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GENERAL
SPECIFICATIONS EB7F495C
Item Specification
Master cylinder
Type Tandem type
I.D. 22.22 mm (0.875 in)
Piston stroke 29 ~ 31 mm
Fluid level warning sensor Provided
Proportioning valve(CBS)
Cut-in pressure(Split point) 35 kg/㎠ (3.43 MPa, 497.8 psi)
Decompression ratio 0.27 : 1
Brake booster
Type Vacuum
Effective diameter 254 mm(10 in)
Boosting ratio 7 : 1
Front brake(Disc)
Type Floating type with ventilated disc
Disc O.D. 256 mm(10 in)
Disc thickness 22 mm(0.87 in)
Pad thickness 11 mm(0.43 in)
Cylinder type Single piston
Cylinder I.D. Ø54 mm(2.12 in)
Rear brake(Disc)
Type Floating type with solid disc
Disc O.D. 262 mm (10.3 in)
Disc thickness 10 mm (0.39 in)
Pad thickness 10 mm (0.39 in)
Cylinder type Single piston
Cylinder I.D. 31 mm (1.22 in)
Rear brake(Drum)
Type Leading trailing
Drum I.D 203.2 mm (8 in)
Brake lining thickness 4.3 mm(0.17 in)
Clearance adjustment Automatic
Parking brake
Actuation Mechanical brake acting on rear wheels
Type Lever
Drum I.D. 168 mm(6.61 in)
NOTE
ABS : Anti-lock Brake System
CBS : Conventional Brake System
BR -4 BRAKE SYSTEM
SPECIFICATION(ABS) EDA60E0F
SPECIFICATION(ESP)
TIGHTENING TORQUE
Yaw rate & Lateral G sensor mounting nut 7.9 ~ 10.79 0.8 ~ 1.1 5.79 ~ 7.95
Master cylinder pressure sensor 22.56 ~ 26.48 2.3 ~ 2.7 16.64 ~ 19.53
GENERAL BR -7
LUBRICANT
ARJE504I
BR -8 BRAKE SYSTEM
TROUBLESHOOTING EEA006CA
Use the table below to help you find the cause of the prob-
lem. The numbers indicate the priority of the like cause of
the problem. Check each part in order. If necessary, re-
place these parts.
BRAKE SYSTEM
OPERATION AND LEAKAGE
CHECK E8ADB1AE
Component Procedure
Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes
do not work properly, check the brake booster. Replace the brake booster as an
assembly if it does not work properly or if there are signs of leakage.
Piston cup and pressure Check brake operation by applying the brakes. Look for damage or signs of
cup inspection (B) fluid leakage. Replace the master cylinder as an assembly if the pedal does not
work properly or if there is damage or signs of fluid leakage.
Check for a difference in brake pedal stroke between quick and slow brake applications.
Replace the master cylinder if there is a difference in pedal stroke
Brake hoses (C ) Look for damage or signs of fluid leakage. Replace the brake hose with
a new one if it is damaged or leaking.
Caliper piston seal and Check brake operation by applying the brakes.
piston boots (D) Look for damage or signs of fluid leakage. If the pedal does not work properly,
the brakes drag, or there is damage or signs of fluid leakage, disassemble
and inspect the brake caliper. Replace the boots and seals with new ones
whenever the brake caliper is disassembled.
Wheel cylinder piston cup Check brake operation by applying the brakes.
and dust cover (E) Look for damage or signs of fluid leakage. If the pedal does not work properly, the
brakes drag, or there is damage or signs of fluid leakage, replace the wheel cylinder.
E C
D/E
LJJF503W
BRAKE SYSTEM BR -11
BRAKE BOOSTER OPERATING TEST 3. With the engine running, step on the brake pedal and
then stop the engine. Hold the pedal depressed for
For simple checking of the brake booster operation, carry 30 seconds. If the pedal height does not change, the
out the following tests : booster is in good condition, if the pedal rises, the
booster is defective. If the above three tests are okay,
1. Run the engine for one or two minutes, and then stop the booster performance can be determined as good.
it. If the pedal depresses fully the first time but grad- Even if one of the above three tests is not okay, check
ually becomes higher when depressed succeeding the check valve, vacuum hose and booster for defect.
times, the booster is operating properly, if the pedal
height remains unchanged, the booster is defective.
Good No good
3rd
2nd
1st
EGGE700C
EJRF500B
EGGB700B
BR -12 BRAKE SYSTEM
AJJF501A C
EJKE001A
Raise
the pedal
A
2.4 ~ 3.5 kgf.m
(23.54 ~ 34.32 Nm, 17.36 ~ 25.32 lb-ft)
LJJF500A
BRAKE SYSTEM BR -13
Screw in the brake switch until its plunger is fully de- 1. With the engine stopped, depress the brake pedal
pressed (threded end (A) touching the pad (B) on the two or three times. After eliminating the vacuum in
pedal arm) then brake off the switch 3/4 turn to make the power brake booster, press the pedal(B) down by
0.5~1.0 mm(0.0197~0.0394 in.) of clearance between the hand, and confirm that the amount of movement(A)
brake switch connector. Make sure that the brake lights before resistance is met (the free play) is within the
go off when the pedal is released. standard value.
A C
B
B
0.5 ~ 1.0mm
AJJF600J
A
EJKE001D
INSPECTION OF FRONT DISC BRAKE PAD INSPECTION OF REAR DISC BRAKE PAD
1. Check the brake pad thickness through the caliper 1. Check the brake pad thickness through the caliper
body inspection hole. body inspection hole.
AJJF502A AJJF503A
CAUTION CAUTION
- If the pad lining thickness is out of specifica- - If the pad thickness is out of specification, left
tion, left and right pads must be replaced as and right pads must be replaced as a com-
a complete set. plete set.
- When the thickness difference between the - When the thickness difference between the
left pad and right pad is large, check the slid- left pad and right pad is large, check the slid-
ing condition of the piston and the guide rod. ing condition of the piston and the guide rod.
BRAKE SYSTEM BR -15
BRAKE BOOSTER
COMPONENTS(1) E3FEFE85
4
1 2
1.3 ~ 1.6
5 (12.74 ~ 15.68,
9.45 ~ 11.63)
2.4 ~ 3.5
6 (23.54 ~ 34.3, 17.36 ~ 25.45)
7
0.8 ~ 1.2
(7.84 ~ 11.76, 5.82 ~ 8.72)
COMPONENTS(2)
Proportioning valve
Pressure
Sensor
GSL TYPE
<ESP Type
DSL TYPE
LJJF500C
BRAKE SYSTEM BR -17
REMOVAL ECEC42CE 5. Remove the brake booster (A) from the engine com-
partment.
1. Remove the master cylinder.( Refer to BR-32)
ARJE500H
AJJF600M
A
B
C
1.3 ~ 1.6 kgf.m
(12.74 ~ 15.68 Nm, 9.45 ~ 11.63 lb-ft)
LJJF501W
INSTALLATION E4A72DD8 4. Install the master cylinder, then install the brake tubes
to the master cylinder.
1. Adjust push rod length of the booster, and then install
the seal on the booster assembly. 5. Connect the vacuum hose to the brake booster.
Standard length(A) : 116.3 ± 0.5 mm (4.58 ± 0.019 in) 6. After filling the brake reservoir with brake fluid, bleed
the system.
ARJE500I
A
B
C
1.3 ~ 1.6 kgf.m
(12.74 ~ 15.68 Nm, 9.45 ~ 11.63 lb-ft)
LJJF501X
CAUTION
Grease the pin before installing the snap pin.
Always use a new snap pin.
BRAKE SYSTEM BR -19
BRAKE LINE
COMPONENTS EBBA9697
Brake hose
to caliper
2.5 ~ 3
(24.5 ~ 29.4,
18.18 ~ 21.81)
Proportioning valve
to brake line
13 ~ 17 Bleed screw
(12.74 ~ 16.66, 0.7 ~ 1.3
9.45 ~ 12.36) (6.86 ~ 12.74, 5.09 ~ 9.45)
Disc brake:
Brake hose to caliper 2.5 ~ 3 (24.5 ~ 29.4, 18.18 ~ 21.81)
Bleed screw 0.7 ~ 1.3 (6.86 ~12.74, 5.09 ~ 9.45)
Drum brake:
Brake line to wheel cylinder 1.3 ~ 1.7 (12.74 ~16.66, 9.45 ~ 12.36)
Bleed screw 0.7~1.3 (6.86 ~12.74, 5.09 ~ 9.45)
1. Disconnect the brake hose(C) from the brake line(A) 1. Install a brake hose(A) on the caliper with tightening
using a flare-nut wrench(B). brake hose bolt(C) and washer(B).
B C
A A
AJJF505A AJJF600Q
2. Remove the brake hose clip(A), and then remove the 2. Install the brake hose clip(C) to the brake hose
brake hose(B). bracket(B), then install the brake hose(A).
A
A
B B
AJJF600P AJJF600R
3. Remove the connector bolt from the caliper, and dis- 3. Connect the brake hose to the brake line.
connect the brake hose from the caliper.
4. After installing the brake hose, bleed the brake
system.
CAUTION
- Check the brake hoses for interference and
twisting.
- Check the brake hose and line joint for leaks,
and tighten if necessary.
BRAKE SYSTEM BR -21
INSPECTION E3FF54EC
2. Check the brake hoses for cracks, damaged and oil Front Right Rear Right
leakage.
3. Check the brake tube flare nuts for damage and oil
leakage.
LJJF500F
BR -22 BRAKE SYSTEM
BRAKE PEDAL
COMPONENTS(1) EA5956F8
[LHD]
0.8 ~ 1.0 (7.84 ~ 9.8, 5.82 ~ 7.27)
2.5 ~ 3.5
(24.5 ~ 34.3,
18.18 ~ 25.45)
4 6
LJJF500G
BRAKE SYSTEM BR -23
COMPONENTS(2)
[RHD]
9
4
3
11 5
10
8
1
(M/T)
(A/T)
1. Remove the lower crash pad.(Refer to BD-“ crash 1. Check the bushing for wear.
pad” )
2. Check the brake pedal for bending or twisting
2. Loosen the brake member assembly bracket two up-
per nuts and 4 lower nuts. 3. Check all parts for crack and wear.
3. Remove the stop lamp switch connector (A). 4. Check the stop lamp switch.
nut
LJJF500H
INSTALLATION E0F0CE0B
CAUTION
Coat the inner surface of the bushings with the
specified grease.
ARJE500U
COMPONENTS(1) E2CE9A2B
2.2 ~ 3.2
(21.56 ~ 31.36, 15.99 ~ 23.26)
5
6
COMPONENTS(2)
5
6
10
0.7 ~ 1.3
(6.86 ~ 12.74,
5.09 ~ 9.45)
9
8
11
13
14
12
13
LJJF500J
BR -28 BRAKE SYSTEM
CAUTION
FRONT BRAKE DISC THICKNESS CHECK
Frequent inhalation of brake pad dust, regardless 1. Remove all rust and contamination from the disc sur-
of material composition, could be hazardous to face, and then measure the disc thickness at 4 posi-
your health. tions at least.
• Avoid breathing dust particles.
• Never use on air hose or brush to clean brake Front brake disc thickness
assemblies. Standard value : 22.0 mm (0.87 in)
Limit : 20.0 mm ( 0.79 in)
1. Remove guide rod bolt(B) and raise the caliper
(A).Check the hoses and pin boots for damage and
2. Thickness variation should not exceed 0.005
deterioration.
mm(0.0002 in) (circumference) and 0.05 mm(0.0020
in) (radius) at any directions.
A
B
2.2 ~ 3.2 kgf.m
(21.56 ~ 31.36 Nm, 15.99 ~ 23.26 lb-ft)
LJJF500K
LJJF500L
C
LJJF503V
BRAKE SYSTEM BR -29
1. Check the pad wear. Measure the pad thickness. re- 1. Remove the brake disc from hub using M8 screw(A)
place it if it is less than the specified value. if the brake disc has been seized with the hub due to
corrosion or overheat.
Pad thickness
Standard value : 11.0 mm (0.43 in) NOTE
Service limit : 2.0 mm (0.0787 in)
Be careful not to use the hammer. The disc can be
damaged if you remove the disc from the hub by ham-
mer.
ARJE501R
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.
2. If the run out of the brake disc exceeds the limit spec-
ification, replace the disc, and then measure the run
out again.
INSTALLATION E33C4CCA
09581-11000
AJJF600Y
A
5. Pivot the caliper down into position. Being careful not
to damage the pin boot(A) , install the guide rod bolt
ARJE501M
(B) and tighten it to the specified torque.
B
2. Check the foreign material at the pad shims (D) and 22~32 Nm(2.2~3.2 kgf.m,
the back of the pads (B). 16.2~23.6 lb-ft)
Contaminated brake discs or pads reduce stopping
A
ability. Keep grease off the discs and pads.
3. Install the brake pads (B) and pad shims (D) on the
pad retainer correctly. Install the pad with the wear
indicator (C) on the inside. If you are reusing the
pads, always reinstall the brake pads in their original
positions to prevent a momentary loss of braking effi-
ciency.
LJJF503S
NOTE
C
Engagement of the brake may require a greater pedal
LJJF503Y stroke immediately after the brake pads have been
replaced as a set. Several applications of the brake
4. Push in the piston (A) using the SST(09581-11000) will restore the normal pedal stroke.
so that the caliper will fit over the pads. Make sure
that the piston boot is in position to prevent damaging 10. After installation, check for leaks at hose and line
it when pivoting the caliper down. joints or connections, and retighten if necessary.
BRAKE SYSTEM BR -31
MASTER CYLINDER
COMPONENTS EF483DAD
4
8
[ABS]
10
[CBS]
3.5 ~ 4.5
(34.3 ~ 44.1,
25.45 ~ 32.72)
LJJF500M
BR -32 BRAKE SYSTEM
REMOVAL EFB687E0 4. Disconnect the brake lines (A) from the master cylin-
der. To prevent spills, cover the hose joints with rags
NOTE or shop towels.
A
C
A
1.3 ~ 1.7 kgf.m
(12.74 ~ 16.66 Nm,
9.45 ~ 12.36 lb-ft) B
0.8 ~ 1.2 kgf.m
(7.84 ~ 11.76 Nm,
5.82 ~ 8.72 lb-ft)
LJJF500N
2. Disconnect the brake fluid level switch connector (A), INSTALLTION E11FF80D
AJJF510A
DISASSEMBLY E6BECAD4 5. Remove the retainer ring by using the snap ring pliers.
B
LJJF503Z
AJJF511A
ARJE501C
A
NOTE
Do not disassemble the primary and secondary piston
AJJF601C assembly.
BR -34 BRAKE SYSTEM
INSPECTION EE7BC2AE 4. Press the piston with a screwdriver and install the re-
tainer ring.
1. Check the master cylinder bore for rust or scratch.
CAUTION
- If the cylinder bore is damaged, replace the
master cylinder assembly.
- Wash the contaminated parts in alcohol.
REASSEMBLY EFCF70D2
ARJE501D
ARJE501E
BRAKE SYSTEM BR -35
DESCRIPTION EFADC65E
NOTE
Do not disassemble the proportioning valve. The propor- This table shows characteristics of the proportioning
tioning valve makes the ideal distribution of fluid pressure valve as the pressure increases.
to the front and rear brakes to prevent the brakes from skid-
ding in the event of rear wheel lock up and to obtain higher Rear
Front
brake efficiency within the range of service brake applica- (Output of proportioning
(Output of master cylinder)
tion. valve)
A : 35 ㎏/㎠ A’ : 35 ㎏/㎠
INSPECTION E6EC99E9 (3.43 MPa, 497 psi) (3.43 MPa, 497 psi)
1. Remove the front brake tube (B) and rear brake tube B’ : 44.5 ± 3.5 ㎏/㎠
B : 70 ㎏/㎠
(C) from the master cylinder (A). (4.36 ± 0.34 MPa,
(6.86 MPa, 996 psi)
633 ± 50 psi)
2. Connect two pressure gauges (D); one to the output
valve of the front (B) and rear (C) brake.
Output pressure (kg/cm2)
C
B’
D
A’
A
B
2
0 A B Input pressure (kg/cm )
LJJF500O
AJJF601D
NOTE
Be sure to bleed the system after connecting the pres-
sure gauges.
COMPONENTS E2BA80EE
1
2
3
4
5
6 9
7 10
8
11
3 12
2.2 ~ 3.2
(21.56 ~ 31.36, 15.99 ~ 23.26) 4
13
14
8
15
LJJF500P
BRAKE SYSTEM BR -37
1. Raise the rear of the vehicle and make sure it is se- REAR BRAKE DISC THICKNESS CHECK
curely supported. Remove the rear wheel.
1. Remove all rust and contamination from the disc sur-
2. Release the parking brake. face, and then measure the disc thickness at 8 posi-
tions at least.
3. Remove the guide rod bolt(A). After raise the caliper
assembly(B) , support it with a wire. Rear brake disc thickness
Standard value : 10.0 mm ( 0.39 in)
Limit : 8.0 mm (0.315 in)
21.56 ~ 31.36 Nm
(2.2 ~ 3.2 kg.m)
A
2. Thickness variation should not exceed
0.005mm(0.0002 in) (circumference) and
0.01mm(0.0004 in) (radius) at any directions.
B 5 mm (measurement position)
AJJF601E
A
LJJF500Q
EJKE600B
BR -38 BRAKE SYSTEM
REAR BRAKE PAD CHECK 2. If the run out of the brake disc exceeds the limit spec-
ification, replace the disc, and then measure the run
1. Check the pad wear. Measure the pad thickness and out again.
replace it, if it is less than the specified value.
3. If the run out does not exceed the limit specification,
Pad thickness install the brake disc after turning it 180 and then
Standard value : 10.0 mm (0.39 in) check the run out of the brake disc again.
Service limit : 2.0 mm (0.0787 in)
4. If the run out cannot be corrected by changing the
position of the brake disc, replace the brake disc.
NOTE
Be careful not to use the hammer. The disc can be
damaged if you remove the disc from the hub by ham-
mer.
ARJE501R
A
Brake disc run out
Limit : 0.03mm (0.0012 in) or less
AJJF601F
A
5 mm
AJJF602R
BRAKE SYSTEM BR -39
INSTALLATION E03660C4 6. Pivot caliper down into position. Being careful not to
damage the pin boot, install the guide rod bolt (A) and
1. Install the pad retainers(A) to the caliper (B). tighten it to the specified torque.
21.56 ~ 31.36 Nm
(2.2 ~ 3.2 kgf.m)
A
AJJF602S
B
7. Install the brake caliper .
EJKE600D
NOTE
Engagement of the brake may require a greater pedal
stroke immediately after the brake pads have been
replaced as a set. Several applications of the brake
pedal will restore the normal pedal stroke.
A
AJGE019D
4. Install the brake pads (B) and pad shim (A) on the
caliper bracket.
COMPONENTS EDCBECAA
2 4
6
1
5 7
LJJF500R
BRAKE SYSTEM BR -41
REMOVAL EA43F67D 7. Remove the bolt (C) and the wheel cylinder(B) from
the backing plate(D).
CAUTION
- Frequent inhalation of brake pad dust, re-
gardless of material composition, could be
hazardous to your health.
- Avoid breathing dust particles A
- Never use an air hose or brush to clean brake 1.3 ~ 1.7 kgf.m
D (12.74 ~ 16.66 Nm,
assemblies. 9.45 ~ 12.36 lb-ft)
1. Remove the shoe hold spring and shoe hold pin (B).
A B
LJJF501Y
B
AJJF603K
A A
AJJF601G
INSPECTION EC8DF780 8. Measure the inside diameter of the brake drum with
inside vernier calipers.
CAUTION
Drum inside diameter
Frequent inhalation of brake pad dust, regardless Standard : 203.2 mm (8.0 in)
of material composition, could be hazardous to Drum roundness
your health. Service limit : 0.06 mm(0.00236 in)
- Avoid breathing dust particles.
- Never use an air hose or brush to clean brake
assemblies.
NOTE
- Contaminated brake linings or drums reduce
stopping ability.
- Block the front wheels before jacking up the rear
of the vehicle.
EJKE800B
11. Inspect the brake lining and drum for proper contact.
C
12. Inspect the wheel cylinder outside for excessive wear
B and damage.
INSTALLATION E287DD5D 5. Hook the shoe adjuster lever, then install it to the
brake shoe.
NOTE
6. Install the adjuster assembly and upper return spring
- Do not spill brake fluid on the vehicle: it may dam- (D) as right direction. Be careful not to damage the
age the paint; if brake fluid does contact the paint. wheel cylinder dust covers.
Wash it off immediately with water.
- To prevent spills, cover the hose joints with rags 7. Install the lower return spring (E).
or shop towels.
- Use only a genuine wheel cylinder special bolt. 8. Apply brake cylinder grease or equivalent rubber
grease to the sliding surfaces shown. Don’t get
1. Apply sealant (C) between the wheel cylinder (A) and grease on the brake linings.
backing plate (B), and install the wheel cylinder.
Sliding surface
D
B 1.3 ~ 1.7 kgf.m
(12.74 ~ 16.66 Nm,
9.45 ~ 12.36 lb-ft)
A
LJJF501Z
LJJF500S
9. Apply brake cylinder grease or equivalent rubber
2. Connect the brake tubes (D) to the wheel cylinder. grease to the brake shoe ends and opposite edges
of the shoes shown. Don’t get grease on the brake
3. Connect the parking brake cable to the parking brake linings.
lever.
C
B
D
LJJF502A
10. Install the brake shoes (A) onto the backing plate. Be
careful not to damage the wheel cylinder dust covers.
E
AJJF603E
BR -44 BRAKE SYSTEM
11. Install the shoe hole down pins (B) and the shoe hole
down springs.
B
A
AJJF602V
14. Depress the brake pedal several times to set the self-
adjusting brake.
COMPONENTS EC7B78AA
5 6 7
10
15 11
14 12
13
1. Pull the parking brake lever (A) with 196 N (20 kg, NOTE
44lbf) force to fully apply the parking brake. The park-
ing brake lever should be locked within the specified After rear brake caliper servicing, loosen the park-
number of clicks (B). ing brake adjusting nut, start the engine and depress
the brake pedal several times to set the self-adjusting
Lever locked clicks: 8~9 clicks brake before adjusting the parking brake.
1. Block the front wheels, then raise the rear of the vehi-
Pulled up with 196 N (20 kgf, 44 lb) cle and make sure it is securely supported.
LJJF503U
AJJF513A
AJJF515A
AJJF601I
A
A
AJJF516A
AJJF514A
AJJF517A
BR -48 BRAKE SYSTEM
8. Remove the parking brake cable(A) from the brake INSTALLATION E4FB9A84
shoe.
1. Check the parking brake cables for an identification
mark paint and install as appropriate on the left and
right sides.
Identification color
Rear drum brake
Left side : Red
Right side : Yellow
Rear disc brake
Left side : Green
Right side : White
10. Remove the parking brake cable retaining ring(B) Specified grease :
from the parking brake cable (A). Multi purpose grease SAE J310, NLGI No.2
ARJE502W
INSPECTION EFDC90BA
AJJF601J
1 2 3
7
6
LJJF500U
ABS (ANTI-LOCK BRAKE SYSTEM) BR -51
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.
LJJF500V
Under the normal braking, voltage is not supplied to solenoid valve, inlet valve is opened and outlet valve is closed.When
the brake is depressed, brake fluid is supplied to the wheel cylinder via solenoid valve to activate the brake.
When the brake is released, brake fluid is back to the master cylinder via inlet valve and check valve.
Pump
Solenoid valve State Valve Passage
motor
Inlet valve (NO) OFF Open Master cylinder ⇔ Wheel cylinder
OFF
Outlet valve (NC) OFF Close Wheel cylinder ⇔ Reservoir
MCS MCP
NO NO NO NO
M
NC NC NC NC
FL RR RL FR
LPA LPA
LJJF500W
BR -54 BRAKE SYSTEM
2. DUMP MODE
Under the emergency braking, if the wheels start to lock up, HECU sends a signal to the solenoid valve
to decrease the brake fluid, then voltage is supplied to each solenoid. At this time inlet valve is closed
and brake fluid is blocked from the master cylinder. Conversely outlet valve is opened and brake fluid
passes through wheel cylinder to reservoir, resulting in pressure decrease.
Pump
Solenoid State Valve Passage
motor
Inlet valve (NO) ON Close Master cylinder ⇔ Wheel cylinder ON
MCS MCP
NO NO NO NO
M
NC NC NC NC
FL RR RL FR
LPA LPA
LJJF500X
ABS (ANTI-LOCK BRAKE SYSTEM) BR -55
3. HOLD MODE
When the brake fluid pressure is maximally decreased in wheel cylinder, HECU sends a signal to solenoid
valve to keep the fluid pressure, voltage is supplied to inlet valve but it is not supplied to outlet valve. At
this time inlet and outlet valves are closed and brake fluid is kept in wheel cylinder.
Pump
Solenoid State Valve Passage
motor
Inlet valve (NO) ON Close Master cylinder ⇔ Wheel cylinder OFF
MCS MCP
NO NO NO NO
M
NC NC NC NC
FL RR RL FR
LPA LPA
LJJF500Y
BR -56 BRAKE SYSTEM
4. INCREASE MODE
If HECU determines there’s no lock-up in the wheel, HECU cuts voltage to solenoid valve. So voltage is not supplied
to each solenoid valve, brake fluid passes through the inlet valve to wheel cylinder, resulting in pressure increase.
Pump
Solenoid State Valve Passage
motor
Inlet valve (NO) OFF Open Master cylinder ⇔ Wheel cylinder ON
MCS MCP
NO NO NO NO
M
NC NC NC NC
FL RR RL FR
LPA LPA
LJJF500Z
ABS (ANTI-LOCK BRAKE SYSTEM) BR -57
N
25
A : Inlet valve(FR)
9
D C B A B : Inlet valve(RL)
C : Inlet valve(RR)
D : Inlet valve(FL)
E : Outlet valve(FR)
F : Outlet valve(RL)
H G F E G : Outlet valve(RR)
H : Outlet valve(FL)
M M : Motor(+)
10
N : Motor(Ground)
17
1
LJJF501A
BR -58 BRAKE SYSTEM
MCS MCP
NO NO NO NO
M
NC NC NC NC
FL RR RL FR
LPA LPA
LJJF501B
BR -59
LJJF501C
HOT IN ON OR START HOT AT ALL TIMES HOT AT ALL TIMES
See Power I/P E/R FUSE &
Distribution JUNCTION RELAY BOX
(Page : SD110-4, BOX
SD110-5) PHOTO 25
ABS-1 ABS-2 INSTRUMENT
ABS STOP LP 40A 40A CLUSTER ECM
10A 15A
See Passenger
Compartment
Fuse Details DATA LINK MULTIPURPOSE
(Page : SD120-9) CONNECTOR CHECK CONNECTOR
1 M33 18 E16 12 M09-3 64 C01
1 10 I/P-F 20 C01-1
PHOTO 25 PHOTO 15 PHOTO
39 PHOTO 27
R
1 E39
W W B/O Br
STOP LAMP
SWITCH
PHOTO PHOTO 25
39 15 EM02 5 EM02 9 EC01
PHOTO PHOTO 27
P 2 E39 R R 39
R/O
R/O W G Br
R/O
See Stop Lamps
(Page : SD927-1)
4 18 9 25 7 16 3 E51
ABS
ON/START Stop Lamp K-Line ABS IND. CONTROL
Input Switch Battery Voltage Control. MODULE
PHOTO 21
Ground
ABS (ANTI-LOCK BRAKE SYSTEM)
B W R L
G O B Y 13 14 11 12 EF01 PHOTO 80
B B
B W R L
ABS CIRCUIT DIAGRAM
7 6 5 4 3 2 1
9 8
16
25 24
* * * * * *
23 22
* 20 19 18 *
LJJF504A
Connector Terminal
Specification Remark
No Description
Over voltage range: 16.5 ± 0.5 V < V
Operating voltage range: 9.5 ± 0.5 V
< V < 16.5 ± 0.5 V
4 IGNITION1(+) Low voltage range: 7.0 ± 0.5 V <
V < 9.5 ± 0.5 V
Max. current: I < 300 mA
Connector Terminal
Specification Remark
No Description
Input voltage :
VI_L < 0.3 IGN[V]
VI_H > 0.7 IGN[V]
7 DIAGNOSIS INPUT/OUTPUT
Output voltage :
VO_L < 0.2 IGN[V]
VO_H > 0.8 IGN[V]
Maxcurrent : I < 2 mA
SENSOR FRONT RIGHT
3 External pull up resister : 10KΩ < R
OUTPUT
Output duty : 50 ± 20 %
BR -62 BRAKE SYSTEM
GROUND ABS
* * 6 5 4 3 2 1
* * * 13 12 11 * 9
Memory power
LJJF501D
* Using the customer problem analysis check sheet for reference, ask the customer as much detail as
possible about the problem.
EJKB055A
Phenomenon Explanation
System check sound When starting the engine, a thudding sound can sometimes
be heard coming from inside the engine compartment. This is
because the system operation check is being performed.
ABS operation sound 1. Sound of the motor inside the ABS hydraulic
unit operation (whine).
2. Sound is generated along with vibration of the
brake pedal (scraping).
3. When ABS operates, sound is generated from the vehicle
chassis due to repeated brake application and release
(Thump : suspension; squeak: tires)
ABS operation (Long braking distance) For road surfaces such as snow-covered and gravel roads, the
braking distance for vehicles with ABS can sometimes be longer
than that for other vehicles. Accordingly, advise the customer to
drive safely on such roads by lowering the vehicle speed.
Diagnosis detection conditions can vary depending on the diagnosis code. When checking the trouble symptom
after the diagnosis code has been erased, ensure that the requirements listed in "Comment" are met.
BR -64 BRAKE SYSTEM
Inspector's
ABS Check Sheet Name
Registration No.
VIN.
Date Vehicle Km
Odometer
Brought In Miles
ABS Warning
Light Abnormal Remains ON Does not light up
EJDA017A
ABS (ANTI-LOCK BRAKE SYSTEM) BR -65
See
Symptom Suspect Area
page
ABS does not operate. Only when 1. -4. are all normal and the problem
is still occurring, replace the HECU.
1. Check the DTC reconfirming that the normal
code is output. BR - 66
2. Power source circuit.
3. Speed sensor circuit.
4. Check the hydraulic circuit for leakage.
ABS does not operate intermittently. Only when 1. -4. are all normal and the problem is still
occurring, replace the ABS actuator assembly.
1. Check the DTC reconfirming that the normal
code is output. BR - 68
2. Wheel speed sensor circuit.
3. Stop lamp switch circuit.
4. Check the hydraulic circuit for leakage.
Communication with Hi-scan (pro) 1. Power source circuit
is not possible. 2. Diagnosis line
BR - 69
(Communication with any system is
not possible)
Communication with Hi-scan (pro) 1. Power source circuit
is not possible. 2. Diagnosis line BR - 70
(Communication with ABS only is not possible) 3. HECU
When ignition key is turned ON (engine OFF), 1. ABS warning lamp circuit
BR - 72
the ABS warning lamp does not light up. 2. HECU
Even after the engine is started, the ABS 1. ABS warning lamp circuit
BR - 73
warning lamp remains ON. 2. HECU
CAUTION
During ABS operation, the brake pedal may vi-
brate or may not be able to be depressed. Such
phenomena are due to intermittent changes in hy-
draulic pressure inside the brake line to prevent
the wheels from locking and is not an abnormal-
ity.
BR -66 BRAKE SYSTEM
DETECTING CONDITION
DTC INSPECTION 1. Disconnect the connector from the ABS control mod-
ule.
1. Connect the Hi-Scan (pro) with the data link connector
and turn the ignition switch ON. 2. Turn the ignition switch ON, measure the voltage be-
tween terminal 4 of the ABS control module harness
2. Verify that the normal code is output. side connector and body ground.
Is the normal code output?
Specification : approximately B+
NO
Is the voltage within specification?
▶ Check the power source circuit.
YES YES
ON (+) (-)
7 6 5 44 3 2 1
9 8
16
25 24
* * * * * *
23 22
* 20 19 18 *
LJJF501E
ABS (ANTI-LOCK BRAKE SYSTEM) BR -67
CHECK THE GROUND CIRCUIT. CHECK THE WHEEL SPEED SENSOR CIRCUIT.
1. Disconnect the connector from the ABS control mod- Refer to the DTC troubleshooting procedures.(See page
ule. BR-78)
Is it normal?
2. Check for continuity between terminals 8, 24 of the
ABS control module harness side connector and YES
ground point.
Is there continuity? ▶ Check the hydraulic circuit for leakage.
YES NO
▶ Check the wheel speed sensor circuit. ▶ Repair or replace the wheel speed sensor.
YES
NO
9 8
7 6 5 4 3 2 1 ▶ Repair the hydraulic lines for leakage.
16
25 24
* * * * * *
23 22
* 20 19 18 *
LJJF501F
BR -68 BRAKE SYSTEM
DETECTING CONDITION
DTC INSPECTION NO
1. Connect the Hi-Scan (pro) with the data link connector
▶ Repair the stop lamp switch. Repair an open in the
and turn the ignition switch ON.
wire between the ABS control module and the stop
2. Verify that the normal code is output. lamp switch.
Is the normal code output?
ON
NO (+) (-)
YES
7 6 5 2 1
▶ Erase the DTC and recheck using Hi-Scan (pro). 9 8 4 3
16
25 24
* * * * * *
23 22
CHECK THE WHEEL SPEED SENSOR CIRCUIT. * 20 19 18 *
NO YES
▶ Repair or replace the wheel speed sensor. ▶ The problem is still occurring, replace the ABS control
module.
CHECK THE STOP LAMP SWITCH CIRCUIT.
NO
1. Check that stop lamp lights up when brake pedal is
depressed and turns off when brake pedal is released.
▶ Repair the hydraulic lines for leakage.
2. Measure the voltage between terminal 18 of the ABS
control module harness side connector and body
ground when brake pedal is depressed.
Specification : approximately B+
YES
ABS (ANTI-LOCK BRAKE SYSTEM) BR -69
DETECTING CONDITION
Specification : approximately B+ NO
NO
13 12 11 9
* * * *
(-) (+)
LJJF501I
* * 6 5 4 3 2 1
13 12 11 9
* * * *
LJJF501H
BR -70 BRAKE SYSTEM
DETECTING CONDITION
YES
Is voltage within specification?
▶ Check the power source of ABS control module. YES
NO
▶ Check for poor ground.
▶ Repair an open in the wire. NO
ON (+) (-)
7 6 5 44 3 2 1
9 8
16
25 24
* * * * * *
23 22
* 20 19 18 *
LJJF501E
ABS (ANTI-LOCK BRAKE SYSTEM) BR -71
YES
NO
* * 6 5 4 3 2 1
13 12 11 9
* * * *
LJJF501I
BR -72 BRAKE SYSTEM
When Ignition Key Is Turned ON (Engine OFF), The ABS Warning Lamp Does Not Light Up.
DETECTING CONDITION
INSPECTION PROCEDURES ON
(+) (-)
PROBLEM VERIFICATION
Disconnect the connector from the ABS control module
and turn the ignition switch ON.
Does the ABS warning lamp light up?
YES
6 4 3 2 1
* * *
▶ It is normal. Recheck the ABS control module.
* 15 14
* 12 11 10 9
NO
LJJF501J
NO
Even After The Engine Is Started, The ABS Warning Lamp Remains ON.
DETECTING CONDITION
INSPECTION PROCEDURES
NO
YES
YES
NO
YES
NO
If there is any brake fluid on any painted surface, 2) Select vehicle name.
wash it off immediately.
3) Select Anti-Lock Brake system.
NOTE
4) Select air bleeding mode.
When pressure bleeding, do not depress the brake
pedal. 5) Press "YES" to operate motor pump and solenoid
Recommended fluid........ DOT3 or DOT4 valve.
2. Connect a clear plastic tube to the wheel cylinder 1.6 AIR BLEEDING MODE
bleeder plug and insert the other end of the tube into ABS AIR BLEEDING STATUS
a half filled clear plastic bottle.
01. SOLENOID VALVE STATUS CLOSE
02. MOTOR PUMP STATUS OFF
DO YOU WANT TO START ?
(PRESS [YES] KEY)
EJDA014F
EJDA014G
ARJE503N
ABS (ANTI-LOCK BRAKE SYSTEM) BR -75
KJKE003B
AJJF601M
The ABS ECU(Electronic Control Unit) checks the battery voltage to determine, as a safety issue, whether the ABS system
can operate normally or not. The normal battery voltage range is essential for controlling the ABS system as intended.
The ABS ECU monitors battery voltage by reading the value of voltage. When the voltage is higher than the expected
normal value, this code is set, and the ABS/EBD/TCS/ESP functions are prohibited. If the voltage recovers, to within
normal operating ranges, then the controller returns to normal operation as well.
1. Many malfunctions in the electrical system are caused by poor harness(es) and terminals. Faults can also be caused
by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or
damage.
YES
NO
▶ Go to next step.
1. Engine "ON".
2. Measure voltage between the battery terminal(+) and the battery terminal(-).
Specification : 10 < V < 16 V
V
1. Battery terminal (+)
2. Battery terminal (-)
Battery
LJJF502E
YES
NO
▶ Check for damaged harness and poor connection between alternator and battery. If OK repair or replace alternator
and then go to "Verification of vehicle Repair" procedure.
BR -80 BRAKE SYSTEM
1. Engine "ON".
2. Measure voltage between the battery terminal(+) and terminal "4" of the HECU harness connector.
7 6 5 4 3 2 1 <ABS, ESP>
9 8 4. IGNITION (+)
16 * * * * * *
25 24 23 22
* 20 19 18 *
Battery
LJJF502F
YES
NO
▶ Check for damaged harness and poor connection between the battery terminal(+) and terminal "4" of the HECU
harness connector. Repair as necessary and then go to "Verification of vehicle Repair" procedure.
1. Ignition "OFF".
3. Measure resistance between terminal "8, 24(ESP : 16, 47)" of the HECU harness connector and chassis ground.
<ABS>
9 8 7 6 5 4 3 2 1 8. GROUND
24. GROUND
16 * * * * * *
25 24 23 22 <ESP>
* 20 19 18 * 16. GROUND
47. GROUND
Ω Ω
LJJF502G
ABS (ANTI-LOCK BRAKE SYSTEM) BR -81
YES
NO
▶ Check for damaged harness and poor connection between terminal " 8, 24( ESP : 16, 47)" of the HECU harness
connector and chassis ground. Repair as necessary and then go to "Verification of vehicle Repair" procedure.
1. Ignition "OFF".
2. Engine "ON".
YES
▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.
NO
▶ Fault is intermittent caused by poor connection in power harness (IGN+), faulty Alternator and/or faulty HECU or
was repaired and HECU memory was not cleared. Go to the applicable troubleshooting procedure.
After a repair, it is essential to verify that the fault has been corrected.
YES
NO
The ABS ECU(Electronic Control Unit) checks the battery voltage to determine, as a safety issue, whether the ABS system
can operate normally or not. The normal battery voltage range is essential for controlling the ABS system as instended.
The ABS ECU monitors the battery voltage by reading the value of voltage. When the voltage is lower than the expected
normal value, this code is set. The ABS/TCS/ESP functions are prohibited and the EBD function is allowed on LOW
VOLTAGE CONDITION, the ABS/EBD/TCS/ESP functions are prohibited on UNDER VOLTAGE CONDITION. If the volt-
age recovers, to within normal operating ranges, then the controller returns to normal operations as well.
1. Ignition "OFF"
4. Measure voltage between terminal "4" of the HECU harness connector and chassis ground.
Specification : Approx. B+
7 6 5 4 3 2 1 <ABS, ESP>
9 8 4. IGNITION (+)
16 * * * * * *
25 24 23 22
* 20 19 18 *
LJJF502H
YES
NO
▶ Check for damaged harness and poor connection between the battery terminal(+) and terminal "4" of the HECU
harness connector. Check for open or blown 10A ABS fuse. Repair as necessary and then go to "Verification of
vehicle Repair" procedure.
AJJF530A
The HECU supplies operating voltage with pressure sensor in master cylinder & lateral G sensor . The HECU monitors
supply voltage of each sensor for normal ESP control. If supply voltage is out of specified range ESP warning lamps are
turned on and TCS/ESP controls are inhibited.
A failure is detected if the external sensor supply voltage is out of the specified range for more than the specified min.
fault duration.
2. Measure voltage between terminal "3" of the Yaw Rate & Lateral G sensor harness connector and chassis ground.
Specification : Approx. 5 V
LJJF502J
YES
NO
▶ Check for short to GND or short to B+ in the Yaw Rate & Lateral G sensor harness between terminal "3" of the Yaw
Rate & Lateral G sensor harness connector and terminal "36" of the HECU harness connector. Repair as necessary
and then go to "Verification of vehicle Repair" procedure. If OK, go to "Component Inspection" procedure.
4. Measure voltage between terminal "2" of the pressure sensor harness connector and chassis ground.
Specification : Approx. 5 V
BR -86 BRAKE SYSTEM
1. Ignition "OFF".
2. Engine "ON".
YES
▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.
NO
▶ Fault is intermittent caused by faulty HECU or was repaired and HECU memory was not cleared. Go to the appli-
cable troubleshooting procedure.
The wheel speed sensor is the essential component the ABS ECU uses to calculate vehicle speed and to determine
whether wheel lock occurs. For example, rear wheel speed signal is used as a referecnce value, for vehicle speed, in
front wheel drive vehicles, and if a difference between front and rear wheel speed occurs, then ABS control is performed.
Wheel speed sensor is active hall-sensor type and good at temperature and noise tolerance. Digital wave is produced as
tone wheel rotate according as hall sensor principle. Frequency of duty wave is changed in proportion to rotation of tone
wheel and HECU calculate vehicle speed by this frequency.
The ABS ECU monitors the wheel speed sensor circuit continuously. If the sensor signal current is continuously out of
the specified range for 140 msec, then the HECU determines that the circuit is open/short, and sets this code. Warning
lamp is turned OFF if the detected fault is not more than when the IG KEY is turned to ON again, and wheel speeds are
more than 10 Km/h.
BR -88 BRAKE SYSTEM
2. Measure voltage between terminal "1" of the wheel speed sensor harness connector and chassis ground.
Specification : Approx. B+
2 1
LJJF502M
YES
NO
▶ Check for open or short to GND in wheel speed sensor harness between terminal 1 of the wheel speed sensor
harness connector and terminal of the HECU harness connector. Repair as necessary and then go to "Verification
of vehicle Repair" procedure.
▶ If OK, go to "Component Inspection" procedure.
3. Measure voltage between terminal "2, 20, 6, 22(ESP : 15, 30, 14, 29)" of the HECU harness connector and chassis
ground.
9 8 7 6 5 4 3 2 1
16 * * * * * *
25 24 23 22
* 20 19 18 *
LJJF502N
YES
NO
▶ Check for open or short to GND in wheel speed sensor harness between terminal "2" of the wheel speed sensor
harness connector and terminal "2, 20, 6, 22(ESP : 15, 30, 14, 29)" of the HECU harness connector. Repair as
necessary and then go to "Verification of vehicle Repair" procedure.
▶ If OK, substitute with a known-good Wheel speed sensor and check for proper operation. If problem is corrected,
replace Wheel speed sensor and then go to "Verification of Vehicle Repair" procedure.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -91
1. Ignition "OFF".
2. Engine "ON".
3. Start and drive vehicle in gear and maintain vehicle speed is approx. 10km/h or more(6mph or more).
YES
▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.
NO
▶ Fault is intermittent caused by open or short of wheel speed sensor harness, faulty wheel speed sensor and/or
faulty HECU or was repaired and HECU memory was not cleared. Go to the applicable troubleshooting procedure.
After a repair, it is essential to verify that the fault has been corrected.
3. Operate the vehicle within DTC Detecting Condition in General Information. (Start and drive vehicle in gear and
maintain vehicle speed is approx. 10km/h or more(6mph or more))
YES
NO
The ABS ECU monitors the wheel speed sensor signal continuously. This code is set if an abnormal speed change ratio
is detected while the vehicle speed is more than 2Km/h . Warning lamp is turned OFF if the detected fault is not more
than when the IG KEY is turned to ON again, and wheel speeds are more than 10 Km/h.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -93
2. Engine "ON".
3. Start and drive vehicle in gear and maintain vehicle speed is approx. 40 km/h or more(24 mph or more)
YES
▶ Fault is intermittent caused by faulty wheel speed sensor and/or faulty HECU or was repaired and HECU memory
was not cleared. Repair or replace as necessary and then go to "Component Inspection" procedure.
NO
▶ Check for improper installation of wheel speed sensor. If NG, repair as necessary and then go to "Verification of
vehicle Repair" procedure.
▶ Check for damage of rotor teeth or wheel bearing. If NG, repair as necessary and then go to "Verification of vehicle
Repair" procedure.
▶ Substitute with a known-good Wheel speed sensor and check for proper operation. If problem is corrected, replace
Wheel speed sensor and then go to "Verification of Vehicle Repair" procedure.
▶ If OK, Go to "Component Inspection" procedure.
1. Ignition "OFF".
2. Engine "ON".
3. Start and drive vehicle in gear and maintain vehicle speed is approx. 40 km/h or more(24 mph or more).
YES
▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.
NO
▶ Fault is intermittent caused by faulty wheel speed sensor and/or faulty HECU or was repaired and HECU memory
was not cleared. Go to the applicable troubleshooting procedure.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -95
After a repair, it is essential to verify that the fault has been corrected.
3. Operate the vehicle within DTC Detecting Condition in General Information. (Start and drive vehicle in gear and
maintain vehicle speed is approx. 40 km/h or more(24 mph or more))
YES
NO
The ABS ECU monitors the wheel speed sensor signal continuously. This code is set when the sensor air gap is out of
specified range or when the ABS control cycle is continued abnormally. The HECU checks for air gap malfunctioning by
monitoring the sensor signal at speeds between 2 Km/h to 10 Km/h. Warning lamp is turned OFF if the detected fault is
not more than when the IG KEY is turned to ON again, and wheel speeds are more than 10 Km/h.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -97
Possible
Item Detecting Condition
cause
DTC Strategy • Signal monitoring
• Outside the ABS control cycle
Detect Mode • Diagnosis mode
• Failure mode
• When the minimum wheel velocity is 2 km/h and the velocity of
other wheels exceed 10 km/h with the acceleration of < 0.4g
, the controller start comparing the velocity of other wheels
except the min. wheel. if their difference below 4 km/h is
Case1 continued for 140 msec, Otherwise, if their difference beyond
(Large 4 km/h or > 0.4 g is continued for 2 minutes.
Air-gap) • In < 0.4 g, when the velocity of more two wheels is 2 km/h and the
Enable
max. wheel velocity exceeds 10 km/h, the condition is continued
Conditions
for 20 sec. Otherwise, In >0.4 g, the condition is 2 minutes.
• After velocity of 4 wheel exceeds 10km/h, when velocity of 1 wheel
or 2 wheel is 2 km/h and difference of other 2 wheel velocity
is less than 4 km/h under that those velocity is more than 10
km/h, if that conditions are continued for 12 seconds. • Improper
- This monitoring is performed for the period that the minimum installa-
velocity rises from 2 km/h to 10 km/h. tion of
Detect Mode • Inside the ABS control cycle wheel
Case2
speed
(long • During the ABS control cycle, if the wheel velocity of 2
Enable sensor
term ABS km/h is lasted for more than 12 sec.
Conditions • Abnormal
mode) • If the ABS control cycle is continued for more than 36 sec. Rotor and
• Sensor failure outside of the ABS control cycle wheel
1) Only one wheel failure : Only the ABS/TCS/ESP functions bearing
are inhibited. The ABS/ESP warning lamps are activated • Faulty
and the EBD warning lamp is not activated Wheel
2) More than two wheels failure : System down. The speed
ABS/EBD/TCS/ESP functions are inhibited. The valve relay sensor
and all solenoids are prevented from being switched on. • Faulty
The ABS/EBD/ESP warning lamps are activated. HECU
2. Engine "ON".
3. Start and drive vehicle in gear and maintain vehicle speed is approx. 10 km/h or more(6mph or more)
YES
▶ Fault is intermittent caused by faulty wheel speed sensor and/or faulty HECU or was repaired and HECU memory
was not cleared. Repair or replace as necessary and then go to "Component Inspection" procedure.
NO
▶ Check for improper installation of wheel speed sensor. If NG, repair as necessary and then go to "Verification of
vehicle Repair" procedure.
▶ Check for damage of rotor teeth or wheel bearing. If NG, repair as necessary and then go to "Verification of vehicle
Repair" procedure.
▶ Substitute with a known-good Wheel speed sensor and check for proper operation. If problem is corrected, replace
Wheel speed sensor and then go to "Verification of Vehicle Repair" procedure.
▶ If OK, Go to "Component Inspection" procedure.
Pressure sensor
LJJF502O
The one pressure sensor ,installed in the master cylinder, sense the brake oil pressure to judge driver’s brake intention
when ESP is operating. If pressure of master cylinder is applied to pressure sensor, the strain of the piezo element
is changed and then the resistance of bridge circuit is changed according to changed strain. Therefore this changed
resistance changes output voltage of bridge circuit and output voltage changes linearly. The sensor output is a analog
signal in proportion to supply voltage, and the HECU recognizes a pressure value according to signal ratio about supply
voltage.
Each unfiltered input signal voltage is monitored to be in the range of 0.2V ± 0.1V < input signal voltage < 4.8V ± 0.1V.
A failure is detected if the output signal value is out of specified range for more than 1s or pressure sensor self test form
is against to specification during self test.
BR -100 BRAKE SYSTEM
2. Measure voltage between terminal "2" of the pressure sensor harness connector and chassis ground.
Specification : Approx. 5 V
LJJF502P
ABS (ANTI-LOCK BRAKE SYSTEM) BR -101
YES
NO
▶ Check for open or short to GND in pressure sensor harness between terminal "2" of the pressure sensor harness
connector and terminal "37" of the ESP HECU harness connector. Repair as necessary and then go to "Verification
of vehicle Repair" procedure. If OK, go to "Component Inspection" precedure.
1. Ignition "OFF".
3. Measure resistance between terminal "3" of the pressure sensor harness connector and chassis ground.
LJJF502Q
YES
NO
▶ Check for open or short in pressure sensor harness between terminal "3" of the pressure sensor harness connector
and terminal "28" of the ESP HECU harness connector. Repair as necessary and then go to "Verification of vehicle
Repair" procedure.
2. Measure voltage between terminal "1" of the pressure sensor harness connector and chassis ground.
LJJF502R
YES
NO
▶ Check for open or short in pressure sensor harness between terminal "1" of the pressure sensor harness connector
and terminal "12" of the HECU harness connector. Repair as necessary and then go to "Verification of vehicle Repair"
procedure.
▶ If OK, substitute with a known-good pressure sensor and check for proper operation. If problem is corrected,
replace pressure sensor and then go to "Verification of Vehicle Repair" procedure.
1. Ignition "OFF".
2. Engine "ON".
3. Start and drive vehicle in gear and maintain vehicle speed is approx. 40 km/h or more(24 mph or more) and then put
on the brake three times.
YES
▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.
NO
▶ Fault is intermittent caused by open or short of pressure sensor harness, faulty pressure sensor and/or faulty
HECU or was repaired and HECU memory was not cleared. Go to the applicable troubleshooting procedure.
The failure is detected if the pressure sensor signal noise is out of normal range, or the pressure sensor signal is changed
abnormally, or In spite of no brake switch signal, master cyclinder pressure exceeds 20 bar when brake switch is normal.
3. Measure voltage between terminal "1" of the pressure sensor harness connector and chassis ground by using the
oscilloscope.
LJJF502S
YES
NO
▶ Check for damaged harness and poor connection in pressure sensor harness between terminal "1" of the pressure
sensor harness connector and terminal "12" of the HECU harness connector. Repair as necessary and then go to
"Verification of vehicle Repair" procedure.
▶ If OK, substitute with a known-good pressure sensor and check for proper operation. If problem is corrected,
replace pressure sensor and then go to "Verification of Vehicle Repair" procedure.
S R S
AIRBAG
S
SR
BAG
AIR
LJJF502T
The Steering wheel angle sensor uses two sensors ( A-sensor and B-sensor ) to determine the direction of the rotation.
The main components of each sensor are LED, photo transistor and slit plate.The slit plate, which has 45 holes, is installed
between LED and photo transistor, and generates signals if slit plate rotates according to the steering wheel rotation.The
sensor signals are generated by photo transistor which is driven whenever the light passes through the holes. The HECU
detects operating speed and direction of the steering wheel by this input signal, and the signal is used to input signal for
anti-roll control.
If some signal voltage stays in abnormal voltage range, the time is counted separately. And if the monitored time exceeds
the specified min. fault duration, failure is detected. The monitoring starts 1sec after Power Up.
2. Measure voltage between terminal "6" of the steering wheel angle sensor harness connector and chassis ground.
Specification : Approx. B+
2. Ground
3. ST1 Signal
4. ST2 Signal
6 5 4 3 2 5. STN Signal
* 6. Power Supply (IG1)
LJJF502U
YES
NO
▶ Check for open or blown 10 A fuse. Repair as necessary and then go to "Verification of vehicle Repair" procedure.
▶ If OK, check for open or short to GND in steering wheel angle sensor harness between the battery terminal(+) and
terminal "2" of the steering wheel angle sensor harness connector. Repair as necessary and then go to "Verification
of vehicle Repair" procedure.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -107
1. Ignition "OFF".
3. Measure resistance between terminal "2" of the steering wheel angle sensor harness connector and chassis ground.
2. Ground
3. ST1 Signal
4. ST2 Signal
6 5 4 3 2 5. STN Signal
* 6. Power Supply (IG1)
LJJF502V
YES
NO
▶ Check for open or short in steering wheel angle sensor harness between terminal "2" of the steering wheel angle
sensor harness connector and terminal "31" of the HECU harness connector. Repair as necessary and then go to
"Verification of vehicle Repair" procedure.
3. Measure signal waveform between terminal "3, 4, 5" of the steering wheel angle sensor harness connector and
chassis ground.
Specification :
HIGH : 2.9 ± 0.1 V ~ 4.4 ± 0.1 V
LOW : 1.2 ± 0.1 V ~ 2.1 ± 0.1 V
BR -108 BRAKE SYSTEM
ST1 STN
ST2
HOLD TIME VOLT GND CHNL MENU HOLD TIME VOLT GND CHNL MENU
Fig1 Fig2
2. Ground
3. ST1 Signal
4. ST2 Signal
6 5 4 3 2 5. STN Signal
* 6. Power Supply (IG1)
LJJF502X
YES
NO
▶ Check for open or short in steering wheel angle sensor harness between terminal "3, 4, 5" of the steering wheel
angle sensorr harness connector and terminal "8, 40, 39" of the HECU harness connector. Repair as necessary and
then go to "Verification of vehicle Repair" procedure.
▶ If OK, substitute with a known-good steering wheel angle sensor and check for proper operation. If problem is
corrected, replace steering wheel angle sensor and then go to "Verification of Vehicle Repair" procedure.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -109
This monitoring function monitors the changing point of N-signal with measured steering angle from ST1 and ST2. If
N-signal changing point differs more than predefined degree, the failure is detected. If there is no variation of the steering
wheel angle for predefined time ECU detect the failure.
3. Measure signal waveform between terminal "1, 4, 5" of the steering wheel angle sensor harness connector and
chassis ground.
Specification :
HIGH : 2.9 ± 0.1 V ~ 4.4 ± 0.1 V
LOW : 1.2 ± 0.1 V ~ 2.1 ± 0.1 V
ST1 STN
ST2
HOLD TIME VOLT GND CHNL MENU HOLD TIME VOLT GND CHNL MENU
Fig1 Fig2
2. Ground
3. ST1 Signal
4. ST2 Signal
6 5 4 3 2 5. STN Signal
* 6. Power Supply (IG1)
LJJF502Z
BR -112 BRAKE SYSTEM
YES
NO
▶ Check for open or short in steering wheel angle sensor harness between terminal "1, 4, 5" of the steering wheel
angle sensorr harness connector and terminal "39, 40, 8" of the HECU harness connector. Repair as necessary and
then go to "Verification of vehicle Repair" procedure.
▶ If STN signal is LOW when the steering wheel is in center position, Check for improper installation of steering
angle sensor. Repair as necessary and then go to "Verification of vehicle Repair" procedure.
▶ If OK, substitute with a known-good steering wheel angle sensor and check for proper operation. If problem is
corrected, replace steering wheel angle sensor and then go to "Verification of Vehicle Repair" procedure.
LJJF503A
When the vehicle is turning with respect to a vertical axis the yaw rate sensor detects the yaw rate electronically by the
vibration change of plate fork inside the yaw rate sensor. If yaw velocity reaches the specific velocity after it detects the
vehicle’ yawing, the ESP control is reactivated. The lateral G sensor senses vehicle’s lateral G. A small element inside
the sensor is attached to a deflectable leverarm by lateral G. Direction and magnitude of lateral G loaded to vehicle can
be known with electrostatic capacity changing according to lateral G. The output voltage of the lateral G sensor is 2.5V
when the vehicle is at a standstill. Only with lateral G sensor, the ESP can not be reactivated.
A failure is detected if the lateral acceleration sensor or yaw rate sensor signal stays in the fault range longer than the
specified failure detection time. The Monitoring starts 1sec after Power Up.
BR -114 BRAKE SYSTEM
2. Measure voltage between terminal "3" of the Yaw Rate & Lateral G sensor harness connector and chassis ground.
Specification : Approx. 5 V
LJJF503B
YES
NO
▶ Check for open or short to GND in the Yaw Rate & Lateral G sensor harness between terminal "3" of the Yaw Rate
& Lateral G sensor harness connector and terminal "36" of the HECU harness connector. Repair as necessary and
then go to "Verification of vehicle Repair" procedure. If OK, go to "Component Inspection" procedure.
1. Ignition "OFF".
3. Measure resistance between terminal "4" of the Yaw Rate & Lateral G sensor harness connector and chassis ground.
LJJF503C
BR -116 BRAKE SYSTEM
YES
▶ Go to next procedure.
NO
▶ Check for open or short in the Yaw Rate & Lateral G sensor harness between terminal "4" of the Yaw Rate &
Lateral G sensor harness connector and terminal "23" of the HECU harness connector. Repair as necessary and
then go to "Verification of vehicle Repair" procedure.
2. Measure voltage between terminal "1, 2" of the Yaw Rate & Lateral G sensor harness connector and chassis ground.
LJJF503D
YES
NO
▶ Check for open or short in the Yaw Rate & Lateral G sensor harness between terminal "1, 2" of the Yaw Rate &
Lateral G sensor harness connector and terminal "41, 9" of the HECU harness connector. Repair as necessary and
then go to "Verification of Vehicle Repair" procedure. If OK, go to "Component Inspection" procedure.
▶ If OK, Substitute with a known-good Yaw Rate & Lateral G sensor and check for proper operation. If problem is
corrected, replace Yaw Rate & Lateral G sensor and then go to "Verification of Vehicle Repair" procedure.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -117
1. Ignition "OFF".
2. Engine "ON".
YES
▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.
NO
▶ Fault is intermittent caused by open or short of Yaw Rate & Lateral G sensor harness and/or faulty Yaw Rate
& Lateral G sensor or was repaired and HECU memory was not cleared. Go to the applicable troubleshooting
procedure.
A lateral acceleration reference signal is calculated from the wheel speeds, the steering angle and the yaw rate signals
to observe the lateral acceleration sensor signal. The difference between the reference signal and the sensor signal is
evaluated for failure detection. A yaw rate reference signal is calculated from the wheel speeds, the steering angle and
the lateral acceleration signals to observe the yaw rate sensor signal. The difference between the reference signal and
the sensor signal, and the gradient of the measured sensor signal is evaluated for the failure detection. If the difference
between estimated value and measured value of the sensor is larger than predefined value for predefined time, the failure
is recognized.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -119
2. Measure voltage between terminal "1, 2" of the Yaw Rate & Lateral G sensor harness connector and chassis ground.
LJJF503E
YES
NO
▶ Check for open or short in the Yaw Rate & Lateral G sensor harness between terminal "1, 2" of the Yaw Rate &
Lateral G sensor harness connector and terminal "41, 9" of the HECU harness connector. Repair as necessary and
then go to "Verification of Vehicle Repair" procedure. If OK, go to "Component Inspection" procedure.
▶ If OK, Substitute with a known-good Yaw Rate & Lateral G sensor and check for proper operation. If problem is
corrected, replace Yaw Rate & Lateral G sensor and then go to "Verification of Vehicle Repair" procedure.
LJJF503G
Driver can inhibit the ESP control by ESP switch. When switch signal send into HECU, ESP warning lamp goes ON and
ESP control is stopped and if next switch signal is inputted again, ESP control is ready. This function is used for sporty
driving or vehicle inspection.
Trouble code is set when the condition that the level of ESP switch is high is continued for 60sec. When the ESP switch
failure is set there is no signal in the warning lamp and HECU inhibits the ESP control and allows the ABS/EBD control.
2. Measure voltage between terminal "27" of the HECU harness connector and chassis ground.
Specification : Approx B+
<ESP>
16 15 14
31 30 29 * 28 12 27 * * 9 24 8 23 7 22 6 21 5 4 19 * 18 * 1
27. ESP switch
* * * *
47 46 45 44 43
* 41 40 39 * 37 36 35 34 * 32
LJJF503H
YES
▶ Fault is intermittent caused by open or short in ESP switch line, faulty ESP switch or was repaired and HECU
memory was not cleared. Go to the applicable troubleshooting procedure.
NO
▶ Check for damaged harness and poor connection in the power harness between the battery terminal(+) and the
terminal "27" of the HECU harness connector . Check for open or blown 10 A fuse referring to "Circuit Diagram" .
Repair as necessary and then go to "Verification of vehicle Repair" procedure.
▶ If OK, go to "Component Inspection" procedure.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -123
1. Ignition "OFF".
4. Measure resistance between terminal "1" of the ESP switch harness connector and terminal "4" of the ESP switch
harness connector
1. POWER SUPPLY
1 2 4. SIGNAL
* 4
* 6
LJJF503I
YES
▶ Fault is intermittent caused by faulty ESP switch or was repaired and HECU memory was not cleared. Go to the
applicable troubleshooting procedure.
NO
▶ Substitute with a known-good ESP switch and check for proper operation. If problem is corrected, replace ESP
switch and then go to "Verification of Vehicle Repair" procedure.
LJJF503J
The brake light switch indicates brake pedal status to the ABS control unit. The switch is turned on when brake is de-
pressed. The brake light switch is a normally-open contact which runs to battery voltage when active (brake depressed).
When passive (brake not depressed), the cable is grounded via the break light bulbs.
The brake light signal is a reference to judge driver’s will for braking. ABS ECU monitor open circuit of brake light switch
for normal ABS control. HECU set the warning lamp if either BLS or BS is fault.
ABS (ANTI-LOCK BRAKE SYSTEM) BR -125
3. Measure voltage between the terminal "5, 21" of the HECU harness connector and chassis ground.
Specification :
Brake Light Switch - Approx. B+
Brake Switch - Approx. 0 V
16 15 14
31 30 29 * 28 12 27 * * 9 24 8 23 7 22 6 21 5 4 19 * 18 * 1
<ESP>
* * * * 5. Brake Light Switch
47 46 45 44 43
* 41 40 39 * 37 36 35 34 * 32
21. Brake Switch
V V
LJJF503K
BR -126 BRAKE SYSTEM
YES
▶ Fault is intermittent caused by open harness in brake light switch and brake switch line, faulty brake light switch or
was repaired and HECU memory was not cleared. Go to the applicable troubleshooting procedure.
NO
▶ Check for damaged harness and poor connection in the power harness between the battery terminal(+) and the
terminal "5, 21" of the HECU harness connector . Check for open or blown 15 A stop fuse. Repair as necessary and
then go to "Verification of vehicle Repair" procedure.
▶ If OK, Go to "Component Inspection" procedure.
1. Connect a ohmmeter to the connector of brake light switch, and check whether or not there is continuity when the
plunger of the brake light switch is pushed in and when it is released.
The switch is in good condition if there is no continuity when the plunger is pushed.
YES
▶ Fault is intermittent caused by open harness in brake light switch line, faulty brake light switch or was repaired and
HECU memory was not cleared. Go to the applicable troubleshooting procedure.
NO
▶ Substitute with a known-good brake light switch and check for proper operation. If problem is corrected, replace
brake light switch and then go to "Verification of Vehicle Repair" procedure.
The HECU is composed of an ECU (Electronic Control Unit ) and a HCU( Hydraulic Control Unit) , so the HECU hardware
includes all solenoid valves inside the unit as well as the ECU.
The HECU monitors the operation of the IC components such as memory, register, A/D converter and so on. The HECU
sets this code when the EEPROM data read by the master processor is different from prior data written, or when the
master/slave processor detects abnormal operation in RAM, Status Register, Interrupt, Timer, A/D converter or cycle
time.
• When the MCU can’ t erase or write a data of the EEPROM. • Faulty HECU
Enable • When the master/slave processor detects abnormal
Conditions operation in RAM, ROM, INTERRUPT, TIMER, A/D
CONVERTER, CYCLE TIME.
• System down. The ABS/EBD/TCS/ESP functions are inhibited.
- The valve relay and all solenoids are prevented
Fail Safe
from being switched on.
• The ABS/EBD/ESP warning lamps are activated.
BR -128 BRAKE SYSTEM
1. Ignition "OFF".
2. Engine "ON".
YES
▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.
NO
▶ Fault is intermittent caused by faulty HECU or was repaired and HECU memory was not cleared. Go to the appli-
cable troubleshooting procedure.
CAN communication is applied just for ESP( Electronic Stability Program) installed in the vehicle for sending requirement
data, such as torque reduction, the number of fuel cut cylinders, and TCS control requests, to the Engine ECM & TCU. The
Engine ECM performs fuel cut functions according to requests from the ABS ECU and retards ignition timing by torque
reduction requests. The TCU maintains current gear positions during TCS/ESP control time, by not increasing power
which causes a kickdown shift.
The HECU checks the CAN RAM for normal TCS/ESP control, and sets this code if a CAN RAM malfunction is detected.
1. Ignition "OFF".
2. Ignition "ON"
YES
▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.
NO
▶ Fault is intermittent caused by short harness in CAN line and/or faulty HECU or was repaired and HECU memory
was not cleared. Go to the applicable troubleshooting procedure.
The HECU checks the CAN communication lines for normal TCS/ESP control, and sets this code if an ECM message is
not received within 500ms. The HECU does not detect this code until 2 seconds after the IG KEY is turned to ON.
1. Ignition "OFF".
2. Ignition "ON"
YES
▶ Substitute with a known-good ECM and check for proper operation. If problem is corrected, replace ECM and then
go to "Verification of Vehicle Repair" procedure. If NG, replace HECU and then go to "Verification of Vehicle Repair"
procedure.
NO
▶ Fault is intermittent caused by faulty ECM and/or faulty HECU or was repaired and HECU memory was not cleared.
Go to the applicable troubleshooting procedure.
The HECU checks the CAN communication lines for normal TCS/ESP control, and sets this code if an TCU message is
not received within 500ms. The HECU does not detect this code until 3 seconds after the IG KEY is turned to ON.
1. Ignition "OFF".
2. Ignition "ON"
YES
▶ Substitute with a known-good TCU and check for proper operation. If problem is corrected, replace TCU and then
go to "Verification of Vehicle Repair" procedure. If NG, replace HECU and then go to "Verification of Vehicle Repair"
procedure.
NO
▶ Fault is intermittent caused by faulty TCU and/or faulty HECU or was repaired and HECU memory was not cleared.
Go to the applicable troubleshooting procedure.
The HECU checks the CAN communication lines for normal TCS/ESP control, and sets this code if the data received
between the EMS2 and TCU is not the same. The HECU will not detect this code until 2 seconds after the IG KEY is
turned ON.
1. Ignition "OFF".
2. Ignition "ON"
YES
▶ Substitute with a known-good ECM and check for proper operation. If problem is corrected, replace TCU and then
go to "Verification of Vehicle Repair" procedure. If NG, replace HECU and then go to "Verification of Vehicle Repair"
procedure.
NO
▶ Fault is intermittent caused by faulty ECM and/or faulty HECU or was repaired and HECU memory was not cleared.
Go to the applicable troubleshooting procedure.
The HECU checks the CAN communication lines for normal TCS/ESP control, and sets this code if CAN BUS OFF status
is detected for more than 100 ms.
1. Ignition "OFF".
2. Measure resistance between terminal "22" of the HECU harness connector and terminal "7" of the HECU harness
connector.
Specification : Approx. 60 Ω
16 15 14
<ESP>
31 30 29 * 28 12 27 * * 9 24 8 23 7 22 6 21 5 4 19 * 18 * 1
7. CAN (HIGH)
* * * *
22. CAN (LOW)
47 46 45 44 43
* 41 40 39 * 37 36 35 34 * 32
LJJF503L
YES
▶ Fault is intermittent caused by open or short in CAN signal harnessor was repaired and HECU memory was not
cleared. Go to the applicable troubleshooting procedure.
NO
▶ Check for open or short in CAN signal harness between terminal "22" of the HECU harness connector and terminal
"7" of the HECU harness connector. Repair as necessary and then go to "Verification of vehicle Repair" procedure.
The ABS ECU supplies battery power to all solonid valves by way of a valve relay which is controlled by the Electronic
Control UNIT(ECU). The valve relay and all solenoid valves are installed inside the HECU ( Hydraulic and Electronic
Control Unit ).
ABS ECU monitors voltage of the valve relay to check if ABS ECU can perform ABS control normally. When the valve
relay is switched to ON, the HECU will set this code if the solenoid drive voltage is below permissible voltage ranges for
a period of time. When the valve relay is switched to OFF, the HECU sets this code if the solenoid drive voltage is over
the permissible voltage range for a period of time.
DURATION 2 SECONDS
METHOD ACTIVATION
STRT
Fig1
LJJF503M
YES
▶ Fault is intermittent caused by poor connection in power harness (ABS1) and/or HECU’s connector or was re-
paired and HECU memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending,
corrosion, contamination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
NO
▶ Go to next step.
1. Ignition "OFF"
4. Measure voltage between terminal "25(ESP : 32)" of the HECU harness connector and chassis ground.
Specification : Approx. B+
7 6 5 4 3 2 1 <ABS>
9 8 25. Battery (ABS1)
16 * * * * * *
25 24 23 22 <ESP>
* 20 19 18 * 32. Battery (ABS1)
LJJF503N
YES
NO
▶ Check for open or short in power harness between battery terminal(+) and terminal "25(ESP : 32) " of the HECU
harness connector. Check for open or blown 40 A ABS1 fuse referring to "Circuit Diagram". Repair as necessary
and then go to "Verification of vehicle Repair" procedure.
BR -140 BRAKE SYSTEM
1. Ignition "OFF".
3. Measure resistance between terminal "8, 24(ESP : 16, 47) " of the HECU harness connector and chassis ground.
<ABS>
9 8 7 6 5 4 3 2 1 8. Ground
16 * * * * * * 24. Ground
25 24 23 22
* 20 19 18 * <ESP>
16. Ground
47. Ground
Ω Ω
LJJF503O
YES
NO
▶ Check for damaged harness and poor connection between terminal "8, 24(ESP : 16, 47)" of the HECU harness
connector and chassis ground. Repair as necessary and then go to "Verification of vehicle Repair" procedure.
BTCS ( Brake Traction Control System ) is operated when the value ( Wheel acceleration value + speed difference value )
exceeds the specified value when vehicle speed is lower than the 50 Km/h. The BTCS intalled HECU calculates the disc
temperature logically, which is an assumed value, by using the value of Wheel speed, vehicle speed change, CONTROL
MODE and BLS SIGNAL. Assumed disc temperature is used to protect DISC overheating, caused by long-time operation,
which may cause a decrease in brake efficiency.
If the HECU decides that the disc is over-heated ( above 500 ℃ ), then it turns the ESP lamp ON and inhibits BTCS
operation to protect overheating of the disc. If the calculated temperature becomes lower than specified value ( aprrox.
250 ℃ ), then the HECU turns the ESP lamp OFF and operates the BTCS again.
1. Ignition "OFF".
2. Ignition "ON"
YES
▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.
NO
▶ Fault is caused by Faulty HECU or was repaired and HECU memory was not cleared.
▶ The DTC code can be set by excessive TCS/ESP control in normal system status. Go to "Verification of Vehicle
Repair" procedure.
The ABS HECU is composed of an ECU (Electronic Control Unit ) and a HCU( Hydraulic Control Unit), so the HECU
hardware includes all solenoid valves inside the unit as well as the ECU. Solenoid valves are switched to ON, OFF by
HECU when the ABS is activated. Solenoid valves function is to increase, decrease or maintain the hydrualic pressure
supplied to a wheel cylinder.
The HECU monitors the operation of the valves by checking the drive circuit of the solenoid valves, and then sets this
code when the unexpcted drive voltage is detected. For example, the HECU sets the DTC if an unexpected high drive
voltage is detected when the valve relay is switched to OFF. (or unexpected low voltage is detected when the solenoid
valve drive TR is switched to ON).
1. Ignition "OFF".
2. Ignition "ON"
3. Start and drive vehicle in gear and maintain vehicle speed is approx. 12 km/h or more(7 mph or more)
YES
▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.
NO
▶ Fault is intermittent caused by faulty HECU or was repaired and HECU memory was not cleared. Go to the appli-
cable troubleshooting procedure.
After a repair, it is essential to verify that the fault has been corrected.
3. Operate the vehicle within DTC Detecting Condition in General Information. (Start and drive vehicle in gear and
maintain vehicle speed is approx. 12 km/h or more(7 mph or more))
YES
NO
The ABS ECU supplies battery power to the electric motor by way of a motor relay which is controlled by the Electronic
Control Unit(ECU). The electric motor pump supplies hydraulic pressure to all wheel brake calipers by operating the piston
inside the pump.
The ABS ECU monitors the pump motor relay or fuse open, open or short in motor or motor lock and then sets this code
if a malfunction is detected.
BR -146 BRAKE SYSTEM
MOTOR
DURATION 2 SECONDS
METHOD ACTIVATION
STRT
Fig1
LJJF503P
YES
▶ Fault is intermittent caused by poor connection in power harness (ABS1) and/or HECU’s connector or was re-
paired and HECU memory was not cleared. Thoroughly check connectors for looseness, poor connection, bending,
corrosion, contamination, deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
NO
1. Ignition "OFF"
4. Measure voltage between terminal "9(ESP : 1)" of the HECU harness connector and chassis ground.
Specification : Approx. B+
7 6 5 4 3 2 1 <ABS>
9 8 9. Battery Voltage (ABS2)
16 * * * * * *
25 24 23 22 <ESP>
* 20 19 18 * 1. Battery Voltage (ABS2)
LJJF503Q
YES
NO
▶ Check for open or short in power harness between battery terminal(+) and terminal "9(ESP : 1)" of the HECU
harness connector. Check for open or blown 40 A ABS2 fuse referring to "Circuit Diagram". Repair as necessary
and then go to "Verification of vehicle Repair" procedure
1. Ignition "OFF".
2. Check for open or short in power harness between battery terminal(+) and terminal "9(ESP :1)" of the HECU harness
connector. Check for open or blown 40A ABS2 fuse referring to "Circuit Diagram". Repair as necessary and then go
to "Verification of vehicle Repair" procedure.
<ABS>
9 8 7 6 5 4 3 2 1 8. Ground
16 * * * * * * 24. Ground
25 24 23 22
* 20 19 18 * <ESP>
16. Ground
47. Ground
Ω Ω
LJJF503R
YES
NO
▶ Check for damaged harness and poor connection between terminal "8, 24(ESP : 16, 47)" of the HECU harness
connector and chassis ground. Repair as necessary and then go to "Verification of vehicle Repair" procedure.
1. Ignition "OFF".
2. Engine "ON".
3. Start and drive vehicle in gear and maintain vehicle speed is approx. 12 km/h or more(7 mph or more)
YES
▶ Substitute with a known-good HECU and check for proper operation. If problem is corrected, replace HECU and
then go to "Verification of Vehicle Repair" procedure.
NO
▶ Fault is intermittent caused by open or short of power harness (ABS2) and/or faulty HECU or was repaired and
HECU memory was not cleared. Go to the applicable troubleshooting procedure.
COMPONENTS EEB9DF59
10
4 6
5
3 2
1
REMOVAL EED88E12 4. Loosen the 3 ABS HECU bracket bolts (A) and 1
nut(B) , then remove HECU and bracket.
1. Turn the ignition switch OFF.
A
2. Pull up the lock(A) of the ABS control unit 25P con-
nector , then disconnect the connector.
A B
AJJF529A
CAUTION
AJJF519A 1. Never attempt to disassemble the HECU.
2. The HECU must be transported and stored in.
3. Disconnect the brake tubes from the HECU by unlock- 3. Never shock to the HECU.
ing the nuts counterclockwise with a spanner.
5. Remove the 3 damper screws and washer , then re-
1.22 ~ 1.63 kgf.m
(11.96 ~ 15.98 Nm, move the bracket.
8.82 ~ 11.79 lb-ft)
INSTALLATION E195F15A
Tightening torque
HECU damper screw :
10.98 ~ 14.02 Nm (1.12 ~ 1.43 kgf.m, 8.1 ~ 10.34 Ib-ft)
HECU bracket mounting bolt, nut :
7.85 ~ 9.8 Nm (0.8 ~ 1.0 kgf.m, 5.79 ~ 7.23 Ib-ft)
LJJF502B
BR -152 BRAKE SYSTEM
COMPONENTS E7C754E6
LJJF501L
ABS (ANTI-LOCK BRAKE SYSTEM) BR -153
A
A
AJJF523A
AJJF532A
AJJF521A
AJJF522A
BR -154 BRAKE SYSTEM
INSPECTION EB1D3836
CAUTION
In order to protect the wheel speed sensor, when
measuring output voltage, a 100 Ω resister must
be used as shown.
Power
DC 12V Ground
Wheel sensor
Vin
Vout
R(100Ω)
Tone wheel
Oscilloscope
Airgap : 0.4 ~ 1.5 mm
LJJF501M
Vhigh
Vlow
0V
t
ARJE503Z
COMPONENTS EA4ECF1C
REMOVAL E44D6BB4
AJJF524A
3. Remove the rear wheel speed house trim and rear pil-
lar trim.Disconnect the rear wheel speed sensor con-
nector.
EBD (ELECTRONIC BRAKE-FORCE DISTRIBUTION) BR -157
Fixed distribution
EJA0032A
BR -158 BRAKE SYSTEM
E E
ESP ESP
S S
Drift-out Yaw-moment
P P
Control Control
LJCD201A
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -159
Master cylinder
Pressure sensor
Steering wheel
Angle sensor
Master
cylinder
EJQE005M
BR -160 BRAKE SYSTEM
Active Wheel
ESP Control
speed sensor
Warning Lamp
(RL)
(ABS, EBD, ESP)
Active Wheel
speed sensor
(RR)
ABS Control
Steering Wheel Diagnosis
Angle sensor K-Line
Master cylinder
pressure sensor
Primary
Secondary Wheel speed
sensor output
Brake switch
CAN ECU
ESP OFF switch
TCU
LJJF501O
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -161
COMPONENTS EEC776A9
5
6
LJJF502C
BR -162 BRAKE SYSTEM
ABS
ESP
MCS MCP
FL RR RL FR
LJJF501P
2. ESP operation
G O B Y 13 14 11 12 EF01
PHOTO 80 B B
B W R L
1 2 E49 1 2 E50 1 2 F31 1 2 F32
FRONT WHEEL FRONT WHEEL REAR WHEEL REAR WHEEL
SENSOR LH SENSOR RH SENSOR LH SENSOR RH
PHOTO 22 PHOTO 22 PHOTO 54 PHOTO 56
P S P S P S P S G01 G02
PHOTO 48 PHOTO 48
BR -164
BR -165
LJJF501S
HOT IN ON OR START HOT WITH MAIN RELAY ON
See Power I/P See Power I/P
Distribution JUNCTION Distribution JUNCTION
(Page : SD110-5) BOX (Page : SD110-2) BOX
CLUSTER PHOTO SNSR PHOTO
10A 62 10A 62
See Passenger
Compartment
Fuse Details
(Page : SD120-1)
ECM
11 I/P-G
MULTIPURPOSE PHOTO
DATA LINK CHECK 62
P CONNECTOR CONNECTOR See Stop Lamps
11 M09-1 1 M33 18 E16 64 C01(M/T) (Page : SD927-1)
PHOTO 25 PHOTO 15 20 C01-1(A/T) W
INSTRUMENT
CLUSTER
PHOTO 55 R
ESP
ABS ESP OFF W W Br
3 1 E39
( ABS ) ESP ESP
OFF STOP LAMP
SWITCH
15 EM02 9 EC01 PHOTO 52
PHOTO 25
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM
PHOTO 27
12 M09-3 1 2 M09-1 4 2 E39
PHOTO
B/O 62 Y/B P/O R/O
W Br
5 EM02 19 17 EM01 R/O
PHOTO PHOTO 55 See Stop Lamps
G 62 Y/B P/O (Page : SD927-1)
18 35 34 19 6 21 E17
ESP
K-Line Vehicle Stop Lamp CONTROL
Speed Input Switch MODLUE
ESP IND. Control
PHOTO
YAW Sensor LG YAW Sensor YAW Sensor 6
Signal Sensor Power Ground CBIT Signal Power Ground CAN Low CAN High
41 9 36 23 24 12 37 28 22 7 E17
Gr/B P/B R/O B/O G/O
4 2 5 6 3 EF01 L R B L R
CIRCUIT DIAGRAM - ESP(2)
PHOTO 81
Gr/B Y/B R/O B/O G/O
1 2 3 4 6 F10 1 2 3 E31
G-YAW PRESSURE
YAW LAR.G VCC GND SELF SENSOR VOUT VCC GND SENSOR
RATE TEST
PHOTO PHOTO See Data Link Details
61 61 (Page : SD200-1)
BR -166 BRAKE SYSTEM
Connector Terminal
Specification Remark
No Description
4 IGNITION1(+)
32 POS.BATTERY.(SOLENOID) Max leakage current : I < 0.8 mA
Operating voltage range:
9.5 ± 0.5 V < V < 16.5 ± 0.5 V
1 POS.BATTERY.(MOTOR) Rush current : I < 100 A
Max current : I < 30 A
Max leakage current : I < 0.2 mA
37
MASTER PRESSURE SENSOR Max Output current : I < 10 mA
POWER Max Output voltage : 4.9 V ≤ V ≤ 5.1 V
Connector Terminal
Specification Remark
No Description
15 SENSOR FRONT LEFT SIGNAL
SENSOR FRONT RIGHT Input current LOW : 5.9 ~ 8.4 ㎃
30 Input current HIGH :11.8 ~ 16.8 ㎃
SIGNAL
Frequency range :1 ~ 2000 Hz
14 SENSOR REAR LEFT SIGNAL Input duty : 50 ± 20 %
29 SENSOR REAR RIGHT SIGNAL
STEERING ANGLE SENSOR
8
PHASE 1 Input duty (ST1, ST2): 50 ± 10
Phase difference (ST1, ST2):
STEERING ANGLE SENSOR
40 2 ± 0.6 deg
PHASE 2
High voltage: 3.0 V < V < 4.1 V
STEERING ANGLE SENSOR Low voltage: 1.3 V < V < 2.0 V
39
PHASE N
1. In principle, ESP and TCS controls are prohibited in 1. Turn the system down and perform the following ac-
case of ABS failure. tions and wait for HECU power OFF.
2. When ESP or TCS fails, only the failed system control 2. Turn the valve relay off.
is prohibited.
3. Stop the control during the operation and do not exe-
3. However, when the solenoid valve relay should be cute any until the normal condition recovers.
turned off in case of ESP failure, refer to the ABS
WARNING LAMP ON
fail-safe.
1. ABS warning lamp turns on when ABS is fail.
4. Information on ABS fail-safe is identical to the fail-safe
in systems where ESP is not installed. 2. ESP operation lamp turns on and ESP OFF warning
MEMORY OF FAIL CODE lamp blinks when ESP is fail.
1. It keeps the code as far as the backup lamp power is When power voltage and valve relay voltage are abnormal,
connected. (O) input/output related failure judgment is not made.
FAILURE CHECKUP
DESCRIPTION E73B8D8C
SPECIFICATIONS
OUTPUT CHARACTERISTIC
[Yaw-rate]
Vcc=5 (V)
5
4.525
4
Zerorate = 2.5 (V
Sensitivity= 27 (mV/deg/s)
3
Output(V)
2.5
0.475
Yaw-rate (deg/s)
EJQE206A
[Lateral G.]
Vcc = 5 (V)
5
4.54
2.5
out 2
0.46
Lateral G. (G)
LJJF502D
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -171
EXTERNAL DIAGRAM
Yaw-rate 1 41
3 2 1 Lateral G. 2 9
6 4
* Sensor Power 3 36
GND 4 23
Self-test 6 24
Lateral G. sensor
LJIF502C
REPLACEMENT E73B8D9C
LJJF538K
BR -172 BRAKE SYSTEM
DESCRIPTION EE2AC6B4
LJJF501T
SPECIFICATIONS
CIRCUIT DIAGRAM
Sensor Signal 1 12
Power 2 37
GND 3 28
[Pressure sensor] [ESP HECU]
1
3 2
LJIF502D
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -173
OUTPUT CHARACTERISTIC
Vcc=5 (V)
5
4.4
4
Zero rate = 2.5 (V)
Sensitivity = 23 (mV/bar)
Output(V)
0.5
0
0 1 50 100 150 171
Pressure(bar)
EJQE206C
REPLACEMENT E74B8D8C
LJJF501T
AJJF509A
ESP SWITCH
DESCRIPTION E3CFAAC7
1. The ESP OFF switch is for the user to turn off the ESP
system.
INSPECTION E9929FC0
LJJF501U
Terminal
2 5 6 3
Function
ON
OFF
LJJF504B
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -175
STEERING WHEEL ANGLE calculates the steering angle by the pulse from the steering
SPEED SENSOR angle sensor.
DESCRIPTION E7AAC47B
MEASUREING PRINCIPLE
SPECIFICATION
Description Specification
Operating voltage 9 ~ 16 V
Operating temperature -30 ~ 75 ℃
Current consumption Max.100 mA
Steering angle velocity Max. ± 1500 /sec
Voltage(high) 3.0 V ~ 4.1 V
Voltage(low) 1.3 V ~ 2.0 V
Pulse duty 40 ~ 60 %
12V IG 6
STN 5 39
1.2KΩ
ST1 3 8
ST2 4 40
GND 2 31
6 5 4 3 2
*
LJJF504C
BR -176 BRAKE SYSTEM
OUTPUT CHARACTERISTIC
H
ST 1
L
H
ST 2
L
H
ST N
L
ARCD204A
ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM BR -177
REPLACEMENT E75B8D8C 4. Remove the steering angle sensor from the clock
spring.
1. Remove the driver airbag.(Refer to RT group )
LJJF501V
ARJF102F