Anti-Lock Brake System

2003 Kia Sorento LX
2004 BRAKES Anti Lock Brakes - Sorento
2004 BRAKES
Anti Lock Brakes - Sorento
GENERAL
SPECIFICATIONS
Fig. 1: Anti Lock Brake Specifications

Courtesy of KIA MOTORS AMERICA, INC.
TIGHTENING TORQUE
TIGHTENING TORQUE
Application Ft. Lbs. (N.m)
Sensor Mounting Bolt On The Brake Plate
Front 5-7 (7-10)
Rear 5-7 (7-10)
Hydraulic & Electronic Control Unit Mounting Nut 6-9 (8-12)
Hydraulic & Electronic Control Unit Mounting Bracket Bolt 14-19 (19-26)
Six Brake Tubes On The Hydraulic Unit 9-16 (13-22)
DESCRIPTION & OPERATION
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5:14:53 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
2003 Kia Sorento LX
SYSTEM COMPONENTS
Fig. 2: Identifying System Components

The Anti-Lock Brake System (ABS) controls the hydraulic brake pressure of all four wheels during sudden
braking and braking on hazardous road surfaces, preventing the wheels from locking up. ABS provides the
following benefits:
1. Enables steering around obstacles with a greater degree of certainty, even during emergency braking.
2. Enables stopping during emergency braking while keeping stability and steerability even on curves.
WARNING LAMP
1. ABS warning lamp:
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2003 Kia Sorento LX
1.
It is turned on for three seconds at time of ON of ignition Key and turns off afterwards.
2.
It is extinguished at start of operation.
3.
It is lighted if system abnormality arise.
4.
It is lighted during self-diagnosis.
5.
During its lighting, ABS control is interrupted and only ordinary brake operates in same way as
ABS non installed vehicle.
6. It is lighted when ECU connector is removed.
2. EBD (electronic brake-force distribution) warning lamp:
1. It is lighted at time of ON of ignition Key.
2. It is extinguished at start of operation.
3. It is lighted when parking brake switch is ON.
4. It is lighted when brake oil is deficient.
5. It is lighted when EBD control is infeasible.
z When there is trouble at solenoid valve.
z When there is trouble in more than one sensor.
z When there is trouble in ECU.
z In case of high voltage.
FAIL-SAFE MODES
EBD TYPE
Fig. 3: EBD Type Fail Safe Description

SAFETY
1. Failure trouble ratio decreases than with ABS because EBD continues to control even in the following
cases among ABS failure causes.
1. One wheel speed sensor failure.
2. Motor pump failure.
3. Failure by low voltage of battery.
2. Though there is no alarm instrument for P-valve by which may always be informed so that drive cannot
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know whether or not of failure trouble, in which case body spin may be generated if taken a sudden
braking under condition of failure situation; in case of EBD failure trouble, the existing parking brake
lamp is lighted to alarm EBD failure situation to driver so that driver can repair.
3. Fail-safe.
Fig. 4: System Failure Description Chart

DIAGNOSTIC INFORMATION
HYDRAULIC MODULE INSPECTION
CAUTION: Turn the ignition switch off before connecting or disconnecting the Hi-
Scan.
1. Jack the vehicle up and support the vehicle with rigid racks at the specified jack-up points or replace the
wheels which are checked on the rollers of the braking force tester.
CAUTION: z The roller of the braking force tester and the tire should be dry
during testing.
z When testing the front brakes, apply the parking brake, and
when testing the rear brakes, stop the front wheels by chocking
them.
2. Release the parking brake and feel the drag force (drag torque) on each road wheel.
When using the braking force tester, take a reading of the brake drag force.
3. Turn the ignition key "OFF" and set the Hi-Scan or Hi-Scan Pro as shown in the diagram.
4. After checking that the shift lever < M/T > or the selector lever < A/T > is in neutral, start the engine.
NOTE: If the ABS is in fail-safe mode, the Hi-Scan actuator test cannot be used.
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5. Use the Hi-Scan to force-drive the ABS actuator.
Fig. 5: Illustrating Hi Scan Operation

SYSTEM DIAGRAM
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Fig. 6: ABS System Diagram

ABS OPERATING MODES
1. Normal brake (ABS is not operated).
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Fig. 7: Illustrating Normal Brake Operating Mode

2. ABS operating (Maintaining pressure mode).
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Fig. 8: Illustrating Maintaining Pressure Mode

3. ABS operation (Decreasing pressure mode).
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Fig. 9: Illustrating Decreasing Pressure Mode

4. ABS Operation (Increasing pressure mode).
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Fig. 10: Illustrating Increasing Pressure Mode

INSPECTION AT HECU TERMINALS
TERMINAL VOLTAGE CHART
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Fig. 11: HECU Pinout

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Fig. 12: Terminal Voltage Chart

INPUT-OUTPUT SPECIFICATION
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Fig. 13: HECU Input-Output Specification Chart

DIAGRAM OF INPUT/OUTPUT FOR HECU
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Fig. 14: HECU Input-Output Diagram

ABS WIRING DIAGRAM
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Fig. 15: ABS Wiring Diagram

TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
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Fig. 16: Illustrating Standard Flow Of Diagnostic Troubleshooting

NOTES WITH REGARD TO DIAGNOSIS
The phenomena listed in the following table are not abnormal.
Fig. 17: Notes With Regard To Diagnosis

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ABS CHECK SHEET
Fig. 18: ABS Check Sheet

HI-SCAN (PRO) CHECK
1. Turn the ignition "OFF".

2. Connect the Hi-scan to the data link connector located underneath low crash pad panel.
3. Turn the ignition "ON".
4. Use the Hi-scan to check the self-diagnosis codes.
5. After completion of the repair or correction of the problems, turn the ignition switch "ON" ; then erase
the stored faults codes using the clear key.
6. Disconnect the Hi-scan.
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Fig. 19: Disconnecting Hi Scan

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Fig. 20: DLC Pinout

INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES
Inspect according to the inspection chart that is appropriate for the malfunction code.
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Fig. 21: DLC Code Chart

ACTUATOR DRIVING
Fig. 22: Actuator Driving Chart

CURRENT DATA
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Fig. 23: Current Data Chart

INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES
DTC INDEX
Fig. 24 Wheel Speed Sensor Open Or Short To GND Circuit
Fig. 26 Wheel Speed Sensor Frequency Error
Fig. 27 G Sensor Signal
Fig. 29 Voltage Out of Range (Low & Over Volt)
Fig. 31 ECU Hardware (EEPROM & ECU Failure)
Fig. 32 Brake Lamp Switch
Fig. 33 Valve Relay (Including Fuse Failure)
Fig. 35 HECU Hardware Error
Fig. 36 Electrical (Motor, Relay, Motor)
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Fig. 24: DTC C0035, C0040, C0045, C0050 - Wheel Speed Sensor Open Or Short To GND Circuit (1 Of
2)
Fig. 25: DTC C0035, C0040, C0045, C0050 - Wheel Speed Sensor Open Or Short To GND Circuit (2 Of
2)
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Fig. 26: DTC C0245 - Wheel Speed Sensor Frequency Error

Fig. 27: DTC C0930 - G Sensor Signal (1 Of 2)

Fig. 28: DTC C0930 - G Sensor Signal (2 Of 2)

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Fig. 29: DTC C0800 - Voltage Out Of Range (Low & Over Volt) (1 Of 2)
CAUTION: If battery voltage drops or rises during inspection, this code will be output
as well. If the voltage returns to the standard value, the code is no longer
output. Before carrying out the following inspection, check the battery
level and refill if necessary.
Fig. 30: DTC C0800 - Voltage Out Of Range (Low & Over Volt) (2 Of 2)
Fig. 31: DTC C0550 - ECU Hardware (EEPROM & ECU Failure)
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Fig. 32: DTC C0161 - Brake Lamp Switch

Fig. 33: DTC C0121 - Valve Relay (Including Fuse Failure) (1 Of 2)

Fig. 34: DTC C0121 - Valve Relay (Including Fuse Failure) (2 Of 2)

Fig. 35: DTC C0060, C0065, C0070, C0075, C0080, C0085, C0090, C0095 - HECU Hardware Error
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Fig. 36: DTC C0110 - Electrical (Motor, Relay, Motor) (1 Of 2)

CAUTION: Because powering of the motor with the Hi-Scan or Hi-Scan Pro 3will
discharge the battery, the engine should be run for a while after testing is
completed.
Fig. 37: DTC C0110 - Electrical (Motor, Relay, Motor) (2 Of 2)

INSPECTION CHART FOR TROUBLE SYMPTOMS
Find out the symptoms and check according to the inspection procedure chart.
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Fig. 38: Trouble Symptoms Inspection Chart

CAUTION: 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.
INSPECTION PROCEDURE 1
Fig. 39: Inspection Procedure 1 Probable Cause Chart


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Fig. 41: Inspection Procedure 2 Troubleshooting Diagram


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This trouble symptom is limited to cases where communication with the Hi-Scan is possible (HECU
power supply is normal) and the diagnosis code is normal.
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SERVICE & ADJUSTMENTS

BLEEDING OF BRAKE SYSTEM
This procedure should be used to insure adequate bleeding and filling of ABS unit, brake lines, master cylinder.
1. Remove the reservoir cap and fill the brake reservoir with brake fluid.
CAUTION: Do not allow brake fluid remain on a painted surface. Wash it off
immediately.
NOTE: When bleeding by pressured fluid, do not depress the brake pedal.
Recommended fluid.....DOT3 or equivalent.
Fig. 48: Identifying Brake Reservoir

2. Connect the clear plastic tube to the wheel cylinder bleeder plug and insert the other end of tube in a half
filled clear plastic bottle.
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Fig. 49: Connecting To Bleeder Plug

3. Connect Hi-Scan to Data Link Connector located underneath the dash panel.
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Fig. 50: Connecting Hi Scan

4. Select and operate according to the instruction on the Hi-Scan screen.
CAUTION: You have to obey maximum operating time (60 sec) of ABS motor with Hi-
Scan to prevent motor pump burnt.
1. Select KIA vehicle diagnosis.
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Fig. 51: Initial Screen Selection

2. Select Anti-Lock brake system.
Fig. 52: Anti-Lock Brake System Selection

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3. Select air bleeding mode.
Fig. 53: Air Bleeding Mode Selection

4. Press 'YES' to operate motor pump and solenoid valve.
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Fig. 54: 'YES' Selection

5. 'ON' and 'OFF' controls are automatically performed to prevent the motor pump from being burnt (if not,
you may damage the motor).
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Fig. 55: Illustrating Air Bleeding Mode Selection

6. 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.
7. Repeat the step 5. until there are no more bubbles in the fluid for each wheel in the sequence shown in the
illustration.
8. Tighten the bleeder screw.
Bleeder screw tightening torque
7-9 Nm (70-90 kg. cm, 5-6.6 lb. ft)
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Fig. 56: Bleeder Tightening Sequence

REMOVAL, INSPECTION & INSTALLATION

ANTI-LOCK BRAKING SYSTEM CONTROL MODULE
COMPONENTS
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Fig. 57: Illustrating Braking System Control Module Components

REMOVAL
1. Disconnect the HECU (Hydraulic and electronic Control Unit) and motor connector.
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Fig. 58: Identifying HECU Connector

2. Disconnect the brake lines from the HECU.

3. Remove the HECU mounting nut, HECU bracket bolt and the HECU.
CAUTION: z Never attempt to disassemble the HECU.

z The HECU must be transported and stored in the upright position
and with sealed ports. The HECU must not be drained.
INSTALLATION
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1. Follow the reverse order for removal.

2. Tighten the modulator mounting nuts, modulator bracket bolts and brake tube nuts to the specified torque.
Tightening torque:
HECU mounting nut:
8-12 Nm (80-120 kg. cm, 6-9 lb. ft)
HECU mounting bracket bolt: 19-26 Nm (190-260 kg. cm, 14-19 lb. ft)
Brake tube nut: 13-22 Nm (130-220 kg. cm, 9-12 lb. ft)
WHEEL SPEED SENSORS
REMOVAL
Front
1. Remove the front wheel speed sensor mounting bolt.
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Fig. 59: Removing The Front Wheel Speed Sensor Mounting Bolt
2. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector.
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Fig. 60: Removing The Front Wheel Speed Sensor

Rear
Remove the rear wheel speed sensor after disconnecting the wheel speed sensor connector.
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Fig. 61: Removing Rear Wheel Sensor

INSPECTION
1. Connect an ohmmeter between the wheel speed sensor terminals and measure the resistance.
Service standard:
Front: 1600ohm +/- 10%.
Rear: 1600ohm +/- 10%.
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Fig. 62: Testing Wheel Speed Sensor Continuity

2. Connect a voltmeter between the wheel speed sensor terminals and measure the voltage by turning the
wheel.
NOTE: Set the voltmeter to measure AC voltage.
Service standard: AC voltage detected.
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Fig. 63: Testing Wheel Speed Sensor Voltage

ABS OPERATION CHECK
WHEEL SPEED SENSOR OUTPUT VOLTAGE CHECK
1. Lift the vehicle up and release the parking brake.

2. Disconnect the HECU harness connector and measure from the harness side connector.
CAUTION: Be sure to remove the connector double lock and insert the probe
into the harness side. Inserting it into the terminal side will result in a
bad connection.
3. Rotate the wheel to be measured at approximately 1/2-1 rotation per second, and check the output voltage
using a circuit tester or an oscilloscope.
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Fig. 64: Wheel Speed Sensor Terminal Numbers

Output voltage
When measuring with an oscilloscope: 120 mV peak-to-peak or more at 2.75 kph.
Fig. 65: HECU Pinout & Testing Points

EBD (ELECTRONIC BRAKE-FORCE DISTRIBUTION)

EBD is additionally applied, instead of the proportioning valve, to deliver ideal distribution of fluid pressure to
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the front and rear brakes. This prevents the brakes from skidding in the event of rear wheel lock up and provides
higher brake efficiency within the range of brake application.
ADVANTAGES
z Functional improvement of base-brake system.

z Compensation of different friction coefficients.
z Elimination of proportioning valve.
z Failure recognition by warning lamp.
COMPARISON BETWEEN PROPORTIONING VALVE AND EBD
Fig. 66: Illustrating Comparison Between Proportioning Valve & EBD

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2003 Kia Sorento LX

2004 BRAKES Anti Lock Brakes - Sorento

Anti Lock Brakes - Sorento

Fig. 1: Anti Lock Brake Specifications

DESCRIPTION & OPERATION

Fig. 2: Identifying System Components

1. ABS warning lamp:

z When there is trouble in more than one sensor.

z When there is trouble in ECU.

z In case of high voltage.

Fig. 3: EBD Type Fail Safe Description

Fig. 4: System Failure Description Chart

5. Use the Hi-Scan to force-drive the ABS actuator.

Fig. 5: Illustrating Hi Scan Operation

Fig. 6: ABS System Diagram

ABS OPERATING MODES

1. Normal brake (ABS is not operated).

Fig. 7: Illustrating Normal Brake Operating Mode

2. ABS operating (Maintaining pressure mode).

Fig. 8: Illustrating Maintaining Pressure Mode

3. ABS operation (Decreasing pressure mode).

Fig. 9: Illustrating Decreasing Pressure Mode

4. ABS Operation (Increasing pressure mode).

Fig. 10: Illustrating Increasing Pressure Mode

INSPECTION AT HECU TERMINALS

TERMINAL VOLTAGE CHART

Fig. 11: HECU Pinout

Fig. 12: Terminal Voltage Chart

Fig. 13: HECU Input-Output Specification Chart

DIAGRAM OF INPUT/OUTPUT FOR HECU

Fig. 14: HECU Input-Output Diagram

ABS WIRING DIAGRAM

Fig. 15: ABS Wiring Diagram

Fig. 16: Illustrating Standard Flow Of Diagnostic Troubleshooting

NOTES WITH REGARD TO DIAGNOSIS

The phenomena listed in the following table are not abnormal.

Fig. 17: Notes With Regard To Diagnosis

ABS CHECK SHEET

Fig. 18: ABS Check Sheet

HI-SCAN (PRO) CHECK

1. Turn the ignition "OFF".

Fig. 19: Disconnecting Hi Scan

Fig. 20: DLC Pinout

INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES

Fig. 21: DLC Code Chart

Fig. 22: Actuator Driving Chart

Fig. 23: Current Data Chart

INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES

Fig. 26: DTC C0245 - Wheel Speed Sensor Frequency Error

Fig. 27: DTC C0930 - G Sensor Signal (1 Of 2)

Fig. 28: DTC C0930 - G Sensor Signal (2 Of 2)

Fig. 32: DTC C0161 - Brake Lamp Switch

Fig. 33: DTC C0121 - Valve Relay (Including Fuse Failure) (1 Of 2)

Fig. 34: DTC C0121 - Valve Relay (Including Fuse Failure) (2 Of 2)

Fig. 36: DTC C0110 - Electrical (Motor, Relay, Motor) (1 Of 2)

Fig. 37: DTC C0110 - Electrical (Motor, Relay, Motor) (2 Of 2)

INSPECTION CHART FOR TROUBLE SYMPTOMS

Fig. 38: Trouble Symptoms Inspection Chart

Fig. 39: Inspection Procedure 1 Probable Cause Chart