Brake System

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RONDO(UN) > 2009 > G 2.4 DOHC > Brake System

Brake System > General Information > Specifications SPECIFICATIONS
Item Master cylinder Type I.D. Piston stroke Fluid level warning sensor Brake booster Type Boosting ratio Front brake(Disc) Type Disc O.D. Disc I.D. Disc thickness Pad thickness Cylinder type Cylinder I.D. Rear brake(Disc) Type Disc O.D. Disc I.D. Disc thickness Pad thickness Cylinder type Cylinder I.D. Parking brake Actuation Type Drum I.D. Tandem type 25.4 mm (1.00 in) 30 mm (1.18 in) Provided Vacuum 9:1 Floating type with ventilated disc 280 mm(11.02 in) 167 mm(6.57 in) 26 mm(1.02 in) 10 mm(0.39 in) Single piston 60.6 mm(2.39 in) Floating type with solid disc 275 mm (10.83 in) 185 mm (7.28 in) 10 mm (0.39 in) 10 mm (0.39 in) Single piston 38.18 mm (1.50 in) DIH (Drum in hat) Pedal 168 mm(6.61 in) Specification
ABS : Anti-lock Brake System CBS : Conventional Brake System
SERVICE STANDARD
Item Standard value Brake pedal height Brake pedal stroke Stop lamp switch outer case to pedal stopper clearance Brake pedal free play Booster push rod to master cylinder piston clearance Parking brake pedal stroke when pedal is pushed with 196N (20Kg, 44lb force) Standard value 143.8 mm (5.66 in) 128 mm (5.04 in) 0.5 ~ 1.0 mm (0.02 ~ 0.04 in) 3 ~ 8 mm (0.11 ~ 0.31 in) 0.6 ~ 1.4 mm(0.02 ~ 0.06 in) (at 500 mmHg vacuum) 88 ~ 98 mm(3.46 ~ 3.86 in)
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Front disc brake pad thickness Front disc thickness Rear disc brake pad thickness Rear disc brake disc thickness Rear brake lining thickness
10 mm (0.39 in.) 26 mm (1.02 in) 10 mm (0.39 in) 10 mm (0.39 in) 3.3 mm (0.13 in)
TIGHTENING TORQUE
Item Master cylinder to booster mounting nut Brake booster mounting nut Bleeder screw Brake tube nut, brake hose Caliper guide rod bolt Caliper mounting bolt (Front) Caliper mounting bolt (Rear) Brake hose to front caliper Brake pedal member assembly bracket mounting nut (cowl side upper mounting) Brake pedal mounting nut Stop lamp switch mounting nut Wheel speed sensor mounting bolt HECU mounting bracket bolt (to body) HECU union screw HECU bracket mounting bolt Yaw rate & Lateral G sensor mounting bolt Nm 9.8 ~ 15.7 12.7 ~ 15.7 6.9 ~ 12.7 12.7 ~ 16.7 21.6 ~ 31.4 78.5 ~ 98.1 49.0 ~ 58.8 24.5 ~ 29.4 16.7 ~ 25.5 12.7 ~ 15.7 7.9 ~ 9.8 6.9 ~ 10.8 19.6 ~ 29.4 12.0 ~ 16.0 11.0 ~ 14.0 0.9 ~ 10.8 kgf.m 1.0 ~ 1.6 1.3 ~ 1.6 0.7 ~ 1.3 1.3 ~ 1.7 2.2 ~ 3.2 8.0 ~ 10.0 5.0 ~ 6.0 2.5 ~ 3.0 1.7 ~ 2.6 1.3 ~ 1.6 0.8 ~ 1.0 0.7 ~ 1.1 2.0 ~ 3.0 1.22 ~ 1.63 1.1 ~ 1.4 0.7 ~ 1.1 lb-ft 7.2 ~ 11.6 9.4 ~ 11.6 5.1 ~ 9.4 9.4 ~ 12.3 15.9 ~ 23.1 57.9 ~ 72.3 36.2 ~ 43.4 18.1 ~ 21.7 12.3 ~ 18.8 9.4 ~ 11.6 5.8 ~ 7.2 5.1 ~ 8.0 14.5 ~ 21.7 8.8 ~ 11.8 8.0 ~ 10.1 5.1 ~ 8.0
SPECIFICATION (ABS)
Part System Type HECU Operating Voltage Operating Temperature Motor power Warning lamp Min. Operating Voltage Max. Current consumption Supply voltage Operating Temperature Active Wheel speed sensor (ABS) Output current low Output current high Output range Item Standard value 4 Channel 4 Sensor (Solenoid) ABS + EBD 10 ~ 15 V -40 ~ 110 C 180 W 1.2 V 120 mA DC 4.5 ~ 20 V -40 ~ 150 C 5.9 ~ 8.4 mA 11.8 ~ 16.8 mA 1 ~ 2500 Hz Typ. 7 mA Typ. 14 mA Remark
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Tone wheel Air gap Output duty SPECIFICATION(ESC) Part System Type HECU Operating Voltage Operating Temperature Motor power Warning lamp Min. Operating Voltage Max. Current consumption Supply voltage Operating Temperature Output current low Active Wheel speed sensor (ABS) Output current high Output range Tone wheel Air gap Output duty Operating Voltage Operating Temperature Steering Wheel Angle Sensor Current Consumption Output Current Operating Angular velocity Operating Voltage Current Consumption Output voltage Yaw rate & Lateral G sensor Operating Temperature Yaw rate sensor measurement range Lateral G sensor measurement range Item
48 teeth(Front), 47 teeth(Rear) 0.2 ~ 1.5 mm 30 ~ 70 %
Standard value 4 Channel 4 Sensor (Solenoid)
Remark
Motor, valve relay intergrated Total control type (ABS, EBD, TCS, ESC) 10 ~ 15 V -40 ~ 110 C 250 W 1.2 V 120 mA DC 4.5 ~ 20 V -40 ~ 150 C 5.9 ~ 8.4 mA 11.8 ~ 16.8 mA 1 ~ 2500 Hz 48 teeth(Front), 47 teeth(Rear) 0.2 ~ 1.5 mm 30 ~ 70 % 9 ~ 16 V -30 ~ 75 C Max. 100 mA Max. 10 mA Max. 1500 /sec 4.8 ~ 5.1 V Max. 90 mA 0.5 ~ 4.5 V -40 ~ 85 C 75 /sec 1.5 g Typ. 7 mA Typ. 14 mA
LUBRICANT
Item Recommended lubricant Quantity
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Brake fluid Brake pedal bushing and brake pedal bolt Parking brake shoe and backing plate contact surfaces Front caliper guide rod bolt and boot Rear caliper guide rod and boot
DOT 3 or DOT 4 Chassis grease Bearing grease AI-II grease AI-II grease
As required As required As required 0.8 ~ 2.2 g 0.8 ~ 1.8 g
Brake System > General Information > Special Service Tools SPECIAL TOOLS
Tool (Number and Name) 09581 - 11000 Piston expander Illustration Use Pushing back of the front disc and rear disc brake piston
Brake System > General Information > Troubleshooting TROUBLESHOOTING

PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the like cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Lower pedal or spongy 1. pedal 2. 3. 4. Brake drag 1. 2. 3. 4. 5. 6. 7. 8. 9. 1. 2. 3. 4. 5. Suspect Area Brake system (Fluid leaks) Brake system (Air in) Piston seals (Worn or damaged) Master cylinder (Faulty) Brake pedal free play (Minimum) Parking brake lever travel (Out of adjustment) Parking brake wire (Sticking) Pad or lining (Cracked or distorted) Piston (Stuck) Piston (Frozen) Return spring (Faulty) Booster system (Vacuum leaks) Master cylinder (Faulty) Piston (sticking) Pad or lining (Oily) Piston (Frozen) Disc (Scored) Pad or lining (Cracked or distorted) Remedy Repair Air bleeding Replace Replace Adjust Adjust Repair Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace
Brake pull
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Hard pedal but brake inefficient
1. 2. 3. 4. 5. 6. 7. 8.
Brake system (Fluid leaks) Brake system (Air in) Pad or lining (Worn) Pad or lining (Cracked or distorted) Pad or lining (Oily) Pad or lining (Glazed) Disc (Scored) Booster system (Vacuum leaks)
Repair Air bleeding Replace Replace Replace Replace Replace Replace Replace Retighten Replace Retighten Replace Clean Replace Replace Replace Replace Replace Replace Replace Replace Replace Replace
Noise from brake
1. Pad or lining (Cracked or distorted) 2. Installation bolt (Loosen) 3. Disc (Scored) 4. Pad retainers (Loosen) 5. Sliding pin (Worn) 6. Pad or lining (Dirty) 7. Pad or lining (Glazed) 8. Return spring (Faulty) 9. Brake pad shim (Damage) 10. Shoe hold-down spring (Damage) 1. Master cylinder 1. 2. 3. 4. 5. Disc (Excessive thickness variation) Disc (Faulty run-out) Disc (Uneven worn or crack) Pad or lining (Uneven worn and contact) Caliper (Faulty pad sliding)
Brake fades Brake vibration, pulsation
Brake chatter
Brake chatter is usually caused by loose or worn components, or glazed or burnt linings. Rotors with hard spots can also contribute to brake chatter. Additional causes of chatter are out-of-tolerance rotors, brake lining not securely attached to the shoes, loose wheel bearings and contaminated brake lining.
Brake System > Brake System > Description and Operation EBD (ELECTRONIC BRAKE-FORCE DISTRIBUTION) OPERATION
The EBD system (Electronic Brake force Distribution) as a sub-system of the ABS system is to control the effective adhesion utilization by the rear wheels. It further utilizes the efficiency of highly developed ABS equipment by controlling the slip of the rear wheels in the partial braking range. The brake force is moved even closer to the optimum and controlled electronically, thus dispensing with the need for the proportioning valve. The proportioning valve, because of a mechanical device, has limitations to achieve an ideal brake force distribution tothe rear wheels as well as to carry out the flexible brake force distribution proportioning to the vehicle load or weight increasing. And in the event of malfunctioning, driver cannot notice whether it fails or not. EBD controlled by the ABS Control Module, calculates the slip ratio of each wheel at all times and controls the brake pressure of the rear wheels not to exceed that of the front wheels. If the EBD fails, the EBD warning lamp (Parking brake lamp) lights up.
ADVANTAGES
- Function improvement of the base-brake system. - Compensation for the different friction coefficients. - Elimination of the proportioning valve.
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- Failure recognition by the warning lamp.
Comparison between Proportioning valve and EBD
Brake System > Brake System > Repair procedures Operation and Leakage Check
Check all of the following items: Component Brake Booster (A) Procedure 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 cup Check brake operation by applying the brakes. Look for damage or signs of fluid leakage. inspection (B) 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 ) Caliper piston seal and piston boots (D) Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it is damaged or leaking. Check brake operation by applying the brakes. 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. Check brake operation by applying the brakes. 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.
Wheel cylinder piston cup and dust cover (E)
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BRAKE BOOSTER OPERATING TEST

For simple checking of the brake booster operation, carry out the following tests : 1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the booster is defective.
2. With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is defective.
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3. With the engine running, step on the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if the pedal rises, the booster is defective. If the above three tests are okay, the booster performance can be determined as good. Even if one of the above three tests is not okay, check the check valve, vacuum hose and booster for defect.
VACUUM HOSE (CHECK VALVE)

INSPECTION 1. Disconnect the brake booster vacuum hose (check valve built in) (A) at the booster . 2. Start the engine and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not working properly. Replace the brake booster vacuum hose and check valve and retest.
BRAKE PEDAL & BRAKE SWITCH ADJUSTMENT

PEDAL HEIGHT 1. Disconnect the brake switch connector, loosen the brake switch locknut (A), and brake off the brake switch (B) until it is no longer touching the brake pedal. 2. On the carpet, measure the pedal height (C) from the middle of the left-side center of the pedal pad (D). Standard pedal height (on the carpet) :
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143.8 mm (5.66 in)
3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod depressed.
BRAKE SWITCH CLEARANCE

Screw in the brake switch until its plunger is fully depressed (threaded end (A) touching the pad (B) on the pedal arm) then brake off the switch 3/4 turn to make 0.5~1.0 mm(0.02~0.04 in.) of clearance between the brake switch connector. Make sure that the brake lights go off when the pedal is released.
PEDAL FREE PLAY

1. With the engine stopped, depress the brake pedal two or three times. After eliminating the vacuum in the power brake booster, press the pedal(B) down by hand, and confirm that the amount of movement(A) before resistance is met (the free play) is within the standard value. Standard value : 3 ~ 8 mm (0.117 - 0.312 in.)
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2. If free play does not reach the standard value, check that clearance between the outer case of stop light switch(C) and brake pedal is within the standard value. If free play exceeds the standard value, it is probably due to excessive clearance between the clevis pin and brake pedal arm. Check for excessive clearance and replace faulty parts as required. 3. Start the engine, depress the brake pedal with approximately 120kg(1176.8N, 264.5 lb) of force, and check for oil leakage in the master cylinder, brake line and each connecting part. Repair the faulty parts as required.
INSPECTION OF FRONT DISC BRAKE PAD

1. Check the brake pad thickness through the caliper body inspection hole. Pad thickness Standard value : 10.0 mm (0.39 in.) Service limit : 2.0 mm (0.0787 in.)
- If the pad lining 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 condition of the piston and the guide rod.
INSPECTION OF REAR DISC BRAKE PAD

1. Check the brake pad thickness through the caliper body inspection hole. Pad thickness Standard value : 10.0 mm (0.39 in.) Service limit : 2.0 mm (0.0787 in.)
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- If the 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 condition of the piston and the guide rod.
Brake System > Brake System > Brake Booster > Components and Components Location COMPONENTS
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Brake System > Brake System > Brake Booster > Repair procedures REMOVAL
1. Disconnect the vacuum hose (B) from the brake booster (A).
[EXCEPT GASOLINE 2.4(A/T)]
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[GASOLINE 2.4(A/T) ONLY]
2. Remove the master cylinder. (Refer to "Master cylinder - Removal") 3. Remove the clevis pin (A) and snap pin (B).
4. Remove the four booster mounting nuts (C). 5. Remove the brake booster (A) from the engine compartment.
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INSTALLATION
1. Adjust push rod length of the booster, and then install the seal on the booster assembly. Standard length(A) : 108 0.5 mm (4.25 0.02 in)
2. Insert the booster and tighten the nuts (C).
3. Connect the booster push rod and brake pedal with a clevis pin (A) and install a snap pin (B) to the clevis pin (A).
Grease the pin before installing the snap pin. Always use a new snap pin. 4. Install the master cylinder, then install the brake tubes to the master cylinder. 5. Connect the vacuum hose to the brake booster. 6. After filling the brake reservoir with brake fluid, bleed the system.
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7. Check for fluid leakage. 8. Check and adjust the brake pedal for proper operation.
Brake System > Brake System > Master Cylinder > Components and Components Location COMPONENTS
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Brake System > Brake System > Master Cylinder > Repair procedures REMOVAL
1. Remove air cleaner assembly (A). (Refer to EM Gr.)
2. Disconnect the brake fluid level switch connector (A), and remove the reservoir cap (B).
3. Remove the brake fluid from the master cylinder reservoir with a syringe.
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. 4. Disconnect the brake lines (A) from the master cylinder. To prevent spills, cover the hose joints with rags or shop towels.
5. Remove the master cylinder mounting nuts (A) and washers. 6. Remove the master cylinder (B) from the brake booster. Be careful not to bend or damage the brake lines when removing the master cylinder.
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DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container. 2. Remove the reservoir (C) from the master cylinder(B) after remove the mounting screw (A).
3. Remove the grommets (D). 4. Remove the retainer ring (A) by using the snap ring pliers. 5. Remove the primary piston assembly (B). 6. Remove the pin (D) with the secondary piston (C) pushed completely using a screwdriver. Remove the secondary piston assembly (C).
Do not disassemble the primary and secondary piston assembly.
INSPECTION
1. Check the master cylinder bore for rust or scratch. 2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.
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1. If the cylinder bore is damaged, replace the master cylinder assembly. 2. Wash the contaminated parts in alcohol.
REASSEMBLY
1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets. 2. Carefully insert the springs and pistons in the proper direction. 3. Press the secondary piston (C) with a screwdriver and install the cylinder pin (D).
4. Install the primary piston assembly (B) and the retainer ring (A). 5. Mount two grommets (D). 6. Install the reservoir (C) to the master cylinder (B) and tighten the screw (A).
INSTALLATION
1. Install the master cylinder (B) to the brake booster. 2. Install the master cylinder mounting nuts (A) and washers. Tightening torque : N.m (kgf.m, lb-ft) 9.8~15.7 (1.0~1.6, 7.2~11.6)
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3. Connect the brake lines (A) and hose (B) to the master cylinder. Tightening torque : N.m (kgf.m, lb-ft) 12.7~16.7 (1.3~1.7, 9.4~12.3)
4. Connect the brake fluid level switch connector (A).
5. Refill the master cylinder reservoir to the MAX line. 6. Bleed the brake system. (Refer to "Bleeding of brake system")
Brake System > Brake System > Brake Line > Components and Components Location components
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Brake System > Brake System > Brake Line > Repair procedures REMOVAL
1. Disconnect the brake hose (C) from the brake line (A) using a flare-nut wrench (B).
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2. Remove the brake hose clip (B), and then remove the brake hose (A).
3. Remove the connector bolt (A) from the caliper, and disconnect the brake hose (B) from the caliper.
INSPECTION
1. Check the brake tubes for cracks, crimps and corrosion. 2. Check the brake hoses for cracks, damaged and oil leakage. 3. Check the brake tube flare nuts for damage and oil leakage.
Brake System Bleeding
- Do not reuse the drained fluid. - Always use Genuine DOT 3 or Brake Fluid. Using a non-Genuine DOT3 or brake fluid can cause corrosion and decrease the life of the system.
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- Make sure no dirt of other foreign matter is allowed to contaminate the brake fluid. - Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. - The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. 1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line. 2. Have someone slowly pump the brake pedal several times, and then apply steady pressure. 3. Loosen the right-rear brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securely. 4. Repeat the procedure for each wheel in the sequence shown below until air bubbles no longer appear in the fluid. 5. Refill the master cylinder reservoir to the MAX (upper) level line.
Front disc brake :
Rear disc brake
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INSTALLATION
1. Install a brake hose (B) on the caliper with tightening brake hose bolt (A) and washer. Tightening torque : N.m (kgf.m, lb-ft) 24.5 ~ 29.4 (2.5 ~ 3.0, 18.1 ~ 21.7)
2. Connect the brake hose (A) to the brake line (C) using a flare-nut wrench (B).
3. Install the brake hose clip (A) to the brake hose bracket.
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4. After installing the brake hose, bleed the brake system.
- Check the brake hoses for interference and twisting. - Check the brake hose and line joint for leaks, and tighten if necessary.
Brake System > Brake System > Brake Pedal > Components and Components Location COMPONENTS
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Brake System > Brake System > Brake Pedal > Repair procedures REMOVAL
1. Remove the lower crash pad.(Refer to BD "crash pad") 2. Pull down steering column shaft after removing 4 bolts. 3. Remove the stop lamp switch connector (A).
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4. Remove the clevis pin and snap pin. 5. Remove the brake pedal member assembly mounting nuts and then remove the brake pedal assembly.
INSPECTION
1. Check the bushing for wear. 2. Check the brake pedal for bending or twisting 3. Check all parts for crack and wear. 4. Check the stop lamp switch. (1) Connect a circuit tester to the connector (1-2 terminals) of stop lamp switch, and check whether or not there is continuity when the plunger of the stop lamp switch is pushed in and when it is released. (2) The stop lamp switch is in good condition if there is no continuity when the plunger is pushed.
INSTALLATION
1. Installation is the reverse of removal. Grease : LiG-2
Coat the inner surface of the bushings with the specified grease. 2. Before inserting the pin, apply the specified grease to the joint pin.
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3. Adjust the brake pedal height and free play.(Refer to "Brake pedal & brake switch adjustment") 4. Install the stop lamp switch.
Brake System > Brake System > Front Disc Brake > Components and Components Location COMPONENTS(1)
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COMPONENTS(2)
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Brake System > Brake System > Front Disc Brake > Repair procedures REMOVAL
1. Remove the brake hose bolt (B) and the guide rod bolts (C) from the caliper assembly (A).
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2. Remove the caliper assembly (A).
3. Remove the pads (B), the pad shims (C) and the pad retainers (D) from the caliper bracket (A).
4. Remove the caliper bracket (B) and the caliper mounting bolts (A).
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5. Remove the brake disc (A) and the screw (B).
Remove the brake disc from hub using M8 bolt (A) if the brake disc has been seized with the hub due to corrosion or overheat. Be careful not to use the hammer. The disc can be damaged if you remove the disc from the hub by hammer.
REPLACEMENT
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. Never use on air hose or brush to clean brake assemblies. 1. Remove guide rod bolt (B) and raise the caliper assembly (A).
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INSPECTION FRONT BRAKE DISC THICKNESS CHECK

1. Remove all rust and contamination from the disc surface, and then measure the disc thickness at 24 positions at least. Front brake disc thickness Standard value : 26.0 mm (1.02 in) Limit : 24.0 mm ( 0.94 in)
2. Thickness variation should not exceed 0.005 mm (0.0002in) (circumference) and 0.01 mm(0.0004 in) (radius) at any directions. 3. If wear exceeds the limit, replace the discs and pad assemblies for left and right of the vehicle.
FRONT BRAKE PAD CHECK

1. Check the pad wear. Measure the pad thickness. replace it if it is less than the specified value.
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Pad thickness Standard value : 10.0 mm (0.39 in) Service limit : 2.0 mm (0.0787 in)
2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
FRONT BRAKE DISC RUN OUT CHECK

1. Place a dial gauge about 5mm (0.2 in) from the outer circumference of the brake disc, and measure the run out of the disc. Brake disc run out Limit : 0.05 mm (0.0020 in) or less
2. If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out again. 3. If the run out does not exceed the limit specification, install the brake disc after turning it and then check the run out of the brake disc again. 4. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc.
INSTALLATION
1. Install the brake disc (A) and tighten the screw (B). Tightening torque : N.m (kgf.m, lb-ft) 4.9~5.9 (0.5~0.6, 3.6~4.3)
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2. Install the caliper bracket (B) and tighten the caliper mounting bolts (A). Tightening torque : N.m (kgf.m, lb-ft) 78.5~98.1 (8.0~10.0, 57.9~72.3)
3. Install the pad retainers (D) to the caliper bracket (A). 4. Install the brake pads (B) and pad shims (C) on the pad retainer correctly. Install the pad with the wear indicator 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 efficiency.
Check the foreign material at the pad shims (A) and the back of the pads (B). Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
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5. Push in the piston using the SST(09581-11000) so that the caliper will fit over the pads. Make sure that the piston boot is in position to prevent damaging it when installing the caliper.
6. Install the caliper assembly(A).
Be careful not to damage the piston pin boot.
7. Install the brake hose bolt (B) and the guide rod bolts (C) to the caliper assembly (A). Tightening torque : N.m (kgf.m, lb-ft) Bolt (B) : 24.5~29.4 (2.5~3.0, 18.1~21.7) Bolt (C) : 21.6~31.4 (2.2~3.2, 15.9~23.1)
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8. Refill the master cylinder reservoir to the MAX line. 9. Bleed the brake system. (Refer to "Bleeding of brake system") 10. Depress the brake pedal several times to make sure the brakes work, then test-drive.
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 will restore the normal pedal stroke. 11. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
Brake System > Brake System > Rear Disc Brake > Components and Components Location COMPONENT LOCATION
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COMPONENTS
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Brake System > Brake System > Rear Disc Brake > Repair procedures REMOVAL
1. Remove the brake hose bolt (B) and the guide rod bolts (C) from the caliper assembly (A).
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2. Remove the caliper assembly (A).
4. Remove the rear upper arm (A).
5. Remove the caliper bracket (B) and the caliper mounting bolts (A).
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6. Remove the brake disc (A) and the screw (B).
Remove the brake disc from hub using M8 bolt (A) if the brake disc has been seized with the hub due to corrosion or overheat. Be careful not to use the hammer. The disc can be damaged if you remove the disc from the hub by hammer.
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REPLACEMENT
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. Never use on air hose or brush to clean brake assemblies. 1. Remove guide rod bolt (B) and raise the caliper assembly (A).
INSPECTION REAR BRAKE DISC THICKNESS CHECK

1. Remove all rust and contamination from the disc surface, and then measure the disc thickness at 8 positions at least. Rear brake disc thickness Standard value : 10.0 mm (0.39 in) Limit : 8.0 mm ( 0.31 in)
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2. Thickness variation should not exceed 0.005 mm (0.0002in) (circumference) and 0.01 mm(0.0004 in) (radius) at any directions. 3. If wear exceeds the limit, replace the discs and pad assemblies for left and right of the vehicle.
REAR BRAKE PAD CHECK

1. Check the pad wear. Measure the pad thickness. replace it if it is less than the specified value. Pad thickness Standard value : 10.0 mm (0.39 in) Service limit : 2.0 mm (0.0787 in)
2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
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 Limit : 0.05 mm (0.0020 in) or less
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2. If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out again. 3. If the run out does not exceed the limit specification, install the brake disc after turning it and then check the run out of the brake disc again. 4. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc.
INSTALLATION
1. Install the brake disc (A) and tighten the screw (B). Tightening torque : N.m (kgf.m, lb-ft) 4.9~5.9 (0.5~0.6, 3.6~4.3)
2. Install the caliper bracket (B) and tighten the caliper mounting bolts (A). Tightening torque : N.m (kgf.m, lb-ft) 49.0~58.8 (5.0~6.0, 36.2~43.4)
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3. Install the rear upper arm (A).
4. Install the pad retainers (D) to the caliper bracket (A). 5. Install the brake pads (B) and pad shims (C) on the pad retainer correctly. Install the pad with the wear indicator 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 efficiency.
Check the foreign material at the pad shims (A) and the back of the pads (B). Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
6. Push in the piston using the SST(09581-11000) so that the caliper will fit over the pads. Make sure that the piston boot is in position to prevent damaging it when installing the caliper.
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7. Install the caliper assembly (A).
Be careful not to damage the piston pin boot.
8. Install the brake hose bolt (B) and the guide rod bolts (C) to the caliper assembly (A). Tightening torque : N.m (kgf.m, lb-ft) Bolt (B) : 24.5~29.4 (2.5~3.0, 18.1~21.7) Bolt (C) : 21.6~31.4 (2.2~3.2, 15.9~23.1)
9. Refill the master cylinder reservoir to the MAX line. 10. Bleed the brake system. (Refer to "Bleeding of brake system") 11. Depress the brake pedal several times to make sure the brakes work, then test-drive.
Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been
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replaced as a set. Several applications of the brake will restore the normal pedal stroke. 12. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
Brake System > Parking Brake System > Parking Brake Assembly > Components and Components Location COMPONENT(1)
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COMPONENT(2) DISC BRAKE TYPE
Brake System > Parking Brake System > Parking Brake Assembly > Repair procedures REMOVAL
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PARKING BRAKE PEDAL

1. Remove the lower panel, after removing the parking brake release lever. (Refer to BD Gr. 'Crash pad') 2. Disconnect the parking brake switch connector(A).
3. Remove the cable adjusting nut(B) and the mounting clip(C), then remove the parking brake cable(D). 4. Remove the parking brake pedal mounting bolts and nut(E), then remove the parking brake pedal. 5. Remove the floor console. (Refer to BD Gr. 'Console'). 6. Remove the parking brake cable(A).
PARKING BRAKE SHOE (DISC BRAKE TYPE)

1. Raise the vehicle, and make sure it is securely supported. 2. Remove the rear tire and wheel, then remove the brake caliper. (Refer to "Rear disc brake removal") 3. Remove the parking brake cable (B), after remove the clip (A).
4. Remove the shoe hold down pin (A) and spring (B) by pressing and rotating the spring.
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5. Remove the adjuster assembly (B) and the lower return spring (A).
6. Remove the upper return spring (C) and the brake shoes (D). 7. Remove the operating lever assembly (E).
ADJUSTMENT PARKING BRAKE SHOE CLEARANCE ADJUSTMENT

DISC BRAKE TYPE 1. Raise the vehicle, and make sure it is securely supported. 2. Remove the rear tire and wheel. 3. Remove the plug from the disc. 4. Rotate the toothed wheel of adjuster by a screw driver until the disc is not moving, and then return it by 5 notches in the opposite direction.
PARKING BRAKE PEDAL STROKE ADJUSTMENT

1. Push the parking brake pedal to its maximum point of travel.
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Releas and repeat 2 additional times. Adjust the nut (B) so that the parking brake pedal stroke is 88 ~ 98mm(3.46 ~ 3.86in) at an operating effort of 196N(20kgf, 44lb).
1. The parking brake adjustment must be carried out after adjusting the rear shoe. 2. After adjusting parking brake, verify the following ; 1) Must be free from interference between adjusting nut and pin. 2) Verify that the brake is not dragging.
INSTALLATION PARKING BRAKE SHOE (DISC BRAKE TYPE)

1. Install the operating lever assembly (E).
2. Install the upper return spring (C) and the brake shoes (D). 3. Install the adjuster assembly (B) and the lower return spring (A). 4. Install the shoe hold down pin (A) and spring (B) by pressing and rotating the spring.
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5. Install the parking brake cable (B), then install the clip (A).
6. Install the rear brake disc, then adjust the rear brake shoe clearance. (1) Remove the plug from the disc. (2) Rotate the toothed wheel of adjuster by a screw driver until the disc is not moving, and then return it by 5 notches in the opposite direction.
7. Install the brake caliper. (Refer to "Rear brake installation") 8. Install the tire and wheel. 9. Adjust the parking brake pedal. 10. If the parking brake shoe or the brake disc are replaced a newly one, perform the brake shoe bed-in procedure. (1) While operating the parking brake pedal for 98 N(10 kgf, 22 lb) effort, drive the vehicle 500 meters (0.31 miles) at the speed of 60 kph (37.3 mph). (2) Repeat the above procedure more than two times. (3) Must be held on at 30% grade.
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After adjusting parking brake, verify the following ; 1. Must be free from malfunction when the parking pedal is operated at 981N(100 kgf, 220 lb). 2. Check that all parts move smoothly. 3. The parking brake indicator lamp must be on after the parking pedal is applied and must be off after the pedal is released.
PARKING BRAKE PEDAL

1. Install the parking brake cable(A).
2. Install the floor console. (Refer to BD Gr. 'Console'). 3. Install the parking brake pedal , and then install the parking brake pedal mounting bolts and nut(E).
4. Install the parking brake cable(D) , and then install the mounting clip(C). 5. Adjust the parking brake pedal stroke by turning the adjusting nut(B). (1) Push the parking brake pedal to its maximum point of travel. Releas and repeat 2 additional times. Adjust the nut (B) so that the parking brake pedal stroke is 88 ~ 98mm(3.46 ~ 3.86in) at an operating effort of 196N(20kgf, 44lb).
1. The parking brake adjustment must be carried out after adjusting the rear shoe. 2. After adjusting parking brake, verify the following ; 1) Must be free from interference between adjusting nut and pin. 2) Verify that the brake is not dragging. 6. Reconnect the parking brake switch connector(A). 7. Install the lower panel, and then install the parking brake release lever. (Refer to BD Gr. 'Crash pad')
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Brake System > ABS(Anti-Lock Brake System) > Components and Components Location COMPONENTS
Brake System > ABS(Anti-Lock Brake System) > Description and Operation DESCRIPTION
This specification applies to HCU(Hydraulic Control Unit) and ECU(Electronic Control Unit) of the HECU.(Hydraulic and Electronic Control Unit)
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This specification is for the wiring design and installation of ABS/ESC ECU. This unit has the functions as follows. - Input of signal from Pressure sensor, Steering angle sensor, Yaw & Lateral G sensor,the wheel speed sensors attached to each wheel. - Control of braking force / traction force / yaw moment. - Failsafe function. - Self diagnosis function. - Interface with the external diagnosis tester. Installation position : engine compartment - Brake tube length from Master cylinder port to HECU inlet port should be max. 1m - 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 actuators.
Wheel Sensor signal processing

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

When one side of the valve coil is connected to the positive voltage that is provided through the valve relay and the other side is connected to the ground by the semiconductor 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
- Overvoltage When overvoltage is detected(above 17 0.5 V), the ECU switches off the valve relay and shuts down the system. When voltage is returned to operating range, the system goes back to the normal condition after the initialization phase. - Undervoltage In the event of undervoltage(below 10V), ABS control shall be inhibited and the warning lamp shall be turned on. When voltage is returned to operating range, the warning 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 12 km/h(7 MPH) 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 Roll and Brake Test line).
WARNING LAMP MODULE
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1. ABS Warning Lamp module The active ABS warning lamp module indicates the self-test and failure status of the ABS. The ABS warning lamp shall be on: A. During the initialization phase after IGN ON. (continuously 3 seconds). B. In the event of inhibition of ABS functions by failure. C. During diagnostic mode. D. When the ECU Connector is seperated from ECU. 2. PARKING/EBD warning lamp module The active EBD warning lamp module indicates the self-test and failure status of the EBD. However, in case the Parking Brake Switch is turned on, the EBD warning lamp is always turned on regardless of EBD functions. The EBD warning lamp shall be on: A. During the initialization phase after IGN ON. (continuously 3 seconds). B. When the Parking Brake Switch is ON or brake fluid level is low. C. When the EBD function is out of order. D. During diagnostic mode. E. When the ECU Connector is seperated from ECU.
ABS CONTROL
1. NORMAL BRAKING without ABS Under the normal braking, voltage is not supplied to solenoid valve, inlet valve is opened and outlet valve is closed.When the brake is depressed, brake fluid is supplied to the wheel cylinder via solenoid valve to activate the brake.When the brake is released, brake fluid is back to the master cylinder via inlet valve and check valve. Solenoid valve Inlet valve (NO) Outlet valve (NC) State OFF OFF Valve Open Close Passage Master cylinder Wheel cylinder Wheel cylinder Reservoir Pump motor OFF
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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. Solenoid Inlet valve (NO) Outlet valve (NC) State ON ON Valve Close Open Passage Master cylinder Wheel cylinder Wheel cylinder Reservoir Pump motor ON
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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. Solenoid Inlet valve (NO) Outlet valve (NC) State ON OFF Valve Close Close Passage Master cylinder Wheel cylinder Wheel cylinder Reservoir Pump motor OFF
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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. Solenoid Inlet valve (NO) Outlet valve (NC) State OFF OFF Valve Open Close Passage Master cylinder Wheel cylinder Wheel cylinder Reservoir Pump motor ON
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ABS HECU EXTERNAL DIAGRAM
HYDRAULIC SYSTEM DIAGRAM
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Brake System > ABS(Anti-Lock Brake System) > Schematic Diagrams ABS CIRCUIT DIAGRAM
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ABS CONNECTOR INPUT/OUTPUT
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Connector Terminal No Description
Specification Over voltage range: 16.5 0.5 V Operating voltage range: 9.5 0.5 V < V < 16.5 0.5 V Low voltage range: 7.0 0.5 V < V < 9.5 0.5 V Max. current: I < 300 mA Max leakage current : I < 0.8 mA Operating voltage range: 9.5 0.5 V < V < 16.5 0.5 V Max current : I < 30 A Operating voltage range: 9.5 0.5 V < V < 16.5 0.5 V Rush current : I < 100 A Max current : I < 30 A Max leakage current : I < 0.2 mA Rated current : I < 300 mA Max. current: I < 30 A Rush current : I < 100 A Max current : I < 30 A Input voltage low: 0 V V 3.0 V Input voltage High: 7.0 V V 16.0 V Max. current: I < 200 mA Max. output low voltage : V < 1.2 V
Remark
IGNITION1( )
25
POS. BATTERY.(SOLENOID)
POS, BATTERY.(MOTOR)
8 24 18 16 1 19 5 23 2 20 6 22
GROUND PUMP MOTOR GROUND BRAKE LIGHT SWITCH ABS/EBD W/LAMP DRIVE SENSOR FRONT LEFT POWER SENSOR FRONT RIGHT POWER SENSOR REAR LEFT POWER SENSOR REAR RIGHT POWER SENSOR FRONT LEFT SIGNAL SENSOR FRONT RIGHT SIGNAL SENSOR REAR LEFT SIGNAL SENSOR REAR RIGHT SIGNAL
- Output voltage : IGN[V] 1 V - Output current : Max 30 mA
Input current LOW : 5.9 ~ 8.4 Input current HIGH : 11.8 ~ 16.8 Frequency range : 1 ~ 2000 Hz Input duty : 50 20 %
DIAGNOSIS INPUT/OUTPUT
Input voltage : VIL < 0.3 IGN[V] VIH > 0.7 IGN[V] Output voltage : VOL < 0.2 IGN[V] VOH > 0.8 IGN[V]
WHEEL SPEED SENSOR OUTPUT(ECM)
Brake System > ABS(Anti-Lock Brake System) > Troubleshooting scan tool CHECK
1. Turn the ignition switch OFF.
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2. Connector the scan tool to the 16P data link connector located the driver'd side kick panel.
3. Turn the ignition switch ON. 4. Check for diagnostic trouble using the scan tool 5. After completion trouble of the repair or correction of the problem, erase the stored fault codes the clear key on the scan tool. 6. Disconnect the scan tool from the 16P data link connector.
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
NOTES WITH REGARD TO DIAGNOSIS

The phenomena listed in the following table are not abnormal.
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Phenomenon System check sound
Explanation 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. 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) 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.
ABS operation sound
ABS operation (Long braking distance)
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 CHECK SHEET
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PROBLEM SYMPTOMS TABLE

If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. Symptom ABS does not operate. Suspect Area 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. 2. Power source circuit. 3. Speed sensor circuit. 4. Check the hydraulic circuit for leakage. Only when 1. -4. are all normal and the problem is still occurring, replace the ABS actuator assembly.
ABS does not operate intermittently.
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1. Check the DTC reconfirming that the normal code is output. 2. Wheel speed sensor circuit. 3. Stop lamp switch circuit. 4. Check the hydraulic circuit for leakage. Communication with Scan tool is not possible. (Communication with any system is not possible) Communication with Scan tool is not possible. (Communication with ABS only is not possible) 1. Power source circuit 2. Diagnosis line 1. Power source circuit 2. Diagnosis line 3. HECU 1. ABS warning lamp circuit 2. HECU 1. ABS warning lamp circuit 2. HECU
When ignition key is turned ON (engine OFF), the ABS warning lamp does not light up. Even after the engine is started, the ABS warning lamp remains ON.
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.
DETECTING CONDITION Trouble Symptoms Brake operation varies depending on driving conditions and road surface conditions, so diagnosis can be difficult.However if a normal DTC is displayed, check the following probable cause. When the problem is still occurring, replace the ABS control module. Faulty Faulty Faulty Faulty Possible Cause power source circuit wheel speed sensor circuit hydraulic circuit for leakage HECU
INSPECTION PROCEDURES
DTC INSPECTION 1. Connect the scan tool with the data link connector and turn the ignition switch ON. 2. Verify that the normal code is output. Is the normal code output? Check the power source circuit. Erase the DTC and recheck using scan tool.
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 harness side connector and body ground. Specification : approximately B+ Is the voltage within specification?
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Check the ground circuit. Check the harness or connector between the fuse (10A) in the engine compartment junction block and the ABS control module. Repair if necessary.
CHECK THE GROUND CIRCUIT.

1. Disconnect the connector from the ABS control module. 2. Check for continuity between terminals 8, 24 of the ABS control module harness side connector and ground point. Is there continuity? Check the wheel speed sensor circuit. Repair an open in the wire and ground point.
CHECK THE WHEEL SPEED SENSOR CIRCUIT.

Refer to the DTC troubleshooting procedures. Is it normal? Check the hydraulic circuit for leakage. Repair or replace the wheel speed sensor.
CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE.

Refer to the hydraulic lines. Inspect leakage of the hydraulic lines. Is it normal? The problem is still occurring, replace the ABS control module. Repair the hydraulic lines for leakage.
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DETECTING CONDITION Trouble Symptoms Brake operation varies depending on driving conditions and road surface conditions, so diagnosis can be difficult. However if a normal DTC is displayed, check the following probable cause. When the problem is still occurring, replace the ABS control module. Faulty Faulty Faulty Faulty Possible Cause power source circuit wheel speed sensor circuit hydraulic circuit for leakage HECU
DTC INSPECTION 1. Connect the scan tool with the data link connector and turn the ignition switch ON. 2. Verify that the normal code is output. Is the normal code output? Check the wheel speed sensor circuit. Erase the DTC and recheck using scan tool.
CHECK THE WHEEL SPEED SENSOR CIRCUIT.

Refer to the DTC troubleshooting procedures. Is it normal? Check the stop lamp switch circuit. Repair or replace the wheel speed sensor.
CHECK THE STOP LAMP SWITCH CIRCUIT.

1. Check that stop lamp lights up when brake pedal is depressed and turns off when brake pedal is released. 2. Measure the voltage between terminal 18 of the ABS control module harness side connector and body ground when brake pedal is depressed. Specification : approximately B+ Is the voltage within specification? Check the hydraulic circuit for leakage. Repair the stop lamp switch. Repair an open in the wire between the ABS control module and the stop lamp switch.
CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE.

Refer to the hydraulic lines. Inspect leakage of the hydraulic lines. Is it normal?
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The problem is still occurring, replace the ABS control module. Repair the hydraulic lines for leakage.
DETECTING CONDITION Trouble Symptoms Possible defect in the power supply system (including ground) for the diagnosis line. Possible Cause - An open in the wire - Poor ground - Faulty power source circuit
CHECK THE POWER SUPPLY CIRCUIT FOR THE DIAGNOSIS Measure the voltage between terminal 9 of the data link connector and body ground. Specification : approximately B+ Is voltage within specification? Check the ground circuit for the diagnosis. Repair an open in the wire. Check and replace fuse (15A) from the engine compartment junction block.
CHECK THE GROUND CIRCUIT FOR THE DIAGNOSIS

Check for continuity between terminal 5 of the data link connector and body ground. Is there continuity? Repair an open in the wire between terminal 5 of the data link connector and ground point.
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DETECTING CONDITION Trouble Symptoms When communication with scan tool is not possible, the cause may be probably an open in the HECU power circuit or an open in the diagnosis output circuit. Possible Cause - An open in the wire - Faulty HECU - Faulty power source circuit
CHECK FOR CONTINUITY IN THE DIAGNOSIS LINE 1. Disconnect the connector from the ABS control module. 2. Check for continuity between terminals 7 of the ABS control module connector and 1 of the data link connector. Is there continuity? Check the power source of ABS control module. Repair an open in the wire.
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 and body ground. Specification : approximately B+ Is voltage within specification? Check for poor ground. Check the harness or connector between the fuse (10A) in the engine compartment junction block and the ABS control module.Repair if necessary.
CHECK FOR POOR GROUND

Check for continuity between terminal 5 of the data link connector and ground point. Replace the ABS control module and recheck. Repair an open in the wire or poor ground.
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DETECTING CONDITION Trouble Symptoms When current flows in the HECU the ABS warning lamp turns from ON to OFF as the initial check.Therefore if the lamp does not light up, the cause may be an open in the lamp power supply circuit, a blown bulb, an open in the both circuits between the ABS warning lamp and the HECU, and the faulty HECU. Possible Cause - Faulty ABS warning lamp bulb - Blown fuse is related to ABS in the engine compartment junction block - Faulty ABS warning lamp module - Faulty HECU
PROBLEM VERIFICATION Disconnect the connector from the ABS control module and turn the ignition switch ON. Does the ABS warning lamp light up? It is normal. Recheck the ABS control module. Check the power source for the ABS warning lamp.
CHECK THE POWER SOURCE FOR THE ABS WARNING LAMP

1. Disconnect the instrument cluster connector (M03-C) and turn the ignition switch ON. 2. Measure the voltage between terminal (M03-C) 16 of the cluster harness side connector and body ground. Specification : approximately B+ Is voltage within specification? Repair bulb or instrument cluster assembly. Check for blown fuse.
CHECK FOR BLOWN FUSE

Check continuity of fuse (10A) from the engine compartment junction block.
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Is there continuity? Repair an open in the wire between ABS fuse and 1 of cluster connector (M03-A). Replace the blown fuse.
DETECTING CONDITION Trouble Symptoms If the HECU detects trouble, it lights the ABS warning lamp while at the same time prohibiting ABS control. At this time, the HECU records a DTC in memory.Even though the normal code is output, the ABS warning lamp remains ON, then the cause may be probably an open or short in the ABS warning lamp circuit. Possible Cause An open in the wire Faulty instrument cluster assembly Faulty ABS warning lamp module Faulty HECU
CHECK DTC OUTPUT. 1. Connect the scan tool to the 16P data link connector located behind the driver's side kick panel. 2. Check the DTC output using scan tool. Is DTC output? Repair circuit indicated by code output. Check instrument cluster.
CHECK INSTRUMENT CLUSTER

Disconnect the cluster connector and turn the ignition switch ON. Does the ABS warning lamp remains ON? Replace the instrument cluster. Check for open the wire.
CHECK FOR OPEN IN THE WIRE

Check for continuity in the wire between cluster and ABS control module. Is there continuity? Replace the ABS control module and recheck. Repair an open in the wire between cluster and ABS control module.
BLEEDING OF BRAKE SYSTEM

This procedure should be followed to ensure adequate bleeding of air and filling of the ABS unit, brake lines and master cylinder with brake fluid. 1. Remove the reservoir cap and fill the brake reservoir with brake fluid.
If there is any brake fluid on any painted surface, wash it off immediately.
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When pressure bleeding, do not depress the brake pedal. Recommended fluid........ DOT3 or DOT4 2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled clear plastic bottle. 3. Connect the scan tool to the data link connector located underneath the dash panel.
4. Select and operate according to the instructions on the scan tool screen.
You must obey the maximum operating time of the ABS motor with the scan tool to prevent the motor pump from burning. (1) Select KIA 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.
(6) Wait 120 sec. before operating the air bleeding. (If not, you may damage the motor.)
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(7) Perform the air bleeding.
5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without bubbles. Then close the bleeder screw.
6. Repeat step 5 until there are no more bubbles in the fluid for each wheel.
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7. Tighten the bleeder screw. Bleed screw tightening torque: 6.86~12.74 Nm (0.7 ~1.3 kgfm, 5.09 ~ 9.45 lb-ft)
DIGNOSTIC TROUBLE CODE CHART(DTC)

DTC C1101 C1102 C1112 C1200 C1201 C1202 C1203 C1204 C1205 C1206 C1207 C1208 C1209 C1210 C1211 C1235 C1237 C1259 C1260 C1282 C1283 Trouble description Battery voltage high Battery voltage low Sensor power voltage Wheel speed sensor front-LH open/short Wheel speed sensor front-LH range / performance / intermittent Wheel speed sensor front-LH invalid/no signal Wheel speed sensor front-RH open/short Wheel speed sensor front-RH range / performance / intermittent Wheel speed sensor front-RH invalid/no signal Wheel speed sensor rear-LH open/short Wheel speed sensor rear-LH range / performance / intermittent Wheel speed sensor rear-LH invalid/no signal Wheel speed sensor rear-RH open/short Wheel speed sensor rear-RH range / performance / intermittent Wheel speed sensor rear-RH invalid/no signal Primary pressure sensor - electrical Primary pressure sensor - signal Steering sensor - electrical Steering sensor circuit - signal Yaw rate & lateral G sensor - electrical Yaw rate & lateral G sensor - signal Warning lamp EBD X/ X X/ X/ X/ X/ X/ X/ X/ X/ X/ X/ X/ X/ X X X X X X ABS X X X X X X X ESC ESC ESC ESC ESC ESC ESC ESC Remarks
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C1503 C1513 C1604 C1605 C1611 C1612 C1613 C1616 C2112 C2227 C2380 C2402
ESC switch error Brake switch error ECU hardware error CAN hardware error CAN time-out EMS CAN time-out TCU CAN wrong message CAN bus off Valve relay error Excessive temperature of brake disc AB/TCSS/ESC valve error Motor electrical
X X X X X X X X X
X X X X X X X X
ESC ESC
ESC ESC ESC ESC ESC
ESC
Brake System > ABS(Anti-Lock Brake System) > ABS Control Unit > Components and Components Location COMPONENTS
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Brake System > ABS(Anti-Lock Brake System) > ABS Control Unit > Repair procedures REMOVAL
1. Turn the ignition switch OFF. 2. Pull up the lock (A) of the ABS control unit 25P connector , then disconnect the connector.
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3. Disconnect the brake tubes from the HECU by unlocking the nuts counterclockwise with a spanner.
4. Loosen the 2 ABS HECU bracket bolts (A), then remove HECU and bracket.
1. Never attempt to disassemble the HECU. 2. The HECU must be transported and stored in. 3. Never shock to the HECU. 5. Remove the 2 bolts, then remove the bracket from HECU.
INSTALLATION
1. Installation is the reverse of removal. 2. Tighten the HECU mounting bolts and nuts to the specified torque. Tightening torque HECU bracket bolts : 11.0 ~ 14.0 Nm (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 Ib-ft)
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HECU bracket mounting bolt : 19.6 ~ 29.4 Nm (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 Ib-ft)
Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Components and Components Location COMPONENTS
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Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Repair procedures REMOVAL
1. Remove the front wheel speed sensor mounting bolt (A) and cable mounting bolt (B).
2. Remove the front wheel speed sensor bracket (A).
3. Remove the front wheel guard . 4. Disconnect the front wheel speed sensor connector (A) , then remove the front wheel speed sensor.
INSPECTION
1. Measure the output voltage between the terminal of the wheel speed sensor and the body ground.
In order to protect the wheel speed sensor, when measuring output voltage, a 100 resister must be used as shown.
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2. Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage as shown below.
V_low : 0.59 V ~ 0.84 V V_high : 1.18 V ~ 1.68 V Frequency range : 1 ~ 2,500 Hz
Brake System > ABS(Anti-Lock Brake System) > Rear Wheel Speed Sensor > Components and Components Location COMPONENTS
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Brake System > ABS(Anti-Lock Brake System) > Rear Wheel Speed Sensor > Repair procedures REMOVAL
1. Remove the rear wheel speed sensor mounting bolt (A).
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2. Remove the sensor cable bracket mounting bolt (A).
3. Disconnect the rear wheel speed sensor connector.
INSPECTION
1. Measure the output voltage between the terminal of the wheel speed sensor and the body ground.
In order to protect the wheel speed sensor, when measuring output voltage, a 100 resister must be used as shown.
2. Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage as shown below.
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V_low : 0.59 V ~ 0.84 V V_high : 1.18 V ~ 1.68 V Frequency range : 1 ~ 2,500 Hz
Brake System > ESP(Electronic Stability Program) System > Components and Components Location COMPONENTS
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Brake System > ESP(Electronic Stability Program) System > Description and Operation description of ESC
Optimum driving safety now has a name : ESC, the Electronic Stability Control. ESC is based on the MGH 25 ABS Hydraulic System. ESC recognizes critical driving conditions, such as panic reactions 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.
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ESC 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 longitudinal dynamics of the vehicle, active yaw control stabilizes the vehicle about its vertical axis. This is achieved by wheel individual brake intervention and adaptation of the momentary engine torque with no need for any action to be taken by the driver. ESC essentially consists of three assemblies : the sensors, the electronic control unit and the actuators. The electronic control unit incorporates the technological experience accumulated in connection with the MGH 25 system, but has been substantially expanded in terms of capacity and monitoring concept in order to permit the additional sensor signals and arithmetic operations to be processed 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 driving and operating conditions. Under certain driving conditions, the ABS/TCS function can be activated simultaneously with the ESC function in response to a command by the driver. In the event of a failure of the stability control function, the basic safety function, ABS, is still maintained.
DESCRIPTION OF ESC CONTROL

ESC system includes ABS/EBD, TCS and AYC function. ABS/EBD 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 speed 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 Wheel Angle Sensor).If vehicle 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)If the system failure is detected, the ECU informs driver of the system failure through the BRAKE/ABS/ESC warning lamp. (fail-safe warning)
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INPUT AND OUTPUT DIAGRAM
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ESC OPERATION MODE

ESC HYDRAULIC SYSTEM DIAGRAM
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1. ESC Non-operation : Normal braking. Solenoid valve IN (NO) OUT (NC) 2. ESC operation Solenoid valve Understeering (Only inside of rear wheel) Oversteering (Only outside of front wheel) IN(NO) OUT(NC) IN(NO) OUT(NC) Continuity OFF OFF OFF OFF Valve OPEN CLOSE ON OPEN CLOSE ON Motor pump TC Valve Continuity OFF OFF Valve OPEN CLOSE Motor pump OFF TC Valve OFF
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ABS Warning Lamp module

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

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

The ESC warning lamp indicates the self-test and failure status of the ESC. The ESC warning lamp is turned on under the following conditions : - During the initialization phase after IGN ON. (continuously 3 seconds). - In the event of inhibition of ESC functions by failure. - When driver trun off the ESC function by on/off switch. - During diagnostic mode.
ESC Function Lamp (ESC system)

The ESC function lamp indicates the self-test and operating status of the ESC. The ESC Function lamp operates under the following conditions : - During the initialization phase after IGN ON. (continuously 3 seconds). - When the ESC control is operating. (Blinking - 2Hz)
ESC On/Off Switch (ESC system)

The ESC On/Off Switch shall be used to toggle the ESC 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 ESC function is on and switch toggle the state.
Brake System > ESP(Electronic Stability Program) System > Schematic Diagrams CIRCUIT DIAGRAM - ESC(1)
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CIRCUIT DIAGRAM - ESC(2)
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ESC connector input/output

Connector Terminal No 4 32 Description IGNITION1(+) POS.BATTERY.(SOLENOID) Max leakage current : I < 0.8 mA Operating voltage range: 9.5 0.5 V < V < 16.5 0.5 V Rush current : I < 100 A Max current : I < 30 A Max leakage Specification Remark
POS.BATTERY.(MOTOR)
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current : I < 0.2 mA Rated current : I <300 mA Max. current: I < 30 A Rush current : I < 100 A Max current : I < 30 A Rated current : I <65 mA Rated current : I <10 mA Rated current : I <100 mA
16
GROUND
47
PUMP MOTOR GROUND
23 28 31
YAW & LATERAL G SENSOR GROUND MASTER PRESSURE SENSOR GROUND STEERING ANGLE SENSOR GROUND
37
Max Output current : I < 10 mA MASTER PRESSURE SENSOR POWER Max Output voltage : 4.9 V V 5.1 V Max Output current : I < 65mA Max Output voltage : 4.9V V 5.1V Input voltage low: 0 V V 3.0 V Input voltage High: 7.0 V V 16.0 V Max current : I < 2 mA External pull up resistance :10 K < R Output duty :50 20 % Max. current: I < 200 mA Max. output low voltage: V < 1.2 V Input voltage low:0 V V 3.0 V Input voltage High: 7.0 V V 16.0 V
36
YAW SENSOR POWER
BRAKE LIGHT SWITCH
21
BRAKE SWITCH
WHEEL SPEED SENSOR OUTPUT(ECM)
18 34 35
ABS/EBD W/LAMP DRIVE ESC OFF W/LAMP DRIVE ESC F/LAMP DRIVE
27
ESC ON/OFF SWITCH
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Max input current:I <10 mA 22 7 46 45 44 43 15 30 14 29 CAN BUS LINE(LOW) CAN BUS LINE(HIGH) SENSOR FRONT LEFT POWER SENSOR FRONT RIGHT POWER SENSOR REAR LEFT POWER SENSOR REAR RIGHT POWER SENSOR FRONT LEFT SIGNAL SENSOR FRONT RIGHT SIGNAL SENSOR REAR LEFT SIGNAL SENSOR REAR RIGHT SIGNAL Max. current : I < 10 mA Output voltage : IGN (V) 1 V Output current : Max 30 mA Input current LOW : 5.9 ~ 8.4 Input current HIGH :11.8 ~ 16.8 Frequency range :1 ~ 2000 Hz Input duty : 50 20 %
40
39
Input duty (ST1, STEERING ANGLE SENSOR PHASE 1 ST2): 50 10 Phase difference (ST1, ST2): 2 STEERING ANGLE SENSOR PHASE 2 0.6 deg High voltage: 3.0 V < V < 4.1 V STEERING ANGLE SENSOR PHASE N Low voltage: 1.3 V < V < 2.0 V Sensor Input Voltage : 0 V V 5.0 V Zero offset MASTER PRESSURE SENSOR SIGNAL Voltage : 0.5 V 0.15 V Input current :Max 2 mA Sensor Input Voltage :0 V V 5.0 V Zero offset Voltage : 2.5 0.1 V Sensor Input Voltage :0 V V 5.0 V Zero offset Voltage : 2.5 0.1 V
12
LATERAL G SENSOR SIGNAL
41
YAW SENSOR SIGNAL
24 19
YAW SENSOR SELF TEST DIAGNOSIS INPUT/OUTPUT Input voltage IL(V) < 0.3 IGN (V)
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IH(V) > 0.7 IGN (V) Output voltage OL(V) < 0.2 IGN (V) OH(V) > 0.8 IGN (V)
Brake System > ESP(Electronic Stability Program) System > Troubleshooting FAILURE DIAGNOSIS
1. In principle, ESC and TCS controls are prohibited in case of ABS failure. 2. When ESC or TCS fails, only the failed system control is prohibited. 3. However, when the solenoid valve relay should be turned off in case of ESC failure, refer to the ABS fail-safe. 4. Information on ABS fail-safe is identical to the fail-safe in systems where ESC is not installed.
MEMORY OF FAIL CODE

1. It keeps the code as far as the backup lamp power is connected. (O) 2. It keeps the code as far as the HCU power is on. (X)
FAILURE CHECKUP
1. Initial checkup is performed immediately after the HECU power on. 2. Valve relay checkup is performed immediately after the IG2 ON. 3. It executes the checkup all the time while the IG2 power is on. 4. Initial checkup is made in the following cases. (1) When the failure is not detected now (2) When ABS and ESC are not in control. (3) Initial checkup is not made after ECU power on. (4) If the vehicle speed is over 5 mph(8 km/h) when the brake lamp switch is off. (5) When the vehicle speed is over 24.8 mph(40 km/h). 5. Though, it keeps on checkup even if the brake lamp switch is on. 6. When performing ABS or ESC control before the initial checkup, stop the initial checkup and wait for the HECU power input again. 7. Judge failure in the following cases. (1) When the power is normal. (2) From the point in which the vehicle speed reaches 4.9 mph(8 km/h) after HECU power on.
COUNTERMEASURES IN FAIL
1. Turn the system down and perform the following actions and wait for HECU power OFF. 2. Turn the valve relay off. 3. Stop the control during the operation and do not execute any until the normal condition recovers.
WARNING LAMP ON
1. ABS warning lamp turns on when ABS is fail. 2. ESC operation lamp turns on and ESC OFF warning lamp blinks when ESC is fail. When power voltage and valve relay voltage are abnormal, input/output related failure judgment is not made.
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Brake System > ESP(Electronic Stability Program) System > Yaw-rate and Lateral G Sensor > Description and Operation DESCRIPTION
1. The yaw-rate & lateral G sensor is applied for the ESC system. 2. The yaw-rate is the angular velocity, when a vehicle turns a corner, and the lateral G is the acceleration to move a vehicle out of the way when cornering. 3. The sensor is located in the front passenger seat lower floor on vehicle.
specifications
Description Operating voltage Current consumption Output voltage range Operating temperature Measurement range Output voltage range Yaw-rate sensor Sensitivity Zero rate output Frequency response Measurement range Output voltage range Lateral G sensor Sensitivity Zero rate output Frequency response Specification 4.75 ~ 5.25 V Max. 65 mA 0.5 ~ 4.5 V -40 ~ 85 C -75 ~ 75 /sec 0.5 ~ 4.5 V 26.67 mV (/sec.) 2.5 V 10 Hz -1.5 ~ 1.5 g 0.5 ~ 4.5 V 1.33 V/g 2.5 V 50 Hz Remarks
output characteristic
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external diagram
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Brake System > ESP(Electronic Stability Program) System > Yaw-rate and Lateral G Sensor > Repair procedures REPLACEMENT
1. Remove the floor console. (refer to BD- "console") 2. Disconnect the yaw rate & lateral G sensor connector. 3. Remove the mounting bolts(A).
Brake System > ESP(Electronic Stability Program) System > Master Cylinder Pressure Sensor > Description and Operation DESCRIPTION
The pressure sensor(A) is connected to the master cylinder, when ESC is on operation, detecting the brake pressure in order to sense the user's will to brake a vehicle.The pressure sensor(A) consists of two ceramic discs, one is fixed and the other movable, so that changes the distance of the two discs.(Max. measurable pressure is 200bar.)
SPECIFICATIONS
Item Supply voltage Supply current Operating temperature Measurement pressure range Max. pressure limit Zero rate output Output range Specification 4.8 V ~ 5.1 V less than 15 mA -40 C ~ 125 C 0 ~ 200 bar 350 bar 0.5 V 0.5 ~ 4.5 V Remark
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CIRCUIT DIAGRAM
OUTPUT CHARACTERISTIC
Brake System > ESP(Electronic Stability Program) System > ESP OFF Switch > Description and Operation DESCRIPTION
1. The ESC OFF switch is for the user to turn off the ESC system. 2. The ESC OFF lamp is on when ESC OFF switch is engaged.
Brake System > ESP(Electronic Stability Program) System > ESP OFF Switch > Repair procedures INSPECTION
1. Remove the ESC OFF switch from the switch panel.
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2. Check the continuity between the switch terminals as the ESC OFF switch is engaged.
Brake System > ESP(Electronic Stability Program) System > Steering Angle Sensor > Description and Operation DESCRIPTION
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.
MEASUREING PRINCIPLE
The split of the steering angle sensor detects a steering angle of the steering wheel by a ON/OFF pulse caused by whether or not the LED lights go through the hole of the split, rotating as the steering wheel revolves. There are three LEDs, two(ST1, ST2) for detecting a steering direction, and the other for the neutral position.The HECU calculates the steering angle by the pulse from the steering angle sensor.
SPECIFICATION
Description Operating voltage Specification 9 ~ 16 V
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Operating temperature Current consumption Steering angle velocity Voltage(high) Voltage(low) Pulse duty
-30 ~ 75 C Max.100 mA Max. 1500 /sec 3.0 V ~ 4.1 V 1.3 V ~ 2.0 V 40 ~ 60 %
CIRCUIT DIAGRAM( STEERING WHEEL SPEED ANGLE SENSOR)
OUTPUT CHARACTERISTIC
No. ST1 1 ST2 ST1
INPUT L L L
OUTPUT L H H
Steering direction Right Left
Remark
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ST2 ST1 2 ST1 ST1 ST2 ST1 3 ST2 ST1 ST2 ST1 4 ST2 ST1 ST2
L L H L H H L H L H H H H
L L L H H H H L L H L L H Left
Right
Left
Right
Right
Left
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Brake System

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Brake System

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RONDO(UN) > 2009 > G 2.4 DOHC > Brake System

ABS : Anti-lock Brake System CBS : Conventional Brake System

48 teeth(Front), 47 teeth(Rear) 0.2 ~ 1.5 mm 30 ~ 70 %

Standard value 4 Channel 4 Sensor (Solenoid)

As required As required As required 0.8 ~ 2.2 g 0.8 ~ 1.8 g

Brake System > General Information > Troubleshooting TROUBLESHOOTING

Hard pedal but brake inefficient

Noise from brake

Brake fades Brake vibration, pulsation

- Failure recognition by the warning lamp.

Comparison between Proportioning valve and EBD

Wheel cylinder piston cup and dust cover (E)

BRAKE BOOSTER OPERATING TEST

VACUUM HOSE (CHECK VALVE)

BRAKE PEDAL & BRAKE SWITCH ADJUSTMENT

143.8 mm (5.66 in)

BRAKE SWITCH CLEARANCE

PEDAL FREE PLAY

INSPECTION OF FRONT DISC BRAKE PAD

INSPECTION OF REAR DISC BRAKE PAD

[EXCEPT GASOLINE 2.4(A/T)]

[GASOLINE 2.4(A/T) ONLY]

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

Do not disassemble the primary and secondary piston assembly.

4. Connect the brake fluid level switch connector (A).

Brake System Bleeding

Front disc brake :

Rear disc brake

4. After installing the brake hose, bleed the brake system.

2. Remove the caliper assembly (A).

5. Remove the brake disc (A) and the screw (B).

INSPECTION FRONT BRAKE DISC THICKNESS CHECK

FRONT BRAKE PAD CHECK

FRONT BRAKE DISC RUN OUT CHECK

6. Install the caliper assembly(A).

Be careful not to damage the piston pin boot.

2. Remove the caliper assembly (A).

4. Remove the rear upper arm (A).

6. Remove the brake disc (A) and the screw (B).

INSPECTION REAR BRAKE DISC THICKNESS CHECK

REAR BRAKE PAD CHECK

REAR BRAKE DISC RUN OUT CHECK

3. Install the rear upper arm (A).

7. Install the caliper assembly (A).

Be careful not to damage the piston pin boot.

COMPONENT(2) DISC BRAKE TYPE

PARKING BRAKE PEDAL

PARKING BRAKE SHOE (DISC BRAKE TYPE)

ADJUSTMENT PARKING BRAKE SHOE CLEARANCE ADJUSTMENT

PARKING BRAKE PEDAL STROKE ADJUSTMENT

INSTALLATION PARKING BRAKE SHOE (DISC BRAKE TYPE)

PARKING BRAKE PEDAL

Wheel Sensor signal processing

Solenoid Valve Control

Pump Motor Checking

WARNING LAMP MODULE

ABS HECU EXTERNAL DIAGRAM

HYDRAULIC SYSTEM DIAGRAM

ABS CONNECTOR INPUT/OUTPUT

Connector Terminal No Description

- Output voltage : IGN[V] 1 V - Output current : Max 30 mA

WHEEL SPEED SENSOR OUTPUT(ECM)