Ake System

Brake System
Specifications
Item Specification
Mse Cyidratrclne
• Type single piston
• I.D. mm (in) 22.22 mm (0.875 in)
45 ± 1 mm
• Piston stroke mm (in)
(1.77 ± 0.039 in)
• Fluid level switch Provided
Brake Booster
• Type 11" single
• Boosting ratio 9:1
Front Brake (Disc)
• Type Ventilated disc
• Disc O.D 305 mm (12.01 in)
• Disc thickness 25 mm (0.98 in)
• Cylinder type single piston
• Cylinder I.D. Ø60 mm (2.36 in)
Rear Brake (Disc)
• Type Solid disc
• Disc O.D 302 mm (11.89 in)
om
• Disc thickness 10 mm (0.39 in)
• Cylinder type single piston
• Cylinder I.D. Ø38 mm (1.5 in)
Parking Brake
• Type
c DIH (Drum in hat)
• Drum I.D Ø 190 mm (7.48 in)
n.
ag
• O.D. : Outer Diameter

• I.D : Inner Diameter
i
Specification(ESC)
rd
Part Item Standard value Remark

HECU System 4 Channel 4 Sensor (Solenoid) Total control
ca
Type Motor, valve relay intergrated type (ABS, EBD, TCS, ESP)
Operating Voltage 10 ~ 16 V
Operating Temperature -40 ~ 120 °C
(-40 ~ 248°F)
Motor power 310W
Active Wheel speed sensor Supply voltage DC 4.5 ~ 20V
Output current low 5.9 ~ 8.4 mA
Output current high 11.8~ 16.8 mA
Output range 1 ~ 2500 Hz
Tone wheel Front : 48 teeth
Rear (2WD) : 47
Rear (4WD) : 48
Air gap Front : 0.4 ~ 1.5 mm
Rear (2WD) : 0.4 ~ 1.5 mm
Rear (4WD) : 0.4 ~ 1.0 mm
Service Standard
Items Standard value
Brake pedal Full stroke 130.5 mm (5.14 in)
Stop lamp switch clearance 1.0 ~ 2.0 mm (0.04 ~ 0.08 in)
Brake pedal free play 3 ~ 8 mm (0.12 ~ 0.31 in)
Front brake disc thickness 25 mm (0.98 in)
Front brake disc service limit 23.4 mm(0.92 in)
Front brake disc pad thickness 11 mm (0.43 in)
Front brake disc pad service limit 2.0 mm (0.079 in)
Rear brake disc thickness 10 mm (0.39 in)
Rear brake disc service limit 8.4 mm (0.33 in)
Rear brake disc pad thickness 10 mm (0.39 in)
Rear brake disc pad thickness 2.0 mm (0.079 in)
Tightening Torques
Items N.m kgf.m lb-ft
Hub nut 88.3 ~ 107.9 9.0 ~ 11.0 65.1 ~ 79.6
Master cylinder to brake booster 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Brake booster mounting nuts 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
Air bleeding screw 6.9 ~ 12.7 0.7 ~ 1.3 5.1 ~ 9.4
Brake tube flare nuts 12.7 ~ 16.7 1.3 ~ 1.7 9.4 ~ 12.3
Front caliper guide rod bolts 21.6 ~ 31.4 2.2 ~ 3.2 15.9 ~ 23.1
Rear caliper guide rod bolts 21.6 ~ 31.4 2.2 ~ 3.2 15.9 ~ 23.1
Front caliper assembly to knuckle 78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3
Rear caliper assembly to knuckle 78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3
Brake hose to caliper 24.5 ~ 29.4 2.5 ~ 3.0 18.1 ~ 21.7
om
Brake pedal member bracket nuts 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
Brake pedal shaft bolt 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
Wheel speed sensor mounting bolt 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 7.6
HECU bracket mounting bolt and nut c 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
Lubricants 7
n.
Items Recommended Quantity
Brake fluid DOT 3 or DOT 4 370±20cc
ag
Brake pedal bushing and bolt Chassis grease As required

Parking brake shoe and backing plate
Heat resistance grease As required
contacting surface
i
rd
Brake System
Special Service Tools

ca
Tool (Number and Name) Illustration Use

09581-11000 Spreading the rear disc brake piston.
Piston expander
09581- 2T100 Spreading the front disc brake piston.

Piston expander
Brake System
Troubleshooting
Problem Symptoms Table
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the like cause of the problem. Check each
part in order.
If necessary, replace these parts.
Symptom Suspect Area Reference
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 (Inoperative) replace
Brake drag 1. Brake pedal free play (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 shoe (Inoperative) replace
9. Booster system (Vacuum leaks) repair
Brake pull 1. Piston (Sticking) replace
2. Pad or lining (Oily) replace
3. Piston (Frozen) replace
4. Disc (Scored) replace
om
Hard pedal but 1. Brake system (Fluid leaks) repair
brake inefficient 2. Brake system (Air in) air·bleed
3. Pad or lining (Worn) replace
c
6. Pad or lining (Oily) adjust
n.
7. Pad or lining (Glazed) replace
9. Booster system (Vacuum leaks) repair
ag
Noise from brake 1. Pad or lining (Cracked or distorted) replace

2. Installation bolt (Loosen) adjust
i
4. Sliding pin (Worn) replace

rd
5. Pad or lining (Dirty) clean

6. Pad or lining (Glazed) replace
7. Anchor or shoe (Faulty) replace
ca
8. Brake pad shim (Damage) replace

9. Shoe hold-down spring (Damage) replace
Brake fades 1. Master cylinder (Inoperative) replace
Brake vibration, 1. Brake booster (Vacuum leaks) replace
pulsation 2. Pedal free play adjust
4. Caliper (Damage) replace
5. Master cylinder cap seal replace
6. Damaged brake lines replace
Brake Chatter Brake chatter is usually caused by loose or worn components, or glazed or burnt
linings. Rotors with hard spots can also contribute to brake chatter. Additional causes
of chatter are out-of-tolerance rotors, brake lining not securely attached to the shoes,
loose wheel bearings and contaminated brake lining.
Brake System
Operation and Leakage Check

Check all of the following items :
Component Procedure
Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes do not work properly,
check the brake booster. Replace the brake booster as an assembly if it does not work properly or if there
are signs of leakage.
•
Piston cup and pressure Check brake operation by applying the brakes. Look for damage or signs of fluid leakage. Replace the
cup inspection (B) 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.
c om
n.
i ag
rd
ca
Brake System Bleeding
• Do not reuse the drained fluid.

• Always use genuine DOT3/DOT4 brake Fluid.
Using a non-genuine DOT3/DOT4 brake fluid can cause corrosion and decrease the life of the system.
• Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
• Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with
water.
• The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure and checked after
bleeding each brake caliper. Add fluid as required.
1. Make sure the brake fluid in the reservoir is at the MAX(upper) level line.
2. Have someone slowly pump the brake pedal several times, and then apply pressure.
3. Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw securely.
[Front]
[Rear]
om
4. Repeat the procedure for wheel in the sequence shown below until air bubbles no longer appear in the fluid.
c
n.
i ag
rd
5. Refill the master cylinder reservoir to MAX (upper) level line.
ESC Bleeding of Brake System

ca
This procedure should be followed to ensure adequate bleeding of air and filling of the ESC 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
2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled clear plastic bottle.
3. Connect the GDS to the data link connector located underneath the dash panel.
4. Select and operate according to the instructions on the GDS screen.
• You must obey the maximum operating time of the ESC motor with the GDS to prevent the motor pump from burning.
(1) Select vehicle name.

(2) Select ABS/ESC System.
(3) Select HCU air bleeding mode.
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
om
screw (A).
[Front]
c
n.
i ag
rd
ca
[Rear]
6. Repeat step 5 following the order described below until there are no more bubbles in the fluid for each wheel.
7. Tighten the bleeder screw.
Bleed screw tightening torque :
6.9 ~ 12.7 N.m (0.7 ~ 1.3 kgf.m, 5.1 ~ 9.4 lb-ft)
Brake System
Components
c om
n.
i ag
rd
ca
1. Brake booster 4. Grommet

2. Screw 5. Master cylinder
3. Reservoir
Brake System
Brake Booster Operating Test

For simple checking of the brake booster operation, carry out the following tests.
1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when
depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the booster is inoperative.
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 inoperative.
c om
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 inoperative.
n.
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 malfunction.
i ag
rd
ca
Removal
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the air cleaner assembly.
(Refer to Engine Mechanical System - "Intake and Exhaust System")
3. Disconnect the brake fluid level switch connector (A).
4. Disconnect the vacuum hose from the brake booster.
5. Remove the brake fluid from the master cylinder reservoir with a syringe.
water.
6. Remove the master cylinder.

(Refer to the Brake System - "Master Cylinder")
7. Remove the snap pin (A) and clevis pin (B).
c om
n.
i ag
8. Remove the mounting nuts (A).

rd
Tightening torque :
16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft)
ca
Inspection
1. Inspect the vacuum hose.
2. Check the boot for damage.
Installation
1. Installation is the reverse of removal
• Before installing the pin, apply the grease to the joint pin.
• Use a new snap pin whenever installing.
2. After installation, bleed the brake system.

(Refer to Brake System - "Brake System Bleeding")
Brake System
Components
[T-GDI Engine Only]
c om
n.
i ag
rd
ca
1. Vacuum pump 2. Bracket
Brake System
Removal
2. Remove the under covers (A).
Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 12.3 ~ 5.8 ~ 8.7 lb-ft)
3. Disconnect the vacuum pump connector (A).
om
4. Disconnect the vacuum hose (A) and then remove the vacuum hose fixed clip (B).
c
n.
i ag
rd
ca
5. Loosen the vacuum pump bracket bolts (A), and then remove vacuum pump and bracket.
Tightening torque :
19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)
6. Remove the 2 bolts, and then remove the bracket from vacuum pump.
Installation
1. Installation is the reverse of removal.
2. Tighten the vacuum pump mounting bolts to the specified torque.
Brake System
Components
c om
n.
ag
1. Reservoir 3. Grommet
2. Screw 4. Master cylinder
i
Brake System
rd
Removal
ca
2. Remove the air cleaner assembly.

(Refer to Engine Mechanical System - "Intake and Exhaust System")
3. Disconnect the brake fluid level switch connector (A).
water.
5. Loosen the screw and then remove the reservoir.
6. Disconnect the brake tube (A) from the master cylinder by loosening the tube flare nut.
Tightening torque :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
c om
n.
i ag
rd
ca
8. Remove the master cylinder (B) from the brake booster after loosening the mounting nuts (A).
Tightening torque :
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 12.3 ~ 5.8 ~ 8.7 lb-ft)
Installation
1. Installation is the reverse of removal
• Before installing the pin, apply the grease to the joint pin.
• Use a new snap pin whenever installing.

Brake System
Components
c om
n.
i ag
rd
ca
Brake System
Removal
1. Disconnect the brake fiuid level switch connector, and remove the reservoir cap.
2. Remove the brake fluid from the master cylinder reservior with a syringe.
water.
3. Remove the wheel & tire.

4. Remove the brake hose clip (A).
5. Disconnect the brake tube by loosening the tube flare nut (B).
Tightening torque :
12.7 ~ 16.7 N.m (1.3 ~ 1.7 kgf.m, 9.4 ~ 12.3 lb-ft)
[Front]
[Rear]
c om
6. Disconnect the brake hose from the brake caliper by loosening the bolt (A).
Tightening torque :
n.
24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)
[Front]
i ag
rd
ca
[Rear]
Inspection
1. Check the brake tubes for cracks, crimps and corrosion.
2. Check the brake hoses for cracks, damage and fluid leakage.
3. Check the brake tube flare nuts for damage and fluid leakage.
4. Check brake hose mounting bracket for crack or deformation.
Installation
• Use a new washer (A) whenever installing.

3. Check the spilled brake oil.
c om
n.
Brake System
ag
Components
i
rd
ca
c om
n.
1. Stop lamp switch 4. Brake pedal member assembly
ag
2. Nut 5. Bolt
3. Return spring 6. Brake pedal arm
Brake System
i
rd
Removal
ca
2. Remove the crash pad lower panel.

(Refer to Body - "CrasH Pad Lower Panel")
3. Disconnect the stop lamp switch connector (A).
4. Remove the brake pedal member mounting bolt (A).

Tightening torque :
16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft)
6. Remove the cable fixed clip from the brake pedal member assembly
c om
n.
i ag
rd
ca
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.
Brake System
Components
c om
n.
1. Caliper body 4. Pad retainer
ag
2. Pad return spring 5. Caliper carrier

3. Brake pad
Brake System
i
rd
Removal
1. Remove the front wheel and tire (A) from front hub .
ca
Tightening torque :
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)
• Be careful not to damage to the hub bolts when removing the front wheel and tire (A).
2. Loosen the guide rod bolt (B) and then pivot the caliper body (A) up out of the way.
Tightening torque :
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
3. Remove the pad return spring (A) and then separate the brake pad.
Brake hose to caliper :

24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)
c om
4. Loosen the hose eyebolt (A) and caliper mounting bolts (B), then remove the front caliper assembly.
Tightening torque
n.
Caliper assembly to knuckle :
78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)
i ag
rd
ca
5. Remove the front brake disc by loosening the screws.

Tightening torque :
4.9 ~ 5.8 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)
Brake Pad Replacement

Tightening torque :
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)
Tightening torque:
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
c om
n.
i ag
3. Replace the pad return spring (A) and brake pad with a new one.
rd
ca
4. Use a SST (09581-2T100) when installing the brake caliper assembly.

• Connect an air hose (B) to the SST after confirming that the valve of the SST is surely closed.
• Input the SST in the caliper and press the caliper piston while opening the valve of the SST slowly couter clock wise.
• Close the valve (A) of the SST and disconnect the air hose (B); then, open the valve again to get the rest of air out and remove
the SST from the caliper.
5. Place the caliper body (A) on the caliper carrier and tighten the guide rod bolts (B).
Tightening torque :
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
Inspection
om
Front brake disc thickness check
1. Check the brake pads for wear and fade. c
2. Check the brake disc for damage and cracks.
3. Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) from the
n.
brake disc outer circle.
Front brake disc thickness
- Standard : 25 mm (0.98 in)
ag
- Service limit : 23.4 mm (0.92 in)

- Deviation : Less than 0.005 mm (0.0002 in)
i
rd
ca
4. If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
Front Brake Pad Check

1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Pad thickness
Standard value : 11 mm (0.43 in)
Service limit : 2.0 mm (0.0787 in)
2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
Front brake disc runout check
1. Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout
Limit : 0.04 mm (0.00157 in.) or less (new one)
c om
n.
2. If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.
3. If the runout does not exceed the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc
ag
again.
4. If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.
i
Installation
rd
1. Install in the reverse order of removal.

2. Use a SST (09581-2T100) when installing the brake caliper assembly.
ca
• Connect an air hose (B) to the SST after confirming that the valve of the SST is surely closed.
• Input the SST in the caliper and press the caliper piston while opening the valve of the SST slowly couter clock wise.
• Close the valve (A) of the SST and disconnect the air hose (B); then, open the valve again to get the rest of air out and remove
the SST from the caliper.

Brake System
Components
c om
n.
ag
1. Caliper carrier 4. Brake pad

2. Pad retainer 5. Caliper body
i
3. Pad return spring

rd
Brake System
ca
Removal
1. Raise the vehicle, and make sure it is securely supported.
2. Remove the rear wheel and tire (A) from rear hub.
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
• Be careful not to damage to the hub bolts when removing the rear wheel and tire (A).
Tightening torque :
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
4. Remove the pad return spring (A) and then separate the brake pad.
5. Loosen the hose eyebolt (B) and then remove brake hose.
c om
n.
Tightening torque :
24.5 ~ 29.4 N.m (2.5 ~ 3.0 kgf.m, 18.1 ~ 21.7 lb-ft)
i ag
rd
ca
6. Loosen the caliper mounting bolts and then removethe rear caliper assembly (A).
Tightening torque :
78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)
7. Remove the rear brake disc by loosening the screws.

Tightening torque :
4.9 ~ 5.8 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)
Brake Pad Replacement
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
c om
n.
ag
Tightening torque :
i
rd
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)

ca
3. Replace the pad return spring (A) and the brake pad.
4. Use a SST (09581-11000) when installing the brake caliper assembly
5. Place the caliper body (A) on the caliper carrier and tighten the guide rod bolts (B).
Tightening torque :
21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)
c om
n.
Inspection
Rear Brake Disc Thickness Check
ag
1. Check the brake pads for wear and fade.

2. Check the brake disc for damage and cracks.
i
3. Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) from the
rd
brake disc outer circle.

Rear Brake disc thickness
Standard : 10 mm (0.39 in)
ca
Service limit : 8.4 mm (0.33 in)

Deviation : less than 0.005 mm (0.0002 in)
4. If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
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 mm (0.393 in)
Service limit :2.0 mm (0.0787 in)
2. Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
Rear Brake Disc Runout Check

1. Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout
Limit : 0.03 mm (0.00118 in.) or less (new one)
2. If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.
3. If the runout exceeds the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc again.
4. If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.
om
Installation
2. Use a SST (09581-11000) when installing the brake caliper assembly.
c
n.
i ag
rd
ca

Brake System
Components
c om
n.
1.Stop lamp switch 4. Brake pedal member assembly
ag
2. Nut 5. Bolt
3. Return spring 6. Brake pedal arm
Brake System
i
rd
Schematic Diagram
ca
System circuit diagram

Terminal function
c om
n.
Teminal Description
1 IGN1
ag
2 Engine Control Module (ECM)

3 B+
4 Stop Lmap
i
rd
Brake System
Troubleshooting
ca
1. Part diagnosis
Items Cause Symptom
– DTC Code : P0504 A waveform
– Symptom : Shifting gear trouble, Starting failure, inspection is
Faulty fuse connection, performed using an
Switch fuse Cruise control function cancelation trouble, EPB
Damaged fuse
function cancelation trouble, Stop lamp lighting trouble, oscilloscope on
ESP OFF light illuminated. each part during
vehicle
– DTC Code : P0504
acceleration/braking.
Faulty fuse connection, – Symptom : Shifting gear trouble, Starting failure, (Refer to stop lamp
Relay fuse Cruise control function cancelation trouble, EPB switch circuit
Damaged fuse
function cancelation trouble, Stop lamp lighting inspection
trouble , ESP OFF light illuminated. procedures)
• Damaged wiring of – DTC Code : P0504
each part – Symptom : Shifting gear trouble, Starting failure, Refer to the
Stop lamp switch • Faulty connection to Cruise control function cancelation trouble, EPB relevant repair
connector function cancelation trouble, Stop lamp lighting procedures of the
• Each part is trouble , ESP OFF light illuminated. part when
defective – DTC Code : P0504, C2130, C2131 something abnormal
is discovered in the
Stop signal electronic – Symptom : Shifting gear trouble, Starting failure, waveform (Refer to
Cruise control function cancelation trouble, EPB the repair
module (If it applies)
function cancelation trouble, Stop lamp lighting procedures of the
trouble , ESP OFF light illuminated. relevant part and if
– DTC Code : P0504 necessary replace it)
Engine control module(ECM) – Symptom :Shifting gear trouble,Cruise control function
cancelation trouble
–
Body control module (BCM) Shifting gear trouble
Shift-lock solenoid – Shifting gear trouble
– Symptom : Shifting gear trouble, Starting failure,
Inhibitor switch Cruise control function cancelation trouble, EPB
function cancelation trouble
Smart Key Unit(SMK) – Starting failure
– Symptom : EPB function cancelation trouble , ESP
Electronic parking brake
OFF light illuminated.
ABS/VDC control module
– Symptom : ESP OFF light illuminated.
(Pressure sensor)
2. Symptom diagnosis
Symptom Part that could be the cause
Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, Inspect waveform using an
Trouble starting
ABS/VDC control module, Each wire, Connector oscilloscope on each part
Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, during vehicle
Trouble shifting gears acceleration/braking. (Refer to
BCM, ECM, Inhibitor switch, Each wire, Connector
stop lamp switch circuit
Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, inspection Procedures)
ESP OFF light illuminated
ABS/VDC control module, Each wire, Connector
Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, Refer to the relevant repair
P0504
ECM, Each wire, Connector procedures of the part when
Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, something abnormal is
Stop lamp does notworking discovered in the waveform
Wire/Connector disconnected
(Refer to the repair procedures
Stop lamp always Stop lamp switch, Stop signal electronic module,
om
of the relevant part and if
turns on Wiring short circuit, Damaged fuse necessary replace it)
3. Stop lamp switch system diagnosis c

n.
i ag
rd
ca
c om
n.
ag
SSEM : Stop Signal Electronic Module

i
4. Refer to DTC guide when the related DTC codes are displayed.
rd
Brake System
Adjustment
ca
2. Remove the lower crash pad.
(Refer to Body - "Crash Pad")
3. Confirm the gap between stop lamp switch and bracket.
Stop lamp clearance (A) :1.0 ~ 2.0 mm (0.04~ 0.08 in.)
4. If the gap between stop lamp switch and bracket is not 1.0~2.0mm (0.04~0.08in), check the mounting clip and other part of around stop
lamp.
5. If there is normal, remove the stop lamp switch and then install again.
Inspection
1. Fuse inspection
Mount the test fuse to the switch fuse and relay fuse part to confirm a normal joint fit.
c om
n.
2. GDS Data Analysis
1. Analyze GDS data and confirm if there is anything wrong with the stop lamp switch.
ag
(1) Connect the GDS to the self-diagnosis connector.

(2) Turn the spark switch on
(3) Step on the brake pedal.
i
rd
(4) Inspect the "brake switch" category that displays the "sensor data" GDS.
Normal waveform :The pressure sensor signal value will change according to the brake ON/OFF switch.
ca
3. Inspection of connector by each part

Check to see whether or not each connector has been damaged, or terminal surge, or incomplete connection has taken place
[Engine room junction box]
[ABS/VDC control module]
om
4. Inspect the stop lamp circuit
Connect probe to each terminal wire and confirm oscilloscope waveform.
[Stop lamp switch input/output]
c
n.
i ag
rd
ca
[Oscilloscope waveform screen]

c om
n.
i ag
Removal
rd
2. Remove the lower crash pad.
ca

3. Disconnect the stop lamp switch connector (A).
4. Pull the locking plate (A) as indicated by the arrow.

5. Turn stop lamp switch 45° counterclockwise and remove it.
6. Inspect a removed stop lamp switch along the below procedures.

(1) Confirm a normal connection with terminal part
c om
– A confirmation can be made to see if the connector has been secured properly and if a connection mark is present.
n.
i ag
rd
ca
(2) Perform the inspection of parts resistance
Resistance (Ω) 3-4 1-2

Non rod protruded
Infinite 0
(switch turned OFF)
Rod protruded
0 Infinite
(switch turned On)
Installation
1. Fix the brake pedal arm and insert fully the stop lamp switch as hiding contact part.
2. After inserting, turn the stop switch (A) 45° clockwise, and then assemble locking plate by pushing.
3. Confirm the gap between stop lamp switch and bracket.

Stop lamp clearance :1.0 ~ 2.0 mm (0.04~ 0.08 in.)
c om
n.
i ag
rd
ca
• If the gap between stop lamp switch and bracket is not 1.0~2.0mm (0.04~0.08in), perform the above process again.
4. Connect the stop lamp switch connector.

5. Install the lower crash pad.
Brake System
Components (1)
c om
n.
i ag
rd
ca
1. Parking brake pedal assembly 3. Equalizer assembly

2. Front parking brake cable 4. Rear parking brake cable
Components (2)
c om
n.
1. Brake shoe 5. Adjuster
ag
2. Operating lever 6. Shoe hold down spring

3. Upper spring 7. Shoe hold down pin
4. Lower spring
i
rd
Brake System
Parking Brake Pedal Assembly

ca
(Refer to Body - "Crash Pad Lower Panel")
3. Remove the Smart Junction Box.
(Refer to Body Electrical System - "Relay Box (Passenger Compartment)")
4. Disconnect the parking brake switch connector(A) and then remove the parking brake pedeal after loosening the mounting bolts.
5. Remove the floor console assembly.

(Refer to Body - "Floor Console")
6. Remove the paring brake cable (B) after removing the cable retainer (A).
7. Remove the front wheel and tire (A) from rear hub.
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
c om
n.
ag
8. Loosen the screw(B) and then remove the clip(A) in order to separate the parking brake cable.
i
rd
ca
9. Loosen the bolt (A) and nut (B) and then remove the parking brake cable from the trailing arm.
Tightening torque
(A) : 8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
(B) : 6.8 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)
10. Loosen the parking brake cable bracket bolts and remove the rear parking brake cable.
Parking Brake Pedal Stroke Adjustment

1. Operate the parking brake pedal through a full stroke over 3 times for setting the parking cables.
2. Adjust the adjusting nut (A) for parking barke pedal stoke 4 notches when operating effort is 196N (20kgf, 66lbf)
c om
n.
ag
1) The parking brake adjustment must be carried out after adjusting the rear shoe.
2) After adjusting parking brake, notice following matter.
i
a. Must be free from clearance between adjusting nut and pin.

rd
b. Check securely that the brake is not dragging.

ca
Brake System
Removal
Parking Brake Shoe
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
3. Remove the rear brake caliper and brake disc.

(Refer to Brake System - "Rear Disc Brake")
4. Loosen the screw (B) and then remove the clip (A) in order to separate the parking brake cable.
5. Remove the shoe hold down pin and the spring (A) by pressing and rotating the spring.
c om
n.
ag
6. Remove the upper return spring (A) operating lever assembly (B).
i
rd
ca
7. Remove the adjuster assembly (B) and the lower return spring (A).
Adjustment
2. Remove the front wheel and tire (A) from front hub.
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
3. Remove the plug from the disc.
c om
n.
ag
4. Rotate the toothed wheel of adjuster by a screw driver until the disc is not moving, and then return it by 3 notches in the opposite direction.
i
rd
ca
5. Install the tire and wheel, after installing the plug on the disc.
6. If the parking brake shoe or the brake disc are replaced a newly one, perform the brake shoe bed-in procedure.
(1) While operating the parking brake for 69N (7kgf, 15lbf) effort, drive the vehicle 500 meters (0.31 miles) at the speed of 60kph (37 mph).
(2) Repeat the above procedure more than two times.
(3) Must be held on 30% uphill.
• After adjusting parking brake, notice following matter;

1) lever type - Must be free from troubles when the parking lever is operated at 686.5N (70 kgf, 154lbf).
Pedal type - Must be free from troubles when the parking pedal is operated at 980N (100kgf, 220lbf)
2) Check that all parts move smoothly.
3) The parking brake indicator lamp must be on after the parking pedal is worked and must be off after the pedal is released.
Brake System
Components
c om
n.
i ag
rd
ca
1. HECU module 4. Rear wheel speed sensor (2WD)

2. Front wheel speed sensor 5. Rear wheel speed sensor (4WD)
3. ESC OFF Switch
Brake System
Description of ESC
Electronic Stability Control (ESC) recognizes critical driving conditions, such as panic reactions in dangerous situations, and stabilizes the
vehicle by wheel-individual braking and engine control intervention.
ESC adds a further function known as Active Yaw Control (AYC) to the ABS, TCS, EBD and ESC functions. Whereas the ABS/TCS function
controls wheel slip during braking and acceleration and, thus, mainly intervenes in the longitudinal dynamics of the vehicle, active yaw control
stabilizes the vehicle about its vertical axis.
This is achieved by wheel individual brake intervention and adaptation of the momentary engine torque with no need for any action to be taken
by the driver.
ESC essentially consists of three assemblies : the sensors, the electronic control unit and the actuators.
The stability control feature works under all driving and operating conditions. Under certain driving conditions, the ABS/TCS function can be
activated simultaneously with the ESC function in response to a command by the driver.
In the event of a failure of the stability control function, the basic safety function, ABS, is still maintained.
Description of ESC Control
om
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.
c
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.
n.
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
ag
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)
i
rd
ca
Input and Output Diagram
om
c
n.
i ag
rd
ca
ESP Operation Mode

ESP Hydraulic System Diagram
c om
n.
1. ESP Non-operation : Normal braking.
ag
Solenoid valve Continuity Valve Motor pump TC Valve

IN (NO) OFF OPEN
OFF OFF
OUT (NC) OFF CLOSE
i
rd
2. ESP operation
Solenoid valve Continuity Valve Motor pump TC Valve
Understeering IN(NO) OFF OPEN
ca
(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
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.
– Cluster lamp is ON when communication is impossible with CAN module.
EBD/Parking Brake Warning Lamp Module

The active EBD warning lamp module indicates the self-test and failure status of the EBD. However, in case the Parking Brake Switch is
turned on, the EBD warning lamp is always turned on regardless of EBD functions. The EBD warning lamp shallbe on:
– When the Parking Brake Switch is ON or brake fluid level is low.
– When the EBD function is out of order .
– During diagnostic mode.
– When the ECU Connector is seperated from ECU.
ESP Function/Warning Lamp (ESP System)

The ESP function/warning lamp indicates the self-test and failure status of the ESP.
The ESP function/warning lamp is turned on under the following conditions :
– When the ESP function is inhibited by system failure.
– When the ESP control is operating. (Blinking - 2Hz)
– During diagnostic mode.(Except standard mode)
om
ESP OFF Lamp (ESP System)
The ESP Off lamp indicates the self-test and operating status of the ESP.
The ESP Off lamp operates under the following conditions :
– During the initialization mode after IGN ON. (continuously 3 seconds).
– ESP Off lamp is On when driver input the ESP Off switch.
c
n.
ESP ON/OFF Switch (ESP System)
The ESP On/Off Switch shall be used to toggle the ESP function between On/Off states based upon driver input.
ag
The On/Off switch shall be a normally open, momentary contact switch.Closed contacts switch the circuit to ignition.
Initial status of the ESP function is on and switch toggle the state.
Brake System
i
rd
Schematic diagram
ca
c om
n.
ag
i
rd
ca
Terminal Function
Current Resistance
Pin No Description Remark
(AMPS) (mΩ)
13 PUMP MOTOR GROUND 137 (RUSH) 10
38 GROUND 40 10
1 POS. BATTERY 2. (MOTOR) 137 (RUSH) 10
25 POS. BATTERY 1. (SOLENOID) 40 10
om
29 IGN1 (+) 50 mA 60
34 SENSOR FRONT LEFT POWER 30 mA 250
18 SENSOR FRONT RIGHT POWER 30 mA 250
33 SENSOR REAR LEFT POWER 30 mA 250
19 SENSOR REAR RIGHT POWER
c 30 mA 250
21 SENSOR FRONT LEFT SIGNAL 16.8 mA 250
n.
31 SENSOR FRONT RIGHT SIGNAL 16.8 mA 250
20 SENSOR REAR LEFT SIGNAL 16.8 mA 250
ag
32 SENSOR REAR RIGHT SIGNAL 16.8 mA 250

23 ESC OFF SWITCH 10mA 250
14 C-CAN High 30 mA 250
2 C-CAN Low 30 mA 250
i
22 L-CAN High 30 mA 250

rd
35 L-CAN Low 30 mA 250

16 BRAKE LIGHT SWITCH 10 mA 250
ca
37 CLUTCH SWITCH 10 mA 250

30 DBC SWITCH 10 mA 250
28 SENSOR REAR RIGHT OUTPUT 16 mA 250
17 SENSOR FRONT RIGHT OUTPUT 16 mA 250
Brake System
ESC Bleeding of Brake System

This procedure should be followed to ensure adequate bleeding of air and filling of the ESC 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
2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half filled clear plastic bottle.
3. Connect the GDS to the data link connector located underneath the dash panel.
4. Select and operate according to the instructions on the GDS screen.
• You must obey the maximum operating time of the ESC motor with the GDS to prevent the motor pump from burning.
(1) Select vehicle name.

(2) Select ABS/ESC system.
(3) Select HCU air bleeding mode.
c om
n.
ag
5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without bubbles. Then close the bleeder
screw (A).
[Front]
i
rd
ca
[Rear]
6. Repeat step 5 following the order described below until there are no more bubbles in the fluid for each wheel.
7. Tighten the bleeder screw.

Bleed screw tightening torque :
6.9 ~ 12.7 N.m (0.7 ~ 1.3 kgf.m, 5.1 ~ 9.4 lb-ft)
c om
n.
Brake System
Failure Diagnosis
ag
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.
i
rd
4. Information on ABS fail-safe is identical to the fail-safe in systems where ESC is not installed.
Memory of Fail Code

ca
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.
Countermeasures in Fail
1. Turn the system down and perform the following actions and wait for HECU power OFF.
2. Turn the valve relay off.
3. Stop the control during the operation and do not execute any until the normal condition recovers.
Warning Lamp ON
1. ESC warning lamp turn on for 3sec after IGN ON.
2. ESC function lamp blinks when ESC Act.
3. If ESC fail occured, ESC warning turns ON.
4. ESC OFF lamp turn on in case of
– ESC Switch OFF
– 3sec after IGN ON
Standard Flow of Diagnostic Troubleshooting
c om
n.
Notes with Regard to Diagnosis
The phenomena listed in the following table are not abnormal.
ag
Condition 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.
i
rd
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
ca
repeated brake application and release

(Thump : suspension; squeak: tires)
ABS operation (Long braking distance) For road surfaces such as snow-covered and gravel roads, the braking distance for vehicles
with ABS can sometimes be longer than that for other vehicles. Accordingly, advise the
customer to drive safely on such roads by lowering the vehicle speed.
Diagnosis detection conditions can vary depending on the diagnosis code. When checking the trouble symptom after
the diagnosis code has been erased, ensure that the requirements listed in "Comment" are met.
ABS Check Sheet

c om
n.
i ag
rd
ca
Problem Symptoms Table

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.
1) Power source circuit
2)
Communication with GDS CAN line
is not possible.
(Communication with any system is
not possible)
Communication with GDS 1) Power source circuit
is not possible. 2) CAN line
(Communication with ABS only is 3) HECU
not possible)
When ignition key is turned ON 1) ABS warning lamp circuit
(engine OFF), 2) HECU
the ABS warning lamp does not light up.
Even after the engine is started, the ABS 1) ABS warning lamp circuit
warning lamp 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
om
Brake operation varies depending on driving conditions and road surface conditions, – Faulty power source circuit
so diagnosis can be difficult. However if a normal DTC is displayed, check the – Faulty wheel speed sensor circuit
following probable cause. When the problem is still occurring, replace the ESC – Faulty hydraulic circuit for leakage
control module.
– Faulty HECU
c
n.
Inspection procedures
DTC Inspection
ag
1. Connect the GDS with the data link connector and turn the ignition switch ON.
2. Verify that the DTC code is output.
3. Is the DTC code output?
i
▶ Check the power source circuit.

rd
▶ Erase the DTC and recheck using GDS.

ca
Check the power source circuit

1. Disconnect the connector from the ESC control module.
2. Turn the ignition switch ON, measure the voltage between terminal 29 of the ESC control module harness side connector and body ground.
Specification:approximately B+
3. 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 ESC
control module. Repair if necessary.
Check the ground circuit

2. Check for continuity between terminals 13, 38 of the ESC control module harness side connector and ground point.
3. Is there continuity?
▶ Check the wheel speed sensor circuit.
▶ Repair an open in the wire and ground point.
Check the wheel speed sensor circuit

1. Refer to the DTC troubleshooting procedures.
2. Is it normal?
▶ Check the hydraulic circuit for leakage.
om
▶ Repair or replace the wheel speed sensor.
Check the hydraulic circuit for leakage

c
1. Refer to the hydraulic lines.
n.
2. Inspect leakage of the hydraulic lines.
3. Is it normal?
ag
▶ The problem is still occurring, replace the ESC control module.

▶ Repair the hydraulic lines for leakage.
i
rd
Detecting condition
ca

Brake operation varies depending on driving conditions and road surface conditions, – Faulty power source circuit
so diagnosis can be difficult. However if a normal DTC is displayed, check the – Faulty wheel speed sensor circuit
following probable cause. When the problem is still occurring, replace the ESC
– Faulty hydraulic circuit for leakage
control module.
– Faulty HECU
DTC Inspection
1. Connect the GDS with the data link connector and turn the ignition switch ON.
2. Verify that the DTC code is output.
3. Is the DTC code output?
▶ Check the wheel speed sensor circuit.
▶ Erase the DTC and recheck using GDS.
Check the wheel speed sensor circuit

1. Refer to the DTC troubleshooting procedures.
2. 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 23 of the ESC control module harness side connector and body ground when brake pedal is
depressed.
Specification :approximately B+
3. Is the voltage within specification?

▶ Check the hydraulic circuit for leakage.
▶ Repair the stop lamp switch. Repair an open in the wire between the ESC control module and the stop lamp switch.
Check the hydraulic circuit for leakage

1. Refer to the hydraulic lines.
2. Inspection leakage of the hydraulic lines.
c om
n.
3. Is it normal?
▶ The problem is still occurring, replace the ESC control module.
ag
▶ Repair the hydraulic lines for leakage.

i
rd
Detecting condition
ca

Possible defect in the power supply system (including ground) for the diagnosis line. – An open in the wire
– Poor ground
– Faulty power source circuit
Check The Power Supply Circuit For The Diagnosis
1. Measure the voltage between terminal 16 of the data link connector and body ground.
2. Is voltage within specification?
▶ Check the ground circuit for the diagnosis.
▶ Repair an open in the wire. Check and replace fuse from the engine compartment junction block.
Check the ground circuit for the diagnosis

1. Check for continuity between terminal 4 of the data link connector and body ground.
c om
n.
ag
▶ Repair an open in the wire between terminal 4 of the data link connector and ground point.
i
rd
ca
Detecting condition
When communication with GDS is not possible, the cause may be probably an open – An open in the wire
in the HECU power circuit or an open in the diagnosis output circuit. – Faulty HECU
– Faulty power source circuit
Check for Continuity in the CAN Line
2. Check for continuity between terminals 26, 14 of the ESC control module connector and 3, 11 of the data link connector.
▶ Check the power source of ESC control module.
▶ Repair an open in the wire.
Check the power source of ESC control module

2. Turn the ignition switch ON, measure the voltage between terminal 29 of the 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 ESC
control module.Repair if necessary.
Check for poor ground

1. Check for continuity between terminal 4 of the data link connector and ground point.
▶ Replace the ESC control module and recheck.
▶ Repair an open in the wire or poor ground
c om
n.
i ag
rd
ca
Detecting condition
When current flows in the HECU the ABS warning lamp turns from ON – Faulty ABS warning lamp bulb
to OFF as the initial check. Therefore if the lamp does not light up, the – Blown fuse is related to ABS in the engine
cause may be an open in the lamp power supply circuit, a blown bulb, compartment junction block
an open in the both circuits between the ABS warning lamp and the – Faulty ABS warning lamp module
HECU, and the faulty HECU. – Faulty HECU
Problem verification
1. Disconnect the connector from the ESC control module and turn the ignition switch ON.
2. Does the ABS warning lamp light up?
▶ Inspectagain after replacing the ESC HECU.
▶ Check the power source for the ABS warning lamp.
Check the power source for the ABS warning lamp

1. Disconnect the instrument cluster connector (M08) and turn the ignition switch ON.
2. Measure the voltage between terminal (M08) 39 of the cluster harness side connector and body ground.
▶ Check the CAN circuit resistance for ABS warning lamp.
▶ Check for blown fuse.
Check the CAN circuit resistance for ABS warning lamp

1. Disconnect the instrument cluster connector (M08) and turn the ignition switch OFF.
2. Measure the resistance between terminal (M08) 32 and 33 of the cluster harness side connector.
Specification :60Ω
c om
n.
i ag
3. Is resistance within specification?

rd
▶ Repair ABS warning lamp bulb or instrument cluster assembly.

▶ Check the CAN circuit wiring for ABS warning lamp.
ca
Check the CAN circuit wiring for ABS warning lamp

1. Disconnect the instrument cluster connector (M08) and ESC HECU connector, and then turn the ignition switch OFF.
2. Check for continuity between terminal (M08) 32 of the cluster harness side connector and terminal 26 of ESC HECU harness side.
Check for continuity between terminal (M08) 33 of the cluster harness side connector and terminal 14 of ESC HECU harness side.
Specification :Below 1Ω

▶ Repair short of wiring between terminal 26, 14 of ESC HECU harness connector and ABS warning lamp module.
▶ Repair open of wiring between terminal 26, 14 of ESC HECU harness connector and ABS warning lamp module.
Detecting condition
If the HECU detects trouble, it lights the ABS warning lamp while at the – An open in the wire
same time prohibiting ABS control. At this time, the HECU records a – Faulty instrument cluster assembly
DTC in memory. Even though the normal code is output, the ABS – Faulty ABS warning lamp module
warning lamp remains ON, then the cause may be probably an open – Faulty HECU
or short in the ABS warning lamp circuit.
Check DTC Output
1. Connect the GDS to the 16P data link connector located behind the driver''s side kick panel.
2. Check the DTC output using GDS.
3. Is DTC output?
▶ Perform the DTC troubleshooting procedure (Refer to DTC troubleshooting).
▶ Check the CAN circuit resistance for ABS warning lamp.
Check the CAN circuit resistance for ABS warning lamp

1. Disconnect the instrument cluster connector (M08) and turn the ignition switch OFF.
2. Measure the resistance between terminal (M08) 32 and 33 of the cluster harness side connector.
Specification :60Ω
c om
n.
▶ Repair ABS warning lamp bulb or instrument cluster assembly.
ag
▶ Check the CAN circuit wiring for ABS warning lamp.

i
Check the CAN circuit wiring for ABS warning lamp

rd
1. Disconnect the instrument cluster connector (M08) and ESC HECU connector, and then turn the ignition switch OFF.
2. Check for continuity between terminal (M08) 32 of the cluster harness side connector and terminal 26 of ESC HECU harness side.
ca
Check for continuity between terminal (M08) 33 of the cluster harness side connector and terminal 14 of ESC HECU harness side.
Specification :Below 1Ω

▶ Repair short of wiring between terminal 26, 14 of ESC HECU harness connector and ABS warning lamp module.
▶ Repair open of wiring between terminal 26, 14 of ESC HECU harness connector and ABS warning lamp module.
Brake System
Components
c om
n.
i ag
1. Front - right tube (FR) 5. MC2 (SEC)

rd
2. Rear - left tube (RL) 6. MC1 (PRI)

3. Rear - right tube (RR) 7. ESC control module (HECU)
4. Front - left tube (FL) 8. Bracket
ca
Brake System
Removal
1. Turn the ignition switch OFF.
• Be sure to completely remove foreign substances from around brake fluid reservoir and cap before opening the reservoir cap. If
not, it may cause contamination of brake fluid and deterioration in braking performance.
water.
3. Pull up the lock of the HECU connector (A) and then disconnect the connector.
4. Loosen the HECU bracket bolts (A) & nut (B) and then remove HECU and bracket.
Tightening torque
Mounting bolts : 16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft)
Mounting nut : 24.5 ~29.4 N.m (2.5 ~3.0 kgf.m, 18.1 ~21.7 lb-ft)
c om
5. Disconnect the brake tubes from the HECU by unlocking the nuts counterclockwise with a spanner.
n.
Tightening torque
A : 12.7 ~ 16.7 N.m (1.3 ~ 1.7 kgf.m, 9.4 ~ 12.3 lb-ft)
i ag
rd
ca
Tightening torque :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
6. Remove the bolts and then remove the bracket from HECU.
Tightening torque :
10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)
1) Never attempt to disassemble the HECU.
2) Never shock the HECU.
Installation
2. Tighten the HECU mounting bolts and nuts to the specified torque.
om
(Refer to Brake system - "Brake system Bleeding")
4. Conduct the Variant coding.
5. Conduct the Auto Detected Sensor Calibration.
6. Conduct the Longitudinal G Sensor Calibration.
c
Diagnosis procedure by using diagnostic device
n.
As manual for diagnosis methods by using diagnosis device, the main contents are as follows:
Connect self-diagnosis connector(16pins) located in the lower of driver side crash pad to self-diagnosis device, and then turn the self-
ag
diagnosis device after key is ON.

Select the "vehicle model" and "ABS/ESC" on GDS vehicle selection screen, then select OK.
[Variant Coding]
i
rd
ca
[Auto Detected Sensor Calibration]
omc
n.
i ag
rd
ca
[Longitudinal G Sensor Calibration]
omc
n.
i ag
rd
ca
Brake System
om
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
c
n.
Inspection
ag

(Refer to Body - "Crash Pad Lower Panel")
3. Remove the crash pad side switch assembly (A) after loosening the screws.
i
rd
ca
4. Check the continuity between the switch terminals as the ESC OFF switch is engaged.
Brake System
om
Description
The DBC function is the acronym word of Downhill Brake Control function. When a vehicle goes down the hill, just pushing the DBC switch
enables the car to keep its vehicle''s speed at a constant value without operating the brake pedal. The DBC function is operat]ed when the
c
vehicle is on the decline and its velocity is under the predetermined speed.
Brake System
n.
Inspection
ag
2. Remove the console upper cover.
(Refer to Body - "Floor Console")
i
3. Disconnect the connector(A).

rd
ca
4. Check the continuity between the switch terminals as the DBC switch is engaged.
Brake System
om
Description
Introduction of quick brake warning system (ESS) c
In case of quick brake by driver, the brake lamp or turn signal is blinked to warn against the vehicle at rear.
n.
i ag
rd
ca
1. Basic function (Blinking the brake lamp/emergency lamp)

– Operation condition: In case of quick brake or operation of ABS above in a certain speed
– Releasing condition: In case of stopping the quick brake or releasing the ABS operation
2. Additional function (Blinking the turn signal)
– Operation condition: In case of quick brake in low speed
– Releasing condition: Releasing at the start of driving
System configuration
c om
n.
ag
i
rd
ca
ESS Circuit diagram

Brake System
Components
c om
n.
i ag
rd
ca
1. Front wheel speed sensor cable 2. Front wheel speed sensor
Brake System
Removal
Tightening torque :
88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)
2. Remove the wheel speed sensor (B) from the front alxe assembly (A),
Tightening torque :
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
c om
n.
ag
3. Remove the wheel speed sensor bracket.

i
rd
ca
4. Remove the wheel speed sensor cable braket bolt.

Tightening torque :
19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)
5. Remove the front wheel guard.
6. Disconnect the front wheel speed sensor connector and then remove the front wheel speed sensor.
Inspection
1. Measure the output voltage between the terminal of the wheel speed sensor and the body ground.
• In order to protect the wheel speed sensor, when measuring output voltage, a 100Ω resister must be used as shown.
c om
n.
i ag
2. Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage as shown below.
rd
ca
V_low : 0.59V ~ 0.84V

V_high : 1.18V ~ 1.68V
Frequency range : 1 ~ 2,500 Hz
Brake System
Components
[2WD]
c om
n.
ag
1. Front wheel speed sensor cable 2. Front wheel speed sensor connector
i
rd
[4WD]
ca
c om
n.
ag
1. Front wheel speed sensor 2. Front wheel speed sensor connector

i
Brake System
rd
Removal
ca
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
2. Disconnect the rear wheel speed sensor connector (A). [2WD only]
3. Remove the wheel speed sensor cable bracket(B). [4WD only]
Tightening torque :
6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
c
4. Remove the rear wheel speed sensor mounting bolt (A). [4WD only]
Tightening torque :
om
n.
6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 7.6 lb-ft)
i ag
rd
ca
5. Loosen the trailing arm mounting nuts(A), and then remove the trailing arm.
Tightening torque :
98.1 ~ 117.7 N.m (10.0 ~ 12.0 kgf.m, 72.3 ~ 86.6 lb-ft)
[2WD]
[4WD]
6. Remove the wheel speed sensor cable by loonsening the bolt (A).
Tightening torque :
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
7. Remove the wheel speed sensor cable braket bolt (A).

Tightening torque :
c om
n.
19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)
i ag
rd
ca
8. Remove the Luggage side trim.

(Refer to Body - "Trunk Trim")
9. Disconnect the rear wheel speed sensor connector and then remove the rear wheel speed sensor.
Inspection
1. Measure the output voltage between the terminal of the wheel speed sensor and the body ground.
• In order to protect the wheel speed sensor, when measuring output voltage, a 100Ω resister must be used as shown.
2. Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage as shown below.
om
V_low : 0.59V ~ 0.84V
V_high : 1.18V ~ 1.68V
Frequency range : 1 ~ 2,500Hz
c
Brake System
n.
Description
ag
– Autonomous Emergency Braking(Autonomous Emergency Braking (AEB)) System is designed to help avoid a potential collision or reduce
its impact when drivers applies inadequate, delayed or no brakes at all to avoid a collision.
– The system detects the risk factors on the road by using the frontal impact sensor and warn the driver and activate the emergency brake
to prevent collision or reduce collision speed.
i
The following is the system control process

rd
1. Detect preceding vehicles (pedestrians) and analyze the data (CAN comm.) by using the radar sensor of the Smart Cruise Control System
(SCC) and the camera sensor of Lane Departure Warning System (LDWS).
ca
2. Confirm the object to be protected by AEB system (vehicles and pedestrians) by using the analyzed data.
3. Calculate the speed reduction depending on the speed, distance, existence or nonexistence of preceding vehicle.
4. Report the "required speed reduction" to Vehicle Dynamics Control (VDC) (CAN Comm.)
5. VDC performs automatic control after calculating the required torque to achieve "required speed reduction" (CAN Comm.).
Operation
※ The time indicated will be changed according to vehicle speeds.
c
• Step 1: Issue a visual (display) and vocal alarm when a danger is detected. om
• Step 2: Reduce engine torque and activates AEB when there is a high chance of collision.
n.
• Step 3: Activate emergency brake when a collision is imminent.
• After stopping the vehicle: Maintain the braking control for a certain time and then release it.
ag
• Braking power is adjusted depending on the risk levels of collision, but it is released immediately when it detects the driver''s action
to avoid a collision.
i
1) When it exceeded the maximum operation speed.

rd
2) When it detected driver''s action to avoid a collision such as sudden steering changes.
3) When the shift lever is in R or P
ca
4) When you pressed the accelerator pedal half way.
1) When you drive at 80km/h or faster, the system does not go to step 3 of emergency braking.
– Full auto braking is not available.
2) While driving at 80km/h or slower on a straight or slightly curved road, the system performs three steps after issuing a warning.
– But a collision may occur at 30km/h or faster depending on the road conditions.
3) While driving at 80km/h or slower on a straight or slightly curved road, after a visual and vocal warning, AEB is activated to reduce
the vehicle speed.
4) At 80km/h or faster, it''s impossible to avoid a collision. Offset should be less than 50%.
5) AEB does not work on the vehicles backing up or resisting.
6) At 70km/h or faster, it does not respond to pedestrians.
Offset : Rate of non-overlapping on the line between the front driving car and my car
1) Offset 0% :
2) Offset 100% :
Brake System
Components
c om
n.
The following is the configuration of the Autonomous Emergency Braking(AEB) system.
– Detection device (radar and camera) that can recognize potential obstacles in the front.
– Human-Machine Interface (HMI) to warn driver or change settings.
ag
– Braking system to automatically brake the car

AEB, contrary to SCC (Smart Cruise Control), has to work on a stationary car so the system uses the Fusion Target system to combine radar
with camera.
i
rd
ca
Brake System
Schematic diagram
c om
n.
Terminal Function
ag i
rd
ca
No Terminal function
1 B+
2 NC
3 NC
4 GND
5 NC
6 NC
7 C-CAN_Low
8 C-CAN_High
9 L-CAN_Low
10 IGN1
11 NC
12 NC
13 NC
14 NC
15 NC
16 NC
17 NC
18 L-CAN_High
Brake System
Inspection
Autonomous Emergency Braking(AEB) function ON / OFF switch was included to USM (User Setting Menu) and the state of the factory is ON.
When the IGN On, maintain ON condition by default. and does not reflect the driver settings when next IGN On.
If turned the ESC function Off, the AEB function is turned off.
– The ON/OFF for AEB is included in the USM (User Setting Menu) and the default is ON.
– While IGN is On, it stays at ON, however, the driver''s settings do not last next time when IGN is newly On.
– When VDC is Off, AEB is also turned Off.
Removal
1. Turn the ignition switch off and disconnect the battery (-) cable.
2. Remove the front bumper cover
(Refer to Body - "Front Bumper")
3. Disconnect the AEB radar connector.
c om
n.
4. Remove AEB radar.
i ag
rd
ca
LDWS camera
Autonomous Emergency Braking(AEB), contrary to SCC (Smart Cruise Control) has to work on a stationary car so the system uses the Fusion
Target system to combine radar and camera.
1. Disconnect the battery (-) cable.
2. Remove the camera.
(Refer to Body Electrical System - "Lane Departure Warning System (LDWS)")
Installation
AEB radar
2. Perform AEB variant coding
3. Perform the AEB radar alignment.
LDWS camera
2. Perform Service Point Target Auto Calibration (SPTAC).
(Refer to Body Electrical System - "Lane Departure Warning System (LDWS)")
Adjust the alignment

When to perform the AEB radar alignment
• When you remount the radar after removing it.
• When you mount a new product.
• When the sensor or the surrounding part received a strong impact after a light collision.
• When it cannot detect a preceding car while driving.
• When you replaced or null-adjusted the steering angle sensor (SAS).
• Things to do before a sensor alignment.

– Remove heavy objects from the interior of the vehicle (passenger space and trunk)
– Adjust the tire pressure level as recommended.
– Check the wheel alignment.
– Check if the sensor cover is clean.
Alignment adjusting
om
No Process Description
• Mount the radar sensor on the proper position of the vehicle bumper.
1 Mounting the sensor
(Check if the bracket or radar is damaged.)
2 Keep the car stationary. • Fix the car on a lift or a flat surface to maintain the car''s horizontality with the ground.
c
• Make sure the interior of the car is empty
(including the trunk).
n.
3 Checking the car • Check if the front of the radar is clean.
• Check the allowed tire pressure and suspension.
ag
• Check the radar sensor is correctly mounted and wired.

• Use a digital meter to measure the alignment. If necessary, adjust the screw to calibrate the
Calibrating the vertical angle (by a angle
4
level meter)
(allowance of vertical angle: ±1.5° or less).
i
1) Turn the Ignition on

rd
(Red light should be on.).

Calibrating the horizontal angle
5 2) Use the GDS diagnosis equipment and start alignment.
(driving)
3) After the startup, drive the car at 50kph (30mph) or faster for five minutes.
ca
4) If the alignment is complete while driving, the warning light on the cluster is turned off.
• The alignment has been completed through the horizontal automatic alignment.
6 Check if the alignment is complete. (If the warning light is on after the alignment is done, check if the bracket or vehicle body is
damaged.)
• At the time of AEB radar alignment, vertical and horizontal processes should be done, respectively.
Adjusting the radar sensor

[Vertical calibration]
• Use an electronic tiltmeter for vertical alignment of the sensor, if not available, use a Bubble Meter.
• Adjusting the screw for vertical alignment
– Changes after rotational calibration: 1.08 degrees.
c om
n.
ag
[Horizontal calibration]
1. For horizontal alignment of the sensor, access GDS and select AEB while the vehicle is turned on
i
rd
• Remove DTC cords before starting the sensor alignment.

ca
2. Select the AEB calibration.

3. Select C2.
• Do not select the C1 while adjusting the INLINE vertical alignment.
4. Perform the alignment of the driving mode sensor before driving. On the console, check if the red warning light is On.
The sensor alignment generally takes 5-10 minutes but it may vary based on the road and/or driving conditions..
To expedite the sensor alignment, comply with the following while driving.
• Driving conditions to expedite the sensor alignment
– Achieve 50km/h or higher speed within five minutes of driving.
– Drive on a road with no curves or slopes.
– Drive on a thickly coated and wide asphalt road.
– Drive on a road with reappearing fixed objects (metallic materials such as streetlight, guardrails).
– Drive on a road in a dry and fine weather without snow or rain.
• Factors stopping or delaying the sensor alignment process
– Drive on a road with a severe curve within 100 m ahead.
– While driving at a speed lower than the required speed or at a stationary state (Traffic light).
– Drive in a tunnel or below an overpass.
– Excessive steering in the right/left direction or changing lanes.
– Drive on a road with not many reappearing fixed objects.
While driving for sensor alignment, pay attention to the following precautions.
• Obey the speed limits.
• Do not hurry to shorten the alignment time and drive safely according to the road conditions.
• Do not operate the GDS device, nor watch the GDS screen long enough to disturb driving.
om
• Always operate the GDS device while your car is stopped.
5. When the sensor alignment is complete, the warning light on the console is turned off.
6. Check if the alignment is complete.
c
n.
• If the alignment has not been completed, check the horizontal angle through GDS.
• If the horizontal angle is over ±3 degrees, check the back beam or mounting assembly. If they are okay, replace the radar unit.
ag
• After replacing the radar unit, you need to perform the sensor alignment again.
i
rd
ca

Ake System

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ake System

Uploaded by

Copyright:

Available Formats

Brake System

• O.D. : Outer Diameter

Part Item Standard value Remark

Brake pedal bushing and bolt Chassis grease As required

Special Service Tools

Tool (Number and Name) Illustration Use

09581- 2T100 Spreading the front disc brake piston.

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

4. Sliding pin (Worn) replace

5. Pad or lining (Dirty) clean

8. Brake pad shim (Damage) replace

Operation and Leakage Check

Brake System Bleeding

• Do not reuse the drained fluid.

5. Refill the master cylinder reservoir to MAX (upper) level line.

ESC Bleeding of Brake System

(1) Select vehicle name.

1. Brake booster 4. Grommet

Brake Booster Operating Test

6. Remove the master cylinder.

8. Remove the mounting nuts (A).

2. After installation, bleed the brake system.

1. Vacuum pump 2. Bracket

2. Remove the air cleaner assembly.

2. After installation, bleed the brake system.

3. Remove the wheel & tire.

• Use a new washer (A) whenever installing.

2. After installation, bleed the brake system.

2. Remove the crash pad lower panel.

4. Remove the brake pedal member mounting bolt (A).

2. Pad return spring 5. Caliper carrier

Brake hose to caliper :

5. Remove the front brake disc by loosening the screws.

Brake Pad Replacement

4. Use a SST (09581-2T100) when installing the brake caliper assembly.

- Service limit : 23.4 mm (0.92 in)

Front Brake Pad Check

1. Install in the reverse order of removal.

3. After installation, bleed the brake system.

1. Caliper carrier 4. Brake pad

3. Pad return spring

7. Remove the rear brake disc by loosening the screws.

21.6 ~ 31.4 N.m (2.2 ~ 3.2 kgf.m, 15.9 ~ 23.1 lb-ft)

1. Check the brake pads for wear and fade.

brake disc outer circle.

Service limit : 8.4 mm (0.33 in)

Rear Brake Pad Check

Rear Brake Disc Runout Check

3. After installation, bleed the brake system.

System circuit diagram

2 Engine Control Module (ECM)

3. Stop lamp switch system diagnosis c

SSEM : Stop Signal Electronic Module

(1) Connect the GDS to the self-diagnosis connector.

3. Inspection of connector by each part

[Oscilloscope waveform screen]

(Refer to Body - "Crash Pad")

4. Pull the locking plate (A) as indicated by the arrow.

6. Inspect a removed stop lamp switch along the below procedures.

(2) Perform the inspection of parts resistance

Resistance (Ω) 3-4 1-2

3. Confirm the gap between stop lamp switch and bracket.

4. Connect the stop lamp switch connector.