVE(FR) INLET VALVE(RL) INLET VALVE(RR) INLET VALVE(FL) : OUTLET VALVE(FR) OUTLET VALVE(RL) : OUTLET VALVE(RA) ‘OUTLET VALVE(FL) "MONITER(+) EMOTER(GND) ZEro7mI0m> [res ecu} INLET VALVE(FR) INLET VALVE(RL) INLET VALVE(RA) A B c D F : OUTLET VALVE(AL) G: OUTLET VALVE(AR) H: OUTLET VALVE(FL) |: TRACTION VALVE(TCR) J: TRACTION VALVE(TCL) M: MOTER() N: MOTER(GND)BR-138 BRAKE SYSTEM CIRCUIT DIAGRAM caoceror [ABs] 4 BATE! 3 - i a Pump +) 3 Pury Hoe “« me TE saseso tain ro | | Pumpi-)) a 1 ns mae] a : ‘Wheel speed(FR) aa 3 Ho vet sescee DOO eae ® vines sensory EXO row Wet sowartts YOO @ ®@ ‘Wheel sensor(AR)| x XX x Power] o4| ® g @ ® @@ Soc} S83 fe an sensor round] ;5| @ @O® oul 2 B® GroundiPump motor) »4| + MAIN CONNECTOR(25P)ABS (ANTI-LOCK BRAKE SYSTEM) res} WLP : Warning lamp FLP : Function lamp +] BATTERY 8 g § Pump() # zs 2 at Gs : = Th ros ELF on LCs Swit Pump(-) su 2S se, ‘switch ABS/EBD WLP 14 Tos HISCAN ‘Wheel speed(FR)———Subut FA) A : win sonore FXO emf i 20) Wheel Sensor(FR) Power 19| : net srs G00 ater | a = ® ® sna ses (F000 ee — | wea Dees Su 000 ean ® ste canton 333 : e-sensor| 1 &8o . SSavo" Leaasrand See 2Se Oo ® Ground _| 5 Ground (Pump moton)| ++ MAIN CONNECTOR(25P)BR-140 BRAKE SYSTEM OR ABS/TCS CONNECTOR INPUT/OUTPUT EC98E439 Connector Specification Remark No [ ‘Over voltage range: 16.540.5V Operating voltage range: 9.620.5V 0.7 IGN Output voltage : VOL < 0.2 IGNIV} VOH > 0.8 IGNIV]BR-142 BRAKE SYSTEM REMOVAL eseszoa0 1. Disconnect the double lock (A) from the Hecu. 2. Disconnect the brake tube from the HECU by unloc- king the nuts centerclockwise with a spanner. ( nore + Donot spill brake fluld on vehicle; it may damage the pail; if brake fluid gets on the paint, wash it off immediately with water. + Take care not to damage or defrom the brake I- nes during remove and water. + To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel ‘or equivalent material 3. Remove the three HECU brake mounting bolts disa- ssemibly the HECU with the bracket. & caution 1, Never attemit to disassemble the HECU. 2. The HECU must be transported and stored in ‘an upright podution and with the ports sealed. 4, Remove the three HECU mounting bolts and disass- embly the HECU from the bracket. INSTALLATION cccaresa 1. Installation is the reverse of removal. 2. Tighten the HECU mounting bolts and brake tube nuts to the specified torque. Tighteming torque HECU mounting bolt: 8~10Nm (80~100 kg-cm, 5.9~7.3 Ibfft) HECU braket mounting bolt: 17-26 Nm (170-260 kg'om, 12.5~19.1 Ibf ft) Brake tube nut 13~17 Nm (130~170 kg-cm, 9.5~12.5 Ibf-ft)ABS (ANTI-LOCK BRAKE SYSTEM) BR-143 ANTI-LOCK BRAKING SYSTEM WHEEL SPEED SENSOR COMPONENTS © ceparaac [Front] Front wheel speed sensor ‘connector Bolt.6-9(80-90,5.9-6.6) ——>o” [Rear] Rear wheel speed sensor connector TORQUE : Nm(kgfom, Int)BR-144 BRAKE SYSTEM DESCRIPTION ‘Atoothed rotor is fixed to the rotating member of the whe~ el, the sensor to the static member of the suspension. As the wheel rotates the toothed rotor causes magnetic flux changes in the magnetic field of the permanent magnet. ESOEAAAA, ‘The sensor element senses these changes. Depending on the flux changes the sensor sends a signal out to the ECU. The change in magnet flux thus the sensor signal is directly correlated to the wheel speed. ‘The controller monitors the sensor signal, compares the four wheel-speed signals and initiates action as required Sensor : 4 UML a : T IL=7mA (6.9-8.4mA) I = 14mA(11.8-11.6mA) SPECIFICATIONS = craxcrer Item Stangard Value Remark ‘Supply voltage De 1av Operating 120" . | ores -40~120°C R=1000 L = os i Output current range - | __ High 14ma(11.8~16.8mA) | : Fruency range 1-200 Oz ‘Airgap (0.5~1.5mm(0.0197~0.0591 in.) Tone | = ecg, | Numper 48ABS (ANTI-LOCK BRAKE SYSTEM) BR-145 REMOVAL eccarozc 7 Remove the front wheel speed sensor after disconn- ecting the wheel speed sensor connector (A). FRONT WHEEL SPEED SENSOR 1 Remove the front wheel speed sensor mounting bolt A). woerion rowoze0a 2. Remove the front wheel guard (B), after removing the ‘mud ground (A)BR-146 BRAKE SYSTEM REAR WHEEL SPEED SENSOR INSPECTION excaoea4 the rear wheel ting bolt Ge telat naanii 41. Measure the output voltage between the teminal of the wheel speed sensor and the body ground, & caution Must use the resistance(100Q), as shown below, in order to protect the active wheel speed sensor, before measuring the output voltage. e12v_ Ground 2. Remove the rear seat side pad then disconnect the rear wheel speed sensor connector (A). Oscilloscope 2. Compare the change of the output voltage of the wh- eel speed sensor to the normal change of the output voltage as shown below. Von Vow oy + Vv: 580mV ~ 840mVv +Vote ~ 1.68 + Frequency range : 1~2,000HzABS (ANTI-LOCK BRAKE SYSTEM) G SENSOR COMPONENTS © esescesr G sensor oe 1.-Sensor voltage 2. Sensor output 3. Ground Output Vottage(V) Lower foo of flor console | 1.langie(): SBS 2. acceleration (m/sec) : 2.8 7.98 o 4795 488 47 [OUTPUT CHARACTERISTIC eaeREenBR148 BRAKE SYSTEM INSPECTION. excorrar Measure the output voltage between 2 and 3 termin- als, posing the arrow mark on the G sensor downwa- 1. Connect a tester to both 2 and 3 terminals of the G sensor. Specification : 3.5V 2. Measure the output voltage when IGN is on. Specification 4, Replace the G sensor if the output voltage is not on the specification,ABS (ANTI-LOCK BRAKE SYSTEM) ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM COMPONENTS = cain 208 BR-149 ESP Control module(HECU) Master cylinder pressure sensor Yaw-rate & Lateral acceleration sensor Front wheel speed sensor ‘ABS warning lamp Parking brake/EBD warning lamp Reear wheel speed sensor Steering angle sensorBRAKE SYSTEM. ESP HECU EXTERNAL DIAGRAM ccerzrer A: INLET VALVE(FR) B : INLET VALVE(RL) INLET VALVE(AR) {INLET VALVE(FL) E : OUTPUT VALVE(FR) F : OUTPUT VALVE(AL) G : OUTPUT VALVE(AR) H: OUTPUT VALVE(FL) |: ELECTRIC SHUTTLE VALVE(ESV-R) J: ELECTRIC SHUTTLE VALVE(ESV-L) K TRACTION VALVE (TCR) LSTRACTION VALVE (TCL) M:MOTOR(+) N:MPTOR(GND)ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR-151 DECRIPTION OF ESP ecezcors ‘Optimum driving safety now has a name : ESP, the Elect- Tonic Stability Program. ESP is based on the MK 25 ABS Hydraulic System. ESP recognizes critical driving conditions, such as panic react- ions in dangerous situations, and stabilizes the vehicle by wheel-individual braking and engine control intervention, with no need for actuating the brake or the gas pedal. ESP adds a further function known as Active Yaw Control {AYC) to the ABS, TCS, EBD and EDC functions. Whereas: the ABS/TCS function controls wheel slip during braking and acceleration and, thus, mainly intervenes in the lon itudinal dynamics of the vehicle, active yaw control stabil- izes the vehicle about its vertical axis. ‘This is achieved by wheel individual brake intervention and adaptation of the momentary engine torque with no need ESP essentially consists of three assemblies : the senso- Ts, the electronic control unit and the actuators The electronic control unit incorporates the technological ‘experience accumulated in connection with the MK 20 sy- stem, but has been substantially expanded in terms of pacity and monitoring concept in order to permit the addi- tional sensor signals and arithmetic operations to be proc- essed and converted into corresponding valve, pump and engine control commands. Two 16-bit processors and one 8-bit processor, which monitor each other, cooperate to handle these requirements. Of course, the stability control feature works under all dri- ving and operating conditions. Under certain driving cond- itions, the ABS/TCS function can be activated simultaneo- usly with the ESP function in response to a command by the driver. In the event of a failure of the stability control function, the for any action to be taken by the driver. basic safety function, ABS, is still maintained. en : TcS Ga bee! esr E a E csr 8 2 a |_| ABS Brake force controlBR-152 BRAKE SYSTEM Raa aoe or DESCRIPTION OF ESP CONTROL ESP system includes ABS/EBD, TCS and AYC function, ‘ABSIEBD function The ECU changes the active sensor signal (current shift) coming from the four wheel sensors to the square wave. By using the input of above signals, the ECU calculates the vehicle speed and the acceleration & deceleration of the four wheels.And, the ECU judges whether the ABS/EBD should be actuated or not. ‘TCS function prevents the wheel slip of drive direction by adding the brake pressure and engine torque reduction via CAN communication. TCS function uses the wheel sp- eed sensor signal to determine the wheel slip as far as ABS function. AYC function prevents unstable maneuver of the vehicle. To determine the vehicle maneuver, AYC function uses the maneuver sensor signals(Yaw Rate Sensor, Lateral ‘Acceleration Sensor, Steering Whee! Angle Sensor) If ve- hicle maneuver is unstable (Over Steer or Under Steer), ‘AYC function applies the brake pressure on certain wheel, ‘and send engine torque reduction signal by CAN. ‘After the key-on, the ECU continually diagnoses the system failure. (self-diagnosis)|f the system failure is detected, the ECU informs driver of the system failure through the BRA- KE/ABS/ESP warning lamp. (fail-safe warning) Master cylinder Pressure sensor Master oylinder Stooring wheel Angle sensor ‘Wheel speed sensor i lateral acceleration sensorESP(ELECTRONIC STABILITY PROGRAM) SYSTEM INPUT AND OUTPUT DIAGRAM re ese ecu out Te ‘speed sensor t+———>} > Hydraulic unit (FL) -Intergrated with HECU Takei soe srr (FR) aaa sae rt ESP Control sent esr L,} wan tamp Fae ——— | | (RR) scone : Seige a ‘Angle sensor Kaine “owt ata a} roscmn Acceleration sensor ase b | “tesese Master cylinder poche Sem @ seca Wel eed = cert Brake switch pees esos ort nich | a poorBRAKE SYSTEM ESP OPERATION MODE ccasraoa 1. ESP Non-operation-Normal braking. Operation . In this position, the inlet valve and the TCS vaive are open, the electrically operated shuttle valve and the outlet valve are closed. * ESV: Electric reversing valve. [- Solenoid valve | Continuity Valve Motor pump TC Valve INNO) | OFF OPEN pa orF ourinc) | OFF CLOSEESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR-155 2. ESP operation Operation The on/off booster builds up a pressure of approx. 10 bar in order to enable the ESP pump to suck brake fluid at low temperatures. In this position, the inlet valve is driven in a pulsed cycle. The TCS valve is closed. The outlet valve remains closed. The electri- cally operated shuttle valve is opened. The hydraulic pressure is led to the wheel brakes which are to be applied for a brief period of time. Solenoid valve Continuity Valve [_ Motorpump [| TC Vane | Understeering | : ees | uno) OFF OPEN : Lerlialieal ‘OUTINO) OFF CLOSE Oversteering | : . rs Career | inno) OFF OPEN of front wheel) | ouTING) OFF CLOSEBRAKE SYSTEM i anaes Ria aoe eae Parking brake/EBD warning lamp ABS Warning lamp [TCS OFF Waring lame ‘TCS Function lamp ABS WARNING LAMP MODULE The active ABS warning lamp module indicates the self est and failure status of the ABS .The ABS warming lamp shall be on: ~ During the initialization phase after IGN ON. (contin uuously 3 seconds). = Inthe event of inhibition of ABS functions by failure = During diagnostic mode. - When the ECU Connector is seperated from ECU. EBD WARNING LAMP MODULE The active EBD warning lamp module indicates the sett est and failure status of the EBD.However, in case the Pa- rking Brake Switch is tumed on, the EBD warning lamp is. always tured on regardless of EBD functions. The EBD ‘warning lamp shall be on: = During the initialization phase after IGN ON. (contin- ously 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- uuously 3 seconds). - Inthe event of inhibition of ESP functions by failure When driver trun off the ESP function by on/off switc- h = During diagnostic mode. 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- ditions : = During the initialization phase after IGN ON. (contin- ously 3 seconds). = When the ESP control is operating.,(Blinking - 2H2) ESP ON/OFF SWITCH (ESP SYSTEM) The ESP On/Off Switch shall be used to toggle the ESP function between On/Off states based upon driver input ‘The On/Off switch shall be a normally open, momentary contact switch.Closed contacts switch the circuit to ignitio- a. Initial status of the ESP function is on and switch toggle the state.ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM. BR-157 ESP CIRCUIT DIAGRAM cacsacea CIRCUIT DIAGRAM(1) eal i io eaeseBR-158 BRAKE SYSTEM CIRCUIT DIAGRAM(2)ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM ESP CIRCUIT DIAGRAM esosoces e 2 iz Pump Motor (+) 8 z = PUMP ESP WLP, - 4) MOTOR a ESP FLP ESP OFF swit | Eumet Parking brake 7} esp |. [Lateral Switch ABS/EBD Warning lamp _|,,} HECU [1] Self test | vawrrate L KLINE lax|Yawerate | HI-SCAN, 9] Power Lateral FR output is ‘Wheel speed(FR) ————"'} lpg} Ground, anne wea senor) 000 ower I B Signal 8 ; vine! sersont) E000 rower f°? Mga ——| Sense | tan i ‘STN, ‘Signal se} be Wheel sensor(Rt) }0COC Foner "4 eq| Ground —_| Sem8 Signal fo l7| Power Whee! sensor(AR) Power | H2{Stanal___| Pressure CAN (HIGH) CAN 7 |g} Ground, Sensor CAN (LOW) 22 G-Sensor | —G-Sensor |19] GN) _awoy 3 Ground He ‘Ground Pump motor | oe cae \Geeeeosoccocese ©} 8 INNECTOR (47P)BR-160 BRAKE SYSTEM ie emu ESP CONNECTOR INPUTIOUTPUT —eszecre0 c ct 1 L = Specification Remark No Description . Re 4 TGNITION((+) 32 | POS BATTERY (SOLENOID) | Max leakage current :| < 0.8mA Operating voltage range: 9.520.5V < V < 16.540.5V 1 POS.BATTERY(MOTOR) | Rush current: < 100A Max current : | < 30A Max leakage current : | < 0.2mA Rated current : |< 300mA [a7 | Puwpmororcrouno | Rus cumerts Sgn 23. | YAWBLATERAL GSENSOR | ate curent :1< 65mA ‘ony with ESP 2 oe Rated curent: 1< 10mA only wth ESP | [a1 | STEERING ANGLE SENSOR | ot curent :1< 100mA [ony win ESS | a7 | MASTER PRESSURE SENSOR |e uu oye 4aveeus sav |emvwn ese ze | YaWSENSORPOwER Max Ouputcurent:| < 66m. | ony wih ESP a 5 | __BRAKELIGHT SWITCH | Input voltage low: OV = V = 3.0V GRAKE SwiTcH ~/ putvetage High: 7.0V'= V = 160V SENSOR FRONT RIGHT | Max current: 1 < 2mA 6 External pull up resister :10KW < R oe Output duty 50 +20% 18 ‘ABS/EBD WILAMP DRIVE z 34 ESP WILAMP DRIVE en ea Max. output iow voltage: V<4.2V | only with ESP. ESP F/LAMP DRIVE Input voltage low:0Vs Vs 3.0V. 27 ESP ON/OFF SWITCH Input voltage High: 7.0V s Vs 16.0V | only with ESP. | Max input current < 10mA. | | GAN UE UNO Ta set 1 < 10m fa 7 CAN BUS LINE(HIGH) 46 _| SENSOR FRONT LEFT POWER = : 45. |__ SENSOR FRONT RIGHT | POWER ‘Output voltage : IGN(V) # 1V. eS ee ieee ee | Ouiput current Max s0mn4) 44__| SENSOR REAR LEFT POWER 43__ | SENSOR REAR RIGHT POWERESP(ELECTRONIC STABILITY PROGRAM) SYSTEM 16 _| SENSOR FRONT LEFT SIGNAL Input current LOW : 5.9 ~8.4 4 Input current HIGH “11.8 ~ 16.8 m Frequency range :1 ~ 2000 Hz 14 | SENSOR REAR LEFT SIGNAL | Input duty: 50 +20% 29 | SENSOR REAR RIGHT SIGNAL SENSOR FRONT RIGHT = SIGNAL 3 | STEERING ANGLE SENSOR PHASE 1 Input duty (ST4, ST2): 60 #10 Phase difference (ST1, ST2): 2+ 7; STEERING ANGLE SENSOR | 0 6deg only with ESP PHASE 2 High voltage: 3.0V < V < 4.1V 39 ‘STEERING ANGLE SENSOR | Low voltage: 1.3V < V < 20V PHASE N "MASTER PRESSURESENSOR | Sensor Input Voltage : OV = V < 5.0V 2 Zero offset Voltage : 0.5V + 0.15V SIGNAL Input current :Max 2 Ma only with ESP | Sensor Input Voltage :0VsV=5.0V | 9 LATERAL G SENSOR SIGNAL Zero offset Voltage : 2.5 + 0.1V | Sensor Input Voltage OV 2V35.0V 4 YAW SENSOR SIGNAL Zero offset Voltage : 2.5 40.1V | only with ESP G SENSOR SIGNAL Input Sore | oe 10 Voltage Input Volge: 0 0.7 IGN (VY) | 19 DIAGNOSIS INPUT/IOUTPUT Output voltage OL(V) < 0.2 IGN (v) OH(V) > 0.8 IGN (v)BR-162 BRAKE SYSTEM FAILURE DIAGNOSIS — ccoascas 4. Inprinciple, ESP and TCS controls are prohibited in case of ABS failure. 2. When ESP or TCS is fail, only the failed system con- trol is prohibited. 3. However, when the solenoid valve relay should be tumed off in case of ESP fail, refer to the ABS fail-s- ate. 4, Information on ABS fail-safe is identical with the fail- -safe in which ESP is not installed MEMORY OF FAIL CODE 4. Itkeeps the code as far as the backup lamp power is connected. (O) 2. Itkeeps 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. Itexecutes the checkup all the time while the IG2 po- wer ison. 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) Ifthe vehicle speed is over 409 mph(8 krvh) when the brake lamp switch is off. 5) When the vehicle speed is over 24.8 mph(40 km- Ih). 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 intial checkup and wait for the HECU power input again 7. Judge fail in the following cases. 1) When the power is normal. 2) From the point in which the vehicle speed reaches 4.9 mph(8 kmih) after HECU power on. COUNTERMEASURES IN FAIL 4. Tum the system down and perform the following ac- tions and wait for HECU power OFF. 2. Tum the valve relay off 3. Stop the control during the operation and do not exe- cute any until the normal condition recovers, WARNING LAMP ON 1. ABS warning lamp tums on when ABS is fail 2. TCS warning lamp turns on when TCS is fail 3. ESP operation lamp tums on and TCS OFF waming lamp blinks when ESP is fail ‘When power voltage and valve relay voltage are abnorm- al, input/output related failure judgment is not made.ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM DIAGNOSTIC TROUBLE CODE CHART Follow an inspection procedure of a detected DTC in the chart below. W® Nore EBD A - warning lamp "ON', in case of errors on more than 2 wheels. pte DESCRIPTION WARNING LAMP "ON" | DTC | REMARK | SEE PAGE ABs | €BD| Tcs| ESP | MEMORY C1104 ~_Battery voltage high Osos: o!|:o [0 BRB4 1102 Battery voltage low ofolfofo on | [__BR87 Wheel speed sensor FR-LH | | | _ 1200 penishort o}o}ojo ° BR-89 Wheel speed sensor FR-LH C1201 | rangelpertormancerintermittent | © | © | © | © 2 ee Wheel speed sensor FRLH | 1202 imnatdino signal o}a}olo ° BR-95 Wheel speed sensor FR-LH 1203 penishort o}a}o}o ° BR-89 ‘Wheel speed sensor FR-LH : ©1204 | sangelpertormancefintermittent | © | © | 0 | O o cael Wheel speed sensor FR-LH ©1205 inakalne sil o}a}o}o ° BR-95 Wheel speed sensor FR-LH ©1206 Sea o}/a}lo}o ° BR-89 Wheel speed sensor FR-LH | C1207 | rangelpertormancefintermittent | © | © | O | © 2 ue Wheel speed sensor FR-LH ee invalidino signal Fee 2 ee og | Wheel speed sensor C1208 penishort o}afofo ° BR-89 Wheel speed sensor FR-LH | C1210 | cangelperformancelintermitient | © | “ | O | O 2 ae Wheel speed sensor RR-RH lo] 7 ee invalid/no signal Cle ele |e ee C1604 ECU hardware error ofofolfo ° BR-98 cane | Valve relay error ofolfolo ° ae __BR-89 ©2360 | ABS/TCS/ESP valve erro Orns 2Oa|hOi no BR-101 2402 | Motor - electrical o}|x][ofo oF BR-103 | cta7a_|_ G sensor - electrical o|xlolo ° WD | BR-108 | cxa7s G sensor signal ofx|ofo|_o WO | BR-108 | [_c1803 TCS switch error _ a) esos |e: ° | BR410 [eres CAN harware error x|x|olo 3 BR113 [cent CAN time-out EMS x[x[ofo o BR-114BR-164 BRAKE SYSTEM WARNING LAMP "ON" | pTc prc DESCRIPTION REMARK | SEE PAC ABs | EBD | Tcs| ESP | MEMORY on C1612 CAN time-out TCU x{| x ][olo ° BR115 C1613 CAN wrong message an eae sO [20 ° BR116 C1616 CAN bus off bee |e OnE. Onna BR-117 cozar | Ercesswetemperaureofbrake | Ty | 5 |g ° aes cna ‘Sensor source voltage eee Ee oO BR419 Pressure sensor(primay)- | , | x | x ©1235 el Jo ° BR-120 zi 1 Pressure sensor(seconday)- | , |, | y 1237 pileraly ° ° ©1259 | Steering angle sensor-electrical | x | x | x | O ° BR-124 ©1260 | Steering angle sensor-signal [| x | x | x | O oO BR-126 Yaw rate & lateral G sensor - : 1282 cee x| x ° ° BR-128 Yaw rate & lateral G sensor - ele 1283 aa x ° ° BR-130 [c1s13 Brake switch error x[*{[xl[o ° s| BR-4132ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM STEERING WHEEL ANGLE SPEED SENSOR DESCRIPTION ceacecat ‘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-Function Switch) under the steering wheel. OPERATION 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 th- tee LEDs, two(ST1, ST2) for detecting a steering direction, and the other for the neutral position. ‘The HECU calculates the steering angle by the pulse from the steering angle sensor. BR-165BR166 BRAKE SYSTEM BR SS SPECIFICATIONS — eicaisi0 [ ~ Hem Specification ‘Operating Voltage = ‘9V~16V | Operating temperature a -30°C-75°C Current cousumption Max. 100mA_ Pulse duty 50410% _ Pulse width _ 8°/1pulse Voltage(HIGH) 30V-4.1V Voltage(LOW) ___1.3V-2.0V ‘Steering angle velocity Max 1500%/sec CIRCUIT DIAGRAM easeosz0 ‘Steering angle sensor ESP HECU w| ie 7 . STN 29 st 8 st 40 eno 3 OTL] 2[sl4[sESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR-167 OUTPUT CHARACTERISTIC EATBAEZA st2 L sty # L roy No. INPUT OUTPUT ‘Steering direction _[ Remark sv L L : 7 : Right st c H Let sT2 L L 1 L LC st 4 cE aie 2 st u 4 Right S12 H 4 st I H 4 i se ce ca tet St H E . ST2 r Ei ae : st H H : sT2 4 u ta svt 4 i sT2 H H LeftBR-168 BRAKE SYSTEM YAW-RATE SENSOR DESCRIPTION = ¢213¢503 1. The yaw-rate & lateral G sensor is applied for the ESP system, 2. The yaw-rate is the angular velocity, when a vehicle tums a comer, and the lateral G is the acceleration to move a vehicle out of the way when cornering. SPECIFICATIONS cccecrea ITEM __ SPECIFICATION ~__REMARK : Operating voltage 475 ~5.25V Current consumption less than 65mA z Output voltage range 05~45V z Operating temperature __|-40~85°C ‘Measurement range “75 ~ #75%isee | Output voltage range 0.5~45V Yaw-rate sensor _| Sensitivity 26.67mV("isec.) Zero rate output 25V = Frequency response 10Hz ‘ | “Measurement range “1.5 ~ 41.589 Output voltage range 05~45V_ | Lateral. sensor _| Sensitivity 1.33Vig fa [Zero rate output 25V = Frequency response S0Hz - : =ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM OUTPUT CHRACTERISTIC —e724¢875 [Yaw-rate} 4 — 2a =25 10 ‘Sent 27 te ‘Yaw-rate (deg/s) were Linens ae : a T Bowers = joes | bis Sa eee | @ Gras 4 ae os 1 wsLz] 2 Lateral 6.)BR-170 BRAKE SYSTEM EXTERNAL DIAGRAM oceans, Tey | a {aw-rale & Lateral G sensors connector} ‘Sensor Powor | 1 tatoraia, | 2 Yawsate | 9 sottest | 4 cond Yawerate & Lateral G. sensor ESP HECUESP(ELECTRONIC STABILITY PROGRAM) SYSTEM. MASTER CYLINDER PRESSURE SENSOR DESCRIPTION cereosex \ ‘The pressure sensor(A) is connected to the master oylind- cer, when ESP is on operation, detecting the brake pressure in order to sense the user’s will to brake a vehicle. ‘The pressure sensor(A) is consisted of two ceramic disks, one is fixed and the other movable, so that changes the distance of the two disks. — (Max. measurable pressure is 200ber.) Ci SPECIFICATIONS — esspazoa : Item iL Specification Remark [ ‘Supply voltage 4.75V ~ 5.25V ‘Supply current Tess than 15mA Operating temperature 40°C ~ 125°C ae Measurement pressure range (0 200bar = Max. pressure limit 350bar Zero rate output __05V [Output range 05-44V CIRCUIT DIAGRAM ceosoze0 Power ] 1 a7 Prossure| 2 2 eno | 3 28 [Pressure sensor) [ESP HECU] {Pressure sensor's connector}BR-172 BRAKE SYSTEM OUTPUT CHARACTERISTIC — cgoszaas Voe=5 (V) 5 — | 45 al bar) £3 5 2 : ie | Gay | 9 eas 100 150 7 Pressure(bar)ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR-173 ESP SWITCH DESCRIPTION eyocsor 1, The ESP OFF switch is for the user to turn off the ESP system. Terminal . Function. 2 _ 2 a 2. The ESP OFF lamp is on when ESP OFF switch is on | oto engaged. OFF INSPECTION — ecroosas, 1, Remove the ESP OFF switch from the switch panel on the crushpad of the driver's side, eoemaor woeoans 2. Check the continuity between the switch terminals as the ESP OFF switch is engaged,