Brake System

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SPORTAGE(KM) > 2009 > G 2.0 DOHC > Brake System
Brake System > General Information > Special Service Tools

SPECIAL TOOL
TOOL(Number and Name) ILLUSTRATION USE
09581-11000 Spreading the front disc brake piston
Piston expander
Brake System > General Information > Troubleshooting

TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Symptom Suspect Area Reference
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Lower pedal or 1. Brake system (Fluid leaks) repair
spongy pedal 2. Brake system (Air in) air·bleed
3. Piston seals (Worn or damaged) replace
4. Rear brake shoe clearance(Out of adjustment) adjust
5. Master cylinder (Faulty) replace
Brake drag 1. Brake pedal freeplay (Minimum)

adjust
2. Parking brake lever travel (Out of adjustment) adjust
3. Parking brake wire (Sticking) repair
5. Pad or lining (Cracked or distorted) replace
6. Piston (Stuck) replace
7. Piston (Frozen) replace
8. Anchor or Return spring (Faulty) replace
9. Booster system (Vacuum leaks) repair
replace
10. Master cylinder (Faulty)
Brake pull 1. Piston (Sticking) replace
2. Pad or lining (Oily) replace
3. Piston (Frozen) replace
4. Disc (Scored) replace
Hard pedal but brake 1. Brake system (Fluid leaks)

repair
inefficient 2. Brake system (Air in) air·bleed
3. Pad or lining (Worn) replace
6. Pad or lining (Oily) adjust
7. Pad or lining (Glazed) replace
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8. Disc (Scored)
9. Booster system (Vacuum leaks) repair
Noise from brake 1. Pad or lining (Cracked or distorted)

replace
2. Installation bolt (Loosen) adjust
4. Sliding pin (Worn) replace
5. Pad or lining (Dirty) clean
6. Pad or lining (Glazed) replace
7. Anchor or Return spring (Faulty) replace
8. Brake pad shim (Damage) replace
9. Shoe hold-down spring (Damage) replace
Brake fades replace

1. master cylinder
1. brake booster replace

2. pedal free play adjust
Brake vibration, replace
3. master cylinder
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pulsation replace
4. caliper
replace
5. master cylinder cap seal replace
6. damaged brake lines
Brake chatter is usually caused by loose or worn components, or
glazed or burnt linings. Rotors with hard spots can also contribute to
Brake Chatter 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 > General Information > Specifications

SPECIFICATIONS
Item Specification
Master cylinder
· Type Tandem type
· I.D. mm(in.)(CBS/ABS) 23.8 / 25.4(0.937 / 1.0)
· Piston stroke mm(in) 30 ~ 32(1.18 ~ 1.26)
· Output port(CBS/ABS) 4port / 4port
· Fluid level warning sensor Provided
Proportioning valve
· Cut-in pressure(Split point) 15 Kgf /cm²
· Decompression ratio 0.27 : 1 (2WD)
0.32 : 1(4WD)
Brake booster
· Type Vacuum
· Effective dia. mm(in.) 8+9 in
· Boosting ratio 9:1
Front brake(Disc)
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· Type Floating type with ventilated disc
· Disc O.D. 280 mm(11.02 in)
· Disc I.D. 172 mm (6.77 in.)
· Disc thickness 26 mm(1.02 in)
· Pad thickness 11 mm(0.43 in)
· Cylinder type single piston
· Cylinder I.D. 60 mm (2.36 in.)
Rear brake(Disc)
· Type Floating type with solid disc
· Disc O.D. (2WD/4WD) 262 / 284 mm (10.31 / 11.18 in.)
· Parking Brake Drum I.D 190 mm(7.48 in.)
· Disc thickness 10 mm (0.39 in.)
· Pad thickness 10 mm (0.39 in.)
· Cylinder type single piston
· Cylinder I.D 34 mm (1.34 in.)
Parking brake
· Type V type
· Actuation Mechanical brake acting on rear wheels
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· Cable arrangement Lever
O.D=Outer Diameter
I.D=Inner Diameter
CBS : Conventional Brake System

SPECIFICATION(ESC)
Part Item Standard value Remark
4 Channel 4 Sensor
System
(MGH-40)
Motor, valve relay
Type
intergrated type Total control
HECU
Operating Voltage 10 ~ 16 V (ABS, EBD, ESC)
-40 ~ 110 °C (-40 ~ 230
Operating Temperature
°F)
Motor power 240 W
Min. Operating Voltage 12 V
Warning lamp
Max. Current consumption 80 mA
Supply voltage DC 6 ~ 16 V
Output current low 5.9 ~ 8.4 mA Typ. 7 mA
Active Wheel speed sensor
Output current high 11.8 ~ 16.8 mA Typ. 14 mA
(ABS)
Output range 1 ~ 2000 Hz
Tone wheel 48 teeth
Operating Voltage 9 ~ 16 V
Operating Angular velocity Max. 1500 °/sec
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-30 ~ 75 °C (-22 ~ 167
Operating temperature
Steering Wheel Angle °F)
Sensor Max Consumption Current 100 mA
Max Output Current 10 mA
Max Output Absorption
50 mA
Current
Operating Voltage 8 V ~ 17 V
Current Consumption Max. 140 mA
-40 ~ 85 °C (-40 ~ 185
Yaw rate & Operating Temperature
°F)
Lateral G sensor
(CAN TYPE) Yaw rate sensor
± 75 °/sec
measurement range
Lateral G sensor
± 1.5 g
measurement range
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SERVICE STANDARD
Standard value Service limit
Brake pedal height 163mm( 6.42 in.)
Brake pedal full stroke 128 mm (5.04 in.)
Brake pedal free play 3~8mm(0.11~0.31in.)
Brake pedal to floorboard clearance 82mm( 3.23 in.)
Stop lamp switch outer case to pedal stopper
1.2 ~ 1.7mm(0.047 ~ 0.067in.)
clearance
Booster push rod to master cylinder piston
0 (at 500 mmHg vacuum)
clearance
Parking brake lever stroke when lever assembly is
7~8 clicks
pulled with 196N (20Kgf, 44lb force)
Front disc brake pad thickness 11 mm (0.43 in.) 2 mm (0.079 in.)
Front disc thickness (minimum) 26 mm (1.02 in.) 24.4 mm ( 0.961in.)
Front disc runout Max.0.03 mm ( 0.001in.)
Front disc thickness variation Max.0.005 mm (0.0002in.)
Rear drum brake lining thickness 4.5 mm (0.177 in.) 1.0 mm (0.039 in.)
Rear drum brake drum I.D. 228.6 mm (9 in.) Max.230.6mm (9.079 in.)
Rear disc brake pad thickness 10 mm (0.394 in.) 2 mm (0.079 in.)
Rear disc brake disc thickness 10 mm (0.394 in.) 8 mm (0.315 in.)
Rear disc runout Max.0.03mm ( 0.001in.)
Max.0.005 mm (
Rear disc thickness variation
0.0002in.)
TIGHTENING TORQUE
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Item Nm Kgf·cm lb-ft
Proportioning valve to master cylinder 34.30~53.90 350~550 25.45~39.99
Master cylinder to booster mounting nut 7.84~11.76 80~120 5.82~8.72
Brake booster mounting nut 12.74~15.68 130~160 9.45~11.63
Brake booster vacuum hose fitting to surge tank 14.70~17.64 150~180 10.91~13.09
Bleeder screw 6.86~12.74 70~130 5.09~9.45
Brake tube nut, brake hose 12.74~16.66 130~170 9.45~12.36
Caliper assembly to knuckle 78.40~98.00 800~1000 58.2~72.7
Brake hose to front caliper 24.50~29.40 250~300 18.18~21.81
Brake hub flange nut 196.00~254.80 2000~2600 145.4~189
Push rod locking nut 15.68~21.56 160~220 11.63~15.99
Caliper guide rod bolt 21.56~31.36 220~320 15.99~23.26
TIGHTENING TORQUE (ESC)
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Item Nm kgf·cm Ib-ft
Active wheel speed sensor mounting
bolt on the brake plate
·Front 7.84~8.82 80~90 5.82~6.54
·Rear 7.84~8.82 80~90 5.82~6.54
Hydraulic & electronic control unit
7.84~8.82 80~100 5.82~7.27
mounting bolt
Hydraulic & electronic control unit
16.66~25.48 170~260 12.36~18.9
mounting bracket bolt
Brake tubes nut 11.74~16.66 130~170 9.45~12.36
Air bleeder screw 6.86~12.74 70~130 5.09~9.45
Yaw rate & lateral acceleration sensor
7.84~10.78 80~110 5.82~8.0
Nut
Steering wheel nut 39.2~49 400~500 29.1~36.4
Master cylinder pressure sensor 22.09~26.13 224~265 16.29~19.27
Brake System > Brake System > Repair procedures

Operation and Leakage Check
Check all of the following items:
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Component Procedure
Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes do
not work properly, check the brake booster. Replace the brake booster as an
assembly if it does not work properly or if there are signs of leakage.
Piston cup and pressure • Check brake operation by applying the brakes. Look for damage or signs of fluid
cup inspection (B) leakage. Replace the master cylinder as an assembly if the pedal does not work
properly or if there is damage or signs of fluid leakage.
• Check for a difference in brake pedal stroke between quick and slow brake
applications. Replace the master cylinder if there is a difference in pedal stroke.
Brake hoses (C ) Look for damage or signs of fluid leakage. Replace the brake hose with a new one if
it is damaged or leaking.
Caliper piston seal and Check brake operation by applying the brakes.
piston boots (D) Look for damage or signs of fluid leakage. If the pedal does not work properly, the
brakes drag, or there is damage or signs of fluid leakage, disassemble and inspect the
brake caliper. Replace the boots and seals with new ones whenever the brake caliper
is disassembled.
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Wheel cylinder piston cup Check brake operation by applying the brakes.
and dust cover (E) Look for damage or signs of fluid leakage. If the pedal does not work properly, the
brakes drag, or there is damage or signs of fluid leakage, replace the wheel cylinder.
BRAKE BOOSTER OPERATING TEST

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

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

PEDAL HEIGHET
1. Disconnect the brake switch connector, loosen the brake switch locknut (A), and brake off the brake switch (B)
unil it is no longer touching the brake pedal.
2. Lift up the carpet. At the insulator cutout, measure the pedal height (C) from the middle of the left-side center of
the pedal pad (D).
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Standard pedal height( with carpet removed): 163mm(6.41 in.)
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3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from
the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod
depressed.
BRAKE SWITCH CLEARANCE

Screw in the brake switch until its plunger is fully depressed (threded end (A) touching the pad (B) on the pedal
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arm) then adjust the switch 3/4 turn to until clearance between the brake switch connector. Make sure that the
brake lights go off when the pedal is released.
PEDAL FREE PLAY

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1. With the engine off, inspect the pedal free play (A) on the pedal pad (B) by pushing the pedal by hand.
Free play: 3 ~ 8 mm (0.11 ~ 0.31 in.)
2. If the pedal free play is out of specification, adjust the brake switch (C). If the pedal free play is insufficient, it
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may result in brake drag.
INSPECTION OF FRONT DISC BRAKE PAD
1. Check the brake pad thickness through the caliper body inspection hole
Pad thickness
Standard value : 11.0 mm ( 0.43 in.)
Service limit : 2.0 mm (0.0787 in.)
• If the pad lining thickness is out of specilfication, left and right pads must be replaced as a complete set.
• When the thickness difference between the left pad and right pad is large, check the sliding condition of
the piston and the guide rod.
INSPECTION OF REAR DISC BRAKE PAD

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1. Check the rear disk brake pad thickness through the caliper body inspection hole.
Pad thickness
Standard value : 10.0 mm (0.39 in.)
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• If the pad thickness is out of specification, left and right pads must be replaced as a complete set.
• When the thickness difference between the left pad and right pad is large, check the sliding condition of
the piston and the guide rod.
Brake System > Brake System > Brake Booster > Components and Components Location
COMPONENTS
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Brake System > Brake System > Brake Booster > Repair procedures
Removal
1. Remove the master cylinder.
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2. Disconnect the vacuum hose (A) from the brake booster (B).
3. Remove the snap pin (A) and pin (B).
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4. Remove the four booster mounting nuts (C).
5. Remove the brake booster (A).
INSTALLATION
1. Adjust push rod length of the booster, and then install the seal on the booster assembly.
Standard length (A): 106 ± 0.5 mm ( 4.173 ± 0.019 in.)

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1. Insert the booster and tighten the nuts (C).
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2. Connect the booster push rod and brake pedal with a pin (B) and install a snap pin (A) to the pin (B).
Grease the pin before installing the snap pin.

Always use a new snap pin.
3. Install the master cylinder.

4. Connect the vacuum hose to the brake booster.
5. After filling the brake reservoir with brake fluid, bleed the system.
6. Check for fluid leakage.
7. Check and adjust the brake pedal for proper operation.
Brake System > Brake System > Master Cylinder > Components and Components Location
COMPONENTS
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Brake System > Brake System > Master Cylinder > Repair procedures
REMOVAL
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.
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1. Remove air cleaner mounting bolts (B) from the air cleaner mounting bracket and air cleaner body (A).
2. Disconnect the brake fluid level switch connectors (A), and remove the reservoir cap (B).
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3. Remove the brake fluid from the master cylinder reservoir (C) with a syringe.
4. Disconnect the brake lines (A) from the master cylinder. To prevent spills, cover the hose joints with rags or shop
towels.
5. Remove the master cylinder mounting nuts (B) and washers.

6. Remove the master cylinder(C) from the brake booster (D). Be careful not to bend or damage the brake lines
when removing the master cylinder.
INSTALLATION
1. Install the master cylinder on the brake booster with 2 nuts.
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2. Connect 2 brake tubes(A) and the brake fluid level sensor connector.
3. Fill the brake reservoir with the brake fluid and bleed the brake system.
DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.
2. Remove the fluid level sensor.
3. Remove the reservoir from the master cylinder, after remove mounting screw (A).
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4. Remove the proportioning valves (A) - CBS only.
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5. Remove the retainer ring by using the snap ring pliers then remove the primary piston assembly.
6. Remove the pin with the secondary piston pushed completely using a screwdriver. Remove the secondary piston
assembly.
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Do not disassemble the primary and secondary piston assembly.
INSPECTION
1. Check the master cylinder bore for rust or scratch.
2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.
• If the cylinder bore is damaged, replace the master cylinder assembly.

• Wash the contaminated parts in alcohol.
REASSEMBLY
1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
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2. Carefully insert the springs and pistons in the proper direction.
3. Press the piston with a screwdriver and install the cylinder pin.
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4. Press the piston with a screwdriver and install the retainer ring.
5. Mount two grommets.

6. Install the reservoir on the cylinder.
Brake System > Brake System > Proportioning Valve > Description and Operation
DESCRIPTION
Do not disassemble the proportioning valve. The proportioning valve makes the ideal distribution of fluid pressure to
the front and rear brakes to prevent the brakes from skidding in the event of rear wheel lock up and to obtain a
higher brake efficiency within the range of service brake application.
Brake System > Brake System > Proportioning Valve > Repair procedures
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INSPECTION
1. Remove the front brake tube (B) and rear brake tube (C) from the master cylinder (A).
2. Connect two pressure gauges (D); one to the output valve of the front (B) and rear (C) brake.
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Be sure to bleed the system after connecting the pressure gauges.
3. With the brake applied, measure the front pressure and the rear pressure.
If the measured pressures are within the specified range as illustrated, the proportioning valve is good.
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4. Reconnect the brake lines in their original positions and bleed the system.
This table shows characteristics of the proportioning valve as the pressure

increases.
2WD
Front Rear
A : 15 kg/cm² A' : 15 kg/cm²
(1.47 MPa, 213 psi) (1.47 MPa, 213 psi)
B : 80 kg/cm² B' : 35.8 ± 3 kg/cm²
(7.84 MPa, 1137 psi) (3.51 ± 0.3 MPa, 509 ± 42 psi)
4WD
Front Rear
A : 15 kg/cm² A' : 15 kg/cm²
(1.47 MPa, 213 psi) (1.47 MPa, 213 psi)
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B : 80 kg/cm² B' : 32.5 ± 3 kg/cm²
(7.84 MPa, 1137 psi) (3.19 ± 0.3 MPa, 462 ± 42 psi)
Brake System > Brake System > Brake Line > Components and Components Location
COMPONENT
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Brake System > Brake System > Brake Line > Repair procedures
REMOVAL
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1. Disconnect the brake hose(C) from the brake line(A) using a 10mm flare-nut wrench(B).
2. Remove the brake hose clip(A) from the brake hose(B).
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3. Remove the connector bolt from the caliper(C), and disconnect the brake hose from the caliper.
INSTALLATION
1. Install the brake hose(A) on the knuckle with 12mm flange bolt (B) first, then connect the brake hose to the
caliper with the connector bolt (C) and new sealing washers (D).
2. Install the brake hose (A) on the upper brake hose bracket (B) with a new brake hose clip (C).
3. Connect the brake hose (D) to the brake line.

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4. After installing the brake hose, bleed the brake system.
INSPECTION
• Check the brake tubes for cracks, crimps and corrosion.
• Check the brake hoses for cracks, damaged and oil leakage.
• Check the brake tube flare nuts for damage and oil leakage.
INSPECTION
• Check the brake tubes for cracks, crimps and corrosion.
• Check the brake hoses for cracks, damaged and oil leakage.
• Check the brake tube flare nuts for damage and oil leakage.
Brake System > Brake System > Brake Pedal > Components and Components Location
COMPONENTS
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Brake System > Brake System > Brake Pedal > Repair procedures
INSPECTION
1. Check the bushing for wear.
2. Check the brake pedal for bending or twisting.
3. Check the brake pedal return spring for damage.
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4. Check the stop lamp switch
(1) Connect a circuit tester to the connector (1-2terminals) of stop lamp switch, and check whether or not there
is continuity when the plunger of the stop lamp switch is pushed in and when it is released.
(2) The stop lamp switch is in good condition if there is no continuity when plunger is pushed.
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REMOVAL
1. Remove the lower crash pad.(reference to BD-"crash pad")
2. Pull down steering column shaft after removing 4 bolts.
3. Remove the stop lamp switch connector (A).
4. Remove the shift lock cable (A/T).
5. Remove the pin and snap pin.

6. Loosen the brake pedal member assembly mounting nuts and then remove the brake pedal assembly.
INSTALLATION
1. Installation is the reverse of removal.
Coat the inner surface of the bushings with the specified grease.
Specified grease:Chassis grease MS 511-3

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2. Before inserting the pin, apply the specified grease to the joint pin.
3. Install the nuts with specified torque, when installing the brake pedal.
TORQUE : Nm(Kgf·cm,lb-ft); 12.74 ~ 15.68(130 ~ 160, 9.45 ~ 11.63)
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4. Adjust the brake pedal height and free play.
5. Install the stop lamp switch.
Brake System > Brake System > Front Disc Brake > Components and Components Location
COMPONENTS
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Brake System > Brake System > Front Disc 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 on air hose or brush to clean brake assemblies.
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1. Lossen the front wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported.
Remove the front wheels.
2. Remove the guide rod bolt(B), After raise the caliper assembly(A), support it with a wire.
3. Remove pad shim(A), pad retainer(B) and pad assembly(C) in the caliper bracket.
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INSTALLATION
1. Install the pad retainers (A) on the caliper bracket.
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2. Check the foreign material at the pad shims (A) and the back of the pads (B).
Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
3. Install the brake pads (B) and pad shims (A) correctly. Install the pad with the wear indicator (C) on the inside.
If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss
of braking efficiency.
4. Push in the piston (A) so that the caliper will fit over the pads. Make sure that the piston boot is in position to
prevent damaging it when pivoting the caliper down.
5. Pivot the caliper down into position. Being careful not to damage the pin boot, install the guide rod bolt (B) and
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torque it to proper specification.
Insert the piston in the cylinder using the special tool (09581-11000).
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6. Depress the brake pedal several times to make sure the brakes work, then test-drive.
Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been
replaced as a set.Several applications of the brake will restore the normal pedal stroke.
Be sure to do this before driving the vehicle.
7. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
INSPECTION
FRONT BRAKE DISC THICKNESS CHECK
1. Remove all rust and contramination from the surface, and measure the disc thickness at 8 points, at least, of same
distance (5 mm) front the brake disc outer circle.
Front brake disc thickness

Standard value : 26.0 mm(1.024 in.)
Limit : 24.4 mm(0.961 in.)
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2. Thickness variation should not exceed 0.005 mm (0.0004 in.) (circumference) and 0.01 mm ( in.)(radius) at any
directions.
3. If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
FRONT BRAKE PAD CHECK

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1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Pad thickness
Standard value : 11 mm (0.43 in.)
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2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
FRONT BRAKE DISC RUN OUT CHECK
1. Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the run out
of the disc.
Brake disc run out

Limit : 0.1 mm (0.004 in.) or less
Extremly tight specification : 0.04 mm (0.0016 in.)
2. If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out
again.
3. If the run out does not exceed the limit specification, install the brake disc after turning it 180° and then check the
run out of the brake disc again.
4. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc.
Seize of Front brake disc

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1. Remove the brake disc from hub using M8 screw(A) if the brake disc has been seized with the hub due to
corrosion or overheat.
Be careful not to use the hammer. The disc can be damaged if you remove the disc from the hub by
hammer.
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Brake System > Brake System > Rear Disc Brake > Components and Components Location
COMPONENTS
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Brake System > Brake System > Rear Disc Brake > Repair procedures
REMOVAL
1. Raise the rear of the vehicle and make sure it is securely supported. Remove the rear wheel.
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2. Remove the guide rod bolt(B), After raise the caliper assembly(A), support it with a wire.
3. Remove pad shim(A), pad retainer(B) and pad assembly(C) in the caliper bracket.
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INSTALLATION
1. Install the pad retainers(A) on the caliper bracket.
2. Check the foreign material at the pad shim (A) and the back of the pads (B).
3. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
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4. Install the brake pads (B) and pad shims (A) correctly. Install the pad with the wear indicator (C) on the inside.
If you are reusing the pads, always reinstall the brake pads in their original position to prevent a momentary loss
of braking efficiency.
5. Push in the piston (A) so that the caliper will fit over the pads. Make sure that the piston boot is in position to
prevent damaging it when pivoting the caliper down.
6. Pivot caliper down into position. Being careful not to damage the pin boot, install the guide rod bolt (B) and
torque it to proper specification
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Insert the piston in the cylinder using the special tool(09581-11000).
7. Depress the brake pedal several time to make sure the brakes work, then test-drive.
Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been
replaced as a set. Several applications of the brake will restore the normal pedal stroke.
8. After installaion, check for leaks at hose and line joints or connections, and retighten if necessary.
INSPECTION
REAR BRAKE DISC THICKNESS CHECK
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1. Remove all rust and contamination from the disc surface, and then measure the disc thickness at 8 points, al least,
of the same distance (5 mm) from the brake disk outer circle.
Rear brake disc thickness

Standard value : 10.0 mm (0.39 in.)
Limit : 8.0 mm (0.315 in.)
2. Thickness variation should not exceed 0.005 mm(0.0002 in.) (circumference) and 0.01 mm(0.0004 in.) (radius)
at any directions.
3. If wear exceeds the limit, replace the discs and pad assembly for left and right of the vehicle.
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REAR BRAKE PAD CHECK
1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Pad thickness
Standard value : 10.0 mm ( 0.39 in.)
2. Check that grease is applied, and the pad and backing metal for damage.
REAR BRAKE DISC RUN OUT CHECK
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1. Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the run out
of the disc.
Brake disc run out

Limit : 0.1 mm (0.004 in.) or less
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2. If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out
again.
3. If the run out does not exceed the limit specification, install the brake disc after turning it 180° and then check the
run out of the brake disc again.
4. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc.
Seize of Rear brake disc
1. Remove the brake disc from hub using M8 screw(A) if the brake disc has been seized with the hub due to
corrosion or overheat.
Be careful not to use the hammer. The disc can be damaged if you remove the disc from the hub by
hammer.
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Brake System > Parking Brake System > Components and Components Location
COMPONENTS
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Brake System > Parking Brake System > Repair procedures

Parking brake check and adjustment
INSPECTION
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1. Pull the parking brake lever (A) with 196 N (20 kg, 44lbf) force to fully apply the parking brake. The parking
brake lever should be locked within the specified number of clicks.
Lever locked clicks:7~8
2. Adjust the parking brake if the lever clicks are out of specification.
ADJUSTMENT
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After rear brake caliper servicing, loosen the parking brake adjusting nut, start the engine and depress the brake
pedal several times to set the self-adjusting brake before adjusting the parking brake.
1. Block the front wheels, then raise the rear of the vehicle and make sure it is securely supported.
2. Pull the parking brake lever up one click.
3. Remove the floor console.

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4. Tighten the adjusting nut (A) until the parking brakes are dragged slightly when the rear wheels are turned.
5. Release the parking brake lever completely, and check if parking brakes are not dragged when the rear wheels
are turned. Readjust if necessary.
6. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up completly.
7. Reinstall the floor console.
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Brake System > Parking Brake System > Parking Brake Switch > Repair procedures
INSPECTION
1. Remove the floor console and the switch (B) from the connector (A).
2. Inspect the continuity between (-) terminal and the ground.

A. When the brake lever is pulled, there should be the continuity between them.
B. When the brake lever is released, there should be no continuity between them.
Brake System > Parking Brake System > Parking Brake Assembly > Repair procedures
Adjustment
Parking Brake Shoe Clearance Adjustment
Disc Brake Type
1. Lift the vehicle, and make sure it is securely supported.
2. Remove the rear tire and wheel.
3. Remove the plug from the disc.
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4. Turn the adjusting wheel in arrow direction as shown until the disc won’t be rotated by tangential force of
29.4N(3kgf, 6.6Ib) using the (-)screw driver (A). Then turn back the adjusting wheel by 5 notches.
5. Install the rear tire and wheel after installing the plug.
Parking Brake Lever Stroke Adjustment
1. Lift the vehicle, and make sure it is securely supported.
2. Remove the floor console. (Refer to BD Gr. - "Floor console")
3. After the full stroke operation of the brake lever over 3 times for setting the cable, the travel must be between 8
notches when applying a force of 196N(20kgf, 44Ib) at 40mm from the end of lever assembly (excluding button)
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by adjusting nut (A).
4. Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are
turned. Readjust if necessary.
5. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully.
6. Parking indicator lamp must be “OFF”when the lever assembly is released. It must be “ON” when the lever
assembly is operated by 1 notch.
7. Install the floor console. (Refer to BD Gr. - "Floor console")
After repairing the parking brake shoe, adjust the brake shoe clearance, and then adjust the parking brake
lever stroke.
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REMOVAL
The parking brake cables must not be bent or distorted.

This will lead to stiff operation and premature failure.
1. Remove the floor console.
2. Loosen the adjusting nut (A) and remove the parking brake cables.
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3. Disconnect the connector(A) of the parking brake switch connector.
4. Remove the bolts and parking brake lever assembly(A).

5. Remove the wheel and tire.
6. Remove the brake drum and the brake shoe (Refer to the rear drum brake).
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7. Remove the parking brake cable(A) from the brake shoe.
8. Remove the parking brake cable retaining ring (B), from the parking brake cable (A).
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9. Remove the parking brake cable assembly.
INSTALLATION
1. Install the removed parts in the reverse order of removal.
2. Apply the specified grease to each sliding parts of the ratchet plate or the ratchet pawl.
Specified grease :
Multi purpose grease SAE J310, NLGI No.2
3. After installing the parking brake cable adjuster, adjust the parking brake lever stroke (Refer to the parking brake
check and adjustment).
Brake System > ESC(Electronic Stability Control) System > Components and Components Location
COMPONENTS
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Brake System > ESC(Electronic Stability Control) System > Description and Operation
description of ESC
Optimum driving safety now has a name : ESC, the Electronic Stability Control.
ESC is based on the MGH 40 ABS Hydraulic System. ESC recognizes critical driving conditions, such as panic
reactions in dangerous situations, and stabilizes the vehicle by wheel-individual braking and engine control
intervention with no need for actuating the brake or the gas pedal.
ESC adds a further function known as Active Yaw Control (AYC) to the ABS, TCS, EBD and EDC functions.
Whereas the ABS/TCS function controls wheel slip during braking and acceleration and, thus, mainly intervenes in
the longitudinal dynamics of the vehicle, active yaw control stabilizes the vehicle about its vertical axis.
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This is achieved by wheel individual brake intervention and adaptation of the momentary engine torque with no need
for any action to be taken by the driver.
ESC essentially consists of three assemblies : the sensors, the electronic control unit and the actuators.
The electronic control unit incorporates the technological experience accumulated in connection with the MGH 40
system, but has been substantially expanded in terms of capacity and monitoring concept in order to permit the
additional sensor signals and arithmetic operations to be processed and converted into corresponding valve, pump
and engine control commands. Two 16-bit processors and one 8-bit processor, which monitor each other,
cooperate to handle these requirements.
Of course, the stability control feature works under all driving and operating conditions. Under certain driving
conditions, the ABS/TCS function can be activated simultaneously with the ESC function in response to a command
by the driver.
In the event of a failure of the stability control function, the basic safety function, ABS, is still maintained.
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DESCRIPTION OF ESC CONTROL
ESC system includes ABS/EBD, TCS and AYC function.
ABS/EBD function : The ECU changes the active sensor signal (current shift) coming from the four wheel sensors to
the square wave.By using the input of above signals, the ECU calculates the vehicle speed and the acceleration &
deceleration of the four wheels.And, the ECU judges whether the ABS/EBD should be actuated or not.
TCS function prevents the wheel slip of drive direction by adding the brake pressure and engine torque reduction via
CAN communication.TCS function uses the wheel speed sensor signal to determine the wheel slip as far as ABS
function.
AYC function prevents unstable maneuver of the vehicle. To determine the vehicle maneuver, AYC function uses the
maneuver sensor signals(Yaw Rate Sensor, Lateral Acceleration Sensor, Steering Wheel Angle Sensor).If vehicle
maneuver is unstable (Over Steer or Under Steer), AYC function applies the brake pressure on certain wheel, and
send engine torque reduction signal by CAN.
After the key-on, the ECU continually diagnoses the system failure. (self-diagnosis)If the system failure is detected,
the ECU informs driver of the system failure through the BRAKE/ABS/ESC warning lamp. (fail-safe warning)
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INPUT AND OUTPUT DIAGRAM
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ESC OPERATION MODE

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

The active ABS warning lamp module indicates the self-test and failure status of the ABS .The ABS warning lamp
shall be on:
- During the initialization phase after IGN ON. (continuously 3 seconds).
- In the event of inhibition of ABS functions by failure.
- During diagnostic mode.
- When the ECU Connector is seperated from ECU.
EBD/PARKING BRAKE WARNING LAMP MODULE
The active EBD warning lamp module indicates the self-test and failure status of the EBD. However, in case the
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Parking Brake Switch is turned on, the EBD warning lamp is always turned on regardless of EBD functions. The
EBD warning lamp shallbe on:
- When the Parking Brake Switch is ON or brake fluid level is low.
- When the EBD function is out of order .
- When the ECU Connector is seperated from ECU.
ESC Warning Lamp (ESC system)
The ESC warning lamp indicates the self-test and failure status of the ESC.
The ESC warning lamp is turned on under the following conditions :
- In the event of inhibition of ESC functions by failure.
- When driver trun off the ESC function by on/off switch.
ESC Function Lamp (ESC system)
The ESC function lamp indicates the self-test and operating status of the ESC.
The ESC Function lamp operates under the following conditions :
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- When the ESC control is operating. (Blinking - 2Hz)
ESC On/Off Switch (ESC system)
The ESC On/Off Switch shall be used to toggle the ESC function between On/Off states based upon driver input.
The On/Off switch shall be a normally open, momentary contact switch.Closed contacts switch the circuit to ignition.
Initial status of the ESC function is on and switch toggle the state.
Brake System > ESC(Electronic Stability Control) System > Schematic Diagrams
CIRCUIT DIAGRAM - ESC(1)
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ESC connector input/output
Connector Terminal
Specification Remark
No Description
Over voltage range : 17 ± 0.5V
Operating voltage range :
9.5 ± 0.5V < V < 17 ± 0.5V
31 IGNITION1(+)
Low voltage range :
7.0 ± 0.5V < V < 9.5 ± 0.5V
Max. current : I < 500mA
Max leakage current : I < 0.8mA
Operating voltage range :
1 POS.BATTERY.(SOLENOID)
9.5 ± 0.5V < V < 17 ± 0.5V
Max. current : I < 40A
Operating voltage range:
9.5 ± 0.5V < V < 16.5 ± 0.5V
2 POS.BATTERY.(MOTOR) Rush current : I < 100A
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Max current : I < 40A
Max leakage current : I < 0.2mA
Rated current : I <500mA
46 GROUND
Max. current: I < 40A
Rush current : I < 100A
45 PUMP MOTOR GROUND
Max current : I < 40A
YAW & LATERAL G
16 Rated current : I <150mA
SENSOR GROUND
STEERING ANGLE SENSOR
30 Rated current : I <100mA
GROUND
Max Output current : I < 150mA
17 YAW SENSOR POWER
Max Output voltage : V(IGN) ± 1V
STEERING ANGLE SENSOR Max Output current : I < 100mA
3
POWER Max Output voltage : V(IGN) ± 1V
34 BRAKE LIGHT SWITCH Input voltage (Low) : 0V ≤ V ≤ 3.0V
32 BRAKE SWITCH Input voltage (High) : 7.0V ≤ V ≤ 16.0V
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Input voltage (Low) : 0V ≤ V_Low ≤ 3.0V
Input voltage (High) : 7.0V ≤ V_High ≤
8 PARKING BRAKE SWITCH
16.0V
Max input current : I < 10mA
Max current : I < 16mA
SENSOR FRONT RIGHT
27 External pull up resistance :1 KΩ < R
OUTPUT
Output duty :50 ± 20%
Input voltage (Low) :0V ≤ V ≤ 3.0V
18 ESC ON/OFF SWITCH Input voltage (High) : 7.0V ≤ V ≤ 16.0V
Max input current:I <10mA
15 CAN BUS LINE(LOW)
Max. current : I < 10mA
14 CAN BUS LINE(HIGH)
SENSOR FRONT LEFT
4
POWER
SENSOR FRONT RIGHT
5
POWER Output voltage : IGN (V) ± 1V
SENSOR REAR LEFT Output current : Max 30mA
7
POWER
SENSOR REAR RIGHT
6
POWER
SENSOR FRONT LEFT
9
SIGNAL
SENSOR FRONT RIGHT Input current LOW : 5.9 ~ 8.4mA
10
SIGNAL Input current HIGH :11.8 ~ 16.8mA Typ. 7mA
SENSOR REAR LEFT Frequency range :1 ~ 2500Hz Typ. 14mA
12 Input duty : 50 ± 20%
SIGNAL
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SENSOR REAR RIGHT
11
SIGNAL
STEERING ANGLE SENSOR
24
PHASE 1
Input duty (ST1, ST2): 50 ± 10%
Typ. 20deg
STEERING ANGLE SENSOR Phase difference (ST1, ST2): 2 ± 0.6deg
25 Typ. 3.5V
PHASE 2 High voltage: 3.0 V < V < 4.1V
Typ. 1.5V
STEERING ANGLE SENSOR Low voltage: 1.3 V < V < 2.0V
26
PHASE N
Input voltage
IL(V) < 0.3 IGN (V)
DIAGNOSIS IH(V) > 0.7 IGN (V)
13
INPUT/OUTPUT Output voltage
OL(V) < 0.2 IGN (V)
OH(V) > 0.8 IGN (V)
37 ESC W/LAMP DRIVE
Current : I < 300mA (12V)
38 ABS/EBD W/LMAP DRIVE Voltage range : 0 ~ 18V
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40 ESC F/LAMP DRIVE Min. shunt resistance : 500KΩ
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 turned off in case of ESC failure, refer to the ABS fail-safe.
4. Information on ABS fail-safe is identical to the fail-safe in systems where ESC is not installed.
MEMORY OF FAIL CODE
1. It keeps the code as far as the backup lamp power is connected. (O)
2. It keeps the code as far as the HCU power is on. (X)
FAILURE CHECKUP
1. Initial checkup is performed immediately after the HECU power on.
2. Valve relay checkup is performed immediately after the IG2 ON.
3. It executes the checkup all the time while the IG2 power is on.
4. Initial checkup is made in the following cases.
(1) When the failure is not detected now
(2) When ABS and ESC are not in control.
(3) Initial checkup is not made after ECU power on.
(4) If the vehicle speed is over 5 mph(8 km/h) when the brake lamp switch is off.
(5) When the vehicle speed is over 24.8 mph(40 km/h).
5. Though, it keeps on checkup even if the brake lamp switch is on.
6. When performing ABS or ESC control before the initial checkup, stop the initial checkup and wait for the HECU
power input again.
7. Judge failure in the following cases.
(1) When the power is normal.
(2) From the point in which the vehicle speed reaches 4.9 mph(8 km/h) after HECU power on.
COUNTERMEASURES IN FAIL
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1. Turn the system down and perform the following actions and wait for HECU power OFF.
2. Turn the valve relay off.
3. Stop the control during the operation and do not execute any until the normal condition recovers.
WARNING LAMP ON
1. ABS warning lamp turns on when ABS is fail.
2. ESC operation lamp turns on and ESC OFF warning lamp blinks when ESC is fail.
When power voltage and valve relay voltage are abnormal, input/output related failure judgment is not made.
scan tool CHECK
1. Turn the ignition switch OFF.
2. Connector the scan tool to the 16P data link connector located the driver'd side kick panel.
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3. Turn the ignition switch ON.
4. Check for diagnostic trouble using the scan tool
5. After completion trouble of the repair or correction of the problem, erase the stored fault codes the clear key on
the scan tool.
6. Disconnect the scan tool from the 16P data link connector.
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
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NOTES WITH REGARD TO DIAGNOSIS
The phenomena listed in the following table are not abnormal.
Phenomenon Explanation
System check sound When starting the engine, a thudding sound can sometimes be heard coming
from inside the engine compartment. This is because the system operation
check is being performed.
ABS operation sound 1. Sound of the motor inside the ABS hydraulic unit operation (whine).
2. Sound is generated along with vibration of the brake pedal (scraping).
3. When ABS operates, sound is generated from the vehicle chassis due to
repeated brake application and release
(Thump : suspension; squeak: tires)
ABS operation (Long braking 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.
Diagnosis detection conditions can vary depending on the diagnosis code. When checking the trouble symptom
after the diagnosis code has been erased, ensure that the requirements listed in "Comment" are met.
ABS CHECK SHEET

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PROBLEM SYMPTOMS TABLE

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If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem
symptom in the order given in the table below and proceed to the relevant troubleshooting page.
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Symptom Suspect Area
ABS does not operate. Only when 1. -4. are all normal and the problem is still
occurring, replace the HECU.
1. Check the DTC reconfirming that the normal code is
output.
2. Power source circuit.
3. Speed sensor circuit.
4. Check the hydraulic circuit for leakage.
ABS does not operate intermittently. Only when 1. -4. are all normal and the problem is still
occurring, replace the ABS actuator assembly.
1. Check the DTC reconfirming that the normal code is
output.
2. Wheel speed sensor circuit.
3. Stop lamp switch circuit.
4. Check the hydraulic circuit for leakage.
Communication with Scan tool is not possible. 1. Power source circuit
(Communication with any system is not possible) 2. Diagnosis line
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Communication with Scan tool is not possible. 1. Power source circuit
(Communication with ABS only is not possible) 2. Diagnosis line
3. HECU
When ignition key is turned ON (engine OFF), the ABS 1. ABS warning lamp circuit
warning lamp does not light up. 2. HECU
Even after the engine is started, the ABS warning lamp 1. ABS warning lamp circuit
remains ON. 2. HECU
During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are due
to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is not an
abnormality.
DETECTING CONDITION
Trouble Symptoms Possible Cause
Brake operation varies depending on driving conditions and road - Faulty power source circuit
surface conditions, so diagnosis can be difficult.However if a normal - Faulty wheel speed sensor circuit
DTC is displayed, check the following probable cause. When the - Faulty hydraulic circuit for leakage
problem is still occurring, replace the ABS control module. - Faulty HECU
INSPECTION PROCEDURES
DTC INSPECTION
1. Connect the scan tool with the data link connector and turn the ignition switch ON.
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2. Verify that the normal code is output.
Is the normal code output?
Check the power source circuit.
Erase the DTC and recheck using scan tool.

CHECK THE POWER SOURCE CIRCUIT.
1. Disconnect the connector from the ABS(ESC) control module.
2. Turn the ignition switch ON, measure the voltage between terminal 3(31) of the ABS(ESC) control module
harness side connector and body ground.
Specification : approximately B+
Is the voltage within specification?
Check the ground circuit.
Check the harness or connector between the fuse (10A) in the engine compartment junction block and the
ABS(ESC) control module. Repair if necessary.
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CHECK THE GROUND CIRCUIT.
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2. Check for continuity between terminals 25(45), 26(46) of the ABS(ESC) control module harness side connector
and ground point.
Is there continuity?
Check the wheel speed sensor circuit.
Repair an open in the wire and ground point.
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CHECK THE WHEEL SPEED SENSOR CIRCUIT.
Refer to the DTC troubleshooting procedures.
Is it normal?
Check the hydraulic circuit for leakage.
Repair or replace the wheel speed sensor.

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

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

CHECK THE STOP LAMP SWITCH CIRCUIT.
1. Check that stop lamp lights up when brake pedal is depressed and turns off when brake pedal is released.
2. Measure the voltage between terminal 14(34) of the ABS(ESC) control module harness side connector and
body ground when brake pedal is depressed.
Is the voltage within specification?
Check the hydraulic circuit for leakage.
Repair the stop lamp switch. Repair an open in the wire between the ABS(ESC) control module and the stop
lamp switch.
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CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE.

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

Check for continuity between terminal 5 of the data link connector and body ground.
Repair an open in the wire between terminal 5 of the data link connector and ground point.
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DETECTING CONDITION
When communication with scan tool is not possible, the cause may - An open in the wire
be probably an open in the HECU power circuit or an open in the - Faulty HECU
diagnosis output circuit. - Faulty power source circuit
CHECK FOR CONTINUITY IN THE DIAGNOSIS LINE
1. Disconnect the connector from the ABS control module.
2. Check for continuity between terminals 11(13) of the ABS(ESC) control module connector and 1 of the data link
connector.
Check the power source of ABS(ESC) control module.
Repair an open in the wire.

CHECK THE POWER SOURCE OF ABS(ESC) CONTROL MODULE
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2. Turn the ignition switch ON, measure the voltage between terminal 3(31) of the ABS(ESC) control module
harness side connector and body ground.
Check for poor ground.
Check the harness or connector between the fuse (10A) in the engine compartment junction block and the
ABS(ESC) control module.Repair if necessary.
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CHECK FOR POOR GROUND
Check for continuity between terminal 5 of the data link connector and ground point.
Replace the ABS(ESC) control module and recheck.
Repair an open in the wire or poor ground.
DETECTING CONDITION
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When current flows in the HECU the ABS warning lamp turns from - Faulty ABS warning lamp bulb
ON to OFF as the initial check.Therefore if the lamp does not light - Blown fuse is related to ABS in the
up, the cause may be an open in the lamp power supply circuit, a engine compartment junction block
blown bulb, an open in the both circuits between the ABS warning - Faulty ABS warning lamp module
lamp and the HECU, and the faulty HECU. - Faulty HECU
PROBLEM VERIFICATION
Disconnect the connector the ABS(ESC) HECU and turn the ignition switch ON.
Does the ABS waring lamp light up?
Check the power source for the ABS warning lamp.
Inspect again after replacing the ABS(ESC) HECU.
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CHECK THE POWER SOURCE FOR THE ABS WARNING LAMP
1. Disconnect the instrument cluster connector (M06-2) and turn the ignition switch ON.
2. Measure the voltage between terminal (M01-C) 16 of the cluster harness side connector and body ground.
Check for blown fuse.
Check the CAN circuit resistance for ABS warning lamp.

CHECK FOR BLOWN FUSE
Check continuity of fuse (10A) from the engine compartment junction block.
Repair an open in the wire between ABS fuse and 1 of cluster connector.
Replace the blown fuse.

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DETECTING CONDITION
If the HECU detects trouble, it lights the ABS warning lamp while at - An open in the wire
the same time prohibiting ABS control. At this time, the HECU - Inoperative instrument cluster assembly
records a DTC in memory.Even though the normal code is output, - Inoperative ABS warning lamp module
the ABS warning lamp remains ON, then the cause may be - Inoperative HECU
probably an open or short in the ABS warning lamp circuit.
CHECK DTC OUTPUT.
1. Connect the Scan Tool to the 16P data link connector located behind the driver's side kick panel.
2. Check the DTC output using Scan Tool.
Is DTC output?
Repair circuit indicated by code output.
Check instrument cluster.

CHECK INSTRUMENT CLUSTER
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Disconnect the cluster connector and turn the ignition switch ON.
Does the ABS warning lamp remains ON?
Replace the instrument cluster.
Check for open the wire.

CHECK FOR OPEN IN THE WIRE
Check for continuity in the wire between cluster and ABS control module.
Replace the ABS control module and recheck.
Repair an open in the wire between cluster and ABS control module.
BLEEDING OF BRAKE SYSTEM
This procedure should be followed to ensure adequate bleeding of air and filling of the ABS unit, brake lines and
master cylinder with brake fluid.
1. Remove the reservoir cap and fill the brake reservoir with brake fluid.
If there is any brake fluid on any painted surface, wash it off

immediately.
When pressure bleeding, do not depress the brake pedal.

Recommended fluid........ DOT3 or DOT4
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2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled
clear plastic bottle.
3. Connect the scan tool to the data link connector located underneath the dash panel.
4. Select and operate according to the instructions on the scan tool screen.
You must obey the maximum operating time of the ABS motor with the scan tool to prevent the motor
pump from burning.
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(1) Select vehicle name.
(2) Select Anti-Lock Brake system.
(3) Select air bleeding mode.
(4) Press "YES" to operate motor pump and solenoid valve.
(5) Wait 120 sec. before operating the air bleeding.

(If not, you may damage the motor.)
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(6) Perform the air bleeding.
5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without
bubbles. Then close the bleeder screw.
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6. Repeat step 5 until there are no more bubbles in the fluid for each wheel.
7. Tighten the bleeder screw.
Bleed screw tightening torque:

7 ~ 13 Nm (0.7 ~ 1.3 kgf.m, 5.4 ~ 9.5 lb-ft)
DIAGNOSTIC TROUBLE CODE CHART(DTC)

Warning lamp
DTC condition
Trouble description Remark
CODE
EBD ABS ESP
1 C1101 Battery Voltage High ● ● ● ABS/ESC
2 C1102 Battery Voltage Low ○/● ● ● ABS/ESC
3 C1112 Sensor Power Voltage ○ ● ● ABS/ESC
4 C1200 Wheel Speed Sensor Front-LH Open/Short ○/● ● ● ABS/ESC
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Wheel Speed Sensor Front-LH Range / Performance /
5 C1201 ○/● ● ● ABS/ESC
Intermittent
6 C1202 Wheel Speed Sensor Front-LH Invalid/no Signal ○/● ● ● ABS/ESC
7 C1203 Wheel Speed Sensor Front-RH Open/Short ○/● ● ● ABS/ESC
Wheel Speed Sensor Front-RH Range / Performance /
8 C1204 ○/● ● ● ABS/ESC
Intermittent
9 C1205 Wheel Speed Sensor Front-RH Invalid/no Signal ○/● ● ● ABS/ESC
10
C1206 Wheel Speed Sensor Rear-LH Open/Short ○/● ● ● ABS/ESC
Wheel Speed Sensor Rear-LH Range / Performance /

11 C1207 ○/● ● ● ABS/ESC
Intermittent
12 C1208 Wheel Speed Sensor Rear-LH Invalid/no Signal ○/● ● ● ABS/ESC
13 C1209 Wheel Speed Sensor Rear-RH Open/Short ○/● ● ● ABS/ESC
Wheel Speed Sensor Rear-RH Range / Performance /
14 C1210 ○/● ● ● ABS/ESC
Intermittent
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15 C1211 Wheel Speed Sensor Rear-RH Invalid/no Signal ○/● ● ● ABS/ESC
16 C1235 Primary Pressure Sensor-Electrical ○ ○ ● ESC only
17
C1237 Primary Pressure Sensor-Signal ○ ○ ● ESC only
18 C1259 Steering Angle Sensor - Electrical ○ ○ ● ESC only

19 C1260 Steering Angle Sensor-Signal ○ ○ ● ESC only
20 C1274 Longitudinal G Sensor Open/Short ○ ● ● 4WD only
21
C1275 Longitudinal G Sensor Range/Performance error ○ ● ● 4WD only
22
C1282 Yaw Rate & Lateral G Sensor-Electrical ○ ○ ● ESC only
23
C1283 Yaw Rate & Lateral G Sensor-Signal ○ ○ ● ESC only
24
C1503 ESC Switch Error ○ ○ ● ESC only
25
C1513 Brake Switch Error ○ ○ ● ESC only
26
C1604 ECU Hardware Error ○ ○ ● ABS/ESC
27
C1605 CAN Hardware Error ○ ○ ● ABS/ESC
28
C1611 CAN Time-out ECM ○ ○ ● ABS/ESC
29
C1612 CAN Time-out TCM ○ ○ ● ABS/ESC
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30
C1613 CAN Wrong Message ○ ○ ● ABS/ESC
31
C1616 CAN Bus off ○ ○ ● ABS/ESC
32
C1647 Sensor CAN Hardware Error ● ● ● ESC only
33
C2112 Valve Relay Error ○ ○ ● ABS/ESC
34
C2227 Excessive Temperature Of Brake Disc ● ● ● ESC only
35
C2380 ABS / ESC Valve Malfunction ○ ● ● ABS/ESC
36
C2402 Motor Electrical ○ ● ● ABS/ESC
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Brake System > ESC(Electronic Stability Control) System > EBD (Electronic Brake-force 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 effective
adhesion utilization by the rear wheels.
It further utilizes the efficiency of highly developed ABS equipment by controlling the slip of the rear wheels in the
partial braking range.
The brake force is moved even closer to the optimum and controlled electronically, thus dispensing with the need for
the proportioning valve.
The proportioning valve, because of a mechanical device, has limitations to achieve an ideal brake force distribution
tothe rear wheels as well as to carry out the flexible brake force distribution proportioning to the vehicle load or
weight increasing. And in the event of malfunctioning, driver cannot notice whether it fails or not.
EBD controlled by the ABS Control Module, calculates the slip ratio of each wheel at all times and controls the
brake pressure of the rear wheels not to exceed that of the front wheels.
If the EBD fails, the EBD warning lamp (Parking brake lamp) lights up.
ADVANTAGES
- Function improvement of the base-brake system.
- Compensation for the different friction coefficients.
- Elimination of the proportioning valve.
- Failure recognition by the warning lamp.
Comparison between Proportioning valve and EBD
Page 75 of 235
Brake System > ESC(Electronic Stability Control) System > ESC Control Module > Components and
Components Location
COMPONENTS
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Page 76 of 235
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Brake System > ESC(Electronic Stability Control) System > ESC Control Module > Repair procedures
REMOVAL
1. Turn the ignition switch OFF.
2. Pull up the lock (A) of the ABS control unit 26P connector , then disconnect the connector.
3. Disconnect the brake tubes from the HECU by unlocking the nuts counterclockwise with a spanner.
Page 77 of 235
4. Loosen the 3 ABS HECU bracket bolts, then remove HECU and bracket.
1. Never attempt to disassemble the HECU.

2. The HECU must be transported and stored in.
3. Never shock to the HECU.
5. Remove the 3 bolts, then remove the bracket from HECU.
INSTALLATION
1. Installation is the reverse of removal.
2. Tighten the HECU mounting bolts and nuts to the specified torque.
Tightening torque
HECU bracket nuts :
11 ~ 14 Nm (1.1 ~ 1.4 kgf.m, 8.1 ~ 10.3 Ib-ft)
HECU bracket mounting bolt :
16.7 ~ 25.5 Nm (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 Ib-ft)
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Brake System > ESC(Electronic Stability Control) System > Front Wheel Speed Sensor > Description
and Operation
DESCRIPTION
A toothed rotor is fixed to the rotating member of the wheel, and the sensor is fixed to the static member of the
suspension. As the wheel rotates the toothed rotor causes magnetic flux changes in the magnetic field of the
permanent magnet. The sensor element senses these changes. Depending on the flux changes the sensor sends a
signal out to the ECU. The change in magnet flux thus the sensor signal is directly related to the wheel speed.
The controller monitors the sensor signal, compares the four wheel-speed signals and initiates action as required.
Page 78 of 235
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SPECIFICATIONS
Item Standard Value Remark
Supply voltage DC 12 V
Operating temperature -40 ~1 20 °C R = 100 Ω
7 mA(5.9 ~
Low
8.4 mA)
Output current range
14 mA(11.8
High
~ 16.8 mA)
Frequency range 1 ~ 2000 Hz
0.5 ~ 1.5 mm(0.0197 ~
Airgap
0.0591 in.)
Tone wheel Number 48
Brake System > ESC(Electronic Stability Control) System > Front Wheel Speed Sensor > Components
and Components Location
COMPONENTS
Page 79 of 235
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Brake System > ESC(Electronic Stability Control) System > Front Wheel Speed Sensor > Repair
procedures
REMOVAL
FRONT WHEEL SPEED SENSOR
Page 80 of 235
1. Remove the front wheel speed sensor mounting bolt (A).
2. Remove the front wheel guard (B), after removing the mud guard (A).
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3. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector (A).
REAR WHEEL SPEED SENSOR

Page 81 of 235
1. Remove the rear wheel speed sensor mounting bolt (A).
2. Remove the rear seat side pad then disconnect the rear wheel speed sensor connector (A).
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INSPECTION
1. Measure the output voltage between the teminal of the wheel speed sensor and the body ground.
In order to protect the wheel speed sensor, when measuring output voltage, a 100Ω resister must be used
as shown.
Page 82 of 235
1. Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage
as shown below.
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• V_low : 590 mV ~ 840 mV
• V_high : 1.18 V ~ 1.68 V
• Frequency range : 1 ~ 2,000 Hz
Brake System > ESC(Electronic Stability Control) System > Yaw-rate and Lateral G Sensor >
Description and Operation
DESCRIPTION
When the vehicle is turning with respect to a vertical axis the yaw rate sensor detects the yaw rate electroniclly 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 leverarm
by later G.
Direction and magnitude of lateral G loaded to vehicle can be known with electrostatic capacity changing according
to lateral G.
The sensor is located in the front passenger seat lower floor on vehicle.
Page 83 of 235
specifications
Description Specification Remarks
Operating voltage 8 ~ 17V
Current consumption Max. 140mA
Operating temperature -40 ~ 85°C
Measurement
-75 ~ 75°/sec
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range
Yaw-rate sensor
Frequency
18 ~ 22Hz
response
Measurement -14.715 ~
range +14.715m/s²
Lateral G sensor
Frequency 50Hz ± 60% (-
response 3dB)
EXTERNAL DIAGRAM
output characteristic
Page 84 of 235
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Brake System > ESC(Electronic Stability Control) System > Yaw-rate and Lateral G Sensor >
Components and Components Location
COMPONENTS
Page 85 of 235
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Brake System > ESC(Electronic Stability Control) System > Yaw-rate and Lateral G Sensor > Repair
procedures
INSPECTION
1. Connect a tester to both 2 and 3 terminals of the G sensor.
2. Measure the output voltage when IGN is on.
Specification : 2.5V
Page 86 of 235
3. Measure the output voltage between 2 and 3 terminals, posing the arrow mark on the G sensor downward.
4. Replace the G sensor if the output voltage is not on the specification.
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Brake System > ESC(Electronic Stability Control) System > ESC OFF Switch > Description and
Operation
DESCRIPTION
1. The ESC OFF switch is for the user to turn off the ESC system.
2. The ESC OFF lamp is on when ESC OFF switch is engaged.
Brake System > ESC(Electronic Stability Control) System > ESC OFF Switch > Repair procedures
INSPECTION
1. Remove the ESC OFF switch from the switch panel on the crushpad of the driver's side.
Page 87 of 235
2. Check the continuity between the switch terminals as the ESC OFF switch is engaged.
Brake System > ESC(Electronic Stability Control) System > G Sensor > Components and Components
Location
COMPONENTS
Brake System > ESC(Electronic Stability Control) System > G Sensor > Repair procedures
cardiagn.com
INSPECTION
1. Connect a tester to both 2 and 3 terminals of the G sensor.
Page 88 of 235
2. Measure the output voltage when IGN is on.
3. Measure the output voltage between 2 and 3 terminals, posing the arrow mark on the G sensor downward.
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4. Replace the G sensor if the output voltage is not on the specification.
Brake System > ESC(Electronic Stability Control) System > Steering Angle Sensor > Description and
Operation
DESCRIPTION
The steering angle speed sensor detects the angle of the steering wheel in order to which direction a user
chooses.The sensor is detached on the MPS(Mutil-Function Switch) under the steering wheel.
MEASUREING PRINCIPLE
The split of the steering angle sensor detects a steering angle of the steering wheel by a ON/OFF pulse caused by
whether or not the LED lights go through the hole of the split, rotating as the steering wheel revolves. There are three
LEDs, two(ST1, ST2) for detecting a steering direction, and the other for the neutral position.The HECU calculates
the steering angle by the pulse from the steering angle sensor.
Page 89 of 235
SPECIFICATION
Description Specification
Operating voltage 9 ~ 16V
Operating
-30 ~ 75°C
temperature
Current
Max.100mA
consumption
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Steering angle
Max. ± 1500°/sec
velocity
Voltage(high) 3.0V ~ 4.1V
Voltage(low) 1.3V ~ 2.0V
Pulse duty 40 ~ 60%
CIRCUIT DIAGRAM( STEERING WHEEL SPEED ANGLE SENSOR)
OUTPUT CHARACTERISTIC
Page 90 of 235
Steering
No. INPUT OUTPUT Remark
direction
ST1 L L
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Right
ST2 L H
1
ST1 L H
Left
ST2 L L
ST1 L L
Left
ST1 H L
2
ST1 L H
Right
ST2 H H
ST1 H H
Left
ST2 L H
3
ST1 H L
Right
ST2 L L
ST1 H H
Right
ST2 H L
4
ST1 H L
Left
ST2 H H
Brake System > Troubleshooting > C1101

GENERAL DESCRIPTION
The ABS ECU(Electronic Control Unit) checks the battery voltage and alternator output voltage to determine, as a
safety issue, whether the ABS system can operate normally or not.
The normal battery voltage range is essential for controlling the ABS system as intended.
DTC DESCRIPTION
Page 91 of 235
The ABS ECU monitors battery voltage and alternator output voltage.
When the voltage is higher than the expected normal value, this code is set, and the ABS/EBD/ESC functions are
prohibited.
If the voltage recovers, to within normal operating ranges, then the controller returns to normal operation as well.
DTC DETECTING CONDITION

Item Detecting Condition Possible cause
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DTC Strategy ● Battery Voltage Monitoring
● When Vign >17V±0.5V is continued for 500msec. ● Poor connection in power
Enable Conditions - If the voltage recovers to normal operating range, the supply circuit (IGN+)
controller returns to normal state. ● Faulty Alterator
● The ABS/EBD/ESC functions are inhibited. ● Faulty HECU
Fail Safe
● The ABS/EBD/ESC warning lamps are activated.
SPECIFICATION
Normal Voltage ENG "ON"
Range 10V ~ 16V
MONITOR SCANTOOL DATA

1. Connect scantool to Data Link Connector(DLC)
2. Ignition "ON" & Engine "ON".
Page 92 of 235
3. Monitor the "BATTERY VOLTAGE" parameter on the scantool.
Specification : Below. 16.7V
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Fig 1) Test Condition : Ignition "ON" & Engine "ON".
Normal Data
4. Is parameter displayed within specifications?
Fault is intermittent caused by poor connection in power harness (IGN+) and/or HECU’s connector or was
repaired and HECU memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
Repair or replace as necessary and then go to "Verification of Vehicle Repair" procedure.
Go to "Terminal and Connector Inspection" procedure.
TERMINAL AND CONNECTOR INSPECTION

1. Many malfunctions in the electrical system are caused by poor harness(es) and terminals. Faults can also be
caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
Verify presence of battery voltage codes in other ECUs (SRS, etc).

If battery voltage codes are not present in other ECUs, go to "Power Circuit Inspection" procedure.
If battery voltage codes are present in other ECUs, go to "Alternator Output Voltage Inspection" procedure.
Alternator Output Voltage Inspection
■ Charging System Check
2. Maintain ENG RPM 2,500RPM over 2 minutes.
Page 93 of 235
3. Measure voltage between the battery terminal(+) and the battery terminal(-).
Specification : Below. 17±0.5V
4. Is the measured value within specifications?
Go to "Power Circuit Inspection" procedure.
Check that the tension of drive belt, ENG RPM, fuse, terminal of battery, all terminals of alternator are in good
condition and Check for damaged harness and poor connection between alternator and battery.
If OK repair or replace alternator and then go to "Verification of vehicle Repair" procedure.
POWER CIRCUIT INSPECTION
■ Open or Short Check
1. Ignition "ON" & Engine "OFF".
2. Measure voltage between the battery terminal(+) and power terminal of the HECU harness connector.
Specification : Approx. below 0.2V
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4. Go to "Ground Circuit Inspection" procedure.
Check for open or blown 10A ABS fuse referring to "Circuit Diagram".
Repair open or short in power circuit between battery and HECU harness connector and then go to
"Verification of vehicle Repair" procedure.
GROUND CIRCUIT INSPECTION
1. Ignition "OFF" & Engine "OFF".
2. Disconnect HECU connector.
3. Measure resistance between ground terminal of the HECU harness connector and chassis ground.
Specification : Approx. below 1Ω
Substitute with a known-good HECU and check for proper operation.

If problem is corrected, replace HECU and then go to "Verification of Vehicle Repair" procedure.
Repair open or short in ground circuit between HECU harness connector and chassis ground and then go to
VERIFICATION OF VEHICLE REPAIR

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and select "Diagnostic Trouble Codes(DTCs)" mode.
2. Using a scantool, Clear DTC.
3. Operate the vehicle within DTC Detecting Condition in General Information.
4. Using a scantool, Check DTC present.
Page 94 of 235
5. Are any DTCs present ?
Go to the applicable troubleshooting procedure.
System performing to specification at this time.
SCHEMATIC DIAGRAM
Brake System > Troubleshooting > C1102 cardiagn.com

GENERAL DESCRIPTION
The ABS ECU(Electronic Control Unit) checks the battery voltage and alternator output voltage to determine, as a
safety issue, whether the ABS system can operate normally or not.
The normal battery voltage range is essential for controlling the ABS system as intended.
DTC DESCRIPTION
The ABS ECU monitors the battery voltage and alternator output voltage by reading the value of voltage.
When the voltage is lower than the expected normal value, this code is set.
The ABS/ESC functions are prohibited and the EBD function is allowed on LOW VOLTAGE CONDITION, the
ABS/EBD/ESC functions are prohibited on UNDER VOLTAGE CONDITION.
If the voltage recovers, to within normal operating ranges, then the controller returns to normal operations as well.
Page 95 of 235

● When Vign<9.5V±0.5V is continued for 500msec
during Vref >= 7Km/h.
Enable ● When Vign<8.5V±0.5V is continued for 500msec
Conditions during Vref < 7Km/h or ABS/ESC control.
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- If IGN voltage is recovered to normal operating
voltage, the system recovers to normal state.
Case1 ● Outside the ABS control cycle : Inhibit the ABS/ESC
(Low control, allow the EBD control , The ABS/ESC warning
voltage) ● Poor connection in power
lamps are activated, When the voltage recovers the
supply circuit (IGN+)
normal operating range, erase the error code.
● Faulty HECU
Fail Safe ● Inside the ABS control cycle : Inhibit the ABS/ESC
● Discharge of electricity
control. The ABS/ESC warning lamps are activated.
Althought the voltage recovers the normal operating
range, warning lamps are illuminated and the error code
is always stored.
● When Vign<7.2V±0.5V is continued for 56msec.
Enable
Case2 - If IGN voltage is recovered to normal operating
Conditions
(Under voltage, the system recovers to normal state.
voltage) ● The ABS/EBD/ESC functions are inhibited.
Fail Safe
SPECIFICATION
Normal Voltage ENG "ON"
Range 10V ~ 16V

Page 96 of 235
Specification : Above. 9±0.5V
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Normal Data
Fault is intermittent caused by poor connection in power harness (IGN+) and/or HECU’s connector or was
or damage.

or damage.
Go to "Alternator Output Voltage Inspection" procedure.

Alternator Output Voltage Inspection
■ Charging System Check
2. Maintain ENG RPM 2,500RPM over 2 minutes.
Specification : Above. 9±0.5V

Page 97 of 235
Check that the tension of drive belt, ENG RPM, fuse, terminal of battery, all terminals of alternator are in good
condition and Check for damaged harness and poor connection between alternator and battery.
If OK repair or replace alternator and then go to "Verification of vehicle Repair" procedure.
2. Measure voltage between the battery terminal(+) and power terminal of the HECU harness connector.
Specification : Approx. below 0.2V
Go to "Ground Circuit Inspection" procedure.
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Check for open or blown 10A ABS fuse referring to "Circuit Diagram".
"Verification of vehicle Repair" procedure..
CONTROL CIRCUIT INSPECTION

Repair open or short in ground circuit between HECU harness connector and chassis ground and then go to


Page 98 of 235
SCHEMATIC DIAGRAM
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GENERAL DESCRIPTION
The HECU supplies operating voltage with Steering angle senor (12V), Yaw rate & lateral G sensor (12V), G
sensor (5V).
The HECU monitors supply voltage of each sensor for normal ESC control.
If supply voltage is out of specified range ABS/ESC warning lamps are turned on and ABS/ESC controls are
inhibited.
DTC DESCRIPTION
A failure is detected if the external sensor supply voltage is out of the specified range for more than the specified min.
fault duration.

Page 99 of 235
Item Detecting Condition Possible Cause
● During sensor power ON, If the voltage of sensor
power is out of the specified range for 500ms. ● Faulty HECU
Enable Conditions
● During sensor power OFF, If the voltage of sensor ● Poor connection in power
power is out of the specified range for 500ms. supply circuit to sensor
● ABS/ESP functions are inhibited, EBD function is
Fail Safe
allowed and the ABS/ESC warning lamps are activated.

1. ConneESCct scantool to Data Link Connector(DLC)
3. Monitor the "BATTERY VOLTAGE, 5 VOLT REFERENCE" parameter on the scantool.
Specification : BATTERY VOLTAGE (Approx. 10V ~ 16V)

5 VOLT REFERENCE (Approx. 5V)
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Normal Data
Fault is intermittent caused by poor connection in HECU’s connector or was repaired and HECU memory
was not cleared.
or damage.

Page 100 of 235
or damage.

2. Measure voltage between power terminal of the steering angle sensor, Yaw rate & lateral G sensor, G sensor
harness connector and chassis ground.
Specification : Specification : Approx. 12V (steering angle sensor, Yaw rate & lateral G sensor),
Approx. 5V (G sensor)
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Repair open or short in power circuit between HECU harness connector and steering angle sensor, Yaw rate
& lateral G sensor, G sensor harness connector and then go to "Verification of vehicle Repair" procedure.
If there is no problem in power circuit, Substitute with a known-good HECU and check for proper operation.

SCHEMATIC DIAGRAM
Page 101 of 235
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GENERAL DESCRIPTION
The wheel speed sensor is the essential component the ABS ECU uses to calculate vehicle speed and to determine
whether wheel lock occurs.
For example, rear wheel speed signal is used as a referecnce value, for vehiclespeed, in front wheel drive vehicles,
and if a difference between front andrear wheel speed occurs, then ABS control is performed.
Wheel speed sensor is active hall-sensor type.
DTC DESCRIPTION
The ABS ECU monitors the wheel speed sensor circuit continuously.
If the sensor signal current is continuously out of the specified range for 140msec, then the HECU determines that
the circuit is open/short, and setsthis code.
Warning lamp is turned OFF unless additional faults are detected when the IG KEY is turned ON again, and wheel
speed is more than 10 Km/h (6.2mph).

Page 102 of 235
DTC Strategy ● Current Monitoring
● When the sensor signal current is continuously out of
Enable Conditions the specified range of 4 mA ± 10% ~ 22 mA ± 10% for
140msec.
● Open or short of Wheel speed
1. Only one wheel failure : Inhibit the ABS/ESC control, sensor circuit
allow the EBD control. The ABS/ESC warning lamps ● Faulty Wheel speed sensor
are activated, the EBD warning lamp is not activated.
Fail Safe
2. More than two wheels failure : The ABS/EBD/ESC
functions are inhibited. The ABS/EBD/ESC warning
lamps are activated.
SIGNAL WAVEFORM AND DATA
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Fig1) Normal waveform of wheel speed sensor (Active type)
- High : Approx. 1.4V, Low : Approx. 0.7V.
SPECIFICATION
Sensor Output Voltage Tooth
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

2. Connect scantool to Data Link Connector(DLC).
3. Start and drive vehicle in gear and maintain vehicle speed at or above 10km/h. (6.2mph)
Page 103 of 235
4. Monitor the "WHEEL SPEED(FL)" parameter on the Scantool.
Specification : Compare with other parameters related to wheel speed sensor.

If it is the same as other parameters, it is in normal condition.
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5.
6.
Fig 1) Test Condition : Drive vehicle at a speed of 10km/h or more. (6.2mph or more)
Normal Data
Abnormal Data (Open)
Page 104 of 235
Fault is intermittent caused by poor connection in wheel speed sensor harness (FL) and/or HECU’s connector
or was repaired and HECU memory was not cleared.
or damage.

or damage.
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2. Measure voltage between power terminal of the wheel speed sensor harness connector and chassis ground.
Specification : Approx. B+
4. Go to "Signal Circuit Inspection" procedure.
Repair open or short in power circuit between HECU harness connector and wheel speed sensor harness
connector and then go to "Verification of vehicle Repair" procedure.
If there is no problem in Power circuit, Substitute with a known-good HECU and check for proper operation.
SIGNAL CIRCUIT INSPECTION
■ Wheel speed sensor circuit check
1. Lift the vehicle.
3. Turn the wheel by hand.
Page 105 of 235
4. Measure waveform between wheel speed sensor signal terminal of the HECU harness connector and chassis ground
with osciloscope.
Specification : High : 1.18~1.68V , Low : 0.59~0.84V
Normal waveform
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Fig 1) Normal waveform of wheel speed sensor (Active type)
-High : Approx. 1.4V, Low : Approx. 0.7V
5. Is the measured waveform within specifications?

Repair open or short in signal circuit between HECU harness connector and wheel speed sensor harness
connector, and then go to "Verification of vehicle Repair" procedure.
If there is no problem in signal circuit, go to "Component Inspection" procedure.
COMPONENT INSPECTION
Page 106 of 235
4. Measure waveform between signal terminal of the wheel speed sensor harness connector and chassis ground with
osciloscope.
Normal waveform
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Fault is intermittent caused by poor connection in wheel speed sensor harness (FL).
Go to "Verification of Vehicle Repair" procedure.
Substitute with a known-good Wheel speed sensor and check for proper operation.
If problem is corrected, replace Wheel speed sensor and then go to "Verification of Vehicle Repair" procedure.

3. Operate the vehicle within DTC Detecting Condition in General Information. (Start and drive vehicle in gear and
maintain vehicle speed at or above 10kmh.(6.2mph))
SCHEMATIC DIAGRAM
Page 107 of 235
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GENERAL DESCRIPTION
For example, rear wheel speed signal is used as a referecnce value, for vehicle speed, in front wheel drive vehicles,
and if a difference between front and rear wheel speed occurs, then ABS control is performed.
DTC DESCRIPTION
The ABS ECU monitors the wheel speed sensor signal continuously.
This code is set if an abnormal speed change ratio is detected while the vehicle speed is more than 2Km/h.
speed is more than 10 Km/h.

Page 108 of 235
DTC Strategy ● Signal monitoring
● Max. wheel velocity exceeds 20km/h and the wheel
velocity is 40% of max. wheel velocity. if this condition
is lasted for 2 minutes.
Case1
● Controller counts the number of the wheel
acceleration of 100g[(25km/h) for 7ms]. When the
numbers at one wheel exceed 56 times, or When the
numbers at more two wheels exceed 5 times, controller
recognize the failure.
acceleration of 70g[(17.5km/h) for 7ms]. When the
numbers at more two wheels exceed 20 times,
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controller recognize the failure.
Enable ● Controller counts the number of the wheel
Conditions deceleration of -100g[(-25km/h) for 7ms]. When the ● Improper installation of wheel
numbers at each wheel exceed 56 times, controller speed sensor
recognize the failure. ● Abnormal Rotor and wheel
Case2 bearing
● The wheel deceleration of -100g[(-25km/h) for 7ms]
causes the controller to start monitoring this failure and ● Faulty Wheel speed sensor
to compare the wheel velocity with the vehicle velocity
from next cycle. When its difference of -100g is
continued for more than 140msec, controller recognize
the failure.
● In case that any sensor failure at other wheel was
already detected, When the numbers of 100g at each
wheel exceed 5 times, or When the numbers of 70g at
each wheel exceed 20 times, controller recognize the
failure.
- The counter of speed jump is cleared every 30min.
- This monitoring is performed for the period that the
velocity of each wheel exceeds 2km/h.
1. Only one wheel failure : Inhibit the ABS/ESC control,
allow the EBD control. The ABS/ESC warning lamps
Fail Safe

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SPECIFICATION
cardiagn.com
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type

3. Start and drive vehicle in gear and maintain vehicle speed at or above 40km/h. (24mph)

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cardiagn.com
Fig 1) Test Condition : Drive vehicle at a speed of 40km/h or more. (24mph or more)
Normal Data
Normal Graph
Abnormal Data
Abnormal Data
or damage.
Go to "Component Inspection" Procedure.
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osciloscope.
Normal waveform
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Fault is intermittent caused by faulty HECU, wheel speed sensor or external noise, an interference between
harnesses.
or damage.
If there is no problem in signal circuit, Substitute with a known-good HECU and check for proper operation.
Check for improper installation of wheel speed sensor. If NG, repair as necessary and then go to "Verification
of vehicle Repair" procedure.
Check for damage of rotor teeth or wheel bearing. If NG, repair as necessary and then go to "Verification of
vehicle Repair" procedure.
Substitute with a known-good Wheel speed sensor and check for proper operation. If problem is corrected,
replace Wheel speed sensor and then go to "Verification of Vehicle Repair" procedure.

1. Connect scantool and select "Diagnostic Trouble Codes(DTCs)" mode
maintain vehicle speed at or above 40kmh. (24mph))
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Go to the applicable troubleshooting procedure
System performing to specification at this time
SCHEMATIC DIAGRAM
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GENERAL DESCRIPTION
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DTC DESCRIPTION
This code is set when the sensor air gap is out of specified range or when the ABS control cycle is continued
abnormally.
The HECU checks for air gap malfunctioning by monitoring the sensor signal at speeds between 2Km/h to 10 Km/h.
SCHEMATIC DIAGRAM
● When the minimum wheel velocity is 2km/h and the
velocity of other wheels exceed 10km/h (6.2mph) with
the acceleration of < 0.4g, the controller start comparing
the velocity of other wheels except the min. wheel. if
their difference below 4km/h (2.5mph) is continued for
140msec, Otherwise, if their difference beyond 4km/h
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(2.5mph) or >0.4g is continued for 2 minutes.
● In < 0.4g, when the velocity of more two wheels is
2km/h (1.2mph) and the max. wheel velocity exceeds
Case1
Enable 10km/h (6.2mph), the condition is continued for 20 sec.
(Large
Conditions Otherwise, In >0.4g, the condition is 2 minutes.
Air-Gap)
● After velocity of 4 wheel exceeds 10km/h (6.2mph),
when velocity of 1 wheel or 2 wheel is 2km/h ● Improper installation of wheel
(1.2mph)and difference of other 2 wheel velocity is less speed sensor
than 4km/h (2.5mph) under that those velocity is more ● Abnormal Rotor and wheel
than 10km/h (6.2mph), if that conditions are continued bearing
for 12 seconds. ● Faulty Wheel speed sensor
minimum velocity rises from 2km/h (1.2mph) to 10km/h
(6.2mph).
Case2 ● During the ABS control cycle, if the wheel velocity of
(Long Enable 2km/h (1.2mph) is lasted for more than 12sec.
term ABS Conditions ● If the ABS control cycle is continued for more than
mode) 36sec.
allow the EBD control. The ABS/ESP warning lamps
Fail Safe
2. Only one wheel failure : Inhibit the ABS/ESP control,

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SPECIFICATION
cardiagn.com
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


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Normal Data
Abnormal Data
or damage.
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osciloscope.
Normal waveform

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vehicle Repair" procedure..

maintain vehicle speed at or above 10kmh. (6.2mph))
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DIAGNOSIC CIRCUIT DIAGRAM

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GENERAL DESCRIPTION
DTC DESCRIPTION

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140msec.
Fail Safe
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SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

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5.
6.
Normal Data
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or damage.

or damage.
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Page 121 of 235
with osciloscope.
Normal waveform
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osciloscope.
Normal waveform
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SCHEMATIC DIAGRAM
Page 123 of 235
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GENERAL DESCRIPTION
DTC DESCRIPTION

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Case1
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Case2 bearing
the failure.
failure.
Fail Safe

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SPECIFICATION
cardiagn.com
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


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cardiagn.com
Normal Data
Normal Graph
Abnormal Data
Abnormal Data
or damage.
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osciloscope.
Normal waveform
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harnesses.
or damage.

Page 128 of 235
SCHEMATIC DIAGRAM
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GENERAL DESCRIPTION
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DTC DESCRIPTION
abnormally.
SCHEMATIC DIAGRAM
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Case1
(Large
Air-Gap)
(6.2mph).
mode) 36sec.
Fail Safe

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SPECIFICATION
cardiagn.com
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


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Normal Data
Abnormal Data
or damage.
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osciloscope.
Normal waveform

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Page 133 of 235
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GENERAL DESCRIPTION
DTC DESCRIPTION

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140msec.
Fail Safe
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SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

Page 135 of 235

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5.
6.
Normal Data
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or damage.

or damage.
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Page 137 of 235
with osciloscope.
Normal waveform
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osciloscope.
Normal waveform
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SCHEMATIC DIAGRAM
Page 139 of 235
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GENERAL DESCRIPTION
DTC DESCRIPTION

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Case1
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Case2 bearing
the failure.
failure.
Fail Safe

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SPECIFICATION
cardiagn.com
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


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cardiagn.com
Normal Data
Normal Graph
Abnormal Data
Abnormal Data
or damage.
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osciloscope.
Normal waveform
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harnesses.
or damage.

Page 144 of 235
SCHEMATIC DIAGRAM
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GENERAL DESCRIPTION
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DTC DESCRIPTION
abnormally.
SCHEMATIC DIAGRAM
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Case1
(Large
Air-Gap)
(6.2mph).
mode) 36sec.
Fail Safe

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SPECIFICATION
cardiagn.com
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


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Normal Data
Abnormal Data
or damage.
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osciloscope.
Normal waveform

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Page 149 of 235
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GENERAL DESCRIPTION
DTC DESCRIPTION

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140msec.
Fail Safe
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SPECIFICATION
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 52 0.4~1.5mm
Type

Page 151 of 235

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5.
6.
Normal Data
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or damage.

or damage.
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with osciloscope.
Normal waveform
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osciloscope.
Normal waveform
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SCHEMATIC DIAGRAM
Page 155 of 235
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GENERAL DESCRIPTION
DTC DESCRIPTION

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Case1
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Case2 bearing
the failure.
failure.
Fail Safe

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SPECIFICATION
cardiagn.com
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


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cardiagn.com
Normal Data
Normal Graph
Abnormal Data
Abnormal Data
or damage.
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osciloscope.
Normal waveform
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harnesses.
or damage.

Page 160 of 235
SCHEMATIC DIAGRAM
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GENERAL DESCRIPTION
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DTC DESCRIPTION
abnormally.
SCHEMATIC DIAGRAM
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Case1
(Large
Air-Gap)
(6.2mph).
mode) 36sec.
Fail Safe

Page 162 of 235

SPECIFICATION
cardiagn.com
Airgap
Type HIGH LOW Count
Active
1.4V 0.7V 48 0.5~1.5mm
Type


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Normal Data
Abnormal Data
or damage.
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osciloscope.
Normal waveform

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Page 165 of 235
cardiagn.com
General Description
This transmitter is a transmitter device with tire valve, which is mounted in the valve hole of the wheel rim and
transmits the pressure and temperature inside the tire, the battery voltage of the transmitter, and the tire identification
code (ID) at normal and abnormal condition with the radio wave (RF) that conforms to the used area. Also this
device has a countermeasure function such as the random delay of transmission time so that the RF signal from each
tire will not interfere due to transmission. Wheel sensors shall support usage on steel or aluminum rims.
Sensor transmissions continue when sensor status is 'Normal Fixed State'. Sensor transmissions stop when sensor
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status is 'Storage State' or the sensor battery runs out. The transmitter should transmit data at vehicle speeds
between 0 mph (0 kph) and 186 mph (300 kph). Operating Temperature Range is -40 to 248 °F(-40 to 120 °C).
Transmitter shall enter thermal shutdown once the measured temperature is greater than or equal to 257 °F(125 °C).
The accuracy of the sensor is -9/12.6 °F (-5/7 °C) at this temperature, therefore the actual temperature may be
244.4 °F (118 °C). The sensor shall exit thermal shutdown once the temperature is less than or equal to 212 °F(100
°C). The transmitter shall have the capability to measure the internal battery voltage as an indicator of the end of life
of the sensor. Since the unit is sealed, this parameter cannot be verified with a production unit..
Tire Pressure Monitoring
When 4 sensors have been learned as road wheels, it shall not be possible to learn new road wheel sensors on the
same Ignition cycle. In normal mode low line, tire pressure and temperature shall be transmitted every 3 minutes 20 s
nominally independent of vehicle operation. Monitoring shall be every 20 s. If sensor detects rapid deflation, then RF
messages will be transmitted every 4 s for 1 minute duration. Communication from wheel sensors shall be via RF at
a frequency of 315 MHz, 5 kBaud. Tire pressure measurement tolerance shall be ±7 kPa from 32 to 122 °F(0 to
50 °C) and ±17.5 kPa from -40 to 248 °F(-40 to 120°C) with a range of 100 to 450 kPa. Tire temperature
measurement tolerance shall be ±37.4 °F(±3 °C) from -4 to 158 °F(-20 to 70 °C) and ±9 °F(±5 °C) from -40 to
194 °F(40 to 90 °C) and -9/12.6 degree Fahrenheit (-5/7 degree Celsius) from -40 to 248 degree Fahrenheit (-40
to 120 degree Celsius).
DTC Description
cardiagn.com
This DTC indicates that the Vehicle speed signal is not inputed normally. The most likely cause is speed sensor
failure/ speed signal line's open.
DTC Detecting Condition

DTC strategy • Check speed signal
Enable
• Vehicle is driving under more than 20 km/h.
conditions
• Open in speed signal line
• Speed Sensor input 2 speed > 20 km/h while Speed
Threshold • Faulty Speed sensor
Sensor input 1 speed < 10 km/h.
value
• Invalid Speed Sensor input 1 is measured.
Diagnosis time • 20 seconds
Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminal condition.Faults can also be
2. Thoroughly check all connectors (and connections) for looseness, bending, corrosion, contamination,
deterioration, and/or damage.
Repair if necessary and then go to "Verification of Vehicle Repair" procedure.
Go to "Signal Circuit Inspection" procedure.

Signal Circuit Inspection
Check Open
1. Ignition "OFF"
2. Disconnect Vehicle speed sensor connector and TPMS receiver connector.
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3. Measure resistance between terminal "3" of Vehicle speed sensor harness connector and terminal "18" of TPMS
receiver harness connector.
Specification : Approx. 0 Ω
4. Is the measured resistance within specifications?
Faulty Vehicle speed sensor may cause this DTC.

Substitute with a known-good component and check for proper operation. If problem is corrected, it's failure
should cause this DTC. After doing an appropriate repair, Go to "Verification of Vehicle Repair" procedure.
Repair as necessary in speed signal circuit and then go to "Verification of Vehicle Repair" procedure.
Verification of Vehicle Repair

1. Connect TPMS exciter or scantool and select "Diagnostic Trouble Codes(DTCs)" mode
2. Using a TPMS exciter or scantool, Clear DTC.
cardiagn.com
3. Operate the vehicle within DTC Enable conditions in General information.

GENERAL DESCRIPTION
The pressure sensor, installed in the HECU, sense the brake oil pressure to judge driver’s brake intention when
ESC is operating.
If pressure of master cyclinder is applied to pressure sensor, the strain of the piezo element is changed and then the
resistance of brige circuit is chanded according to changed strain.
Therefore this changed resistance changes output voltage of brige circuit and output voltage changes linearly.
The sensor output is a analog signal in proportion to supply voltage, and the HECU recognizes a pressure value
according to signal ratio about supply voltage.
DTC DESCRIPTION
A failure is detected if the output signal voltage of the pressure sensor is out of specified range.

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DTC Strategy ● Voltage Monitoring
● The output signal voltage of the pressure sensor is out
Enable Conditions of the specified range. ● Open or short of pressure
- The monitoring starts 1sec after power up. sensor circuit
● Faulty pressure sensor
● Inhibit the ESC control and allow the ABS/EBD
Fail Safe control.
● The ESC warning lamp is activated.

3. Press the brake pedal.
4. Monitor the "PRESSURE SENSOR" parameter on the Scantool.
Specification : Approx. 60bar ~150bar (There is difference in displayed parameter according to
cardiagn.com
braking force)

Normal data
Fig 2) Test Condition : Ignition "ON" & Engine "ON" & Brake "ON".
Normal data (There is difference in displayed parameter according to braking force)
5. Whenever brake pedal is pushed down, is the pressure sensor’s scantool data changed?
Fault is caused by having been repaired and HECU memory was not cleared.
Clear the DTC and then go to "Verification of Vehicle Repair" procedure.
Go to "Component Inspection" procedure.
1. Ignition "OFF".
Page 169 of 235
5. Select "Diagnostic Trouble Codes(DTCs)" mode again.

Fault is intermittent caused by faulty HECU.


cardiagn.com
SCHEMATIC DIAGRAM
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GENERAL DESCRIPTION
The pressure sensor, installed in the HECU, sense the brake oil pressure to judge driver’s brake intention when
ESC is operating.
If pressure of master cyclinder is applied to pressure sensor, the strain of the piezo element is changed and then the
resistance of brige circuit is chanded according to changed strain.
Therefore this changed resistance changes output voltage of brige circuit and output voltage changes linearly.
The sensor output is a analog signal in proportion to supply voltage, and the HECU recognizes a pressure value
according to signal ratio about supply voltage.
DTC DESCRIPTION
The failure is detected if the pressure sensor signal noise is out of normal range, or the pressure sensor signal is
changed abnormally.
In spite of no brake switch signal, master cylinder pressure exceeds 20bar when brake switch is normal.

cardiagn.com
● If input signal is noisy, Which the gradient of the
sensor signal is larger than predefined value for specific
times, ECU detect the failure.
Enable Conditions ● Outside an ABS/ESC control, And after normal
● External noise.
operation of BLS, If the pressure sensor signal is higher
● Faulty pressure sensor
than 20bar and BLS is low for 3sec, ECU detect the
failure.
Fail Safe control. .

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4. Monitor the "PRESSURE SENSOR" parameter on the Scantool.
Specification : Approx. 60bar ~150bar (There is difference in displayed parameter according to

braking force)
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Normal data
Fig 2) Test Condition : Ignition "ON" & Engine "ON" & Brake "ON".
Normal data (There is difference in displayed parameter according to braking force)
5. Whenever brake pedal is pushed down, is the pressure sensor’s scantool data changed?
Fault is caused by having been repaired and HECU memory was not cleared.
Clear the DTC and then go to "Verification of Vehicle Repair" procedure.
1. Ignition "OFF".

Fault is intermittent caused by faulty HECU.


Page 172 of 235
SCHEMATIC DIAGRAM

General Description
This transmitter is a transmitter device with tire valve, which is mounted in the valve hole of the wheel rim and
transmits the pressure and temperature inside the tire, the battery voltage of the transmitter, and the tire identification
code (ID) at normal and abnormal condition with the radio wave (RF) that conforms to the used area. Also this
device has a countermeasure function such as the random delay of transmission time so that the RF signal from each
Page 173 of 235
tire will not interfere due to transmission. Wheel sensors shall support usage on steel or aluminum rims.
Sensor transmissions continue when sensor status is 'Normal Fixed State'. Sensor transmissions stop when sensor
status is 'Storage State' or the sensor battery runs out. The transmitter should transmit data at vehicle speeds
between 0 mph (0 kph) and 186 mph (300 kph). Operating Temperature Range is -40 to 248 °F(-40 to 120 °C).
Transmitter shall enter thermal shutdown once the measured temperature is greater than or equal to 257 °F(125 °C).
The accuracy of the sensor is -9/12.6 °F (-5/7 °C) at this temperature, therefore the actual temperature may be
244.4 °F (118 °C). The sensor shall exit thermal shutdown once the temperature is less than or equal to 212 °F(100
°C). The transmitter shall have the capability to measure the internal battery voltage as an indicator of the end of life
of the sensor. Since the unit is sealed, this parameter cannot be verified with a production unit..
Tire Pressure Monitoring
When 4 sensors have been learned as road wheels, it shall not be possible to learn new road wheel sensors on the
same Ignition cycle. In normal mode low line, tire pressure and temperature shall be transmitted every 3 minutes 20 s
nominally independent of vehicle operation. Monitoring shall be every 20 s. If sensor detects rapid deflation, then RF
messages will be transmitted every 4 s for 1 minute duration. Communication from wheel sensors shall be via RF at
a frequency of 315 MHz, 5 kBaud. Tire pressure measurement tolerance shall be ±7 kPa from 32 to 122 °F(0 to
50 °C) and ±17.5 kPa from -40 to 248 °F(-40 to 120°C) with a range of 100 to 450 kPa. Tire temperature
measurement tolerance shall be ±37.4 °F(±3 °C) from -4 to 158 °F(-20 to 70 °C) and ±9 °F(±5 °C) from -40 to
194 °F(40 to 90 °C) and -9/12.6 degree Fahrenheit (-5/7 degree Celsius) from -40 to 248 degree Fahrenheit (-40
to 120 degree Celsius).
cardiagn.com
DTC Description
This DTC indicates that the Vehicle speed signal is not inputed normally. The most likely cause is speed sensor
failure/ speed signal line's open.
DTC Detecting Condition

DTC strategy • Check speed signal
Enable
• Vehicle is driving under more than 20 km/h.
conditions
• Open in speed signal line
• Speed Sensor input 1 speed >20 km/h while Speed
Threshold • Faulty Speed sensor
Sensor input 2 speed < 10 km/h.
value
• Invalid Speed Sensor input 2 is measured.
Diagnosis time • 20 seconds
Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminal condition.Faults can also be
2. Thoroughly check all connectors (and connections) for looseness, bending, corrosion, contamination,
deterioration, and/or damage.
Repair if necessary and then go to "Verification of Vehicle Repair" procedure.

Signal Circuit Inspection
Check Open
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1. Ignition "OFF"
2. Disconnect ECM connector and TPMS receiver connector.
3. Measure resistance between terminal "22(39)" of ECM harness connector and terminal "6" of TPMS receiver
harness connector.
Faulty Vehicle speed sensor may cause this DTC.

Substitute with a known-good component and check for proper operation. If problem is corrected, it's failure
should cause this DTC. After doing an appropriate repair, Go to "Verification of Vehicle Repair" procedure.
Repair as necessary in speed signal circuit and then go to "Verification of Vehicle Repair" procedure.
Verification of Vehicle Repair

cardiagn.com
1. Connect TPMS exciter or scantool and select "Diagnostic Trouble Codes(DTCs)" mode
2. Using a TPMS exciter or scantool, Clear DTC.
3. Operate the vehicle within DTC Enable conditions in General information.

GENERAL DESCRIPTION
The Steering wheel angle sensor uses two sensors ( A-sensor and B-sensor ) to determine the direction of the
rotation.
The main components of each sensor are LED, photo transistor and slit plate.
The slit plate, which has 45 holes, is installed between LED and photo transistor, and generates signals if slit plate
rotates according to the steering wheel rotation.
The sensor signals are generated by photo transistor which is driven whenever the light passes through the holes. The
HECU detects operating speed and direction of the steering wheel by this input signal, and the signal is used to input
signal for anti-roll control.
DTC DESCRIPTION
If some signal voltage stays in abnormal voltage range, the time is counted seperately.
And if the monitored time exceeds the specified min. fault duration, failure is detected.
The monitoring starts 1sec after Power Up.

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● When Vsas >4.2±0.1V or Vsas<1.2±0.1V or
2.1±0.1V<Vsas<2.9±0.1V continue 1sec.
Enable Conditions ● Open or short of steering
- The monitoring starts 1sec after Power Up.
wheel sensor circuit
Vsas : Voltage of the steering angle sensor.
● Faulty steering wheel sensor
Fail Safe control.

3. Turn the steering wheel to the left or right.
4. Monitor the "STEERING SNSR" parameters on the Scantool.
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Specification : If the parameters are changed according to wheel position during steering the wheel,
it is normal condition.

Normal Data
5. Whenever steering wheel is turned, is the steering sensor’s scantool data changed?
Fault is intermittent caused by poor connection in steering sensor harness and/or HECU’s connector or was
or damage.

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or damage.

2. Measure voltage between power terminal of the steering angle sensor harness connector and chassis ground.
Specification : Approx. 12V
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Repair open or short in power circuit between steering angle sensor harness connector and HECU harness
3. Disconnect steering angle sensor connector.
4. Measure resistance between ground terminal of the steering angle sensor harness connector and chassis ground.
Repair open or short in ground circuit between steering angle sensor harness connector and HECU harness
connector and then, go to "Verification of vehicle Repair" procedure.
2. Measure voltage between signal terminal of the HECU harness connector and chassis ground.
Specification : HIGH : 2.9±0.1V ~ 4.4±0.1V, LOW : 1.2±0.1V ~ 2.1±0.1V

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Repair open or short in signal circuit between the steering angle sensor harness connector and HECU harness
connector and then, go to "Verification of vehicle Repair" procedure.
2. Measure voltage between signal terminal of the steering angle sensor harness connector and chassis ground.
Specification : High : HIGH : 2.9±0.1V ~ 4.4±0.1V, LOW : 1.2±0.1V ~ 2.1±0.1V
cardiagn.com
Fault is intermittent caused by poor connection in steering sensor harness and/or HECU’s connector.
Substitute with a known-good steering angle sensor and check for proper operation
If problem is corrected, replace steering angle sensor and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 178 of 235
cardiagn.com
GENERAL DESCRIPTION
The Steering wheel angle sensor uses two sensors ( A-sensor and B-sensor ) to determine the direction of the
rotation.
The main components of each sensor are LED, photo transistor and slit plate.
The slit plate, which has 45 holes, is installed between LED and photo transistor, and generates signals if slit plate
rotates according to the steering wheel rotation.
The sensor signals are generated by photo transistor which is driven whenever the light passes through the holes. The
HECU detects operating speed and direction of the steering wheel by this input signal, and the signal is used to input
signal for anti-roll control.
DTC DESCRIPTION
This monitoring function monitors the changing point of N-signal with measured steering angle from ST1 and ST2.
If N-signal changing point differs more than predefined degree, the failure is detected.
If there is no variation of the steering wheel angle for predefined time ECU detect the failure.

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DTC Strategy ● Signal Monitoring
● The STN is low more than ±20 degrees for 70msec.
● When the steering wheel is turned more than 370±5
degrees, if center is not detected, ECU detects the
failure.
● When the steering wheel angle is higher than 700
degrees ECU detects the failure.
● During straight driving, if the steering wheel angle is
larger than 55±5 degree ECU detects the failure.
Enable Conditions ● When the curve is detected after driving straight, if
● External noise
there is no variation of the steering wheel angle for 3sec,
● Faulty steering wheel sensor
ECU detect the failure.
● While the vehicle drive 60±5 degree ↔ -60±5
degree, if STN is not detected low, ECU detect the
failure.
● While steering angle sensor wheel through center, if
steering angle sensor is against specification three times,
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ECU detect the failure.
Fail Safe control.
Fig 1) Normal waveform of steering angle sensor with turning left after ENG "ON"
: Output signal change ("LOW" → "HIGH") is detected first in ST1.
Fig 2) Normal waveform of steering angle sensor with turning right after ENG "ON"
Fig 3) Normal waveform of steering angle sensor being center position after ENG "ON"
: Output signal change ("HIGH (approx 3.5V)" → "LOW") is detected when steering wheel is passing by on center
position.
"LOW" : approx 1.5V, "HIGH" : approx 3.5V.

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4. Monitor the "STEERING ANGLE SNSR" parameters on the Scantool.
Specification : If the parameters are changed according to wheel position during steering the wheel,
it is normal condition.
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Normal Data
Normal Graph
Abnormal Graph
5. Whenever steering wheel is turned, is the steering sensor’s scantool data changed?
Fault is intermittent caused by poor connection in steering sensor harness and/or HECU’s connector or was
or damage.

Page 181 of 235
or damage.

3. Measure waveform between signal terminal of the HECU harness connector and chassis ground with osciloscope.
Specification : Check the voltage range (HIGH : 2.9±0.1V ~ 4.4±0.1V LOW : 1.2±0.1V ~
2.1±0.1V) of the sensor signal in case of turning left, turning right, center position. If normal
cardiagn.com
waveforms such as fig1, 2, 3 are detected in each condition, It is normal.
Normal waveform
: Output signal change ("HIGH" → "LOW") is detected when steering wheel is passing by on center position.

Repair open or short in signal circuit between steering angle sensor harness connector and HECU harness
connector, and then go to "Verification of vehicle Repair"
If there is no problem in Signal circuit, Substitute with a known-good HECU and check for proper operation.
Page 182 of 235
■ Steering Angel Sensor Check
3. Measure waveform between signal terminal of the steering angle sensor harness connector and chassis ground with
osciloscope.
Specification : Check the voltage range (HIGH : 2.9±0.1V ~ 4.4±0.1V LOW : 1.2±0.1V ~
2.1±0.1V) of the sensor signal in case of turning left, turning right, center position. If normal
waveforms such as fig1, 2, 3 are detected in each condition, It is normal.
Normal waveform
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: Output signal change ("HIGH" → "LOW") is detected when steering wheel is passing by on center position.
Fault is intermittent caused by poor connection in steering sensor harness and/or HECU’s connector.
Go to "Verification of vehicle Repair" procedure.
If STN signal is HIGH on center position, Check for improper installation of steering angle sensor.
Repair as necessary and then go to "Verification of vehicle Repair" procedure.
If sensor mounting state is normal, Substitute with a known-good steering angle sensor and check for proper
operation.
If problem is corrected, replace steering angle sensor and then go to "Verification of Vehicle Repair" procedure.

Page 183 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
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The 4WD vehicle measures the G-sensor signal to solve for 4WD vehicle unique problems. For example all 4
wheels are locked early on a low-friction road or control response is delayed when road friction coefficients vary.
The HECU uses a filtered signal, as a supplementary value, to determine the road friction coefficient. This value is
used for the accurate calculations of assumed vehicle speed, or precise division of control starting points.
DTC DESCRIPTION
The HECU monitors the G-sensor voltage continuosly,and sets this code if the voltage is either higher than the
permissible normal value ( approx. 4.5 V ) or lower than the value ( approx. 0.6V ) for more than 250ms.

Page 184 of 235
●When the voltage of G sensor signal is >4.5±0.1V or ● Open or short of G-Sensor
Enable Conditions
<0.6±0.1V for 250msec continuously. circuit
● Faulty G-Sensor
● ABS/ESC functions are inhibited, EBD function is
Fail Safe

3. Monitor the "G Sensor" parameter on the Scantool.
Specification : Approx. ±0.01G
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Fig 1) Test Condition : Ignition "ON" & Engine "OFF"
Normal Data
G-sensor open circuit Data
Fault is intermittent caused by poor connection in G sensor harness and/or HECU’s connector or was repaired
and HECU memory was not cleared.
or damage.

1. Many malfunctions in the electrical system are caused by poor harness(es) and terminal condition. Faults can also
be caused by interference from other electrical systems, and mechanical or chemical damage.
or damage.
Page 185 of 235

2. Measure voltage between power terminal of the G sensor harness connector and chassis ground.
Repair open or short in power circuit between the G sensor harness connector and HECU harness connector
and then, go to "Verification of vehicle Repair" procedure.
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2. Disconnect the G sensor connector.
3. Measure resistance between ground terminal of the G sensor harness connector and chassis ground.
Repair open or short in ground circuit between the G sensor harness connector and HECU harness connector
and then, go to "Verification of vehicle Repair" procedure.
2. Measure voltage between G sensor signal terminal of the HECU harness connector and chassis ground.
Specification : Approx. 2.5V

Repair open or short in signal circuit between the G sensor harness connector and HECU harness connector,
and then go to "Verification of vehicle Repair" procedure.
If there is no problem in Signal circuit, Go to "Component Inspection" procedure.
Page 186 of 235
2. Measure voltage between signal terminal of the G sensor harness connector and chassis ground.
Fault is intermittent caused by poor connection in G sensor harness and/or HECU’s connector.
Substitute with a known-good G sensor and check for proper operation

If problem is corrected, replace G sensor and then go to "Verification of Vehicle Repair" procedure.

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SCHEMATIC DIAGRAM
Page 187 of 235
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GENERAL DESCRIPTION
The 4WD vehicle measures the G-sensor signal to solve for 4WD vehicle unique problems. For example all 4
wheels are locked early on a low-friction road or control response is delayed when road friction coefficients vary.
The HECU uses a filtered signal, as a supplementary value, to determine the road friction coefficient. This value is
used for the accurate calculations of assumed vehicle speed, or precise division of control starting points.
DTC DESCRIPTION
The HECU monitors the G-sensor voltage continuosly,and sets this code if the G-sensor value is either higher than
0.5G for more than 20 seconds when vehicle speed is above 10 Km/h and brake switch is OFF, or if G-sensor
value is lower than 0.1G for more than 60 seconds when wheel sensor minimum value is above 0.2G.

DTC Strategy ● Signal Monitoring
●When vehicle speed is >10km/h and the brake light ● Improper installation of G-
switch is off, |G>0.5G for 20sec continuously. Sensor
Enable Conditions
● When |min wheel speed| / dt ≥0.2G and |G| ≤0.1G for ● Abnormal Rotor and wheel
60sec continuously. bearing
● Faulty G-Sensor
● ABS/ESC functions are inhibited, EBD function is
Fail Safe
Page 188 of 235

3. Start and drive vehicle in gear and maintain vehicle speed is approx. 10km/h or more (6mph or more) and then
accelerate and decelerate the vehicle several times.
4. Monitor the "G-sensor" parameter on the Scantool.
Specification : Below 0.4G (at a uniform speed)

It is a normal condition if the data is changed while accelerating or decelerating the vehicle
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Fig 1) Test Condition : Drive vehicle in 10km/h or more (6mph or more)
Normal Data
Fault is intermittent caused by poor connection in G sensor harness and/or HECU’s connector or was repaired
and HECU memory was not cleared.
or damage.

1. Many malfunctions in the electrical system are caused by poor harness(es) and terminal condition. Faults can also
be caused by interference from other electrical systems, and mechanical or chemical damage.
or damage.

Page 189 of 235
■ G Sensor Check
1. Check installation condition of G-sensor. If NG, repair as necessary and go to "Verification vehicle Repair"
procedure.
2. Check damage of rotor teeth or wheel bearing. If NG, repair as necessary and go to "Verification vehicle Repair"
procedure.
4. Measure waveform between signal terminal of the G sensor harness connector and chassis ground with
osciloscope.

0.3V ~ 4.7V (acceleration or deceleration)
Fault is intermittent caused by poor connection in G sensor harness and/or HECU’s connector.
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Substitute with a known-good G sensor and check for proper operation.
If problem is corrected, replace G sensor and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 190 of 235
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GENERAL DESCRIPTION
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 leverarm
by later G.
to lateral G.
It interchanges signals with HECU through extra CAN line which only used for communication between HECU and
sensor.
DTC DESCRIPTION
A failure is detected if the Yaw rate & later G sensor message was not received or HECU detects sensor CAN Bus
off state for more than the specified failure detection time.
The Monitoring starts 1sec after Power Up.
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DTC
● Yaw rate & later G sensor message monitoring
Strategy
Case1 ● In case that Yaw rate & later G sensor message was
Enable not received for more than 500ms within normal voltage
Conditions condition.
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- The Monitoring starts 1s after Power Up. ● Faulty Yaw Rate & Lateral G
sensor
DTC
● Open, short monitoring ● Open or short of Yaw Rate &
Strategy
Case2 Lateral G sensor
Enable ● In case sensor CAN BUS off state continued for
Conditions more than 100ms.
Fail Safe control.

3. Monitor the "Lateral G Sensor, Yaw Rate Sensor" parameter on the Scantool.
Specification : Lateral G Sensor : approx. ± 0.0 G, YAW Rate Sensor :approx. ± 0.0 deg/s
Page 192 of 235
Fig 1) Test Condition : Ignition "ON" & Engine "OFF".

Yaw Rate Sensor Normal Data
Lateral G Sensor Normal Data
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Fault is intermittent caused by poor connection in Yaw Rate & Lateral G sensor harness and/or HECU’s
connector or was repaired and HECU memory was not cleared.
or damage.

1. Many malfunctions in the electrical system are caused by poor harness(es) and terminal condition.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
or damage.

2. Measure voltage between power terminal of the Yaw Rate & Lateral G sensor harness connector and chassis
ground.

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Go to "Ground Circuit Inspection" procedure
Repair open or short in power circuit between the yaw rate & lateral G sensor harness connector and HECU
harness connector and then, go to "Verification of vehicle Repair"
2. Disconnect yaw rate & lateral G sensor connector.
3. Measure resistance between ground terminal of the yaw rate & lateral G sensor harness connector and chassis
ground.
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Repair open or short in ground circuit between the yaw rate & lateral G sensor harness connector and HECU
harness connector and then, go to "Verification of vehicle Repair"
■ Short Check (to ground)
2. Disconnect yaw rate & lateral G sensor, HECU connector.
3. Measure resistance between CAN LOW terminal, CAN HIGH terminal of the yaw rate & lateral G sensor
harness connector and chassis ground.
Specification : ∞ Ω
Go to next procedure.
Repair short to ground in CAN signal circuit in case of abnormal resistance measured and then go to
■ Short Check (to battery)
3. Measure voltage between CAN LOW terminal, CAN HIGH terminal of the HECU harness connector and
chassis ground.
Specification : Approx. 0 V
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Repair short to battery in CAN signal circuit in case of abnormal voltage measured and then, go to
■ Internal Resistance Check
3. Measure resistance between CAN LOW terminal and CAN HIGH terminal of the HECU connector.
Go to "Component Circuit Inspection" procedure.

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■ Component Resistance Check
3. Measure resistance between CAN LOW terminal and CAN HIGH terminal of the HECU harness connector.
Fault is intermittent caused by poor connection in yaw rate & lateral G sensor harness and/or HECU’s
connector.
Go to "Verification of vehicle Repair" procedure.
In case of the resistance "approx. 1Ω" : Repair mutual short in CAN signal circuit of the yaw rate & lateral G
sensor and then go to "Verification of vehicle Repair" procedure.
In case of the resistance "∞ Ω" : Repair open in CAN signal circuit of the yaw rate & lateral G sensor and then
go to "Verification of vehicle Repair" procedure.
If there is no problem in CAN signal circuit, Substitute with a known-good yaw rate & lateral G sensor and
check for proper operation.
If problem is corrected, replace the yaw rate & lateral G sensor and then go to "Verification of Vehicle Repair"
procedure.

Page 195 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
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by later G.
to lateral G.
sensor.
DTC DESCRIPTION
A lateral acceleration reference signal is calculated from the wheel speeds, the steering angle and the yaw rate signals
to observe the lateral acceleration sensor signal.
Page 196 of 235
The difference between the reference signal and the sensor signal is evaluated for failure detection. A yaw rate
reference signal is calculated from the wheel speeds, the steering angle and the lateral acceleration signals to observe
the yaw rate sensor signal.
The difference between the reference signal and the sensor signal, and the gradient of the measured sensor signal is
evaluated for the failure detection.
If the difference between estimated value and measured value of the sensor is larger than predefined value for
predefined time, the failure is recognized.

● When the difference between estimated value and
Enable
Case1 measured value of the yaw rate sensor is lager than
Conditions
Predefined value for specific time , ECU detects failure.
● When the difference between estimated value and
Enable
Case2 measured value of the lateral G sensor is lager than
Conditions
Predefined value for specific time , ECU detects failure.
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● Yaw signal is smaller than predefined value when ● Faulty Yaw Rate & Lateral G
CBIT is transmitted sensor
Enable
Case3 ● Lateral G signal is smaller than defined value when
Conditions
CBIT is transmitted.
CBIT : Commanded Built In Test
Enable ● In case that Yaw&LG Sensor Fail Flag is detected for
Case4
Conditions defined time
Fail Safe control.

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3. Monitor the "Lateral G Sensor, Yaw Rate Sensor" parameter on the Scantool.
Specification : Lateral G Sensor : approx. ± 0.0 G, YAW Rate Sensor :approx. ± 0.0 deg/s
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Yaw Rate Sensor Normal Data
Lateral G Sensor Normal Data
Fault is intermittent caused by poor connection in Yaw Rate & Lateral G sensor harness and/or HECU’s
connector or was repaired and HECU memory was not cleared.
or damage.

1. Many malfunctions in the electrical system are caused by poor harness(es) and terminal condition.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
or damage.
1. Ignition "OFF".
Page 198 of 235
1) Substitute with a known-good Yaw Rate & Lateral G sensor and check for proper operation.
If problem is corrected, replace Yaw Rate & Lateral G sensor and then go to "Verification of Vehicle Repair"
procedure.
2) Substitute with a known-good HECU and check for proper operation.
Fault is intermittent caused by faulty Yaw Rate & Lateral G sensor or poor connection in Yaw Rate & Lateral
G sensor harness and/or HECU’s connector. Go to "Verification of Vehicle Repair" procedure.

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SCHEMATIC DIAGRAM
Page 199 of 235
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GENERAL DESCRIPTION
Driver can inhibit the ESC control by ESC switch.
When switch signal send into HECU, ESC warning lamp go ON and ESC control is stopped and if next switch
signal is inputted again, ESC control is ready. This function is used for sporty driving or vehicle inspection.
DTC DESCRIPTION
Trouble code is set when the condition that the level of ESC switch is high is continued for 60sec.
When the ESC switch failure is set, Warning lamps won't illuminate and HECU allow the ABS/EBD/ESC control.

DTC Strategy ● Circuit Monitoring
Enable Conditions ● When the ESC switch is ON for 1 minute. ● Open or short ESC switch
circuit
Fail Safe ● Faulty ESC switch
control.
SPECIFICATION
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ESC switch ESC switch
Engine ON HIGH LOW
7.0V ~ 16.0V 0V ~ 3.0V

3. Press the ESC SWITCH.
4. Monitor the "ESC SWITCH" parameter on the scantool.
Specification : It is changed to ON/OFF.
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Normal Data
5. Whenever the switch is pushed up/down, is the ESC off switch’s scantool data changed ON/OFF?
Fault is intermittent caused by poor connection in ESC switch line or was repaired and HECU memory was
not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage.

or damage.
Page 201 of 235

2. Press the ESC SWITCH.
3. Measure voltage between ESC switch signal terminal of the HECU harness connector and chassis ground.
Specification : Approx B+
Check for open or blown 10A fuse referring to "Circuit Diagram".
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Repair open or short in power circuit between battery and HECU harness connector and then, go to
If there is no problem in circuit, Go to "Component Inspection" procedure.
■ ESC switch Check
2. Disconnect the ESC switch connector.
3. Measure resistance between power terminal and siganl terminal of the ESC switch connector.
Specification : Approx. below 1Ω (In case of pressing the ESC switch)

Approx. ∞ Ω (In case of not pressing the ESC switch)
Fault is intermittent caused by poor connection in ESC switch harness and/or HECU’s connector.
Substitute with a known-good ESC switch and check for proper operation.
If problem is corrected, replace ESC switch and then go to "Verification of Vehicle Repair" procedure.

Page 202 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
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This switch is mounted on the pedal assembly and is used to indicate brake pedal status to the HECU.
The switch is turned on when brake is depressed.
The brake light switch is a normally-open contact which runs to battery voltage when active (brake depressed).
When passive (brake not depressed), the cable is grounded via the brake light bulbs.
DTC DESCRIPTION
The brake light signal is a reference to judge driver's intention for braking.
The HECU checks open or short circuit of brake light switch for normal ESC control.
f an error is present, the warning lamp will illuminate.

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DTC Strategy ● Open circuit monitoring
● If both BLS(brake lamp switch) and BS(brake switch) have a same state
and MCP (Master Cylinder Pressure) >15bar for 500ms. ● Open circuit in
● Outside an ABS/ESC control, and after normal operation of MCP, If the brake switch line
Enable
pressure sensor signal is higher than 15bar and BLS is low for 3sec. ● Faulty brake light
Conditions
● If the BLS/BS changed more than 40times and MCP>15bar for 5sec. switch
● While Vehicle speed > 10km/h, MCP<7bar, if BLS is the same with BS ● Faulty input stage
over 1min. in HECU
● Inhibit the ESC control and allow the ABS/EBD control.
Fail Safe
SPECIFICATION
Voltage Range of "High" Voltage Range of "Low"
Brake Light Switch
7.0V ~ 16.0V 0V ~ 3V
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4. Monitor the "BRAKE SWITCH" parameter on the scantool.
Specification : It is changed to ON/OFF.

Normal Data
Page 204 of 235
5. Whenever brake pedal is pushed down, is the brake switch’s scantool data changed ON/OFF?
Fault is intermittent caused by poor connection in brake light switch harness and/or HECU’s connector or was
or damage.

or damage.
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Go to "Signal Circuit Inspection (brake pedal isn’t depressed)" procedure.
Signal circuit inspection (brake pedal isn’t depressed)
2. Measure voltage between stop lamp switch (brake switch) terminal of the HECU harness connector and hassis
ground.
Specification : Stop lamp switch - 0V

Brake switch B - B+
Go to "Signal Circuit Inspection (brake pedal is depressed)" procedure.
Check for open or blown 15A, 10A fuse referring to "Circuit Diagram".
Signal circuit inspection (brake pedal is depressed)
3. Measure voltage between stop lamp switch (brake switch) terminal of the HECU harness connector and chassis
ground.
Specification : Stop lamp switch - B+

Brake switch B - 0 V
Page 205 of 235
Fault is intermittent caused by poor connection in brake light switch harness and/or HECU’s connector.
Check for open or blown 15A, 10A fuse referring to "Circuit Diagram".
■ Brake light switch Check
2. Disconnect the stop lamp switch connector.
3. Measure resistance between power terminal and siganl terminal of the stop lamp switch connector.
Specification : Resistance between terminals of the stop lamp switch - ∞Ω (when the plunger is
pushed down), 0Ω (when the plunger isn’t pushed down).
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Fault is intermittent caused by poor connection in brake light switch harness and/or HECU’s connector.
Substitute with a known-good brake light switch and check for proper operation.
If problem is corrected, replace brake light switch and then go to "Verification of Vehicle Repair" procedure.

SCHEMATIC DIAGRAM
Page 206 of 235
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GENERAL DESCRIPTION
The HECU consists of an ECU (Electronic Control Unit ) and a HCU( Hydraulic Control Unit).
The HCU portion of the assembly contains a pump motor, solenoid valves, and accumulator.
Increase and decrease of hydraulic pressure is opreated by electronic motor, according to a measured signal by
wheel speed sensor.
The function of HCU is to increase, decrease or maintain the hydralic pressure supplied to a wheel cylinder by
operating return pump according to HECU control signal while ABS control is active.
The ECU monitors various sensor and switch inputs.
These inputs are used to make decisions regarding HCU component operation.
DTC DESCRIPTION
The HECU monitors the operation of the IC components such as memory, register, A/D converter and so on.
The ECU sets this code when the EEPROM data read by the master processor is different than prior data written,
or when the master/slave processor detects abnormal operation in RAM, Status Register, Interrupt, Timer, A/D
converter or cycle time.

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Possible
Item Detecting Condition
cause
DTC Strategy ● Internal monitoring
● When the MCU can't erase or write a data of the EEPROM.
Enable
● When the master/slave processor detects abnormal operation in RAM, status ● Faulty
Conditions
register, interrupt, timer, A/D converter and cycle time. HECU
● The ABS/EBD/ESC functions are inhibited.
Fail Safe

or damage.
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Go to "Component Inspection" procedure

Fault is intermittent caused by faulty HECU or was repaired and HECU memory was not cleared.

SCHEMATIC DIAGRAM
Page 208 of 235
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GENERAL DESCRIPTION
The HECU sends requirement data, such as Torque reduction, the number of fuel cut cylinders, and ESC control
requests, to the Engine PCM(ECM & TCM) through CAN bus line.
The Engine PCM(ECM) performs fuel cut functions according to requests from the HECU and retards ignition
timing by torque reduction requests.
The PCM(TCM) maintains current gear positions during ESC control time, in order not to increase power which
causes a Kickdown shift.
DTC DESCRIPTION
The HECU checks the CAN RAM for normal TCS control, and sets this code if a CAN RAM malfunction is
detected.

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DTC Strategy ● CAN RAM monitoring
Enable Conditions ● CAN Hardware failure.
● Faulty HECU
● Inhibit the ESC control and allow the
Fail Safe ABS/EBD control.

or damage.
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Go to "Component Inspection" procedure


SCHEMATIC DIAGRAM
Page 210 of 235
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GENERAL DESCRIPTION
DTC DESCRIPTION
The HECU checks the CAN communcation lines for normal ESC control, and sets this code if an ECM message is
not received within 500ms.
The HECU does not detect this code until 2 seconds after the IG KEY is turned to ON.

Page 211 of 235
DTC Strategy ● CAN message monitoring
● In case that EMS1 or EMS2 message was not
received for more than 500ms within normal voltage
Enable Conditions
condition. ● Faulty PCM(ECM)
- The Monitoring starts 2000 ms after Power Up. ● Faulty HECU
Fail Safe control.

or damage.
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Go to "Signal circuit inspection" procedure.

■ Open Check
2. Disconnect HECU and ECM connector.
3. Measure resistance between CAN HIGH, LOW terminal of the HECU harness connector and CAN HIGH,
LOW terminal terminal of the ECM harness connector.
Specification : Approx. 0Ω
Go to "Component inspection" procedure.
Repair open in CAN BUS line between HECU harness connector and ECM harness connector and then go
to "Verification of Vehicle Repair" procedure.
1. Ignition "OFF".
Page 212 of 235
Substitute with a known-good PCM and check for proper operation. If problem is corrected, replace PCM
and then go to "Verification of Vehicle Repair" procedure.
If NG, replace HECU and then go to "Verification of Vehicle Repair" procedure.
Fault is intermittent caused by faulty HECU, faulty PCM(ECM) or was repaired and HECU memory was not
cleared.

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SCHEMATIC DIAGRAM
Page 213 of 235
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GENERAL DESCRIPTION
Page 214 of 235
DTC DESCRIPTION
The HECU checks the CAN communication lines for normal ESC control, and sets this code if a TCM message is
not received within 500ms.
The HECU does not detect this code until 2 seconds after the IG KEY is turned to ON.

● In case that TCU message was not received for more
Enable Conditions than 500ms within normal voltage condition.
● Faulty PCM(TCM)
- The Monitoring starts 2000 ms after Power Up.
● Faulty HECU
Fail Safe control.
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or damage.

■ Open Check
2. Disconnect HECU and TCM connector.
LOW terminal terminal of the TCM harness connector.
Repair open in CAN BUS line between HECU harness connector and TCM harness connector and then go
to "Verification of Vehicle Repair" procedure.
1. Ignition "OFF".
Page 215 of 235
Substitute with a known-good PCM(TCM) and check for proper operation. If problem is corrected, replace
PCM(TCM) and then go to "Verification of Vehicle Repair" procedure..
Fault is intermittent caused by faulty HECU, faulty PCM(TCM) or was repaired and HECU memory was not
cleared.

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SCHEMATIC DIAGRAM
Page 216 of 235
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GENERAL DESCRIPTION
The HECU send requirement data, such as Torque reduction, the number of fuel cut cylinders, and ESC control
DTC DESCRIPTION
The HECU checks the CAN communcation lines for normal ESC control, and sets this code if the data received
between the EMS2 and TCM is not the same.
The HECU will not detect this code until 2 seconds after the IG KEY is turned ON.

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● In case that the information about transmission is
different in the EMS2 message and TCM message
Enable Conditions
within normal voltage condition. ● Faulty PCM(ECM)
- The Monitoring starts 2000 ms after Power Up. ● Faulty HECU
Fail Safe control.

or damage.
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■ Open Check
2. Disconnect HECU and ECM connector.
LOW terminal terminal of the ECM harness connector.
Repair open in CAN BUS line between HECU and ECM and then go to "Verification of Vehicle Repair"
procedure.
1. Ignition "OFF".
Page 218 of 235
Substitute with a known-good PCM(ECM) and check for proper operation. If problem is corrected, replace
PCM(ECM) and then go to "Verification of Vehicle Repair" procedure.
Fault is intermittent caused by faulty HECU, faulty PCM(ECM) or was repaired and HECU memory was not
cleared.

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SCHEMATIC DIAGRAM
Page 219 of 235
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GENERAL DESCRIPTION
Page 220 of 235
DTC DESCRIPTION
The HECU checks the CAN communication lines for normal TCS control, and sets this code if CAN BUS OFF
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status is detected for more than 100ms.

DTC Strategy ● Open or short circuit monitoring
● In case CAN BUS off state continued for more than
Enable Conditions ● Open or short circuit in CAN
100ms.
line
● Inhibit the ESC control and allow the ABS/EBD ● Faulty HECU
Fail Safe control.

or damage.
Go to "CAN Signal Circuit Inspection" procedure.

CAN Signal Circuit Inspection
■ Short Check (to ground)
2. Disconnect the HECU connector.
Page 221 of 235
3. Measure resistance between CAN LOW terminal, CAN HIGH terminal of the HECU harness connector and
chassis ground.
Specification : ∞ Ω
If abnormal resistance is detected in CAN HIGH circuit, Repair short to ground in CAN HIGH circuit and
then go to "Verification of vehicle Repair" procedure.
If abnormal resistance is detected in CAN LOW circuit, Repair short to ground in CAN LOW circuit and then
go to "Verification of vehicle Repair" procedure.
■ CAN BUS Resistance Check
3. Measure resistance between CAN LOW terminal and CAN HIGH terminal of the HECU harness connector.
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In case of the resistance "approx. 1Ω" : Repair mutual short in CAN signal circuit of the HECU and then go to
In case of the resistance "∞ Ω" : Repair open in CAN signal circuit of the HECU and then go to "Verification of
In case of the resistance "approx. 120 Ω" : Check the resistances(122Ω) in I/P junction box and ECM, repair
as necessary and then go to "Verification of vehicle Repair" procedure.
1. Ignition "OFF".

Fault is intermittent caused by poor connection in CAN signal harness and/or HECU’s connector.

Page 222 of 235
SCHEMATIC DIAGRAM

GENERAL DESCRIPTION
by later G.
to lateral G.
sensor.
DTC DESCRIPTION
The HECU checks the sensor CAN H/W for normal ESC control, and sets this code if a sensor CAN H/W
Page 223 of 235
malfunction is detected.

DTC Strategy ● Internal Monitoring
Enable Conditions ● Sensor CAN H/W failure ● Faulty HECU
● Faulty Yaw Rate & Lateral G
sensor
Fail Safe control.

or damage.
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Page 224 of 235
SCHEMATIC DIAGRAM
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GENERAL DESCRIPTION
The HECU supplies battery power to all soleonid valves with a valve relay which is controlled by the Electronic
Control UNIT(ECU).
The valve relay and all solenoid valves are installed inside the HECU ( Hydraulic and Electronic Control Unit ).
DTC DESCRIPTION
ABS ECU monitors voltage of the valve relay to check if ABS ECU can perform ABS control normally.
When the valve relay is switched to ON, the HECU will set this code if the solenoid drive voltage is below
permissible voltage ranges for a period of time.
When the valve relay is switched to OFF, the HECU sets this code if the solenoid drive voltage is over the
permissible voltage range for a period of time.

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● If the valve relay is switched on and the reference
Case1 Enable
voltage of valve relay < 5±0.5V continuously for
(Open) Conditions
56ms, the failure is detected. ● Open or short of power
● If the valve relay is switched off and voltage of valve supply circuit (ABS2)
Case2(Short Enable
relay > 6±0.5V or < 2.5±0.5V continuously for 56ms, ● Faulty HECU
or Leakage) Conditions
the failure is detected.
Fail Safe
MONITOR ACTUATION TEST

3. Select the "Actuation Test" mode on the scantool.
4. Inspect opearating status of all vlaves with Actuation Test.
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Specification : It’s normal if operating sound is heard.

Ex) Actuation Test on Front left valve(in)
5. Do all valves operate normally?
Fault is intermittent caused by poor connection in power harness (ABS2) and/or HECU’s connector or was
or damage.

Page 226 of 235
or damage.

2. Measure voltage between power(ABS2) terminal of the HECU harness connector and chassis ground.
Specification : B+
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Check for open or blown 40A (ABS2) fuse referring to "Circuit Diagram".

Repair open or short in ground circuit between HECU harness connector and chassis ground, and then go to

Page 227 of 235
SCHEMATIC DIAGRAM

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GENERAL DESCRIPTION
BTCS ( Brake Traction Control System ) is operated when the value ( Wheel acceleration value + speed difference
value ) exceeds the specified value when vehicle speed is lower than the 50 Km/h.
The BTCS intalled HECU calculates the DISC temperature logically, which is an assumed value, by using the value
of Wheel speed, vehicle speed change, CONTROL MODE and BLS SIGNAL.
Assumed DISC Temperature is used to protect DISC overheating, caused by long-time operation, which may cause
a decrease in brake efficiency.
DTC DESCRIPTION
If the HECU decides that the Disc is over-heated ( above 500 °C ), then it turns the ESC lamp ON and inhibits
BTCS operation to protect overheating of the disc.
If the calculated temperature becomes lower than specified value ( arrox. 300 °C ), then the HECU turns the ESC
Page 228 of 235
lamp OFF and operates the BTCS again.

● When the calculated temperature of disc is higher than
predefined value(500°C).
If the calculated temperature drops below 300°C, the
Enable Conditions controller recovers to normal state.
● Faulty HECU
- When IGN switched OFF, HECU calculate
● Brake disk over heat
temperature of disc until calculated temperature drops
below 80°C by BATT1 power.
Fail Safe control.
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1. Wait untill the brake disc cool down sufficiently.

Fault is caused by Faulty HECU or was repaired and HECU memory was not cleared.
The DTC code can be set by excessive TCS control in normal system status. Go to "Verification of Vehicle
Repair" procedure.


GENERAL DESCRIPTION
Page 229 of 235
The ABS HECU is composed of a ECU (Electronic Control Unit ) and an HCU( Hydraulic Control Unit), so the
HECU hardware includes all solenoid valves inside the unit as well as the ECU.
Solenoid valves are switched to ON, OFF by HECU when the ABS is activated. Solenoid valves function is to
increase, decrease or maintain the hydralic pressure supplied to a wheel cylinder.
DTC DESCRIPTION
The HECU monitors the operation of the valves by checking the drive circuit of the solenid valves, and then sets this
code when the unexpcted drive voltage is detected.
For example, the HECU sets the DTC if an unexpected high drive voltage is detected when the valve relay is
switched to OFF. (or unexpected low voltage is detected when the solenoid valve drive TR is switched to ON)

● If the valve relay is switched ON and corresponding
solenoid driver OFF and the voltage of solenoid <
3.5±0.5V continuously for 56ms, the failure is detected.
Enable Conditions
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● If the valve relay is switched ON and corresponding ● Faulty HECU
solenoid driver ON and the voltage of solenoid >
1.5±0.5V continuously for 56ms, the failure is detected.
Fail Safe


Page 230 of 235
or damage.

or damage.
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maintain vehicle speed at or above 40kmh. (24mph)).
SCHEMATIC DIAGRAM
Page 231 of 235
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GENERAL DESCRIPTION
The ABS ECU supplies battery power to the electric motor by way of a motor relay which is controlled by the
Electronic Control Unit(ECU).
The electric motor pump supplies hydraulic pressure to all wheel brake calipers by operating the piston inside the
pump.
DTC DESCRIPTION
The ABS ECU monitors the pump motor relay or fuse open, open or short in motor or motor lock and then sets this
code if a malfunction is detected.

Page 232 of 235
Case1
(Motor
Relay ● If the motor relay is switched ON and motor voltage
Enable
Open or < (IGN voltage - 4V±0.5V) continued for 49msec, the
Conditions
Motor failure is detected.
Short to
GND)
● After motor relay is switched OFF, VMR is
measured. If the time which VMR > 1±0.1V is less than
Case2
Enable evaluation time, recheck is performed again for a
(Motor
Conditions maximum of three times.
Lock)
When VMR is not normal even on the third recheck, the ● Open or short of power
controller recognizes it as failure. supply circuit (ABS1)
● Faulty HECU
Case3
(Motor
● After 1.8sec from the time that motor relay is
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Open, Enable
switched OFF, VMR > 4±0.5V continued for 1.8sec,
Motor Conditions
the failure is detected.
Short to
BATT)
Case4
● If the motor relay is switched OFF and VMRP
(Motor Enable
(Motor power supply voltage) < 4±0.5V continued for
Fuse Conditions
1sec, the failure is detected.
Open)
●ABS/ESC functions are inhibited, EBD function is
Fail Safe

Page 233 of 235
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or damage.

or damage.

2. Measure voltage between power(ABS1) terminal of the HECU harness connector and chassis ground.
Specification : B+
Page 234 of 235
Check for open or blown 40A (ABS1) fuse referring to "Circuit Diagram".
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Repair open or short in ground circuit between HECU harness connector and chassis ground, and then go to

SCHEMATIC DIAGRAM
Page 235 of 235
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Page 1 of 235

SPORTAGE(KM) > 2009 > G 2.0 DOHC > Brake System

Brake System > General Information > Special Service Tools

Brake System > General Information > Troubleshooting

Brake drag 1. Brake pedal freeplay (Minimum)

Hard pedal but brake 1. Brake system (Fluid leaks)

Noise from brake 1. Pad or lining (Cracked or distorted)

Brake fades replace

1. brake booster replace

Brake System > General Information > Specifications

CBS : Conventional Brake System

TIGHTENING TORQUE (ESC)

Brake System > Brake System > Repair procedures

BRAKE BOOSTER OPERATING TEST

VACUUM HOSE (CHECK VALVE)

BRAKE PEDAL BRAKE SWITCH ADJUSTMENT

BRAKE SWITCH CLEARANCE

PEDAL FREE PLAY

Free play: 3 ~ 8 mm (0.11 ~ 0.31 in.)

INSPECTION OF REAR DISC BRAKE PAD

3. Remove the snap pin (A) and pin (B).

Standard length (A): 106 ± 0.5 mm ( 4.173 ± 0.019 in.)

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

Grease the pin before installing the snap pin.

3. Install the master cylinder.

5. Remove the master cylinder mounting nuts (B) and washers.

• If the cylinder bore is damaged, replace the master cylinder assembly.

5. Mount two grommets.

This table shows characteristics of the proportioning valve as the pressure

2. Remove the brake hose clip(A) from the brake hose(B).

3. Connect the brake hose (D) to the brake line.

5. Remove the pin and snap pin.

Specified grease:Chassis grease MS 511-3

TORQUE : Nm(Kgf·cm,lb-ft); 12.74 ~ 15.68(130 ~ 160, 9.45 ~ 11.63)

Front brake disc thickness

FRONT BRAKE PAD CHECK

Brake disc run out

Seize of Front brake disc

Rear brake disc thickness

Brake disc run out

Brake System > Parking Brake System > Repair procedures

Lever locked clicks:7~8

3. Remove the floor console.

2. Inspect the continuity between (-) terminal and the ground.

The parking brake cables must not be bent or distorted.

4. Remove the bolts and parking brake lever assembly(A).

ESC OPERATION MODE

ESC HECU EXTERNAL DIAGRAM

ABS Warning Lamp module

Brake System > ESC(Electronic Stability Control) System > Troubleshooting

ABS CHECK SHEET

PROBLEM SYMPTOMS TABLE

Check the power source circuit.

Erase the DTC and recheck using scan tool.

Is the voltage within specification?

Check the ground circuit.

Check the wheel speed sensor circuit.

Repair an open in the wire and ground point.

Check the hydraulic circuit for leakage.

Repair or replace the wheel speed sensor.

The problem is still occurring, replace the ABS(ESC) control module.

Repair the hydraulic lines for leakage.

Check the wheel speed sensor circuit.

Erase the DTC and recheck using scan tool.