SOUL(AM) > 2013 > G 2.0 DOHC > Brake System Page | of 87 Brake System > General Information > Specifications Specifications Item Specification Master cylinder Type Tandem type Piston stroke 45 mm (1.77 in) Fluid level waming sensor _| Provided Brake booster Type ‘Vacuum, Boosting ratio 9:1 Front brake (Disc) Floating type with ventilated Type disc Dise O.D. 280 mm (11.02 in) Dise LD. 172. mm (6.77 in) Disc thickness 26 mm (1.02 in) Pad thickness 11 mm (043 in) Cylinder LD. Single piston 57.0 mm (2.24 in) Rear brake (Disc) Type Floating type with solid dise Disc OD. 262 mm (10.31 in) Disc LD. 185 mm (7.28 in) Dise thickness 10mm (0.39 in) Pad thickness 10mm (0.39 in) Cylinder type Single piston Cylinder LD. 30.0 mm (1.22 in) Rear brake (Drum) Type Leading wailing Drum LD. 203.2 mm (8.00 in) Brake lining thickness 5.14 mm (0.20 in) Clearance adjustment Automatic Parking brake (Dise type) ‘Actuation DIH Daum in hat) Type Lever Drum LD. 168 mm(6.61 in) am OD. : Outer Diameter LD : Inner Diameter Specification (ESC)Page 2 of 87 Part Item Standard value Remark System 4 Channel 4 Sensor (Solenoid) Type ‘Motor, valve relay intergrated ecu type Total control Operating Voltage __|10~ 16V. (ABS, EBD. TCS, ESC) Operating Temperature|-40 ~ 120°C(-40 ~ 248°F) Motor power 270W Supply voltage DC4.5~20V Output curentlow —_|5.9~ 8.4m Active Whee specs] Cumateumentieh_[11.8- 168mA sensor Output range 1 ~ 2500Hz Tone witeel 47 teeth wom ita Operating Voltage _|10 V~ 16V Vow nites Curent Consumption |Max. 150m. Lateral G sensor _ | Yaw rate sensor -75 ~75*/see (CAN TYPE) measurement range Service Standard Item Standard value Brake pedal height 194 mm (7.64 in) Brake pedal stroke 135 mm ($.31 in) Stop lamp switeh outer case to pedal stopper clearance 1 ~2 mm (0.039 ~ 0.047 in) Brake pedal free play 3 ~8 mm (0.08 ~ 0.20 in) Booster push rod to master eylinder piston clearance 0.6 ~ 1.4 mm (at 500 mm#g vacuum) Parking brake lever stroke when lever assembly i pulled with | «> 46 196N (20Kg, 44lb force) Front dise brake pad thickness LL mm (043 in.) Front dise thickness 26 mm (1.02 in) Rear dise brake pad thickness 10mm (0.35 in) ‘Rear disc brake disc thickness 10 mm (0.39 in) ‘Rear brake lining thickness. Disc Brake : 2.6 mm (0.10 in) ‘Drum Brake : 5.14 mm (0.20 in) Tightening TorquesItem Nam kgtm Ib-ft ‘Master cylinder to booster mounting nut 127~16.7| 13~17 | 94~123 Brake booster mounting nut 16.7 ~25.5| 17~26 |123~18.8 Bleeder screw 69~127| 07~13 | 51~94 Brake tube to HECU-CBS/ABS 127~16.7| 13~17 | 94~123 Brake tube to HECU-ESt 18.6 ~ 22. 13.7 ~ 16.6 Caliper guide rod bolt 21.6~314] 2.2~32 |159~23.1 Caliper mounting bolt (Front) 78.5 ~98.1| 8.0~ 10.0 |57.9~72.3 Caliper mounting bolt (Rear) 63.7~73.6| 6.5~7.5 |47.0~34.3 Brake hose to caliper 24.5~29.4| 2.5~3.0 | 18.1~21.7 Brake peal member assembly bracket mounting | 167 555! 17-96 |123-188 Brake pedal member assembly bracket mounting | 7.8~9.8 | 08~1.0 | 58~7.2 bolt Page 3 of 87 Stop lamp switch mounting mut LL8 ~ 14. 8 ‘Wheel speed sensor mounting bolt 69~108 | 07~1.1 | 5.1~80 ‘HECU mounting bracket bolt 16,7~25.5| 17~26 |123~18.8 HECU bracket mounting nut 10.8~13.7| 11~14 | 8.0~101 ‘Yaw rate & Lateral G sensor mounting bolt 78~108 | 08~11 | 58~80 Lubricant Item Recommended lubricant Quantity Brake fluid DOT3 or DOT4 As required Bake pedal bushing and brake pedal Chassis grease ‘As reat Parking brake shoe and backing plate . A contact sutaces Bearing grease As required f Front : 1.2~1.7g Caliper guide rod bolt and boot AF-LIP grease Rew 08-13e Brake System > General Information > Special Service Tools Special Service ToolsTool (Number and Name) Ilustration | Page 4 of 87 Use 09581 - 11000 Piston expander ar Pushing back of the front dise and rear dise 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 possible cause of the problem. Check each part in order. If necessary, replace these parts Symptom, Suspect Area Remedy Lower pedal or 1. Brake system (Fluid leaks) Repair spongy pedal 2. Brake system (Air in) Air bleeding 3. Piston seals (Wom or damaged) Replace 4. Master cylinder (Faulty) Replace Brake drag 1. Brake pedal free play (Minimum) Adiust 2. Parking brake lever travel (Out of adjustment) Adjust 3. Parking brake wire (Sticking) Repair 4, Pad or lining (Cracked or distorted) Replace 5. Piston (Stuck) Replace 6. Piston (Frozen) Replace 7. Retumn spring (Faulty) Replace 8. Booster system (Vacuum leaks) Replace 9. Master cylinder Faulty) Replace Brake pull 1. Piston (sticking) Replace 2. Pad or lining (Oily) Replace 3. Piston (Frozen) Replace 4. Dise (Scored) Replace 5. Pad or lining (Cracked or distorted) Replace Hard pedal but brake | 1. Brake system (Fluid leaks) Repair ineflicient 2. Brake system (Air in) Air bleeding 3. Pad or lining (Worn) Replace 4, Pad or lining (Cracked or distorted) Replace 5. Pad or lining (ily) Replace 6, Pad or lining (Glazed) Replace 7. Disc (Scored) Replace 8. Booster system (Vacuum leaks) Replace Noise from brake | 1, Pad or lining (Cracked or distorted) Replace 2. Installation bolt (Loosen) RetightenPage 5 of 87 properly or if there are signs of leakage. 3. Dise (Scored) Replace 4. Sliding pin (Wom) Replace 5. Pad or lining (Ditty) Clean 6, Pad or lining (Glazed) Replace 7. Retum spring (Faulty) Replace 8. Brake pad shim (Damage) Replace 9. Shoe hold-down spring (Damage) Replace Brake fades 1, Master eylinder Replace Brake vibration, _| 1. Dise (Exeessive thickness variation) Replace pulsation 2. Disc (Faulty run-out) Replace 3. Dise (Uneven worn or crack) Replace 4, Pad or lining (Uneven worn and contact) Replace 5. Caliper (Faulty pad sliding) Replace Brake chatter Brake chatter is usually caused by loose or worn components, or glazed or bumt 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 > 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. Ifthe brakes do not work properly, check the brake booster(Refer to "Brake Booster Operating Test" in this group). Replace the brake booster as an assembly if it does not work properly or if there is damage or signs of fiuid leakage. Piston cup and pressure | + Check brake operation by applying the brakes. Look for damage or signs of fluid cup inspection (B) leakage. Replace the master cylinder as an assembly if the pedal does not work + Check for a difference in brake pedal stroke between quick and slow brake applications. Replace the master cylinder if there isa difference in pedal stroke. it is damaged or leaking. Brake hoses (C) Look for damage or signs of fluid leakage. Replace the brake hose with a new one if Caliper piston seal and | Check brake operation by applying the brakes. is disassembled, piston boots (D) Look for damage or signs of fluid leakage. Ifthe pedal does not work properly, the brakes drag, or there is damage or signs of uid leakage, disassemble anc inspect the brake caliper. Replace the boots and seals with new ones whenever the brake caliperPage 6 of 87 Brake System Bleeding en + Do not reuse the drained fluid + Always use genuine DOT3/DOTS brake Fluid, Using a non-genuine DOT3/DOTA brake fluid can cause corrosion and deerease the life of the system. + Make sure no dirt or 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 mack at the start of bleeding procedure and checked after bleeding each brake caliper. Add fluid as required. 1, Make sure the brake fluid in the reservoir is at the MAX (upper) level line 2. Have someone slowly pump the brake pedal several times, and then apply pressure.Page 7 of 87 3. Loosen the right-rear brake bleed serew (A) to allow air to escape from the system. Then tighten the bleed screw securely. Front Rear 4, Repeat the procedure for wheel in the sequence shown below until air bubbles no longer appear in the fluid. © Front ght Dee tit =) = 2 Front .et oa Lot 5. Refill the master eylinder reservoir to MAX (upper) level line. Brake System > Brake System > Brake Booster > Components and Components Location ComponentsPage 8 of 87 12.7 ~ 16.7 (1.3 ~ 1.7, 9.4 ~ 12.3) Torque : N.m (kgf.m, Ib-ft) 1. Brake booster 2, Master eylinder assembly 3. Vacuum hose Brake System > Brake System > Brake Booster > Repair procedures Brake Booster Operating Test For simple checking of the brake booster operation, catty out the following testsPage 9 of 87 1, Run the engine for one or two minutes, and then stop it, Ifthe pedal depresses fully the frst time but gradually becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the booster is inoperative ana \ a ye “het 2. With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. Ifthe pedal moves downward slightly, the booster is in good. condition, If there is no change, the booster is inoperative. When engine is topped | When engine is started 9 3. With the engine running, step on the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. Ifthe pedal height does not change, the booster is in good condition, if the pedal rises, the booster is inoperative. Ifthe 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 malfunction. Good No good Removal 1, Tum ignition switch OFF and disconnect the negative (-) battery cable.Page 10 of 87 2. Disconnect the vacuum hose (A) from the brake booster. ~ihe 3. Remove the master cylinder. (Refer to Master eylinder) 4, Remove the snap pin (A) and clevis pin (B). 5. Remove the mounting nuts. Tightening torque : 16.7 ~ 25.5N.m (1.7 ~ 2.6kgim, 12.3 ~ 18.81b-ft) Ca) oe >o Oe 6, Remove the brake booster.Page 11 of 87 Inspection 1 Inspect the check valve in the vacuum hose. Do not remove the check valve from the vacuum hose. 2. Cheek the boot for damage. Installation, 1. Installation is the reverse of removal. + Before installing the pin, apply the grease to the joint pin. + Use a new snap pin whenever installing. 2. After installing, bleed the brake system, (Refer to Brake system bleeding) 3. Adjust the brake pedal height and free play (Refer to Brake pedal height and free play adjustment) Brake System > Brake System > Master Cylinder > Components and Components Location ComponentsPage 12 of 87 1. Reservoir cap 2. Reservoir 3. Grommet 4, Master eylinder body 5.0-Ring Brake System > Brake System > Master Cylinder > Repair procedures Removal, 1, Tum ignition switch OFF and disconnect the negative (-) battery cable.Page 13 of 87 2, Remove the cowl top cover. (Refer to the Body group-Cowl top Cover) 4, Remove the brake fluid from the master cylinder reservoir with a syringe. + Be sure to completely remove foreign substances from around brake fluid reservoir and cap before ‘opening the reservoir cap. If not, it may cause contamination of brake fluid and deterioration in braking performance. + 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. 5, Disconnect the brake tube (A) fiom the muster cylinder by loosening the tube flare nut. Tightening torque : CBS/ABS : 12.7 ~ 16,7N.m (1.3 ~ L.7kgfim , 9.4 ~ 12.31b-ft) ESC : 18.6 ~ 22.6N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-it) 6, Remove the clutch hose. (MT Only)Page 14 of 87 7. Remove the reservoir (C) fiom the master cylinder (B), after removing mounting serew (A). 8, Remove the two grommets. 9, Remove the master cylinder (B) from the brake booster after loosening the mounting nuts (A). Tightening torque : 12.7 ~ 16.7N.m (1.3 ~ [Link], 9.4 ~ 12.31b-f) Installation 1. Installation is the reverse of removal. 2. After installation, bleed the brake system, (Refer to Brake system bleeding) Brake System > Brake System > Brake Line > Components and Components Location ComponentsPage 15 of 87 Disc brake: Blood screw 6.9 -12.7 (0.7 ~ 1 Brake hose to caliper 24.5 ~ 29. 51-94) (25 ~ 3.0, 18.1 ~21.7) Brake line to brake hose 12.7 ~ 16.7 (1.3 ~ 1.7, 9.4 ~ 12.3) Brake hose to caliper 24.5 ~29.4 (2.5 ~ 3.0, 18.1 -21.7) ‘Master cylinder to brake line CBSIABS: 12.7 ~ 16.7 (1.3 ~ 17, 9.4 ~ 12.3) ESC : 18.6 ~ 22.6 (1.9 ~ 2.3, 13.7 ~ 16.6) Brake line to brake hose 12.7 ~ 16.7 (1.3 ~ 1.7, 9.4 ~ 12.3) Bleed screw 6.9 ~ 12.7 (0.7 ~ 1.3, 5.1 ~ 9.4) Torque : Nm (kgf.m, Ib-ft) ‘When installing brake hose, be sure to comply with the torque specification to prevent twisted hose: Brake System > Brake System > Brake Line > Repair procedures Removal 1, Remove the wheel & tire.Page 16 of 87 2, Remove the brake hose clip (C). 3. Disconnect the brake tube by loosening the tube flare nut (B), Tightening torque : 12.7 ~ 16.7N.m (1.3 ~ [Link], 9.4 ~ 12.31b-ft) 4, Disconnect the brake hose from the brake caliper by loosening the bolt (A). Tightening torque : 24.5 ~ 29.4N.m (2.5 ~ .0kgfam, 18.1 ~ 21.7Ib-) Front Inspection 1. Check the brake tubes for cracks, crimps and corrosion, 2. Check the brake hoses for cracks, damage and fluid leakage. 3. Check the brake tube flare nuts for damage and fluid leakagePage 17 of 87 4, Check the brake hose mounting bracket for erack or deformation. Installation 1. Installation is the reverse of removal. ‘Use a new washer(A) whenever installing em, 2. Affer installation, bleed the brake system. (Refer to Brake system bleeding) 3. Inspeet for brake fluid leaks. Brake System > Brake System > Brake Pedal > Components and Components Location. ComponentsPage 18 of 87 _ 25.5 (1.7 ~ 2.6, 123 ~ 4 . O<— 7.9 ~ 9.8 (0.8 ~ 1.0, 5.8 ~7.2) = 24.5 ~ 34.3 (2.5 ~ 3.5, 18.0 ~ 25.3) 8) © .m (kgf.m, Ib-ft) Torque : 1, Brake pedal member |3. Brake pedal assembly 4, Mounting bracket 2, Stop lamp switeh Brake System > Brake System > Brake Pedal > Repair procedures Removal 1, Remove the lower crash pad, (Refer to the Body group- crash pad).Page 19 of 87 2, Disconnect the stop lamp switch connector (A). 3. Remove the mounting bracket bolt (B) Tightening torque : 16.7 ~25.5N.m (1.7 ~ 2.6kgfm, 12.3 ~ 18.81b-ft) 4, Remove the snap pin (A) and clevis pin (B). 5, Remove the shift lock cable after removing the snap pin (C) and the elip (D). 6, Remove the brake pedal member assembly mounting nuts and then remove the brake pedal assembly. Tightening torque : 16.7 ~ 25.5N.m (1.7 ~ 2.6kgfm, 12.3 ~ 18.8Ib-ft) 7 { 5 ® oe 9 6 ipl Inspection 1. Check the bushing for wear. 2. Check the brake pedal for bending or twisting. 3. Check the brake pedal retum spring for damage.Page 20 of 87 4, Check the stop lamp switeh, (1) Connect a circuit tester to the connector of stop lamp switch, and check whether or not there is continuity ‘when the plunger of the stop lamp switeh is pushed in and when itis released. (2) The stop lamp switch isin good condition if there is no continuity when plunger() is pushed. Installation 1. Installation is the reverse of removal. + Before installing the pin, apply the grease tothe clevis pin + Use a new snap pin whenever installing, 2. Cheek the brake pedal operation. Brake System > Brake System > Front Disc Brake > Components and Components Location ComponentsPage 21 of 87 6.9 ~ 12.7 (0.7 ~ 1.3, 5.1 - 9.4) 21.6 ~ 31.4 (22 ~ 3.2, 15.9 ~ 23.1) >a, Torque : N.m (kgt.m, lb-ft) 1, Guide rod bott |5. Inner pad shim [Link] screw |6. Brake pad 3. Caliper 7. Pad retainer bracket 4. Caliper body Brake System > Brake System > Front Dise Brake > Repair procedures Removal 1, Remove the front wheel & tire, Tightening torque : 88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~79.61b-ft)Page 22 of 87 2, Loosen the hose eye-bolt (B) and caliper mounting bolts (C), then remove the front caliper assembly (A). Tightening torque Brake hose to caliper(B): 5. 29.4N.m (2.5 Caliper assembly to knuckle(C): 78.5 ~ 98.1N.m (8.0 ~ 10.0kgf.m, 57.9 ~ Okgfim, 18.1 ~ 21.7Ib-ft) 3. Remove the front brake dise by loosening the screws. Replacement Front Brake Pads 1, Remove the brake hose mounting bracket knuckle mounting partPage 23 of 87 2, Loosen the guide rod bolt (B) and pivot the caliper up out of the way. Tightening torque : 21.6 ~ 31.4N.m (2.2 2kgfim, 15.9 ~ 23.11b-ft) Laspection Front Brake Dise Thickness Check 1. Check the brake pads for wear and fade. 2. Cheek the brake disc for damage and cracks. 3, Remove all rust and contamination from the surface, and measure the dise thickness at 8 points, at least, of same distance (Smm) from the brake disc outer circle. Brake dise thickness Standard: 26mm (1.02in) Service limit: 24.4mm (0.96in) Deviation: Less than 0,005unm (0,0002in)Page 24 of 87 4, If wear exceeds the limit, replace the dises and pad assembly left and right of the vehicle. Front Brake Pad Check 1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specitied value. Pad thickness Standard value : 1 Imm (0.43in) Service limit : 2.0mm (0.0787in) 2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage. Front Brake Dise Runout Check 1. Place a dial gauge about Smm (0.2 in.) from the outer cireumference of the brake disc, and measure the runout of the dise. Brake dise runout Limit : 0.025mm (0,00098in.) or less (new one) \ \S 2, Ifthe runout of the brake dise exceeds the limit specification, replace the dise, and then measure the run out again, 3. Ifthe replacement brake disc runout exceeds the limit specification rotate the 180° and check again. 4, Ifthe runout cannot be corrected by changing the position of the brake dise, replace the brake disc. Installation 1. Installation is the reverse of removal. 2. Use a SST (09581-11000) when installing the brake caliper assembly. 3. After installation, bleed the brake system. (Refer to Brake system bleeding) Brake System > Brake System > Rear Dise Brake > Components and Components LocationPage 25 of 87 Components 6.7 ~12.7(0.7~1.3,5.1~9.4) 21.6 ~ 31.4 (2.2 ~ 3.2, 15.9 ~ 23.1) Ww Torque : N.m (kgf.m, lb-ft) 1, Guide rod bolt |. Inner pad shim [Link] screw |6, Brake pad 3. Caliper 7. Pad retainer bracket 4, Caliper body Brake System > Brake System > Rear Dise Brake > Repair procedures RemovalPage 26 of 87 1, Remove the rear wheel & tire Tightening torque : 88.3 ~ 107.9N.m (9.0 ~ 11.0kgfm, 65.1 ~ 79.61b-ft) 2. Loosen the hose eye-bolt (B) and caliper mounting bolts (C), then remove the rear caliper assembly (A). Tightening torque Brake hose to caliper(B): 24.5 ~ 29.4N.m (2.5 ~ 3.0kgfan, 18.1 ~ 21.7Ib-f) Caliper assembly to cattien(C): 63.7 ~ 73.6N.m (6.5 ~ 7.5kgfm, 47.0 ~ $4.3lb-ft) Replacement Rear Brake PadsPage 27 of 87 1, Loosen the guide rod bolt (B) and pivot the caliper up out of the way. Tightening torque : 21.6 ~ 31.4N.m (2.2 ~ 2kgfim, 15.9 ~ 23.11b-ft) Inspection. Rear Brake Dise Thickness Check 1. Check the brake pads for wear and fade 2. Check the brake dise for damage and cracks. 3. Remove all rust and contamination from the surface, and measure the dise thickness at 8 points, at least, of same distance (Smm) fiom the brake dise outer circle. Brake disc thickness ‘Standard: 10mm (0.39in) Service limit: 8.4mm (0.33in) Deviation: less than 0.01mm (0.00039in) 4, If wear exceeds the limit, replace the dises and pad assembly left and right of the vehicle.Page 28 of 87 Rear Brake Pad Check 1. Check the pad wear. Measure the pad thickness and replace it, fit is less than the specified value. Pad thickness Standard value: 10mm (0.39 n) Service limit; 2.0 mm (0.0787 in) 2. Cheek: that grease is applied, to sliding contact points and the pad and backing metal for damage Rear Brake Dise Runout Check 1. Place a dial gauge about Smam (0.2 in.) from the outer circumference of the brake dise, and measure the runout of the dise. Brake dise runout Limit: 0.0Smm (0,00197in.) or ess (new one) 2. Ifthe runout of the brake dise exceeds the limit specification, replace the disc, and then measure the runout again, 3. Ifthe replacement brake dise runout exceed the limit specification rotate the 180° and check again. 4, Ifthe runout cannot be corrected by changing the position of the brake disc, replace the brake disc. Installation 1 Installation is the reverse of removal. 2. Use a SST (09581-11000) when installing the brake caliper assembly. 3. After installation, bleed the brake system. (Refer to Brake system bleeding) Brake System > Brake System > Rear Drum Brake > Components and Components Location ComponentsPage 29 of 87 1. Shoe hold down pin | 6. Adjusting lever 2. Shoe 7. Adjusting lever 3. Shoe hold spring | spring 4, Upper retum spring | 8. Lower retum spring 3. Shoe adjuster 9. Brake drum Brake System > Brake System > Rear Drum Brake > Repair procedures Removal + Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health, + Avoid breathing dust particles. + Never use an air hose or brush to clean brake assemblies.Page 30 of 87 1, Release the parking brake, 2, Remove the rear tie and wheel, 3. Remove the rear brake drum (A). 4, Remove the shoe hold spring and shoe hold pin (B). 5, Remove the upper retum spring (A). 6. Lower the brake shoe assembly (A), and remove the lower retumn spring (B). Make sure not to damage the dust cover on the wheel cylinder. 8, Remove the brake shoe assembly. 9. Disconnect brake tubes (A) from the wheel cylinder (B).Page 31 of 87 10, Remove the bolt (C) and the wheel cylinder (B) from the backing plate (D). vy Tnstallation ana + Do not spill brake fhuid on the vehicle: it may damage the paint; if brake fluid does contact the paint, Wash it off immediately with water. + To preveat spills, cover the hose joints with rags or shop towels + Use only a genuine wheel cylinder special bolt. 1. Apply sealant (C) between the wheel cylinder (A) and backing plate (B), and install the wheel cylinder. 2. Connect the brake tubes (D) to the wheel cylinder. 3. Connect the parking brake cable (A) to the brake assembly.Page 32 of 87 4, Clean the threaded portions of adjuster sleeve (A) and push rod female (B), Coat the threads of the adjuster assembly with grease. To shorten the clevises, tum the adjuster bolt (C). 5. Hook the shoe adjuster lever (A), then install it to the brake shoe, 6. Install the adjuster assembly (B) and upper retum spring (C) as right direction. Be careful not to damage the wheel cylinder dust covers. 7. Install the lower return spring (D). 8. Apply brake cylinder grease or equivalent ru brake linings. ibber grease to the sliding surfaces shown. Don't get grease on the 1m Sing srlcePage 33 of 87 9. Apply brake cylinder grease or equivalent rubber grease to the brake shoe ends and opposite edges of the shoes shown, Dont get grease on the brake linings. 10, Install the brake shoes (A) onto the backing plate. Be careful not to damage the wheel cylinder dust covers. 11. Install the shoe hold down pins (B) and the shoe hold down springs. 12. Install the rear brake drum (A). 13. Ifthe wheel cylinder has been removed, bleed the brake system, 14, Depress the brake pedal several times to set the self-adjusting brake. 15, Adjust the parking brake. Inspection + Frequent inhalation of brake pad dust, regardless of material composition, could he hazardous to your health, + Avoid breathing dust particles. + Never use an air hose or brush to clean brake assemblies. + Contaminated brake linings or drums reduce stopping ability. + Block the front wheels before jacking up the rear of the vehicle,Page 34 of 87 1. Raise the rear of the vehicle, and make sure itis securely supported. 2, Release the parking brake, and remove the rear brake drum. 3. Check the wheel cylinder (A) for leakage. 4, Check the brake linings (B) for cracking, glazing, wear, and contamination, 5. Measure the brake lining thickness (C). ‘Measurement does not include brake shoe thickness. Brake lining thickness Standard : 5.14mm (0.202in) Service limit : 1.0mm (0.039in) 6. Ifthe brake lining thickness is less than the service limit, replace the brake shoes as a set. 7. Check the bearings in the hub unit for smooth operation. If it requires servicing, replace it 8. Measure the inside diameter of the brake drum with inside vemier calipers. Drum inside diameter Standard : 203.2mm (8.0in) Service limit : 205.2mm (8.08in) Drum roundness Service limit : 0,06mm (0,00236in) 9, Ifthe inside diameter of the brake drum is more than the service limit, replace the brake drum. 10. Check the brake drum for scoring, grooves, and cracks.Page 35 of 87 11. Inspect the brake Lining and drum for proper contact. 12, Inspect the wheel cylinder outside for excessive wear and damage. 13, Inspect the backing plate for wear or damage. Brake System > Parking Brake System > Parking Brake Assembly > Components and Components Location Component LocationPage 36 of 87 1. Parking brake 3, Parking brake 2. Parking brake lever | cable 4, Equalizer assembly Component Dise Brake TypePage 37 of 87 1. Back plate 2. Strut spring 3. strut 4, Shoe & lining 5, Shoe guie 6. Retum spring 7. Adjuster 8, Retum spring 9. Cup washer 10. Shoe hold down spring Drum Brake TypePage 38 of 87 1. Shoe hold down pin | 6. Adjusting lever 2. Shoe 7. Adjusting lever 3. Shoe hold spring | spring 4, Upper return spring. | 8. Lower return spring 5. Shoe adjuster 9. Brake drum Brake System > Parking Brake System > Parking Brake Assembly > Repair procedures Removal Parking Brake LeverPage 39 of 87 ana The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature failure. 1, Remove the floor console, (Refer to Body group. -"Floor console") 2. Loosen the adjusting nut (A) and the parking brake cables. L ig 3. Disconnect the connector (A) of parking brake switch. gee 4, Remove the parking brake lever assembly after removing the 4 bolts shown. 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 dise brake removal")3, Remove the brake Dise (A), Page 40 of 87 5, Remove the shoe hold down pin (A) and the spring (B) by pushing the retainer spring and tuming the pin.Page 41 of 87 7. Remove the parking brake cable (B) from the brake shoe (A). 9, Remove the brake shoe. 10, Remove the parking brake cable retaining (B), from the parking brake cable (A). Parking Brake Shoe (Dram Brake Type) 1 Raise the vehicle, and make sure it is securely supported 2. Remove the rear tire and wheel, then remove the brake drum (A).3. Remove the brake shoe (A). (Refer to "Rear drum brake removal") Installation Parking Brake Shoe (Dise Brake Type) spring (D) 4. Install the parking brake cable (A), then install the retaining (B). 1. Install the brake shoe(A) to the back plate(B). Page 42 of 87 2. Install the shoe hold down pin(C) and the spring(D) by pushing the retainer spring (D) and turning the pins. 3. After installing the strut (A) and upper retum spring (B), install the adjuster assembly (C) and the lower retum,Page 43 of 87 5. Apply a coating of the specified grease to each sliding parts of parking brake as shown. Specified grease : Multi purpose grease SAE J310, NLGT e Grease 6. Install the rear brake dise, then adjust the rear brake shoe clearance. (1) Remove the plug from the dise. (2) Rotate the toothed wheel of adjuster by a screw driver until the dise is not moving, and then retum it by 3 ~ 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 lever. Parking Brake Shoe (Drum Brake Type)1, Install the brake shoe (A). (Refer to "Rear drum brake installation") 4, Adjust the parking brake lever. Parking Brake Lever 1. Install the parking brake lever assembly, then 3. Depress the brake pedal several times fo set the self-adjusting brake. tighten the mounting bolts. Page 44 of 87Page 45 of 87 2. Apply a coating of the specified grease to each sliding parts (A) of the ratchet plate or the ratchet pawl. Specified grease : Multi purpose grease SAE J310, NLGT SS 4 of” 3. Install the parking brake cable adjuster, then adjust the parking brake lever stroke by tuming adjusting nut (A). Parking brake lever stroke : 5~7 cliks (Pull the lever with 20kg) ‘After repairing the parking brake shoe, adjust the brake shoe clearance, and then adjust the parking brake lever stroke. (Refer to "Parking brake shoe installation") Pulag up win 138 ong, <4) 4, Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are turned, Reagjust if necessary. 5. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully.Page 46 of 87 6. Reconnect the connector (A) of parking brake switch. Inspect the continuity of parking brake switch. When the brake lever is pulled : continuity When the brake lever is released : no continuity 7. Install the floor console. (Refer to Body group - "Floor console") 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 fiom the disc. 4, Rotate the toothed wheel of adjuster by a screw driver until the disc is not moving, and then retum it by 3~$ notches in the opposite direction,Page 47 of 87 Parking Brake Shoe Clearance Adjustment Drum Brake Type 1, Depress the brake pedal several times to set the self-adjusting brake For Drum Brake type, shoe clearance is automatically adjusted by the adjuster and adjusting lever. Parking Brake Lever Stoke Adjustment 1, Raise the vehicle, and make sure it is securely supported 2, Remove the floor console rear covert). 3. Adjust the parking brake lever stroke by turning adjusting nut (A). Parking brake lever stroke : 547 eliks (Pull the lever with 20kg) fier repairing the parking brake shoe, adjust the brake shoe clearance, and then adjust the parking brake lever stroke. (Refer to "Parking brake shoe installation") ~ OK \ C/oPage 48 of 87 4, Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are tumed. Readjust if necessary. 5. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully 6. Install the floor console rear covert A). Brake System > ESC(Electronic Stability Control) System > Components and Components Location ComponentsPage 49 of 87 1, HECU module 6. ESC OFF lamp 2. Yaw rate & Lateral G sensor | 7. Front wheel speed sensor 3. Parking brake/EBD waming | 8. Steering angle sensor 9. Rear wheel speed sensor 4, ABS waming lamp [Link] function / waming lamp Brake System > ESC(Electronic Stability Control) System > Description and Operation Description of ESC Optimum driving safety now has a name : ESC, the Electronie Stability Control. ESC recognizes critical driving conditions, such as panic reactions in dangerous situations, and stabilizes the vehicle by wheel-individual braking and engine control intervention.Page 50 of 87 ESC adds a futher fiction known as Active Yaw Control (AYC) to the ABS, TCS, EBD and EDC functions. ‘Whereas the ABS/TCS fiction 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 stability control feature works under all driving and operating conditions. Under certain driving conditions, the ABSVTCS function can be activated simultaneously with the ESC function in response to a commiand by the driver. In the event of a failure of the stability control function, the basic safety function, ABS, is still maintained. Driving force contre! TCs — —_ Ls E ese luni ° ae we cI — | Hel Brake force contrcl esc Drit-out Contrat oom Description of ESC control ESC system includes ABS/EBD, TCS and AYC function, ABSEBD 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 [Link], 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 funetion uses the maneuver sensor signals(Yaw Rate Sensor, Lateral Acceleration Sensor, Steering Whee] 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 faiture is detected, the ECU informs driver of the system failure through the BRAKE/ABSESC waming lamp. (fail-safe warning)Page 51 of 87 Master cylinder Prossure sensor Steering whee 7 A Master cylinder rh woven / 4 Oh Yaw-rate& lateral acceleration sensor Wheel speed Input and output diagramPage 52 of 87 Input ESC HECU Output ‘Active Wheol ‘speed sensor Hydraulic unit eo }——>)__-imergrates with HECU ‘ative Wheel speed sensor eR) }——>} ESC OFF Lamp ‘Active Wheel a speed sensor > £8C Contos eu || Waring Lamp (A3S, EBD, ESC) ‘Active Wheel ‘poe sensor — (FA) ‘ABS Control Steering Wheel Diagnosis ‘Angle sensor CAN Yaw-rate & Lateral “103 Contol neon Acceleration sensor |__| ‘unction Lamp (eso) | Wheel speed ‘sensor output Brake switch > ESCOFF switch = |») can | ecu Tou ESC Operation mode ESC Hydraulic system diagramPage 53 of 87 1. ESC Non-operation : Normal braking. Solenotd | Continuity, Valve | Mr | te-vatve valve pump IN(NO) | OFF | OPEN oFF | OFF OUuT(NC)| OFF | CLOSE 2. ESC operation Solenoid valve Continuity} Vaive | Morr | TC pump | Valve Understeering | IN(NO) | OFF | OPEN (Only inside of rearwheel) OUT(NC)| OFF | CLOSE on | ON Oversteering | IN@NO) | OFF | OPEN (Only outside of front wheel) |OUT(NC)| OFF | CLOSEPage 54 of 87 ESC iaring! ESC OFF are Pakeg aD ABS Waning lamp The active ABS waming lamp 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) - Inthe event of inhibition of ABS fnetions by failure. ~ During diagnostic mode ~ When the ECU Connector is seperated from ECU. ~ Cluster lamp is ON when communication is impossible when CAN module. EBD Parking brake warning lamp ‘The active EBD waming lamp indicates the self-test and failure status of the EBD. However, in case the Parking Brake Switch is tumed on, the EBD warning lamp is always fumed on regardless of EBD functions. The EBD waning lamp shall be on: ~ During the initialization phase after IGN ON. (continuously 3 seconds) ~ When the Parking Brake Switch is ON or brake fluid level is low. ~ When the EBD function is out of order ~ During diagnostic mode ~ When the ECU Connector is seperated from ECU. ~ Cluster lamp is ON when communication is impossible when CAN module. ESC Warning lamp (ESC system) The ESC warning lamp indicates the self-test and failure status of the ESC. The ESC waming lamp is tumed on under the following conditions ~ During the initialization phase after IGN ON. (continuously 3 seconds) - Inthe event of inhibition of ESC functions by failure, ~ During diagnostic mode ESC Funetion 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 contol is operating. (Blinking - 2Hz) ESC OFF lamp (ESC System) ~ When the driver truns off the ESC function with the on/off switeh. ESC OFF switch (ESC system) The ESC OOf Switeh shall be used to toggle the ESC fimetion between On/Off states based upon driver input. The On/Off switch shall be a normally open, momentary contact switch, Closed contacts switeh the circuit to ignition, Initial status of the ESC function is on and switch toggle the state Brake System > ESC(Electronic Stability Control) System > Schematic Diagrams Circuit Diagram - ESC (1)Page 55 of 87 Circuit Diagram - ESC (2)Page 56 of 87 Circuit Diagram - ESC (3) [Link]Page 57 of 87 ‘NHAC pst Ant Cnot) Circuit Diagram - ESC (4)Page 58 of 87 ESC Connector Input/Output sinio.o a 7/6 s\4 3/2 ‘9 24.23.22 21 2019181718 1514 0 [7/36/3634 30132 510)20128 27 26 2 Connector Terminal Specification No Description High level of wake up voltage :4.5V 6V 9_| BRAKE SWITCH Max. input current:1 < 3mA (@12.8V) 15_|BACK-UP LAMP SWITCH 22 |PARKING BRAKE SWITCH Input voltage (Low) : V <2V. Input voltage (High) : V > 6V 33. | CLUTCH SWITCH ‘Max input current : 1 < SmA (@12.8V) External pull up resistance :] KQ 6V Max. Input current : I< 10mA (@12.8V)Page 60 of 87 Brake System > ESC(Electronic Stability Control) 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 tumed off in case of ESC failure, refer to the ABS fail-safe. 4, Infomation 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. Itexecutes the checkup all the time while the [G2 power is on. Countermeasures In Fail 1, Tum the system down and perform the following actions and wait for HECU power OFF. 2. Tum 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, ESC waming lamp tum on for 3sec afier IGN ON. 2. ESC fimetion lamp blinks when ESC Act. 3. ESC OFF lamp tum on in case of [Link] Switch OFF B. 3sec after IGN ON Standard Flow of Diagnostic Troubleshooting Gathering information from customer Reocours Does not reoccur ‘Check diagnostic code [ ‘Check diagnostic code No trouble code Trouble code displayed Trouble code | No trouble displayed |code Record trouble code(s) then Erase a Basic brake system is normal or not Recheck rouble symptom Yrrenat | Norma 1 Notioubie code Refer to BA-Troubleshooting Check trouble codes te Trouble code displayed Problem is intermittent of was. Inspection chart for diagnostic trouble repaired and memory not cleared. codes Intermittent maifunction * Using the customer problem analysis check sheet for reference, ask the customer as much detail as possible about the problem. Notes with regard to diagnosis The condition listed in the following table are not abnormalPage 61 of 87 Condition Explanation System cheek 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 —_| 1. Sound of the motor inside the ABS hydraulic unit operation (witine). sound 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 _| For road surfaces such as snow-covered and gravel roads, the braking distance for vehicles (Long braking —_| with ABS can sometimes be longer than that for other vehicles. Accordingly, advise the distance) 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Page 62 of 87 Inspector's ABS Check Sheet Inspec License No. Customer's Name License Year / / VIN. Date Vehicle | Kn Brought In / / Odometer Mies Date the Problem First Occurred / / Frequency of Occurence of Problem Continuous Intermittent {times a day) | ABS does not operate ‘Symptoms | ABS does not operate etficienty. Intermittent { times a day) ‘ABS Warnin Light Abnormal |“) Remains ON } Does not light up Diagnostic Ast Time Normal Code ) Malfunction Code (Code) Trouble Code Check 2nd Time 5 Normal Code ] Malfunction Code (Code ) Problem symptoms tablePage 63 of 87 ‘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 tie hydraulic circuit for leakage. ‘ABS does not operate Only when 1.~4, are all normal and the problem is sill occurring, replace the intermittently. ABS actuator assembly. 1. Check the DTC reconfirming thatthe normal code is output. 2. Wheel speed sensor circuit, 3, Stop lamp switeh circuit, 4, Check the hydraulic cireuit for leakage, Communication with GDS is not 1. Power source circuit Possible. 2. CAN line (Communication with any system is not possible) Communication with GDS isnot | 1, Power source circuit possible. 2. CAN line (Communication with ABS only is | 3. ECU not possible) ‘When ignition key istumed ON | 1. ABS warning lamp circuit (engine OFF), 2. HECU the ABS waming lamp does not light up. Evenafier the engine is started, the | 1. ABS waming lamp circuit ABS 2. HECU ‘warming lamp remains ON. en During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is not an abnormality. ABS Does Not Operate Detecting condition Trouble Symptoms Possible Cause Brake operation varies depending on driving conditions and rond surface conditions, so diagnosis can be difficult. However if'a 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 cixeuit ~ Faulty hydraulic cireuit for leakage ~ Faulty HECU Inspection procedures DIC InspectionPage 64 of 87 1, Conneet the GDS with the data link connector and turn the ignition switch ON. 2. Verify that the normal code is output. [Link] the normal code output? WEE | Check the power source cireuit. (EI Erase the DTC and recheck using GDS. Check the power source circuit 1, Disconnect the connector from the ABS control module. 2. Tum the ignition switch ON, measure the voltage between terminal 29 of the ABS control module hamess side connector and body ground Specification: approximately B+ 3. Isthe voltage within specification? [ives] Cheek the ground circuit Pro | ‘Check the hamess or connector between the fuse (10) in the engine compartment junction block and the ABS control module. Repair if necessary. eo eck the ground circuit Disconnect the connector from the ABS control module. Check for continuity between terminals 13, 38 of the ABS control module hamess side connector and ground point. 3. Is there continuity? Check the wheel speed sensor circuit, OEE | Repair an open in the wire and ground point Check the wheel speed sensor cireuit 1. Refer to the DTC troubleshooting procedures2. Isit normal? Cheek the hydraulic circuit for leakage. Repair or replace the wheel speed sensor. Check the hydraulic cireuit for leakage Refer to the hydraulic lines Inspect leakage of the hydraulic lines. Isitnomal? Page 65 of 87 module. ‘The problem is still occurring, replace the ABS control Repair the hydraulic lines for leakage ABS Does Not Operate (intermittently). 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 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 DIC Inspection 1. Connect the GDS with the data link connector and tum the ignition switch ON. 2. Verify that the normal code is output. 3. s the normal code output? Check the wheel speed sensor circuit. Erase the DTC and recheck using GDS. Check the wheel speed sensor circuit 1 Refer to the DTC troubleshooting procedures. [Link]? Cheek the stop lamp switch eireuit, Repair or replace the wheel speed sensor. Cheek the stop lamp switch circuit 1. Check that stop lamp lights up when brake pedal is depressed and tums off when brake pedal is released.Page 66 of 87 2, Measure the voltage between terminal 23 of the ABS control module harness side connector and body ground when brake pedal is depressed. Specification : approximately B= 3. Isthe voltage within specification? ves] Check the hydraulic circuit for leakage [No | Repair the stop lamp switch, Repair an open in the wire between the ABS control module and the stop lamp switch. Cheek the hydraulic cireuit for leakage 1. Refer to the hydraulic lines. 2, Inspection leakage of the hydraulic lines. 3.[sitnormal? ‘The problem is still occurring, replace the ABS control module, = Repair the hydraulic lines for leakage, Communication with GDS is not possible. (Communication with any system is not possible) Detecting condition ‘Trouble Symptoms Possible Cause Possible defect in the power supply system (including ground) for | ~ An open in the wire the diagnosis line. ~ Poor ground ~ Faulty power source circuit Inspection procedures Check The Power Supply Circuit For The DiagnosisPage 67 of 87 1, Measure the voltage between terminal 16 of the data link connector and body ground Specification : approximately B= Te \-etifeloes s voltage within specification? Check the ground cireuit for the diagnosis. |junetion block. Repair an open in the wire, Check and replace fuse (15) from the engine compartment Check the ground eireuit for the diagnosis 1 ele? “J Ts there continuity? . Check for continuity between terminal 4 of the data link connector and body ground. Repair an open in the wire between terminal 4 of the data link connector and ground point. ‘Communication with GDS is not possible. (Communication with ABS only is not possible) Detecting condition ‘Trouble Symptoms Possible Cause ‘When communication with GDS is not possible, the cause may be | - An open in the wire probably an open in the HECU power circuit or an open in the - Faulty HECU diagnosis output circuit. ~ Faulty power source circuit Inspection procedures Check for Continuity in the Diagnosis LinePage 68 of 87 1, Disconnect the connector fiom the ABS control module. 2. Check for continuity between terminals 30 of the ABS control module connector and 8 of the data link connector. 3. Is there continuity? (EEI—Cheeck the power sourve of ABS control module. WEEE Repairan open in the wire. Check the power source of ABS control module 1. Disconnect the connector fiom the ABS control module. 2. Tum the ignition switch ON, measure the voltage between terminal 29 of the ABS control module hamess side connector and body ground, Specification : approximately B= >) S s voltage within specification? [ives] Check for poor ground ™ Check the hamess or connector between the fuse (10A) in the engine compartment junction block and the ABS control module. Repair if necessary. Check for poor ground 1. Check for continuity between terminal 4 of the data link connector and ground point. ck. Replace the ABS control module and Pro | Repair an open in the wire or poor ground. When Ignition Key Is Turned ON (engine OFF), The ABS Warning Lamp Does Not Light Up.Detecting condition Trouble Symptoms Page 69 of 87 Possible Cause ‘When current flows in the HECU the ABS waming lamp tums from (oOFF as the initial check. Therefore ifthe lamp does not light up, case nay be an open in the lamp power supply circuit, a blown, mops in the both cireuits 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 Inspection procedures Problem verification 1. Disconnect the connector from the ABS control module and tum the ignition switch ON. 2. Does the ABS waming lamp light up? (HEED | _ Inspect again after replacing the ABS HECU. WEE | Check the power souree for the ABS waning lamp. Check the power source for the ABS warning lamp 1. Disconnect the instrument cluster connector (M01) and tum the ignition switch ON. 2. Measure the voltage between terminal (M01) 40 of the cluster hamess side connector and body ground. approximately B= Pape ee s voltage within specification? EES | Cheek the CAN circuit resistance for ABS warning lamp. EEE Cheek for blown fuse. Cheek the CAN cireuit resistance for ABS warning lamp 1. Tum the ignition switch OFF. Disconnect the instrument cluster connector (MOL).Page 70 of 87 2, Measure the resistance between terminal (MO1) 35 aud 36 of the cluster hamess side connector. Specification : 60Q 3. Isresistance within specification? (EGER) Repair ABS waming lamp bulb or instrument cluster assembly. (Ee Check the CAN circuit wiring for ABS waming lamp. Check the CAN circuit wiring for ABS waming lamp 1, Tum the ignition switch OFF. Disconnect the instrument cluster connector (MO1) and ABS HECU connector. 2. Check for continuity between terminal (MO1) 35 of the cluster hamess side connector and terminal 26 of ABS HECU hamess side. Check for continuity between terminal (M01) 36 of the cluster hamess side connector and terminal 14 of ABS HECU hamess side. Specification : Below 10 3. Is resistance within specification? (BEER) Repair short circuit wiring between terminal 26, 14 of ABS HECU hamess connector and ABS ‘waning lamp module. MEE) Repair open circuit wiring between terminal 26, 14 of ABS HECU hamess connector and ABS swaming lamp module. Even After The Engine Is Started, The ABS Warning Lamp Remains ON. Detecting condition Trouble Symptoms Possible Cause Ifthe HECU detects trouble. it lights the ABS waming lamp and at | - An open in the wire the ~ Faulty instrument cluster assembly same time prohibits ABS control, The HECU then records a ~ Faulty ABS warning lamp module DIC in memory Ifthe ABS waming lamp remains ON, even after | _Faulyy HECU the problem with the DTC is repaired and cleared, then the cause ‘may be an open or short in the ABS waming lamp cireuit. Inspection procedures Check DIC Output 1, Conneet the GDS to the 16P data link connector located behind the driver's side kick panel,Page 71 of 87 2. Check the DTC output using GDS. [Link] output? mm Perform the DIC troubleshooting procedure (Refer to DTC troubleshooting). Pro | Cheek the CAN cireuit resistance for ABS warning lamp. Check the CAN circuit resistance for ABS waning lamp 1, Tum the ignition OFF. Disconnect the instrument cluster connector (MOL). 2, Measure the resistance between terminal (M01) 35 and 36 of the cluster hamess side connector, Specification : 600 aera Tess] SPEER SESS PSSST PEEP 3. Isresistance within specification? fives | Repair ABS waming lamp bulb or instrument cluster assembly. PPro | Check the CAN eireuit wiring for ABS warning lamp. Check the CAN circuit wiring for ABS waming lamp 1, Tum the ignition switch OFF. Disconnect the instrument cluster connector (M01) and ABS HECU connector. 2. Check for continuity between terminal (MO1) 35 of the cluster hamess side connector and terminal 26 of ABS HECU hamess side. Check for continuity between terminal (M01) 36 of the cluster hamess side connector and terminal 14 of ABS HECU hamess side. Specification : Below 10 3. Is there continuity? Repair short circuit wiring between terminal 26, 14 of ABS HECU hamess connector and ABS waming lamp module. {f no trouble in wiring, inspect again after replacing the ABS HECU. Pro | Repair short circuit wiring between terminal 26, 14 of ABS HECU hamess connector and ‘ABS waming lamp module.[f no trouble in wiring, inspect again after replacing the ABS HECU, 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.Page 72 of 87 1, Remove the reservoir cap and fil the brake reservoir with brake fluid en If there is any brake fluid on any painted surface, wash it off immediately. ano ‘When pressure bleeding, do not depress the brake pedal Recommended fluid....... DOT3 or DOTS 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 GDS to the data link connector located undemeath the dash panel. 44. Select and operate according to the instructions on the GDS screen. ‘You must obey the maxintam operating time of the ABS motor with the GDS to prevent the motor pump fiom t (1) Select vehicle name (2) Select Anti-Lock Brake system. (3) Select HCU air bleeding mode. ID Register © System Identification Inspection / Test ‘© HCU Air Bleeding ModePage 73 of 87 (4) Press "OK" to operate motor pump and solenoid valve. | HCU Air Bleeding Mode LABS Air Bleeding Status ] 1. Solenoid Valve Status. Close 2. Motor Pump Status: Off Press [OK ] button, if you are ready. (5) Wait 60 see. before operating the air bleeding. (Ifuot, you may damage the motor.)fier bees Page 74 of 87 LABS Air Bleeding Mode ] Now, all NC valves and pump motor are activating Depress the brake pedal to floor Release the brak pump motor activation stops. Repeat until TIME rea seconds. TIME : 05 SEC (6) Perform the air bleeding.Page 75 of 87 Patten tr [ABS Air Bleeding Mode ] Now, all NC valves and pump motor are activating Test completed !! Press (OK) button, 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(A). Front RearPage 76 of 87 6. Repeat step 5 until there are no more bubbles in the fluid for each wheel & Front ight 2 Front wt 7, Tighten the bleeder screw. Bleed screw tightening torque: 6.9~ 12.7N.m (0.7 ~ 1.3kgem, 5.1 ~ [Link]-ft) Brake System > ESC (Electronic Stability Control) System > EBD(Eleetronic Brake-foree Distribution) > 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 Maxinmum braking effectiveness by the rear wheels, It fther 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, Ifthe EBD fails, the EBD waming lamp (Parking brake lamp) lights up. Advantages ~ Function improvement of the base-brake system. ~ Compensation for the different fiction coefficients ~ Elimination of the proportioning valve. + Failure recognition by the waming lamp. Compatison between proportioning valve and EBDPage 77 of 87 [With P-Valve] [With EBD] Fixed distribution Idoal distribution _— deal distribution Rear pressure Rear prossure Cut-in point “~ eo ‘starting point Front pressure Front pressure Brake System > ESC(Electronic Stability Control System > ESC Control Module > Components and ‘Components Location ComponentsPage 78 of 87 @ @ @ Y 108 ~ 13.7 (1.4~ 114,81 10.1) 16.7 ~ 25.5 (1.7 ~26, 12.3 ~ 18.8) Torque: N.m (kgf.m, Ib-tt) 1 Front-left tube 5.MC2 2. Rear -right tube 6.MC1 3. Rearleft tube 7. ESC control module 4, Front-right tube (HECU) 8. Bracket Brake System > ESC(Electronie Stability Control) System > ESC Control Module > Repair procedures Removal 1, Tum the ignition switch OFF and disconnect the negative (-) battery cable. 2. Pull up the lock of the ABS control unit connector, then disconnect the connecter.Page 79 of 87 3. Disconnect the brake tubes from the HECU by unlocking the nuts counterclockwise with a spanner. Tightening torque: 18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgm, 13.7 ~ 16.6 Ib-ft) 4, Loosen the HECU bracket bolts and nut, then remove HECU and bracket. Tightening torque: 16.7 ~ 25.5 Nm (1.7 ~ 2.6 kgfim, 12.3 ~ 18.8 Ib-ft) 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 bolts, then remove the bracket from HECU, Tightening torque: 10.8 ~ 13.7 Nm (1.1 ~ 1.4 kgm, 8.0 ~ 10.1 Ib-ft) Installation 1 Installation is the reverse of removal. 2. Tighten the HECU mounting bolts and nuts to the specified torque. Brake System > ESC(Electronie Stability Control) System > Front Wheel Speed Sensor > Components and Components LocationPage 80 of 87 Components 1. Front wheel speed sensor cable! 2. Front wheel speed sensor Brake System > ESC(Electronie Stability Control) System > Front Wheel Speed Sensor > Repair procedures RemovalPage 81 of 87 1, Remove the ffont wheel speed sensor mounting bolt (A). Tightening torque: 6.9~10.8N.m (0.7 ~ 1.1 kgm, 5.1 ~ 8.0 Ib-ft) 2. Remove the front wheel guard. 3. Disconnect the front wheel speed sensor connector. And remove the front wheel speed sensor. 4, Installation is the reverse of removal. Inspection 1, Measure the output voltage between the terminal of the wheel speed sensor and the body ground. em In order to protect the wheel speed sensor, when measuring output voltage, a 100 resister must be used as shown. 00 12V Grane Sategan 05-150Page 82 of 87 2. Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage as shown below. LU V_low : 0.59V ~0.84V V_high : L18V~ 1.68V Frequency range : | ~ 2,500Hz Brake System > ESC(Electronie Stability Control) System > Rear Wheel Speed Sensor > Components and Components Location ComponentsPage 83 of 87 1, Rear wheel speed sensor cable 2. Rear wheel speed sensor Brake System > ESC(Electronic Stability Control) System > Rear Wheel Speed Sensor > Repair procedures RemovalPage 84 of 87 1, Remove the connector after(A) removing the rear wheel speed sensor clip. 2. Remove the rear wheel speed sensor. (Refer to Driveshaft and axle group - Rear axle assembly) 3. Installation isthe reverse of removal. Inspection 1. Measure the output voltage between the terminal of the wheel speed sensor and the body ground. ir In order to protect the wheel speed sensor, when measuring output voltage, a 100 @ resister must be used as shown. = we lye {= [Rn ~ “Se Argap 0S im 2, Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage as shown below. LU V_low : 0,59V ~ 0.84V V high : 1.18V ~1.68V Frequency range : 1 ~2,500HzPage 85 of 87 Brake System > ESC(Electronic Stability Control) System > Yaw-rate and Lateral G Sensor > Description and Operation Description When the vehicle is tuming with respect to a vertical axis the yaw rate sensor detects the yaw rate electronically by the vibration change of plate fork inside the yaw rate sensor. If yaw velocity reaches the specific velocity after it detects the vehicle’ yawing, the ESC control is reactivated. The later G sensor senses vehicle's lateral G. A small element inside the sensor is attached to a deflectable lever arm by later G. Direction and magnitude of lateral G loaded to vehicle can be known with electrostatic capacity changing according to lateral G, It interchanges signals with HECU through extra CAN line which only used for communication between HECU and sensor. a NN .s / awa 2) ) Specifications Description Specification Remarks Operating voltage 0~ 16V Output signal CAN Interface Operating temperature | -40 ~ 85°C(-40 ~ 185°) ‘Measurement 95 95° -15 ~ 15%/see ‘Yaw-rate range sensor Frequency 18 ~ 22H response Measurement 515 -15~ 15g Lateral G range sensor Frequency 50H2=60% response Extemal DiagramPage 86 of 87 (Yawsate & Lateral & Longtudinal G senscr's) ‘ures Coon Yaw-rva & Lateral ESC HECU Longitudinal G sensor Brake System > ESC (Electronic Stability Control) System > Yaw-rate and Lateral G Sensor > Repair procedures Removal 1, Tum ignition switch OFF and disconnect the negative (-) battery cable. 2. Remove the passenger seat assembly. (Refer to the Body group - "Seat") 3. Clear away the floor mat. 4, Disconnect the yaw rate & lateral G sensor connector. 5, Remove the mounting bolts (A). Tightening torque: 7.9 ~ 10.8N.m (0.8 ~ [Link], 5.8 ~ 8.01b-ft) a 6, Installation is the reverse of removal. Brake System > ESC (Electronic Stability Control) System > ESC OFF Switch > Description and Operation Description 1. The ESC OFF switch is for the user to tun off the ESC system. 2. The ESC OFF lamp is on when ESC OFF switch is engaged. Brake System > ESC(Electronic Stability Control) System > ESC OFF Switch > Repair proceduresPage 87 of 87 Inspection 1, Tum ignition switch OFF and disconnect the negative (-) battery cable. 2. Remove the lower crash pad switch assembly by using the scraper and then disconnect the connectors. Check the continuity between the switch terminals as the ESC OFF switeh is engaged, ery ps De) Brake System > ESC(Electronic Stability Control) System > Steering Wheel Angle Sensor > Description and Operation Deseription The Steering Angle Sensor (SAS) is installed in MDPS (Motor Driven Power Steering) and it sends messages to HECU through CAN communication line. The SAS is used to determine tuming direction and speed of the steering wineel The HECU uses the signals fiom the SAS when performing ESC-related calculations Components (Steering Angle Sensor, Torque Sensor, Failsafe relay, ete.) of the EPS system are located inside the steering column & EPS unit assembly and the steering column. EPS unit assembly nnust not be disassemble to be inspected. They must be replaced. (Refer to “ST (Steering system) Gr.”)