Brake System GENERAL ... - BR-2 BRAKE SYSTEM + BRO PARKING BRAKE SYSTEM .... .. BR-29 ABS (ANTI-LOCK BRAKE SYSTEM) ....BR GENERAL SPECIFICATIONS | exes BRAKE SYSTEM Master cylinder Type Tandem type LD. mm(in.) 23.81 (0.937) Fluid level warning sensor Provided Brake booster Type Vacuum Effective dia.mm(in.) Tandem type with 748 in. Boosting ratio 70:1 Proportioning valve Cut.in pressure (Split point) 2.6 MPa (26.52 kglom?, 377 psi) Decompression ratio 27:4 Front brake pe Floating type with ventilated dise Dise O.D. 257 mm (10.12 in) Disc thickness 24 mm (0.94 in) Pad thickness 11 mm (0.43 In.) Cylinder 1.0. 54 mm (2.13 in) Rear brake (Drum) . Type Leading trailing drum Drum 1.0. 203.2 mm (8 in.) Drum thickness Brake lining thickness Clearance adjustment Parking brake ‘Actuation Type Cable arrangement ©.D = Outer Diameter LD = Inner Diameter 9.4 mm (0.37 in.) 4.5 mm (0.17 in.) Automatic ‘Mechanical brake acting on rear wheels Lever V typeGENERAL SPECIFICATION (ABS) soso. Part Item Standard value Remarks ‘ABSCM ‘Operating voltage 10V - 16 | ABS, EBD Integrated control unit Operating temp 40" - 110°C Warning Lamp ABS Operating voltage tev BRAKE : Parking, Brake oll, EBD fail BRAKE (EBD) Consumption current _| 80ma Wheel Speed Sensor _| Internal resistance 1275 = 14959 “Ambient temperature Output range 15 - 2000Hz | Air gap 0.2 mm -1.2 mm Min, sensor Volt :160mV HECU (Hydraulic and | Weight 2.5 kg NO : Normal Open Electronic Control Unit) | s4otor 12V, 300 NC : Normal Close Motor power 180w LPA : Low Pressure Accumulator Pump capacity S.Scolsec HPA : High Pressure Accumulator Accumulator amount LPA:2.1¢0, HPA : 6cc Vaive NO NC Operating voltage : 12V SERVICE STANDARD Standard value Service limit Brake pedal height 178.8 mm (7.04 in.) Brake pedal stroke 4135 mm (6.31 in.) Stop lamp switch outer case to pedal stopper clearance 0.5-1.0 mm (0.02-0.04 in.) Brake pedal free play 3-8 mm (0.11-0.31in.) Booster push rod to master cylinder piston clearance 0 (at S00 mmHg vacuum) Parking brake lever stroke when lever assembly 7-8 clicks is pulled with 196N (20kg, 44lb force) Front disc brake pad thickness 11 mm (0.43 in.) 2 mm (0.08 in.) Front disc thickness (minimum ) Drum brake fining thickness Brake drum ILD. (maximum) 24 mm (0.95 in.) 4.5 mm (0.177 in) 203.2 mm (8 in.) 22.4 mm (0.88 in.) 4.5 mm (0.06 in) 205.2 mm (8.08 in.)BR-4 BRAKE SYSTEM TIGHTENING TORQUE exc Nm Kgem bit Master cylinder to booster mounting nut 842 80-120 68 Brake booster mounting nut 13:16 130-160 4012 Brake booster vacuum hose fiting to surge tank 15:18 150-180 11643 Proportioning valve mounting 3555 35:55 34 Bleeder screw 743 70-130 542 Brake tube flare nut, brake hose 19.17 190-170 to-12 Caliper guide rod bolt 22-82 220-320 16-24 Caliper assembly to knuckle 65-75 650-750 48-55 Brake hose to front caliper 25-80 250-300 18:22 AQ cauTion Replace self-locking nuts with new ones after removal. TIGHTENING TORQUE (ABS) cow = = Nm kgm Ibtt ‘Wheel speed sensor mounting bolton the brake plate Front 895 80-95 56-67 Rear 155-165 155-165, 1-12 Hydraulic & electronic contro! unit mounting bolt 840 80-100 5669 Hydraulic & electronic control unit mounting bracket bolt 940 90-100 6269 Six brake tubes on the Hydraulic Unit 16 160 12 SPECIAL TOOLS exci Tool (Number and Name) Mlustration Use 09581 - 11000 Piston expander ‘Spreading the front brake pistonGENERAL TROUBLESHOOTING cx ‘Symptom I Probable cause Remedy Noise or vibration when brakes are applied Backing plate or caliper improperly mounted Loose backing plate or caliper mounting bolts. Unevenly worn or cracked brake drum or brake disc Foreign material in brake drum Seized pad or lining contact surface Excessive caliper to pad assembly clearance Correct Retighten Replace Clean Replace Correct Uneven pad contact, Correct Lack of lubrication in sliding parts Lubricate Loose suspension parts Retighten Vehicle pulls to one side | Difference in left and right tre inflation pressure Adjust when brakes are applied improper front wheel alignment, ‘Adjust Inadequate contact of pad or lining Correct Grease or oit on pad or lining surface Replace Drum warpage or uneven wear Replace Incorrect whee! cylinder installation Correct ‘Auto adjuster malfunction Correct Insufficient braking power Low or deteriorated brake fluid Air in the brake system Brake booster matfunction Inadequate contact of pad or lining Grease or oil on pad or lining surface ‘Auto adjuster malfunction Overheated brake rotor due to dragging of pad or lining Restricted brake line Proportioning valve matfunction Refill or change Bleed the system Correct Correct Replace Correct Correct Replace Replace Increased pedal stroke required (Reduced pedal to floorboard clearance) Air in the system Brake fluid leaks Auto adjuster malfunction Excessive push rod to master cylinder clearance Bleed the system Correct Correct AdjustBR BRAKE SYSTEM ‘Symptom Probable cause Remedy Brake drag Incomplete release of parking brake ‘Agust Incorrect parking brake adjustment Adjust Worn brake pedal return spring Replace Restricted master oylinder return port Correct | Broken rear drum brake shoe return spring Replace Lack of lubrication in sliding parts Lubricate Detective master cylinder check valve or Replace piston return spring Insufficient push rod to master cylinder clearance _| Replace Insufficient parking brake | Worn brake lining or pad Replace Pee Grease oF oll on lining or pad surface Replace | Parking brake cable sticking Replace ‘Auto adjuster malfunction Adjust Excessive parking brake lever stroke ‘Adjust the parking brake lever stroke or check the parking | brake cable routing | SERVICE BRAKE PEDAL INSPECTION AND ADJUSTMENT = excox0 1. Turn the stop lamp switch until the clearance be- ‘tween the stop lamp switch outer case and pedal arm reaches the standard value, and secure the stop lamp switch withthe lock nut Clearance between pedal and stop lamp switch A= _0.5-1.0 mm (0.02-0.039 in. a BRAKE BOOSTER OPERATION TEST WITHOUT A TESTER ceo For a simple check of brake booster operation, perform the following tests. 1. Run the engine for one minute or two minutes, and then shut it off. Depress the brake pedal several times at normal foot pressure. If the pedal goes down fur- ther first but rises gradually ater the second or third ae time, the brake booster is functioning properly. If the 2. Free play of brake pedal, pedal height doesn't chango, the booster is damaged. aS 2 WRT the engine stopped. depress the brale pedal Brake pedal froo play B : several times and check the pedal height changes. 3-8 mm (0.117-0.312 in.) After that, with the pedal depressed, start the engine. If the pedal goes down slightly, the booster is in good condition. If the pedal height doesn’t change, the booster is damaged.GENERAL BR-7 3, BLEEDING THE BRAKE SYSTEM 1 With the engine running, depress 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 goes up, the booster is damaged If one of the above three tests is not okay, check the vacuum hoses and the brake booster and make any necessary corrections. If all tests are OK, the booster is good, Good No good ‘When engine's stopped | When engine is started Remove the reservoir cap and fill he brake reservoir with brake fluid. AX cauTion If there is any brake fluid on any painted surtace, wash it off immediately. Gore When bleeding pressurized fud, donot depress the brake pedal 2. Connect a vinyl tube to the wheel cylinder bleeder plug, and insert the other end of tube in the container ‘of brake fluid 3. Depress the brake pedal several times. 4, While depressing the brake pedal fully, loosen the bleeder plug until the fluid starts to run out. Then close the bleeder plug. we 5. Repeat steps 3 and 4 until there are no more bubbles in the fluid, 6. Tighten the bleeder plug screw. Bleeder screw tightening torque 3. Nm (70-130 kgf-r 0 Ib)BR-8 BRAKE SYSTEM 7. Repeat the above procedure for each wheel in the sequence shown in the illustration. ADJUSTMENT OF PARKING BRAKE STROKE excoxo 1, Pull the brake lever with a force of approx. 196 N (20 kg, 44 Ibs.) and check the number of clicks. Parking brake lever stroke (Standard value) 8 clicks 2. If the number of notches is not the standard value, agjust the cable length with the adjusting nut on the equalizer. 3. The indicator light will go out when the brake lever is fully released, and will ight up with the lever pulled ‘one notch. If it does not operate property, replace it 4. After the adjustment, check that the rear brakes do not drag with the parking brake lever released.BRAKE SYSTEM BR-9 BRAKE SYSTEM BRAKE BOOSTER COMPONENTS | exxcoico Spacer Vacuum hose levis pin 8-12 (80-120, 6-9) > Clamp Split pin Brake booster assembly TORQUE : Nm (kgf.cm, Ib-ft) REMOVAL encore 1. Disconnect the brake tube from the master cylinder, 2. Remove the master cylinder. AN caution If there is any brake fluid on any painted surface, wash it off immediately. 3. Disconnect the vacuum hose from the booster. 4, Remove the operating rod from the brake pedal. 5. Loosen the booster mounting nuts.BR -10 BRAKE SYSTEM 6, Lift cut the booster assembly. INSTALLATION | =ncot2 1. When the booster assembly is installed, replace the packing at each end of the booster mounting holder, it necessary. 2. Install the brake booster and tighten the mounting nuts. Tightening torque 18-16 Nm (130-160 kgf.cm, 10-12 Ib.tt) 3. Apply sufficient grease inside the brake pedal hole. 4, Connect the clevis to the brake pedal with the clevis, pin and install the split pin to the clevis pin. 5. Install the master cylinder and connect the brake tube to the master cylinder. 6. Connect the vacuum hose to the brake booster. 7. Fillthe brake reservoir with brake fluid and bleed the system, 8. Check for fluid leakage. 9. Check and adjust the brake pedal. 10. After installation, apply sufficient grease to contact points of the clevis and brake pedal.BRAKE SYSTEM BR-11 BRAKE LINE COMPONENTS | exxso20 [CBs] Master eylnder FR | RR mf) FL RL [ABS] | Baa booster \ Master oyndor = a (| Es Hycraule — unit { Rear whee! Font whos Uh ted Sonor ‘speed sensor aed [E=ee aBR -12 BRAKE SYSTEM INSPECTION | cose. 1. Check the brake tubes for cracks, crimps and corro- sion, 2, Check the brake hoses for cracks, damage and leak- age, 3. Check the brake tube flare nuts for damage and leak- age. INSTALLATION | ences 1, Install the brake hoses so as they do not twist. 2, The brake tubes should be installed away from edges, weld beads or moving parts. 3, Tighten the connections to the specified torque. Flare nuts : 18-17 Nm (180-170 kgFom, 10-12 Ib‘) Brake hose to front caliper : Nm (250-300 kgfom, 18-22 lb)BRAKE SYSTEM. BR -13 BRAKE PEDAL COMPONENTS | ancoiee Brake member assembly Spring switch Nut 2.53.5 (250-350, 19-26) pring washer Pedal bushing TORQUE : Nm (kgf.cm, Ib.ft) REMOVAL | encom 3. Remove the split pin and clovis pin. 1. Remove the stop lamp switch 4. Remove the flange nuts of the brake mounting bracket. 2, Remove the shift lock cable (ABS). 5. Remove the brake pedal assembly.BR-14 BRAKE SYSTEM INSPECTION crows 1. Check the bushing for wear. 2. Check the brake pedal for distortion. 8. Check the brake pedal return spring for damage. 4, Check the stop lamp switch 1) With an ohmmeter connected to the stop lamp switch terminals, check for continuity. 2) If there is no continuity when the plunger is de- pressed and there is continuity when the plunger is released, the stop lamp switch is normal. 0; Brake switch check INSTALLATION | eco 1. Installation is the reverse of removal (nore Be sure to install the split pin on the operating rod levis pin, 2. Install the brake pedal assembly and tighten the flange nuts (booster mounting nuts) and bolt. Tightening torque + 9-14 Nm (90-140 kgf.cm, 7-10 lb-ft 3. Adjust the brake pedal height and free play. 4, Install the stop lamp switch.BRAKE SYSTEM. FRONT DISC BRAKE COMPONENTS | xnomco Fo 65-75 (650-750, 48-56) NS 1 Removal order 1, Connecting tube (Brake hose and brake tube) 2. Front brake assembly 8. Brake dise TORQUE : Nm (kgf.cm, Ib.ft) BRAKE PAD exesx0 REMOVAL 1. Remove the lower bolt and lit the caliper assembly up and secure it with a wire or some other retaining method. 2. Remove the pads. AY CAUTION enna Do not depress the brake pedal while disassem- bling the pads.BR-16 BRAKE SYSTEM INSPECTION exexs0 4. Check the pads for wear or oil contamination and re- place, it necessary. A cauTion + The pads for the right and left wheels should be replaced at the same time. Never "drop" or intermix brake pad sets. + All four pads must be replaced as a complete set + When replacing the brake pad, check for de- formation. When replacing the guide spring, use a new one or the used one after cleaning away foreign material, 2, Check the pad for damage or deformation. Brake pad thickness Standard value : 11mm (0.433 in.) Service limited value : 2mm (0.0788 in.) 2mm 1mm INSTALLATION | ewox220 1. Install the pad ops. a Dore Position the pad with its pad wear indicator upward on the piston side. Guide spring Insert the piston in the cylinder using the Special Too! (09581-11000), Install the new pads. The shims are attached to the each pad as illustrated, AS cauion Be careful so that the disc or pad isn’t contami- nated by grease. shim Inner pad ais Install the bolt and tighten to the specified value. Tightening torque Guide rod bolt: 22-32 Nm (220-320 kgf-cm, 16-24 Ib)BRAKE SYSTEM CALIPER ASSEMBLY =xsar REMOVAL, 1 Remove the wheel and tire 2, Disconnect the brake hose 3. Remove the oyinder mounting bot, 4. Remove cylinder and pads. 5. Remove the caliper mounting bolts (2EA) from the koko, 6. Remove the caliper. DISASSEMBLY | exxsczn0 1. Remove the piston boot 2. Remove the piston using compressed ai, ore 1. Donot put your fingers in front ofthe piston when using compressed alr 2, Be careful not to splatter the brake fluc. 3, Remove the piston seal from the caliper by using a screwdriver. INSPECTION 1. Check the caliper for wear, damage, cracks and dust. 2. Check the piston for dust, damage, cracks and wear on the outer surface, 3. Check the sleeve and pin for damage and dust. 4, Check the pad spring and boots for damage. 5. Check the carrier for damage, dust, wear and cracks. &S caution 1. Do not use sand paper on the piston surface. 2. All rubber parts must be replaced with new parts. 6. Inspect the disc by using a calipers and a dial gauge. Thickness of dise mm (in.) Standard value : 24 (0.98) Service limit : 22.4 (0.88) Runout of the disc mm (in.) : 0.08 (0.003) Difference of thickness : 0.01mm (0.0004 in.)BR-18 BRAKE SYSTEM NOTE Using a micrometer, measure the disc thickness at eight positions approximately 10mm from the ‘outer edge of the disc and at 45° intervals. Ifyou substract the minimum of measurements from the maximum, you get the difference of the disc thickness. 2, When measuring the disc runout, fix a dial gauge ‘approximately 5mm from the outer edge of the disc, and rotate the disc 360°. At this time, if you subtract the minimum of mea- ‘surements from the maximum, you get the disc runout 7. I necessary, replace the brake disc. REASSEMBLY excoxo 1. Clean all components except the pads and shims with isopropyl! aleohol. 2. Apply rubber grease on the piston seal and install the piston seal in the cylinder. Piston piston boot 3. Assemble the piston and piston boots according to the following procedure, 1) Apply rubber grease to the caliper bore, the out- side surface of the piston and the piston boot. 2) Install the piston boot on the piston as illustrated. 3) Insert the piston boot in the inner groove of the caliper and push the piston into the caliper. 4. Assemble the sliding parts according to the following procedure. 1) Apply rubber grease to the outside surface of the sleeve and pin, pin and sleeve bore of the caliper, pin boot and sleeve boot, 2) Insert the boot into the groove of the caliper. Caliper dgo Ce Sieove Sloove side Pin side VY Pin WHBRAKE SYSTEM 5. Install the pads. Be careful so that the disc or pad is contaminated by grease Pin side ou Narrow "Wide acts Ye fy oylindor 6. Tighten the brake hose connecting bolt. Tightening torque Nm (kgf.om, lb-ft) Sliding pin 134-44 (350-450, 26-33) Sliding bott 22-31 (220-920, 16-23) Carrier mounting bolt 65-75 (650-750, 48-54) Brake hose mounting bolt 25-30 (250-300, 18-22) NOTE Check that the surface of the pin and bolts is not damaged before tightening. 2. Bleed the system. Depress the pedal several times and check for fluid leakage from all con- necting parts.BR -20 BRAKE SYSTEM MASTER CYLINDER COMPONENTS | cinoxso Ca. Reservoircap Brake ier Reservoir assombly 0 Primary piston assembly | | ‘Screw ‘Secondary piston assembly REMOVAL 1. Remove the fluid level warning device connector. 2. Detach the brake tubes from the master cylinder, and then install the plug. AN caution Painted on the surface, wash it off immediately. If there is brake fluid. ercorasa 3. Remove master cylinder mounting nuts and then lift out the master cylinder. DISASSEMBLY | excxs0 1. Remove the reservoir cap and drain the brake fluid into a suitable container. 2, Alter disconnecting the mounting screws, pry the reservoir free from the master cylinder.BRAKE SYSTEM 3. Using snap ring pliers, remove the retainer ring. 4, Remove the primary cylinder pin, pushing the primary piston with a screwdriver and remove the primary pis- ton assembly. i ovina << 5. Remove the secondary cylinder pin. Push the sec- ‘ondary piston with a screwdriver and remove the sec- ‘ondary piston assembly. NOTE Donot disassemble the primary and secondary piston assembly. ylinder pin INSPECTION 1. Check the master cyli jer bore for rust or scoring. 2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder. NOTE 1. Ifthe cylinder bore is damaged, replace the mas- ter cylinder assembly. 2, Wash the parts in alohohol REASSEMBLY | encox 1. Apply genuine brake fluid to the rubber parts of the oylinder kit and grommets. x DO 2. Carefully insert the springs and pistons in the proper sirection. 3. Press against the pistons with a screwdriver and in- stall the retainer ring,BR -22 4. With the piston pushed completely by a screwcriver, install the cylinder pin, 5. Mount two grommets. 6. Install the reservoir on the cylinder. otto oservor assembly Mounting Master ylindor INSTALLATION | essoi 1. Install the master cylinder to the brake booster. 2. Install the booster and master cylinder to the dash panel, Connect the brake tubes to the master cylinder. Install the vacuum hose tightly. Connect the operating rod to the brake pedal eon e Alter filing the brake reservoir with the brake fluid, bleed the system. AX caution Don't disassemble the brake booster. BRAKE SYSTEMBRAKE SYSTEM. PROPORTIONING VALVE PROPORTIONING VALVE The proportioning valve distributes the proper fluid pres- sure to the front and rear wheels to obtain greater braking efficiency and prevents premature rear wheel lock-up. You should not disassemble it because the performance of the valve Is closely connected with the mounting tension of the spring. PROPORTIONING VALVE FUNCTION TEST 1, Remove the proportioning valve from the master eylin- der. 2. Connect two pressure gauges; one to the input side, and one to the output side. NOTE Be sure to bleed the system after connecting the pres- sure gauges. With the brakes applied, measure the input pressure and the output pressure. If the measured pressures are within the specified range as illustrated, the pro portioning valve is good. Reconnect the brake lines in their original positions and bleed the system. nore This figure shows characteristics of the proportioning valve as the pressure incrases. STANDARD VALUE _ ‘A (40.6 # 3 kgticn) BY (66.8 + 4 kotlom®) TEMS A (80 katem?) B (140 katfom®) BR AEE ETE = atapaten aia curate a8 (Output pressurelkgtiom’) Li | ae af) a | Input pressuretkgten?) INSTALLATION OF PROPORTIONING VALVE excaseo 1. Insta the master eylinder according to the illustration. Mastoroylndor Proporioning valve 2. Tighten the flare nuts and bleed the system, Tightening torque Brake tube flare nut : 18-17 Nm (130-170 kgtom, 9-12 Ib.) Proportioning valve mounting nut : 35-55 Nm (350-560 kgf.om, 30-40 Ib.BR -24 BRAKE SYSTEM REAR DRUM BRAKE COMPONENTS | ansoo 150-60 (500-600, 37-44) Backing plate | Whee! cylinder assembly Shoe hold down pin fps Operating lever Shoe return upper spring Show hold down spring distr ae Lined shoe assembly Shoe retum lower spring Brake drum TORQUE : Nm (kgf.cm, Ib-ft) Jee /s— REMOVAL cocxs0 Av \\ Zs, 1. After removing the whee, remove the brake drum. of — ) 2, Remove the shoe return lower spring and shoe hold down spring, 3. Remove the shoes and adjuster as an assembly.BRAKE SYSTEM INSPECTION | cunts 1, Measure the inside diameter of the brake drum. Check the runout of the brake drum by using a dial indicator. Standart Service limit Inside diameter mm (in) 203.2 (8) | 205.2 (6.079) Outofround (orake | — jum) mm (in) i cane INSTALLATION | enc 1. Apply the specified grease to the locations indicated in the illustration and to each component, * Shoe and backing plate contact surfaces. * Shoe and anchor plate contact surfaces. Recommended grease Multipurpose grease SAE J310, NLGI No.2 2. Measure the brake shoe lining thickness. Standard value | Service limit Lining thickness mm (in.) 45 (0.177) | 1.5 (0.089) 2 3. Inspect the brake lining and drum for proper contact. 4. Inspect the wheel cylinder outside for excessive woar and damage. ranma 5. Inspect the backing plate for wear or damage. 3. Assemble the return spring by pressing the push rod.BR -26 BRAKE SYSTEM 1) Check the cylinder and piston for wear, damage — and dust. Shoo return upper spring 2) Check the oylinder body for damage and cracks. 3) Check the contact surface of the piston and shoes for wear. Shoe return: 4) Check the piston spring for looseness. lower sri co 8. Assembly is the reverse of removal. After assembling the drum and components, pull and (G) nore release the parking brake lever several times. 1, Clean the cylinder with Isopropyl alcohol before assembly. 2. Appl iste d REPLACEMENT OF WHEEL CYLINDER ee exec 3. Be sure to use new piston cups and dust boots. Rlomove the brake shoe. AS caumon 2, Disconnect the brake tube. Be careful not to lose the stee! ball in the bleeder. 3. Remove the wheel cylinder assembly. 4, Remove the dust boot. 5, Remove the piston and piston cup. 6. Remove the return spring. 7. Before assembling the whee! cylinder, inspect the fol- lowingPARKING BRAKE SYSTEM PARKING BRAKE SYSTEM PARKING BRAKE PARKING BRAKE | excoseo Parking brake lever — Parking brake cable REMOVAL | xrcosoe 1. Remove the rear console. 2. Loosen the adjusting nut and detach the parking brake cable. 3. Detach the parking brake switch assembly. 4. Remove the parking brake lever assembly. 5. Remove the rear wheel, 6. Remove the brake drum. 7. Detach the parking brake cable from the brake shoe.BR -28 BRAKE SYSTEM 2. Move the adjusting lever back when installing the shoe return spring 8. Remove tho parking brake cable retaining ring in the rear of the backing plate, exono.0n 3, Install the parking brake cable in the direction shown in the illustration, 98. Loosen the parking brake cable clamp and remove the parking brake cable assembly. eona0n 4, Apply the specified grease to the moving parts of the INSPECTION | exces ratchet plate and raichet pawl. 1. Check the parking brake switch operation. Specified grease : - 2. Check the parking brake lever ratchet for wear. Multipurpose grease SAE J310, NLGI No.2 3. Check the parking brake cable for wear or damage. Aer installing the cable adjuster, adjust the parking brake lever stroke. INSTALLATION | exncouo (GW nore 1. Check the parking brake cables for left and right and When pulling up the point where Is at a distance of install accordingly. 40mm from the end of the lever, adjust the adjusting nut to the lever assembly so that the lever is fixed to 7-8 notches,ABS (ANTI-LOCK BRAKE SYSTE! BR -29 ABS (ANTI-LOCK BRAKE SYSTEM) SYSTEM COMPONENT Rear wheel speed sensor HECU Master cylinder & Boostor Front wheel speed sensor The Anti-Lock Brake System (ABS) controls the hydraulic brake pressure of all four wheels during braking on haz- ardous road surfaces, preventing the wheels from locking Up. ABS provides the following benefits 1. Enables steering around obstacles with a greater de- gree of certainty, even during emergency braking. 2. Enables stopping during emergency braking while keeping stability and steerabilty even on curves. It a matfunction occurs, a diagnosis function and fail-safe system are included for serviceability. ‘The Hydraulic and Electronic Control Unit (HECU) re- ceives signals about the vehicle's speed, direction and road conditions from sensors at the wheels. Basad on these signals, the control unit will determine the optimum amount of wheel spin,BR -30 BRAKE SYSTEM BR EBD (ELECTRONIC BRAKE-FORCE ADVANTAGES DISTRIBUTION) ex = Funcinaliproverent othe basiorako system : 00, rstoadof ho proporioning ae, devers eal ds. Gampensatlon eileen ton cottons tribution of hydraulic pressure to the front and rear brakes. This prevents rear wheel lock up and provides higher brake efficiency within the range of brake application. Failure notification by warning lamp COMPARISON BETWEEN PROPORTIONING VALVE AND EBD [with P-Vaive] [With EBD] s Fixod detibton g i le dtibution : _— le dsttoton é é ~ Cutin point —~ EBD starting point Front pressure Front pressureABS (ANTI-LOCK BRAKE SYSTEM) BR-31 INSPECTION AT HECU TERMINALS | sxx TERMINAL VOLTAGE CHART Terminal No. | _ Description Condition ] Output ; * Battery power source 1 Always System voltage + Solenoid valve power source : Ground Always - In ABS control Diagnosis interface terminal (K-Line) Data tothe Hi-Sean (Pro) Wheel speed sensor (Left rear) Resistance Fe1278-1495 0 2 Wheel speed sensor (Lett front) 20 | Wheel speed sensor (Right front) 23 __| wheel speed sensor (Right rear) | 5 Wheel speed sensor (Loft rear) Wheel speed sensor (Left fron!) 19 Wheel speed sensor (Right front) 22 ___| Whoo! speed sensor (Right rear) 4 Power input via ignition 2 switch Ignition 2 condition” | High voltage detection | 16 - 20V Suspend voltage detection : 65-10 25 * Battery power source 2 Always = System voltage + Motor power source * Max. current < | 100A (time < 100 msec) + Rated current < 308 (time > 100 msec) 24 Ground - 2 (Motor) ai7 = ABS Indicator control Energized ABS relay | Max. current < 200 mA Max. voltage < 40 V 18 Brake lamp switch input terminal Input voltage threshold 1.0- 2.75 : 50 - 16.0V 37 __ | TOS warning lamp Max. current < 200mA 13 | TCS switch “ON Input voltage “1.0 - 16.0V 3 Vohiole speed signal Max. current < Toma | Extemal resistance : TOKO oF more2 DIAGRAM OF INPUT/OUTPUT FOR HECU cxcoso BRAKE SYSTEM Wheel Speed Sensors HECU ABS indicator controlABS (ANTI-LOCK BRAKE SYSTEM BR -33 COMPONENT SPECIFICATION eno : Item Content ‘Wheel sensor Type : Electromagnetic induction type | Resistance : 11000 + 50% Output range : 30 - 2000Hz Inductance : 0.7H + 50% "ABS/EBD Warning amp circuit | Type : Active ABS and EBD warning module Max. Current : I< 200mA “taNedonsGNTION 1 civ ABSIEBD eeu Sanrorsaue hay, [| Sw 7 eT, FN soy. 1 rosin | sequence pce eso wit et cn Vous Vor: Vollags of ECU so Diagnosis tester Communication type : HMC Specification ES 95620-01 Pulled up in ignition voltage by 20k°2 ecu IGN 20K. Je kineBR -34 BRAKE SYSTEM tem Content Wheel speed output Max. current : |< 10mA. ‘Output voltage : V < IGN External resistor : Must use resistance above 10k?.. veton Re soun, Brake lamp switch “Type : Contact type (Normal open) Pulled up in ignition voltage by 15k9 ay vw TCS Warning/Function Max. current : 1 < 200mA lamp circuit (Only TOS (@TCS or Ps FrC8) system) @ iABS (ANTI-LOCK BRAKE SYSTEM) EXTERNAL WIRING DIAGRAM (ABS) encss BR -35 ‘a dl 4 BRAKE SWITCH WAIN CONNECTOR [ cee £ 5 EBD ABS ‘ 2 2 WP 6 Pes oe a . wor pas |, ‘Wheel Speed Out (FA) ———FROUT_} 3 EcuBR -36 BRAKE SYSTEM EXTERNAL WIRING DIAGRAM (BTCS) cxneseo BRAKE SWITCH WAN CONNECTOR J i 28 . E 7 : Pes ‘TCS LAMP Rae: Z B ur pas | 7 Whee! Sosed Out (FA) sour |} ECU wraisensorinn Ge) )K ai snetsens on Ht wl, CONNECTORABS (ANTI-LOCK BRAKE SYSTEM) BR -37 INPUT/OUTPUT SPECIFICATION eacsoo ~___ Connector terminal I Specification Note No [Mark | Terminal name Over voltage range : 16.5 = 0.5V 130mVpp 4) & Resistance : 11008 + 50% Wheel sensor input | input range : 90 - 2000Hz : ru. | terminal Inductance : 0.7H + 50% oe Permissible offset voltage range : a Hie 2ABV < Vortset < 3.5V 2 | RR te | wip | ABS.and EBD warning | Max. current : |< 200mA lamp output terminal ~ | Saturation voltage, at | = 200mA : Veat< 1.5V jag, | Diagnosis interface | Input voltage : Vi < 0.3VBV, Vui> 0.7VBV_ 7 | Pi@a | terminal Output voltage : Vou < 0.2VeV, Vou? 0.8VeV | 8 ‘nition vottage Max. current : |< 10mA 3 | FRout | Wheel speed output | Eternal pull up resistance : above 10k"? (Open collector type) Battery power : Max. current (Inside control): 1<30A 25 | Batt | Source 1 terminal {Vato power source) _| M@% Curent (Ousiée canto : |< 20m In ABS control Max. rush current : |< 100A (< 100 msec) Battery power ° fae lee Max. current: | <30A (t> 100 msec) : Tho running time (Motor power source) | ar gy oft | Dark current : 1 < 0.5mABR -38 (BTCS) exces BRAKE SYSTEM BTCS/INPUT OUTPUT SPECIFICATION Connector terminal speciation Note Wo [Ware [Terminal name Over voltage range : 16.5 + 0.5V 120mVee oo) Mosisanco 1106 » 50% wet sensor input | Input range: 80 = 200082 > | a ternal Ineuclango 0.7 2 80% 3 rae Permissible offset voltage range : SL te 218V Vere = 88 22 RR- ve) wip | ABSand EBD warning | Max: curent: 1 <200mA famp ouput terminal "| Saturation votage, at 200m: Vag 1.8 Diagnosis nee — | Input votage: Vi <0.3VeV, i> O7VaV ; z Diag. terminal Output voltage : Vo. < 0.2VaV, Von> 0.8VeV Vo : Ignition voltage Max. caro: |< 10m 3 | FAout | Wheel speed opt | Sera pulp este : above 10k L (Open collector type) os | want |euteT ame [ax curont (ni conto) :1<308 | | 1 | Sous tera | Mo. cent Ou cont) 1 < 20a iy ABS con Max. rush current : | < 100A (t < 100 msec) Battery power : : 0 | ane [RRR EME gy [Max cient 308 > T00meee) |: Tearing tre (Motor power e000} | ae an ot Dark curent: 1< mA 65 WaringFunction ; 17, | TCS lamp lamp output Max. current : | < 200mAABS (ANTI-LOCK BRAKE SYSTEM) BLEEDING OF BRAKE SYSTEM cis This procedure should be followed to ensure adequate bleeding of air and filing of the ABS unit, brake lines and master cylinder with brake fluid. 1. Remove the reservoir cap and fll the brake reservoir with brake flu, Q cauTion if there is any brake fluid on any painted surface, wash it off immediately. NOTE When pressure bleeding, do not depress the brake pedal. Recommended fluid... DOT3 or equivalent 2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert tho other end of the tube into a half filed clear plastic bottle. 3. Connect the Hi-Scan (Pro) tothe Data Link Connector located underneath the dash panel Select and operate according to the instructions on the Hi-Scan (Pro) screen. As caution You must obey the maximum operating time of the ABS motor with the Hi-Scan (Pro) to prevent the ‘motor pump from burning. 1) Select hyundai vehicle diagnosis. INITIAL SCREEN CET 12, TOOL NOX 3, CARB ORDA DIAGNOSIS (0, FLIGHT RECORD REVIEW (0, SYSTEM SETUP, 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. LGAIR BLEEDING MODE [ADS AIR BLEEDING STATUS, 01, SOLENOID VALVE STATUS CLOSE 02, MOTOR PUMP STATUS OFF DO YOU WANT TO START? (PRESS [YES] KEY)BR -40 BRAKE SYSTEM 6) Wait 60 sec. before operating the air bleeding, (lf not, you may damage the motor) 1.6 AIR BLEEDING MODE {ABS AIR BLEEDING STATUS, (01, SOLENOID VALVE STATUS OPEN (2, MOTOR PUMP STATUS ON ‘TIME : AUTOMATIC COUNT (1-60 SEC) 5. Pump the brake pedal several times, and then loosen the bleeder screw unti fluid starts to run out without bubbles. Then close the bleeder screw. 6. Repeat step 5 until there are no more bubbles in the fluid for each wheel. 7. Tighten the bleeder screw. Bleeder screw tightening torque : 7-9 Nm (70-90 kg-om, 5:6. Ib)ABS (ANTI-LOCK BRAKE SYSTEM) BR -41 STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING | exxsc:co Gathering information from customer Reoccurs Does not reoccur Check diagnostic code Check diagnostic code No trouble code Trouble code cisplayed Trouble code | No trouble displayed code Recheck trouble code(s) then erase v Basic brake system is normal or not | Recheck trouble symptom _ ero! Normal J fe code Refer to BR-Troubleshooting | Check trouble codes t Toute code displayed Problem is intermittent or was Inspection chart for diagnostic trouble repaired and memory was not cleared} _| codes Intermittent malfunction * Using the customer problem analysis check sheetfor. NOTES WITH REGARD TO reference, ask the customer as much detail as possi- DIAGNOSIS ble about the problem. exeren ‘The phenomena listed in the following table are not abnor- mal Phenomenon Explanation System check sound When starting the engine, a thudding sound can sometimes be heard Coming from inside the engine compariment. 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 | For road surfaces such as snow-covered and gravel roads, the braking distance) 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, Pedal kick back Pedal kick back is normal operation. Diagnosis detection conditions can vary depending on the diagnosis code. When checking the trouble symptom aiter the diagnosis code has been erased, ensure that the requirements listed in "Comment" are met.BR ~42 BRAKE SYSTEM ABS CHECK SHEET como ABS Check Sheet Inspector's Name Registration No. Customer's Name Registration Year / 7 vIN. Date Vehicle Km Brought In / / Odometer in Date the Problem First Occurred 7 / Frequency of Occurence of Problem |] Continuous CJ Intermittent (times a day) ABS does not operate, ‘Symptoms ABS does not operate efficiently. C1 Intermittent (times a day) ‘ABS Warning f Light Abnormal | Remains ON Does not light up Diagnostic Ast Time 1 Normal Code 1 Malfunction Code (Code) TroubleCode = | —_____| | Check 2nd Time Normal Code (1 Malfunction Code (Code)ABS (ANTI-LOCK BRAKE SYSTEM) HI-SCAN (PRO) CHECK exaccro 4. Turn the ignition OFF. 2. Connect the Hi-Scan (Pro) to the Data Link Connector located underneath the lower crash pad panel. 3. Turn the ignition ON. 4, Use the HisScan (Pro) to check for diagnostic trouble codes. 5, After completion of the repair or correction of the prob- lem, erase the stored fault codes using the clear key con the Hi-Scan (Pro). 6. Disconnect the Hi-Scan (Pro). ABS TCS GROUND DATA LINK CONNECTOR CONNECTOR CHECK 1. Remove the negative battery (-) terminal. 2. Disconnect the connectors and check terminals fol lowing the troubleshooting procedure. When you check the terminals, be sure to use a small enough pin so as to not damage the connector termi- rls. BR -43 INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES e:ux0 Inspect according to the inspection chart that is appropri- ate for the malfunction code.= a & o 2 a wy x < & o prcon | Faiture | Failure Co Management/Detect Mode Hi-Scan (Pro}| Location | Cause (a ECM ECece as FL:C1200 | SENSOR | Shortto | The wheel velocity is below 7kmih and the offset voltage of the +3) | +3) | +4)| +3) | +3) FR:C1203 | (wiring, | GND, i permitted range (2.15-3.5V). +3) | +3) RL: C1206 | hamoss, | Short to ian 140msec. 43) | +3) RR: C1209 | exciter, | BATT, 43) | +3) ‘ABSOM) | Open FL: C1201 ‘Speed | The wheel deceleration of -100g[-25kmv/h) for 7ms] causes the - [+9 FR: C1204 Jump — | controller to start monitoring ire and to compare the wheel 43) RL: C1207 ‘velocity with the vehicle velocity from the next col. +3) AR: C1210 ‘When this decelaration of -100g is continued for more than 140msec, +3) the controller recongnizes the failure. FL: C1202 Large | This monitoring is performed for the period that the minimum velocity! - | +3) | - | +3) | +3) FR: C1205, Air-Gap | rises from 2km/h to 10kmi/h, + | 43) +3) | 43) RL: C1208 1. When the minimum wheel velocity is 2km/h andthe velocity ot | - | +3) +3) | +3) RR: C1211 other wheels exceeds 10kmih with an acceleration 20.49, - | 43) +3) | +3) the controller starts comparing the velocity of the other wheels with each other. If their difference is below 4km/h and continues for 140msec. 2. Except case 1, when the min. wheel velocity is 2kni/h and the max. wheel velocity exceeds 10km/h, the condition continues. for 20 sec. FL: C1201 Wrong | 1. Max. wheel velocity exceeds 20km/h and the wheel velocity is 40%4 +3) | +4)| 43) | 43) FR :C1204 oxciter +3) | +4)| +3) | 43) AL: C1207 2 +3) | +4)) +3) | +3) RR: C1210 43) | +4)| +3) | +3)BR -45 ABS (ANTI-LOCK BRAKE SYSTEM) orcon | Failure Chie ManagemenvDetect Mode Hi-Scan (Pro}| Location 0 AlLBl cl ole FL: C1202 | SENSOR | Long term 7 abe FR: C1205 ABS : AL: 61208 mode : RR: Ciait cate Open | When the valve relay is switched on, the reference voltage of the valvq +1) | 41) | +1) relay is outside the permitted range, and this continues for 56msec. Wiring | Short | When the valve relay is switched otf, the reference voltage of the vatnq +t) | - | = | - | aay hamess) relay is over the criterion, and this continues for 5émsec. C1604 Solenoid | Open, | 1. When the valve relay is switched off, the drain voltage of the 4 Valve | Shor, solenoid drive MOSFET is over (ABSCM, | Leakage] — for 56msec. wiring "| Current | 2. When the valve relay is switch on and the sol hamess) voltage of the solen MOSFET is under the criterion, msec. 3. When the valve relay and a solenoid are switched voltage of the solenoid drive MOSFET is over the this co S6msec, c24o2 Motor | Motor switched on, the reference voltage of the | - | 42) |42)| 22) | - Relay | Relay or n, and this continues for 4omsec. Motor | Fuse (aBscm, | Open, wiring "| Motor hamess) | Short to GND Motor +2) |+2) | 42) Lock for 49mse¢, after 1.8s0c from driving the motor off, the motor is reactivated for tsec and the above check is perfor- ain. In second check, ion for 49msec, the controller recongnizes the failure.BRAKE SYSTEM BR -46 otCon | Failure | Failure ae Managemenv/Detect Mode HiScan (Pro)} Location | Cause al BI ClLDLE 202 Motor | Motor ler starts monitoring the motor after 1.8sec from the time | +2) | +2) 42) | 42) Relay | Short tor relay is switched off. Ifthe motor voltage is over the Motor | to BATT (aBscM, wiring" | Motor jor starts monitoring the motor after 42) | 42) 42) | 42) hamess) |Open | when the motor relay is switched off. Ifthe motor voltage is outside the permitted range for 200msec. crit02 Power |Low 1. When Vign<9.4V continues for 500msec. +5) | +5) | +5)| +5) | +5) Supply | Voltage | 2. Ifthe voltage reaches more than 9.6V, the control recovers to normal state 8. When Vign<7.2V is detected during stat 4 44) | 41) | 41) | 41) | 4) 4, If the voltage reaches to more than 7.5V, the controller recovers to state 1. crtot Over 1. When Vign>16V continues for 500msec, of when Vign>18V 44) | 41) [41] 4] + Voltage | — continues for 49msec. the voltage recovers its normal operating range, the controller is reset. 1604 ‘Asscm | EEPROM | Alter the master processor writes the pre-defined data to the +1) | 4) + Failure ECU 44) | +1) J ty] +1) | + Failure NOTE The Vign means ignition voltage.ABS (ANTI-LOCK BRAKE SYSTEM) BR-47 DETECT MODE A: Intial cheok B : Outside the ABS control cycle Inside the ABS control cycle D : Diagnosis mode E : Failure mode THE ABILITY TO DETECT A FAILURE +: Deteot the failure =: Not detect the failure ‘THE MANAGEMENT OF FAILURE DETECTION 1. System down. Both the ABS and the EBD function are inhibited and the ABS andthe EBD warning lamps ate activated If this happens, the vaive relay and all solenoids are prevented from being switched on. 2. Only the ABS function is inhibited. The ABS warning lamp is activated and the EBD warning lamp is not activated. 3. Sensor failure outside the ABS control cycle. 1) Only one sensor fails : take the same action as management 2. 2) More than two sensors fail: take the same action as in management 1. 4. Sensor failure inside the ABS control cycle. 1) One front sensor fails : inhibit the ABS control of the failed-wheel and maintain ABS control of the normal wheels. After the controller completes the ABS control, take the same action as in management 2. 2) One rear sensor fails : inhibit ABS control of both front wheels and the pressure of both rear wheels is decreased. After the controller completes the ABS control, take the same action as in management 2. take the same action 3) More than two sensor fail: as in management 1 5. Low operating voltage 1) Outside the ABS control cycle : inhibit the ABS control of front wheels and allow ABS control of rear wheels, deactivating the motor. The ABS warning lamp is directly switched on. When the voltage recovers to the normal operat- ing range, enable the ABS function and the ABS warning lamp is switched off and erases the error code of low voltage. 2) Inside the ABS control cycle : inhibit the ABS control of the front wheels and allow the the ABS. control of rear wheels, deactivating the motor. The ABS warning lamp is directly switched on and remains on. The error code is always stored. Inhibit the ABS control of the front wheels and allow the ABS control of rear wheels, while deactivating the motor. (Only in motor failure). Aiter the controller completes the ABS control, take the same action as in management 2.BRAKE SYSTEM ACTUATOR DRIVING cxsoss0 el Facogson Tine o1 Motor Motor pump relay operation (Click sounds) 2 seconds: 02 | Rent a Font aslo vate operation (Chk sounds) 03 | Fett abe Front ot sled vale epoaton (Ck sounds) 04 Rear left valve (In) Rear left solenoid valve operation (Click sounds) os | rear rntvave cn) | eX QM. | nears serosa operation (ick sounds) 06 Front left valve (Out) Front left solenoid valve operation (Click sounds) 07 Front right valve (Out) Front right solenoid valve operation (Click sounds) 08 Rear left valve (Out) Rear left solenoid valve operation (Click sounds) 02 _| Rear gate (Ou) fant soln vate operation (ick sounds) CURRENT DATA esos No. Deseription Recognition Unit 1 | Battery Battery Voltage 2 | FLwheel speed SNSR | Front left wheel speed sensor kvh 3 | FRwheel speed SNSR | Front right wheel speed sensor 4 | RL wheel speed SNSR | Rear left wheel speed sensor 5 _| RRwheel speed SNSR | Rear right wheel speed sensor 6 7 8 9 [ABS SAI status Warning lamp ONIOFF Brake SW Brake switch Motor pump rolay | Motor relay | Valve relay Valve relay | 10 | Motor pump status | Motor 41 | FL valve (In) Front lft valve (In) 12. | FR valve (in) Front right valve (In) 13. | RL valve (in) Rear lett valve (In) 14 | RR vane (In) Rear right valve (In) 15 | FL valve (Ou) Front lett valve (Out) 16 | FR valve (Out) Front right valve (Out) 17 | AL vate (Ou) Rear lett valve (Out) 18 _| RR valve (Out) Rear right valve (Out)ABS (ANTI-LOCK BRAKE SYSTEM) BR -49 ANTI-LOCK BRAKE SYSTEM eivoxoo ‘SCHEMATIC DIAGRAM (1) ROT ATONOA START 2 carer eu Sata MEHR, LEFT FRONT flGiT FRONT uGHT REAR Wee Waeee ware Saison SENSOR SENSORBR -50 BRAKE SYSTEM SCHEMATIC DIAGRAM (2) ser DATA.LINK CONNECTOR round sy wor sal ‘tims JOT \gohNecroR eyesABS (ANTI-LOCK BRAKE SYSTEM) INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES | rss BR -51 DTC No. C1200, 01203, 01206, Wheel speed sensor open or short to GND circuit ©1200 Probable cause ‘The HECU determines that an open or short circuit has occured in more than one wire of a whee! * Malfunction of wheel speed sensor ‘speed sensor. ‘+ Malfunction of wiring harness or connector ‘+ Malfunction of HECU Inspect wheel speed sensor NG [> Repair installation qo Measure at the HECU connectors} E37 Replace the HECU ‘© Disconnect connector NG, J Check the following connectors. | NG, : ‘and measure from the hamess | —>| ga E39, Med, Mes [> Repair sido, © Resistance values between 1 and 2, 19 and 20, § and 6, 22 lok Check the hamess wire between and 23 No. | each wheel speed sensor and OK: 4,275 ~ 1,495 Check aymptoms oftrouble FNS} ECU, and repair if necessary OK v Inspect wheel speed sensor NG NG output votago ‘or [ [West speed sensor inspection _}—[ Replace the wheel speed sensor « lok NG. ¥ NG. Check the following connector _ | [Rotor inspection Replace the rotor loK [oK v yv ‘Check symptoms of trouble Wheel bearing inspection ING ¥BR -52 BRAKE SYSTEM DTC No, C1201, C1204, 01207, C1210 (Speed jump or wrong exciter) Probable cause ‘Abnormal output signal from a wheel speed sensor other * Improper installation of wheel than an open or short circuit. speed sensor + Malfunction of wheel speed sensor + Maifunction of rotor + Maifunction of wheel beating + Malfunction of wiring harness or connector + Malfunction of HECU Inspect wheel speed sensor [NG instalation Pe OK ‘" NG NG Inspect wheel speed sensor aes [© }[Inspect wheel speed sensor _ | [Replace the wheel speed sensor OK loK v NG ¥. NG. Check the connector [inspect rotor }-—>[ Replace the rotor [oK OK’ ¥ ¥ ok Gheck symptoms of trouble Check symptoms of rouble }—“p{ Check the hamess wire between nie each wheel speed sensor and Y HECU, and repair if necessary Replace the HECUABS (ANTI-LOCK BRAKE SYSTEM) BR -53 DTC No. 61202, 61205, 01208, C1211 (Large air gap) No wheel speed sensor output signal Probable cause ‘Malfunction of wheel speed sensor + Improper installation of wheel speed sensor Malfunction of rotor (excitor) Malfunction of wiring harness or connector + Matfunction of HECU Inspect wheel speed sensor NG . installation [> Repair (oK y Inspect air gap between wheel | speed sensor and tone wheel : Air gap : 0.2-1.2 mm Une 1* Check the following connectors E02, £39, M64, M65 (OK y Replace the HECUBR-54 BRAKE SYSTEM DTC No. C1101, C1102 Voltage out of range ey (Low and over voltage) The voltage of the HECU power supply drops lower than or ‘+ Malfunction of wiring hamess or connector rises higher than the specified value. if the voltage returns to ‘+ Malfunction of HECU. the specified value, this code is no longer output. A caution ‘output. Before carrying out the following Inspec- tion, check the battery level, and refill If neces- If battery voltage drops or rises during inspection, sary. this code will be output as well. If the voltage re- turns to the standard value, the code is no longer NG NG Measure at the HECU connector |—®{ Check symptoms of rouble | >| Check the hamess wire between E37 OK ‘each wheel speed sensor and 6 Disconnect he connector and i PHECU and repair necessary measure from the harness side © Start the engine. Voltage ek ne eee between terminal 1 and body ground OK : System voltage 1 Ne ‘Check symptoms of rouble __ | —>| Replace the HECU.ABS (ANTI-LOCK BRAKE SYSTEM) BR -55 DTC No. C1604 ECU Hardware (EEPROM and ECU failure) ee The HECU always monitors the solenoid valve drive circuit. © Malfunction of wiring harness It determines that there is an open or short-circut in the * Maifunction of hydraulic unit solenoid coil or in a harness even if no current flows in + Matfunction of HECU the solenoid or through the HECU. DTC No. C2112 Valve relay (Including fuse failure) Probable cause the valve power monitor line. If no current is detected i an open circuit and DTC C2112 is recorded. valve power monitor line, the HECU determines that there is, | When the ignition switch is turned ON, the HECU switches the + Malfunction of wiring harness or connector valve relay on and off during its initial check. During this time, voltage sent to the valve relay is compared to the voltage in Malfunction of HECU in the | NG Fuse (30A/20A) inspection J Replace the fuse OK Replace the HECUBR -56 BRAKE SYSTEM DTC No. C2402 Electrical (Motor relay, motor) Probable cause When the motor power line is normal but no signal is in * Malfunction of hydraulic unit detacted in the motor monitor line. [+ Malfunction of HECU A cavrion Powering the motor with the Hi-Scan (Pro) will dis- charge the battery. Start and run the engine for a while after testing is complete. Hi-Scan (Pro) actuator test | yES 7 igins sound ne Weise ‘Check the hamess and repair if loperating heard? necessary ys Motor power source inspection (torminal 25 of the connector 37) ye Disconnect the connector E37 |_YES Jo. Check the voltage from [> Replace the HECU terminal 25 OK : Systom voltage ye [Repair the harness or connectorABS (AN’ OCK BRAKE SYSTEM) INSPECTION CHART FOR TROUBLE SYMPTOMS | cxcexro Find out the symptom and check according to the inspec- tion procedure chart, BR -57 Trouble system Inspection procedure No. warning lamp does not illuminat 9. Communication with Hi-Scan | Communication with any system is not possible i (Pro) Is not possible Communication with ABS only is nat possible. 2 When the ignition Key is turned to “ON® (engine OFF), the ABS : Atter the engine starts, the lamp remains illuminated. Faulty ABS operation Unequal braking power on both sides Insufficient braking power ‘ABS operates under normal braking conditions ‘ABS operates before vehicle stops under normal braking conditions: Large brake pedal vibration (See Caution) QS caution During ABS operation, the brake pedal may vi- brate or may not be able to be depressed. Such Phenomena are due to intermittent changes in hy- draulic pressure inside the brake line to prevent the wheels from locking and is not an abnormal- ity.BR-58 BRAKE SYSTEM INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS | exo INSPECTION PROCEDURE 1 ‘Communication with Hi-Scan (Pro) is not possible. (Communication with all systems is not possible.) Lacing ees Possible defect in the power supply system (including ground) for the diagnosis line. Malfunction of connector Malfunction of wiring harness INSPECTION PROCEDURE 2 ‘Communication with Hi-Scan (Pro) is not possible. (Communication with ABS only is not possible.) When communication with H+Scan (Pro) is not possible, the cause may be probably an open circuit in the HECU power circuit (oF an open circuit in the diagnosis output circult Probable cause Blown fuse Maifunction of wiring harness or connector Matfunction of HECU NG. NG, Measure the resistance between DL ‘Check the following connector and HECU connector E37,Terminal 7[ > | EMoa foe (© Disconnect the connector and ‘© Continuity between the follow- Ng. [Check the harness between the ing terminals [Check symptoms of trouble |} | HECU and diagnosis connector, between terminal 7 on HECU and repair if necessary ‘side and terminal 1 on DLC side OK : continuity yx Measure the resistance HECU og, [ Oaeek the Ramess between sed connector E37 NG, NG, } EA) inside the junction block © Disconnect the connector and Check symptoms of trouble ‘and HECU, and repair if neces- measure at the harness side. sary 6 Ignition switch ON Voltage between terminal 1 andl body ground. OK : System voltage eK Measure the resistance HECU connector E37 ‘© Disconnect the connector and measure at the hamess side. ‘© Continuity between terminal 18 and body ground. OK = Continuity y* (Check the following connector €47 | —p Repair «x Na [Check symptoms of rouble }-—P[ Replace the HECU NG. |» RepairABS (AN INSPECTION PROCEDURE 3 OCK BRAKE SYSTEM) [ When ignition Key is turned "ON" (engine OFF), the ABS [warming lamp does not illuminate Probable cause ‘When current flows in the HECU, the ABS relay turns from on . to off as the initial check. The ABS warning lamp wil iluminate . when the ABS relay is off even if there is a problem with the . circuit between the ABS warning lamp and the HECU. Therefore, if the lamp does not illuminate, the cause may be an open circuit in the lamp power supply circuit, a blown bulb, an open circuit in both the circuits between the ABS warning lamp and the HECU, and in the circuit between the ABS warning lamp and the ABS relay. Blown fuse Burnt out ABS warning lamp bulb Malfunction of wiring harness or connector Fuse (10A) inspection * OK : Iluminates fo« Check the hamess. Repair, if necessary ‘Measure the resistance at NG, I Check whether the ABS waming [NG Replace the ABS warning lamp connector MO9-3 (W/O Trip com- lamp bulb fe bumt out bulb puter) oF M10-1 (With Trip com- OK Pater) A © Disconnect the connector and Ghack the connactors > Repair measure at the pin. o Boosie ASS ring ap ag iluminate when terminal(6) is NG ‘grounded? ‘Check symptoms of rouble __ | —®[Replace the combination meterBR -60 BRAKE SYSTEM INSPECTION PROCEDURE 4 Even after the engine is started, the ABS warning Probable cause lamp remains illuminated A possible short-circuit in the ABS warning lamp illumination circuit |» Matfunction of combination meter * Matfunction of HECU + Malfunction of wiring harness: This trouble symptom is limited to cases where com- munication with the Hi-Scan (Pro) is possible (HECU power supply is normal) and DTC is normal. Disconnect connector M09-3 (W/O Trip computer) or | veg M10-1 (With Trip computer) and turn the ignition |“ Sy Replace the combination meter ‘switch ON © Does the ABS waning lamp remain illuminated? NO y ‘0 Disconnect HECU connector E37 YES © Ignition switch : ON |-—>| Replace the HECU © Does the ABS warning lamp switch off ? NO y Check the hamesses between the combination meter| and the HECU, and between the combination meter and the ABS relay. Repair, if necessaryABS (AN INSPECTION PROCEDURE 5 OCK BRAKE SYSTEM) BR -61 Brake operation is abnormal Probable cause: Brake operation varies depending on driving conditions and road surface conditions, so diagnosis can be difficult. However, if a normal DTC is displayed, carry out the following inspection. Inspect wheel speed sensor | NG, installation yo« Inspect wheel speed sensor output voltage o« Hydraulic unit inspection speed sensor * Incorrect sensor harness contact + Foreign material on whee! speed sensor [—> Repair © Improper installation of whee! * Malfunction of wheel speed sensor * Malfunction of rotor ‘+ Malfunction of whee! bearing ‘+ Malfunction of hydraulic unit ‘+ Matfunction of HECU NG. NG. |** }[[inspect wheel speed sensor} >| Replace the wheel speed sensor eK NG. Inspect rotor | [Replace the rotor (or exciton) yx NG. Inspect wheel bearing |» Repair er (Check the following connectors | NG. E02, E39, M64, M65 ea! ye« Check symptoms of trouble We Measure the resistance at HECU | OK ‘connector E37 [> Repair © Disconnect the connector and ‘measure at the hamess side © Resistance value between ter- minals 1-2, 19-20, 5-6 and 22-2 OK: 1275-14950 (The sensor hamess and con- nector should be moved around \while these measurements are cartied out to detect intermittent connections.) ag A OK, [Gheck the folowing connector EST] OK, eK ok [Check symptoms of rouble }- [Replace the HECUBR -62 BRAKE SYSTEM ABS OPERATION CHECK WHEEL SPEED SENSOR OUTPUT VOLTAGE CHECK 1, Raise the vehicle and release the parking brake. 2. Disconnect the HECU harness connector’s and mea- ‘sure from the harness side connector. & caution Be sure to remove the connector’s double lock and insert the probe into the harness side (back- probe). Inserting it into the terminal side may re~ ‘sult in a bad connection. 3. Rotate the wheel to be measured approximately 1/2. to 1 rotation per second, and check the output voltage using a circuit tester or an oscilloscope. Wheel | Front | Front | Rear speed Rear left sorsor | left | tight right 8 22, 4 19 Terminal 9 23 5 20 Output voltage : When measuring with an oscilloscope : 100mV peak-to-peak or more ANTI-LOCK BRAKING SYSTEM CONTROL MODULE COMPONENTS | excsox TORQUE : Nm (kg-em, tb-ft)ABS (ANTI-LOCK BRAKE SYSTEM) REMOVAL | exoscseo INSTALLATION | eoses0 41, Disconnect the brake tubes from the HECU. 1. Installation is the reverse of removal. 2. Tighten the modulator mounting botts and brake tube nuts to the spectied torque. Tightening toque : HECU mounting bolt 8-10 Nm (80-100 kgrem, 5.6-6.9 Ib) Brake tube nut 13417 Nm (130-170 kgrom, 9-12 Ibi) 2, Remove the HECU bracket mounting bolt and rernove the HECU, QS caution 1. Never attempt to disassemble the HECU. 2. The HECU must be transported and stored in an upright position and with the ports sealed. The HECU must not be drained. 3. Disconnect the HECU (Hydraulic and Electronic Con- trol Unit) and motor connector.BR -64 BRAKE SYSTEM BR ANTI-LOCK BRAKING SYSTEM WHEEL SPEED SENSOR COMPONENTS | xcsi00 ‘Tone whee! Front wheel speed sensor 82-97 (82-97, 5.7.6.8) Rear wheel speed sensor 8.2-9,7 (82-97, 5.7-6.8) ‘TORQUE : Nm (kg-om, Ib-ft) REMOVAL | exon FRONT WHEEL SPEED SENSOR 1. Remove the front wheel speed sensor mounting bolt, REAR WHEEL SPEED SENSOR 1. Remove the rear seat cushion, 2. Remove the rear pillar trim assembly. Eusoors 3, Romove the tire assembly. 2. Remove the front wheel speed sensor after discon- necting the wheel speed sensor connector.ABS (ANTI-LOCK BRAKE SYSTEM) 4, Remove the rear wheel speed sensor after discon- nection the wheel speed sensor connector. INSPECTION | exwono 1. Connect an ohmmeter between the wheel speed sen- sor terminals and measure the resistance. Service standard 275 - 14950. Rear: 1275 - 14950 Front 2, Connect a voltmeter between the wheel speed sen- sor terminals and measure the voltage by turning the wheel (nore Set the voltmeter to measure AC voltage. Service standard : AC voltage detected. BR -65