Brake System

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

Brake System > General Information > Specifications

SPECIFICATIONS

Item Specification

Master cylinder

Type

I.D.

Piston stroke

Fluid level warning sensor

Tandem type

25.4 mm (1.00 in)

30 mm (1.18 in)

Provided

Brake booster

Type

Boosting ratio

Vacuum

9 : 1

Front brake(Disc)

Type

Disc O.D.

Disc I.D.

Disc thickness

Pad thickness

Cylinder type

Cylinder I.D.

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)

Rear brake(Disc)

Type

Disc O.D.

Disc I.D.

Disc thickness

Pad thickness

Cylinder type

Cylinder I.D.

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)

Parking brake

Actuation

Type

Drum I.D.

DIH (Drum in hat)

Pedal

168 mm(6.61 in)

ABS : Anti-lock Brake System

CBS : Conventional Brake System

SERVICE STANDARD

Item Standard value

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)

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)

http://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenge...

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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 Nm kgf.m lb-ft

Master cylinder to booster mounting nut 9.8 ~ 15.7 1.0 ~ 1.6 7.2 ~ 11.6

Brake booster mounting nut 12.7 ~ 15.7 1.3 ~ 1.6 9.4 ~ 11.6

Bleeder screw 6.9 ~ 12.7 0.7 ~ 1.3 5.1 ~ 9.4

Brake tube nut, brake hose 12.7 ~ 16.7 1.3 ~ 1.7 9.4 ~ 12.3

Caliper guide rod bolt 21.6 ~ 31.4 2.2 ~ 3.2 15.9 ~ 23.1

Caliper mounting bolt (Front) 78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3

Caliper mounting bolt (Rear) 49.0 ~ 58.8 5.0 ~ 6.0 36.2 ~ 43.4

Brake hose to front caliper 24.5 ~ 29.4 2.5 ~ 3.0 18.1 ~ 21.7

Brake pedal member assembly bracket

mounting nut (cowl side upper mounting)16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8

Brake pedal mounting nut 12.7 ~ 15.7 1.3 ~ 1.6 9.4 ~ 11.6

Stop lamp switch mounting nut 7.9 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2

Wheel speed sensor mounting bolt 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0

HECU mounting bracket bolt (to body) 19.6 ~ 29.4 2.0 ~ 3.0 14.5 ~ 21.7

HECU union screw 12.0 ~ 16.0 1.22 ~ 1.63 8.8 ~ 11.8

HECU bracket mounting bolt 11.0 ~ 14.0 1.1 ~ 1.4 8.0 ~ 10.1

Yaw rate & Lateral G sensor mounting bolt 0.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0

SPECIFICATION (ABS)

Part Item Standard value Remark

HECU

System4 Channel 4 Sensor

(Solenoid)

Type ABS + EBD

Operating Voltage 10 ~ 15 V

Operating Temperature -40 ~ 110 C

Motor power 180 W

Warning lampMin. Operating Voltage 1.2 V

Max. Current consumption 120 mA

Active Wheel speed sensor

(ABS)

Supply voltage DC 4.5 ~ 20 V


Output current low 5.9 ~ 8.4 mA Typ. 7 mA

Output current high 11.8 ~ 16.8 mA Typ. 14 mA

Output range 1 ~ 2500 Hz


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Tone wheel48 teeth(Front),

47 teeth(Rear)

Air gap 0.2 ~ 1.5 mm

Output duty 30 ~ 70 %

SPECIFICATION(ESC)

Part Item Standard value Remark

HECU

System4 Channel 4 Sensor

(Solenoid)

Total control

(ABS, EBD, TCS, ESC)

TypeMotor, valve relay intergrated

type



Motor power 250 W

Warning lampMin. Operating Voltage 1.2 V

Max. Current consumption 120 mA

Active Wheel speed sensor

(ABS)

Supply voltage DC 4.5 ~ 20 V


Output current low 5.9 ~ 8.4 mA Typ. 7 mA

Output current high 11.8 ~ 16.8 mA Typ. 14 mA

Output range 1 ~ 2500 Hz

Tone wheel48 teeth(Front),

47 teeth(Rear)

Air gap 0.2 ~ 1.5 mm

Output duty 30 ~ 70 %

Steering Wheel Angle Sensor



Current Consumption Max. 100 mA

Output Current Max. 10 mA

Operating Angular velocity Max. 1500 /sec

Yaw rate &

Lateral G sensor

Operating Voltage 4.8 ~ 5.1 V

Current Consumption Max. 90 mA

Output voltage 0.5 ~ 4.5 V


Yaw rate sensor

measurement range 75 /sec

Lateral G sensor

measurement range 1.5 g

LUBRICANT

Item Recommended lubricant Quantity


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Brake fluid DOT 3 or DOT 4 As required

Brake pedal bushing and brake pedal bolt Chassis grease As required

Parking brake shoe and backing plate contact

surfacesBearing grease As required

Front caliper guide rod bolt and boot AI-II grease 0.8 ~ 2.2 g

Rear caliper guide rod and boot AI-II grease 0.8 ~ 1.8 g

Brake System > General Information > Special Service Tools

SPECIAL TOOLS

Tool (Number and Name) Illustration Use

09581 - 11000

Piston expander

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 Suspect Area Remedy

Lower pedal or spongy

pedal

1. Brake system (Fluid leaks)

2. Brake system (Air in)

3. Piston seals (Worn or damaged)

4. Master cylinder (Faulty)

Repair

Air bleeding

Replace

Replace

Brake drag 1. Brake pedal free play (Minimum)

2. Parking brake lever travel (Out of adjustment)

3. Parking brake wire (Sticking)

4. Pad or lining (Cracked or distorted)

5. Piston (Stuck)

6. Piston (Frozen)

7. Return spring (Faulty)

8. Booster system (Vacuum leaks)

9. Master cylinder (Faulty)

Adjust

Adjust

Repair

Replace

Replace

Replace

Replace

Replace

Replace

Brake pull 1. Piston (sticking)

2. Pad or lining (Oily)

3. Piston (Frozen)

4. Disc (Scored)


Replace

Replace

Replace

Replace

Replace


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Hard pedal but brake

inefficient

1. Brake system (Fluid leaks)

2. Brake system (Air in)

3. Pad or lining (Worn)


5. Pad or lining (Oily)

6. Pad or lining (Glazed)

7. Disc (Scored)

8. Booster system (Vacuum leaks)

Repair

Air bleeding

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)

Replace

Retighten

Replace

Retighten

Replace

Clean

Replace

Replace

Replace

Replace

Brake fades 1. Master cylinder Replace

Brake vibration,

pulsation

1. Disc (Excessive thickness variation)

2. Disc (Faulty run-out)

3. Disc (Uneven worn or crack)

4. Pad or lining (Uneven worn and contact)

5. Caliper (Faulty pad sliding)

Replace

Replace

Replace

Replace

Replace

Brake chatter Brake chatter is usually caused by loose or worn components, or glazed

or burnt linings. Rotors with hard spots can also contribute to brake

chatter. Additional causes of chatter are out-of-tolerance rotors, brake

lining not securely attached to the shoes, loose wheel bearings and

contaminated brake lining.

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 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 cup

inspection (B)

Check brake operation by applying the brakes. Look for damage or signs of 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

piston boots (D)

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.

Wheel cylinder piston cup

and dust cover (E)

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.


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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.


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.


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


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).


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).


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).


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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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


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


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).


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).


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).


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)



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 andComponents 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 State Valve PassagePump

motor

Inlet valve (NO) OFF Open Master cylinder Wheel cylinderOFF

Outlet valve (NC) OFF Close Wheel cylinder Reservoir


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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 State Valve PassagePump

motor

Inlet valve (NO) ON Close Master cylinder Wheel cylinder ON

Outlet valve (NC) ON Open Wheel cylinder Reservoir


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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.


motor

Inlet valve (NO) ON Close Master cylinder Wheel cylinder 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.


motor

Inlet valve (NO) OFF Open Master cylinder Wheel cylinder 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 TerminalSpecification Remark

No Description

4 IGNITION1()

Over voltage range: 16.5 0.5 V

Operating voltage range: 9.5 0.5 V < V 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 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.

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 Suspect Area

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.

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.


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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)

1. Power source circuit

2. Diagnosis line

Communication with Scan tool is not possible.

(Communication with ABS only is not possible)

1. Power source circuit

2. Diagnosis line

3. HECU

When ignition key is turned ON (engine OFF), the ABS

warning lamp does not light up.

1. ABS warning lamp circuit

2. HECU

Even after the engine is started, the ABS warning lamp

remains ON.

1. ABS warning lamp circuit

2. HECU

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 Possible Cause

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 power source circuit

- Faulty wheel speed sensor circuit

- Faulty hydraulic circuit for leakage

- Faulty 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.


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


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 wheel speed sensor circuit

- Faulty hydraulic circuit for leakage

- Faulty 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.


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


Possible defect in the power supply system (including ground) for the

diagnosis line.

- An open in the wire

- Poor ground



CHECK THE POWER SUPPLY CIRCUIT FOR THE DIAGNOSIS

Measure the voltage between terminal 9 of the data link connector and body ground.


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.


Repair an open in the wire between terminal 5 of the data link connector and ground point.


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DETECTING CONDITION


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.


- Faulty HECU



CHECK FOR CONTINUITY IN THE DIAGNOSIS LINE


2. Check for continuity between terminals 7 of the ABS control module connector and 1 of the data link connector.


Check the power source of ABS control module.

Repair an open in the wire.

CHECK THE POWER SOURCE OF 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.



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


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.

- 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.



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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Repair an open in the wire between ABS fuse and 1 of cluster connector (M03-A).

Replace the blown fuse.

DETECTING CONDITION


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.


- 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.


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 Trouble descriptionWarning lamp

RemarksEBD ABS ESC

C1101 Battery voltage high

C1102 Battery voltage low X/

C1112 Sensor power voltage X X ESC

C1200 Wheel speed sensor front-LH open/short X/

C1201Wheel speed sensor front-LH range / performance /

intermittentX/

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

C1203 Wheel speed sensor front-RH open/short X/

C1204Wheel speed sensor front-RH range / performance /

intermittentX/

C1205 Wheel speed sensor front-RH invalid/no signal X/

C1206 Wheel speed sensor rear-LH open/short X/

C1207Wheel speed sensor rear-LH range / performance /

intermittentX/

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

C1209 Wheel speed sensor rear-RH open/short X/

C1210Wheel speed sensor rear-RH range / performance /

intermittentX/

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

C1235 Primary pressure sensor - electrical X X ESC

C1237 Primary pressure sensor - signal X X ESC

C1259 Steering sensor - electrical X X ESC

C1260 Steering sensor circuit - signal X X ESC

C1282 Yaw rate & lateral G sensor - electrical X X ESC

C1283 Yaw rate & lateral G sensor - signal X X ESC


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C1503 ESC switch error X X ESC

C1513 Brake switch error X X ESC

C1604 ECU hardware error

C1605 CAN hardware error X X ESC

C1611 CAN time-out EMS X X ESC

C1612 CAN time-out TCU X X ESC

C1613 CAN wrong message X X ESC

C1616 CAN bus off X X ESC

C2112 Valve relay error

C2227 Excessive temperature of brake disc X X ESC

C2380 AB/TCSS/ESC valve error

C2402 Motor electrical X

Brake System > ABS(Anti-Lock Brake System) > ABS Control Unit > Components andComponents 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 > Componentsand Components Location

COMPONENTS


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Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Repairprocedures

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 > Componentsand Components Location

COMPONENTS


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Brake System > ABS(Anti-Lock Brake System) > Rear Wheel Speed Sensor > Repairprocedures

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 ComponentsLocation

COMPONENTS


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Brake System

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