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SOUL(AM) > 2013 > G 1.6 GDI > Brake System

Brake System > General Information > Specifications

Specifications
Item Specification
Master cylinder
Type Tandem type
Piston stroke 45 mm (1.77 in)
Fluid level warning sensor Provided
Brake booster
Type Vacuum
Boosting ratio 9:1
Front brake (Disc) Floating type with ventilated
Type disc
Disc O.D. 280 mm (11.02 in)
Disc I.D. 172 mm (6.77 in)

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Disc thickness 26 mm (1.02 in)
Pad thickness 11 mm (0.43 in)
Cylinder I.D. Single piston
Ø57.0 mm (2.24 in)
Rear brake (Disc)
Type Floating type with solid disc
Disc O.D. 262 mm (10.31 in)
Disc I.D. 185 mm (7.28 in)
Disc thickness 10 mm (0.39 in)
Pad thickness 10 mm (0.39 in)
Cylinder type Single piston
Cylinder I.D. Ø30.0 mm (1.22 in)
Rear brake (Drum)
Type Leading trailing
Drum I.D. Ø203.2 mm (8.00 in)
Brake lining thickness 5.14 mm (0.20 in)
Clearance adjustment Automatic
Parking brake (Disc type)
Actuation DIH (Drum in hat)
Type Lever
Drum I.D. 168 mm(6.61 in)

O.D. : Outer Diameter

I.D : Inner Diameter
Specification (ESC)
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Part Item Standard value Remark
System 4 Channel 4 Sensor (Solenoid)
Motor, valve relay intergrated
Type
type
Total control
HECU
Operating Voltage 10 ~ 16V (ABS, EBD, TCS, ESC)
Operating Temperature -40 ~ 120°C(-40 ~ 248°F)
Motor power 270W
Supply voltage DC 4.5 ~ 20V
Output current low 5.9 ~ 8.4mA
Output current high 11.8~ 16.8mA
Active Wheel speed
sensor Output range 1 ~ 2500Hz
Tone wheel 47 teeth
Front : 0.5 ~ 1.5 mm
Air gap
Rear : 0.5 mm

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Operating Voltage 10 V ~ 16V
Current Consumption Max. 150mA
Yaw rate&
Lateral G sensor Yaw rate sensor
-75 ~ 75°/sec
(CAN TYPE) measurement range
Lateral G sensor
-1.5 ~ 1.5gN
measurement range

Service Standard
Item Standard value
Brake pedal height 194 mm (7.64 in)
Brake pedal stroke 135 mm (5.31 in)
Stop lamp switch outer case to pedal stopper clearance 1 ~ 2 mm (0.039 ~ 0.047 in)
Brake pedal free play 3 ~ 8 mm (0.08 ~ 0.20 in)
Booster push rod to master cylinder piston clearance 0.6 ~ 1.4 mm (at 500 mmHg vacuum)
Parking brake lever stroke when lever assembly is pulled with
5 ~ 7 clicks
196N (20Kg, 44lb force)
Front disc brake pad thickness 11 mm (0.43 in.)
Front disc thickness 26 mm (1.02 in)
Rear disc brake pad thickness 10 mm (0.35 in)
Rear disc brake disc thickness 10 mm (0.39 in)
Rear brake lining thickness Disc Brake : 2.6 mm (0.10 in)
Drum Brake : 5.14 mm (0.20 in)

Tightening Torques
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Item N.m kgf.m lb-ft
Master cylinder to booster mounting nut 12.7 ~ 16.7 1.3 ~ 1.7 9.4 ~ 12.3
Brake booster mounting nut 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
Bleeder screw 6.9 ~ 12.7 0.7 ~ 1.3 5.1 ~ 9.4
Brake tube to HECU-CBS/ABS 12.7 ~ 16.7 1.3 ~ 1.7 9.4 ~ 12.3
Brake tube to HECU-ESC 18.6 ~ 22.6 1.9 ~ 2.3 13.7 ~ 16.6
Caliper guide rod bolt 21.6 ~ 31.4 2.2 ~ 3.2 15.9 ~ 23.1
Caliper mounting bolt (Front) 78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3
Caliper mounting bolt (Rear) 63.7 ~ 73.6 6.5 ~ 7.5 47.0 ~ 54.3
Brake hose to caliper 24.5 ~ 29.4 2.5 ~ 3.0 18.1 ~ 21.7
Brake pedal member assembly bracket mounting
16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
nut
Brake pedal member assembly bracket mounting 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
bolt

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Stop lamp switch mounting nut 11.8 ~ 14.7 1.2 ~ 1.5 8.7 ~ 10.8
Wheel speed sensor mounting bolt 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0
HECU mounting bracket bolt 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
HECU bracket mounting nut 10.8 ~ 13.7 1.1 ~ 1.4 8.0 ~ 10.1
Yaw rate & Lateral G sensor mounting bolt 7.8 ~ 10.8 0.8 ~ 1.1 5.8 ~ 8.0

Lubricant
Item Recommended lubricant Quantity
Brake fluid DOT 3 or DOT 4 As required
Brake pedal bushing and brake pedal
Chassis grease As required
bolt
Parking brake shoe and backing plate
Bearing grease As required
contact surfaces
Front : 1.2 ~ 1.7g
Caliper guide rod bolt and boot AI-11P grease
Rear : 0.8 ~ 1.3g

Brake System > General Information > Special Service Tools

Special Service Tools
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Tool (Number and Name) Illustration Use
09581 - 11000 Pushing back of the front disc and rear
Piston expander disc
brake piston

Brake System > General Information > Troubleshooting

Troubleshooting
Problem Symptoms Table
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the possible
cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspect Area Remedy
Lower pedal or 1. Brake system (Fluid leaks) Repair

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spongy pedal 2. Brake system (Air in) Air bleeding
3. Piston seals (Worn or damaged) Replace
4. Master cylinder (Faulty) 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
4. Pad or lining (Cracked or distorted) Replace
5. Piston (Stuck) Replace
6. Piston (Frozen) Replace
7. Return spring (Faulty) Replace
8. Booster system (Vacuum leaks) Replace
Replace
9. Master cylinder (Faulty)
Brake pull 1. Piston (sticking) Replace
2. Pad or lining (Oily) Replace
3. Piston (Frozen) Replace
4. Disc (Scored) Replace
5. Pad or lining (Cracked or distorted) Replace

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

Repair
inefficient 2. Brake system (Air in) Air bleeding
3. Pad or lining (Worn) Replace
4. Pad or lining (Cracked or distorted) Replace
5. Pad or lining (Oily) Replace
6. Pad or lining (Glazed) Replace
7. Disc (Scored) Replace
8. Booster system (Vacuum leaks) Replace

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

2. Installation bolt (Loosen) Retighten
3. Disc (Scored)
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3. Disc (Scored) Replace
4. Sliding pin (Worn) Replace
5. Pad or lining (Dirty) Clean
6. Pad or lining (Glazed) Replace
7. Return spring (Faulty) Replace
8. Brake pad shim (Damage) Replace
Replace
9. Shoe hold-down spring (Damage)
Brake fades 1. Master cylinder Replace
Brake vibration, 1. Disc (Excessive thickness variation) Replace
pulsation 2. Disc (Faulty run-out) Replace
3. Disc (Uneven worn or crack) Replace
4. Pad or lining (Uneven worn and contact) Replace
5. Caliper (Faulty pad sliding) Replace

Brake chatter Brake chatter is usually caused by loose or worn components, or

glazed or 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

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bearings
and contaminated brake lining.

Brake System > Brake System > Repair procedures

Operation and Leakage Check
Check all of the following items
Component Procedure
Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes do
not work properly, check the brake booster(Refer to "Brake Booster Operating
Test" in this group). Replace the brake booster as an assembly if it does not work
properly or if there 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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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.
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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

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4. Repeat the procedure for wheel in the sequence shown below until air bubbles no longer appear in the fluid.

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

Brake System > Brake System > Brake Booster > Components and Components Location
Components
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1. Brake booster
2. Master cylinder assembly cardiagn.com
3. Vacuum hose

Brake System > Brake System > Brake Booster > Repair procedures
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 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.

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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 inoperative.
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.

Removal
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
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2. Disconnect the vacuum hose (A) from the brake booster.

3. Remove the master cylinder. (Refer to Master cylinder)

4. Remove the snap pin (A) and clevis pin (B).

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5. Remove the mounting nuts.

Tightening torque :
16.7 ~ 25.5N.m (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8lb-ft)

6. Remove the brake booster.

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Inspection
1. Inspect the check valve in the vacuum hose.

Do not remove the check valve from 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 installing, bleed the brake system. (Refer to Brake system bleeding)

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3. Adjust the brake pedal height and free play.
(Refer to Brake pedal height and free play adjustment)

Brake System > Brake System > Master Cylinder > Components and Components Location
Components
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1. Reservoir cap 4. Master cylinder cardiagn.com

2. Reservoir body
3. Grommet 5. O-Ring

Brake System > Brake System > Master Cylinder > Repair procedures
Removal
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
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2. Remove the cowl top cover. (Refer to the Body group-Cowl top Cover)

3. Disconnect the brake fluid level switch connector (A) from the reservoir.

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4. Remove the brake fluid from the master cylinder reservoir with a syringe.

• Be sure to completely remove foreign substances from around brake fluid reservoir and cap before
opening the reservoir cap. If not, it may cause contamination of brake fluid and deterioration in braking
performance.
• Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint,
wash it off immediately with water.

5. Disconnect the brake tube (A) from the master cylinder by loosening the tube flare nut.

Tightening torque :
CBS/ABS : 12.7 ~ 16.7N.m (1.3 ~ 1.7kgf.m , 9.4 ~ 12.3lb-ft)
ESC : 18.6 ~ 22.6N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-ft)

6. Remove the clutch hose. (MT Only)

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7. Remove the reservoir (C) from the master cylinder (B), after removing mounting screw (A).

8. Remove the two grommets.

9. Remove the master cylinder (B) from the brake booster after loosening the mounting nuts (A).

Tightening torque :
12.7 ~ 16.7N.m (1.3 ~ 1.7kgf.m, 9.4 ~ 12.3lb-ft)

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Installation
1. Installation is the reverse of removal.
2. After installation, bleed the brake system. (Refer to Brake system bleeding)

Brake System > Brake System > Brake Line > Components and Components Location
Components
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When installing brake hose, be sure to comply with the torque specification to prevent twisted hose.

Brake System > Brake System > Brake Line > Repair procedures
Removal
1. Remove the wheel & tire.
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2. Remove the brake hose clip (C).

3. Disconnect the brake tube by loosening the tube flare nut (B).

Tightening torque :
12.7 ~ 16.7N.m (1.3 ~ 1.7kgf.m, 9.4 ~ 12.3lb-ft)

4. Disconnect the brake hose from the brake caliper by loosening the bolt (A).

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Tightening torque :
24.5 ~ 29.4N.m (2.5 ~ 3.0kgf.m, 18.1 ~ 21.7lb-ft)

Front

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.
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4. Check the brake hose mounting bracket for crack or deformation.

Installation
1. Installation is the reverse of removal.

Use a new washer(A) whenever

installing.

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2. After installation, bleed the brake system. (Refer to Brake system bleeding)
3. Inspect for brake fluid leaks.

Brake System > Brake System > Brake Pedal > Components and Components Location
Components
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1. Brake pedal member 3. Brake pedal

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assembly 4. Mounting bracket
2. Stop lamp switch

Brake System > Brake System > Brake Pedal > Repair procedures
Removal
1. Remove the lower crash pad. (Refer to the Body group- crash pad).
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2. Disconnect the stop lamp switch connector (A).

3. Remove the mounting bracket bolt (B).

Tightening torque :
16.7 ~ 25.5N.m (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8lb-ft)

4. Remove the snap pin (A) and clevis pin (B).

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5. Remove the shift lock cable after removing the snap pin (C) and the clip (D).
6. Remove the brake pedal member assembly mounting nuts and then remove the brake pedal assembly.

Tightening torque :
16.7 ~ 25.5N.m (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8lb-ft)

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 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(A) is pushed.

Installation
1. Installation is the reverse of removal.

• Before installing the pin, apply the grease to the clevis

pin.

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• Use a new snap pin whenever installing.

2. Check the brake pedal operation.

Brake System > Brake System > Front Disc Brake > Components and Components Location
Components
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1. Guide rod bolt 5. Inner pad shim

2. Bleed screw 6. Brake pad cardiagn.com
3. Caliper 7. Pad retainer
bracket
4. Caliper body

Brake System > Brake System > Front Disc Brake > Repair procedures
Removal
1. Remove the front wheel & tire.

Tightening torque :
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
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2. Loosen the hose eye-bolt (B) and caliper mounting bolts (C), then remove the front caliper assembly (A).

Tightening torque
Brake hose to caliper(B):
24.5 ~ 29.4N.m (2.5 ~ 3.0kgf.m, 18.1 ~ 21.7lb-ft)
Caliper assembly to knuckle(C):
78.5 ~ 98.1N.m (8.0 ~ 10.0kgf.m, 57.9 ~ 72.3lb-ft)

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

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Replacement
Front Brake Pads
1. Remove the brake hose mounting bracket knuckle mounting part.
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2. Loosen the guide rod bolt (B) and pivot the caliper up out of the way.

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

3. Replace pad shim (B), pad retainers (C) and brake pads (B) in the caliper bracket (A).

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Inspection
Front Brake Disc Thickness Check
1. Check the brake pads for wear and fade.
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 brake disc outer circle.

Brake disc thickness

Standard: 26mm (1.02in)
Service limit: 24.4mm (0.96in)
Deviation: Less than 0.005mm (0.0002in)
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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 : 11mm (0.43in)
Service limit : 2.0mm (0.0787in)

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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 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 : 0.025mm (0.00098in.) or less (new one)

2. If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the run out
again.
3. If the replacement brake disc runout exceeds the limit specification rotate the 180° and check again.
4. If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.

Installation
1. Installation is the reverse of removal.
2. Use a SST (09581-11000) when installing the brake caliper assembly.
3. After installation, bleed the brake system. (Refer to Brake system bleeding)

Brake System > Brake System > Rear Disc Brake > Components and Components Location
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Components

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1. Guide rod bolt 5. Inner pad shim
2. Bleed screw 6. Brake pad
3. Caliper 7. Pad retainer
bracket
4. Caliper body

Brake System > Brake System > Rear Disc Brake > Repair procedures
Removal
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1. Remove the rear wheel & tire.

Tightening torque :
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)

2. Loosen the hose eye-bolt (B) and caliper mounting bolts (C), then remove the rear caliper assembly (A).

Tightening torque
Brake hose to caliper(B):
24.5 ~ 29.4N.m (2.5 ~ 3.0kgf.m, 18.1 ~ 21.7lb-ft)
Caliper assembly to carrier(C):
63.7 ~ 73.6N.m (6.5 ~ 7.5kgf.m, 47.0 ~ 54.3lb-ft)

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3. Remove the rear brake disc by loosening the screws (A).

Replacement
Rear Brake Pads
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1. Loosen the guide rod bolt (B) and pivot the caliper up out of the way.

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

2. Replace pad shim, pad retainers (C) and brake pads (B) in the caliper bracket (A).

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Inspection
Rear Brake Disc Thickness Check
1. Check the brake pads for wear and fade.
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 brake disc outer circle.

Brake disc thickness

Standard: 10mm (0.39in)
Service limit: 8.4mm (0.33in)
Deviation: less than 0.01mm (0.00039in)

4. If wear exceeds the limit, replace the discs and pad assembly 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: 10mm (0.39 n)
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: 0.05mm (0.00197in.) or less (new one)

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2. If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.
3. If the replacement brake disc runout exceed the limit specification rotate the 180° and check again.
4. If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.

Installation
1. Installation is the reverse of removal.
2. Use a SST (09581-11000) when installing the brake caliper assembly.
3. After installation, bleed the brake system. (Refer to Brake system bleeding)

Brake System > Brake System > Rear Drum Brake > Components and Components Location
Components
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1. Shoe hold down pin

2. Shoe
6. Adjusting lever
7. Adjusting lever cardiagn.com
3. Shoe hold spring spring
4. Upper return spring 8. Lower return spring
5. Shoe adjuster 9. Brake drum

Brake System > Brake System > Rear Drum Brake > Repair procedures
Removal

• Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies.
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1. Release the parking brake.
2. Remove the rear tire and wheel.
3. Remove the rear brake drum (A).

4. Remove the shoe hold spring and shoe hold pin (B).
5. Remove the upper return spring (A).

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6. Lower the brake shoe assembly (A), and remove the lower return spring (B). Make sure not to damage the dust
cover on the wheel cylinder.

7. Remove the parking brake cable (A) from the brake assembly.

8. Remove the brake shoe assembly.

9. Disconnect brake tubes (A) from the wheel cylinder (B).
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10. Remove the bolt (C) and the wheel cylinder (B) from the backing plate (D).

Installation

• 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.
• To prevent spills, cover the hose joints with rags or shop towels.
• Use only a genuine wheel cylinder special bolt.

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1. Apply sealant (C) between the wheel cylinder (A) and backing plate (B), and install the wheel cylinder.

2. Connect the brake tubes (D) to the wheel cylinder.

3. Connect the parking brake cable (A) to the brake assembly.
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4. Clean the threaded portions of adjuster sleeve (A) and push rod female (B). Coat the threads of the adjuster
assembly with grease. To shorten the clevises, turn the adjuster bolt (C).

5. Hook the shoe adjuster lever (A), then install it to the brake shoe.

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6. Install the adjuster assembly (B) and upper return spring (C) as right direction. Be careful not to damage the
wheel cylinder dust covers.
7. Install the lower return spring (D).
8. Apply brake cylinder grease or equivalent rubber grease to the sliding surfaces shown. Don't get grease on the
brake linings.
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9. Apply brake cylinder grease or equivalent rubber grease to the brake shoe ends and opposite edges of the shoes
shown. Don't get grease on the brake linings.

10. Install the brake shoes (A) onto the backing plate. Be careful not to damage the wheel cylinder dust covers.
11. Install the shoe hold down pins (B) and the shoe hold down springs.

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12. Install the rear brake drum (A).

13. If the wheel cylinder has been removed, bleed the brake system.
14. Depress the brake pedal several times to set the self-adjusting brake.
15. Adjust the parking brake.

Inspection

• Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
• Avoid breathing dust particles.
• Never use an air hose or brush to clean brake assemblies.

• Contaminated brake linings or drums reduce stopping ability.

• Block the front wheels before jacking up the rear of the vehicle.
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1. Raise the rear of the vehicle, and make sure it is securely supported.
2. Release the parking brake, and remove the rear brake drum.
3. Check the wheel cylinder (A) for leakage.
4. Check the brake linings (B) for cracking, glazing, wear, and contamination.
5. Measure the brake lining thickness (C).
Measurement does not include brake shoe thickness.

Brake lining thickness

Standard : 5.14mm (0.202in)
Service limit : 1.0mm (0.039in)

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6. If the brake lining thickness is less than the service limit, replace the brake shoes as a set.
7. Check the bearings in the hub unit for smooth operation. If it requires servicing, replace it.
8. Measure the inside diameter of the brake drum with inside vernier calipers.

Drum inside diameter

Standard : 203.2mm (8.0in)
Service limit : 205.2mm (8.08in)
Drum roundness
Service limit : 0.06mm (0.00236in)

9. If the inside diameter of the brake drum is more than the service limit, replace the brake drum.
10. Check the brake drum for scoring, grooves, and cracks.
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11. Inspect the brake lining and drum for proper contact.

12. Inspect the wheel cylinder outside for excessive wear and damage.
13. Inspect the backing plate for wear or damage.

Brake System > Parking Brake System > Parking Brake Assembly > Components and Components

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Location
Component Location
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1. Parking brake 3. Parking brake
2. Parking brake lever cable
4. Equalizer assembly

Component
Disc Brake Type
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1. Back plate 6. Return spring
2. Strut spring 7. Adjuster
3. strut 8. Return spring
4. Shoe & lining 9. Cup washer
5. Shoe guie 10. Shoe hold down
spring

Drum Brake Type

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1. Shoe hold down pin 6. Adjusting lever
2. Shoe 7. Adjusting lever
3. Shoe hold spring spring
4. Upper return spring 8. Lower return spring
5. Shoe adjuster 9. Brake drum

Brake System > Parking Brake System > Parking Brake Assembly > Repair procedures
Removal
Parking Brake Lever
 Page 39 of 87

The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature failure.
1. Remove the floor console. (Refer to Body group. -"Floor console")
2. Loosen the adjusting nut (A) and the parking brake cables.

3. Disconnect the connector (A) of parking brake switch.

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4. Remove the parking brake lever assembly after removing the 4 bolts shown.

Parking Brake Shoe (Disc Brake Type)

1. Raise the vehicle, and make sure it is securely supported.
2. Remove the rear tire and wheel, then remove the brake caliper. (Refer to "Rear disc brake removal")
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3. Remove the brake Disc (A).

4. Remove the rear hub unit bearing (A).

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5. Remove the shoe hold down pin (A) and the spring (B) by pushing the retainer spring and turning the pin.

6. Remove the adjuster assembly (A) and the return spring (B).
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7. Remove the parking brake cable (B) from the brake shoe (A).

8. Remove the strut (C) and the strut spring (D).

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9. Remove the brake shoe.
10. Remove the parking brake cable retaining (B), from the parking brake cable (A).

Parking Brake Shoe (Drum Brake Type)

1. Raise the vehicle, and make sure it is securely supported.
2. Remove the rear tire and wheel, then remove the brake drum (A).
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3. Remove the brake shoe (A). (Refer to "Rear drum brake removal")

Installation
Parking Brake Shoe (Disc Brake Type)
1. Install the brake shoe(A) to the back plate(B).

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2. Install the shoe hold down pin(C) and the spring(D) by pushing the retainer spring (D) and turning the pins.
3. After installing the strut (A) and upper return spring (B), install the adjuster assembly (C) and the lower return
spring (D).

4. Install the parking brake cable (A), then install the retaining (B).
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5. Apply a coating of the specified grease to each sliding parts of parking brake as shown.

Specified grease :
Multi purpose grease SAE J310, NLGI No.2

6. Install the rear brake disc, then adjust the rear brake shoe clearance.
(1) Remove the plug from the disc.

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(2) Rotate the toothed wheel of adjuster by a screw driver until the disc is not moving, and then return it by 3 ~ 5
notches in the opposite direction.

7. Install the brake caliper. (Refer to "Rear brake installation")

8. Install the tire and wheel.
9. Adjust the parking brake lever.
Parking Brake Shoe (Drum Brake Type)
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1. Install the brake shoe (A). (Refer to "Rear drum brake installation")

2. Install the brake drum (A).

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3. Depress the brake pedal several times to set the self-adjusting brake.
4. Adjust the parking brake lever.
Parking Brake Lever
1. Install the parking brake lever assembly, then tighten the mounting bolts.
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2. Apply a coating of the specified grease to each sliding parts (A) of the ratchet plate or the ratchet pawl.

Specified grease :
Multi purpose grease SAE J310, NLGI No.2

3. Install the parking brake cable adjuster, then adjust the parking brake lever stroke by turning adjusting nut (A).

Parking brake lever stroke :

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5 ~ 7 cliks (Pull the lever with 20kg)

After repairing the parking brake shoe, adjust the brake shoe clearance, and then adjust the parking brake
lever stroke. (Refer to "Parking brake shoe installation")

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.
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6. Reconnect the connector (A) of parking brake switch.

Inspect the continuity of parking brake switch.

When the brake lever is pulled : continuity

When the brake lever is released : no continuity

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7. Install the floor console. (Refer to Body group - "Floor console")

Adjustment
Parking Brake Shoe Clearance Adjustment
Disc Brake Type
1. Raise the vehicle, and make sure it is securely supported.
2. Remove the rear tire and wheel.
3. Remove the plug from the disc.

4. Rotate the toothed wheel of adjuster by a screw driver until the disc is not moving, and then return it by 3~5
notches in the opposite direction.
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Parking Brake Shoe Clearance Adjustment
Drum Brake Type
1. Depress the brake pedal several times to set the self-adjusting brake.

For Drum Brake type, shoe clearance is automatically adjusted by the adjuster and adjusting
lever.
Parking Brake Lever Stroke Adjustment
1. Raise the vehicle, and make sure it is securely supported.
2. Remove the floor console rear cover(A).

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3. Adjust the parking brake lever stroke by turning adjusting nut (A).

Parking brake lever stroke :

5~7 cliks (Pull the lever with 20kg)

After repairing the parking brake shoe, adjust the brake shoe clearance, and then adjust the parking brake
lever stroke. (Refer to "Parking brake shoe installation")
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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. Install the floor console rear cover(A).

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Brake System > ESC(Electronic Stability Control) System > Components and Components Location
Components
 Page 49 of 87

1. HECU module 6. ESC OFF lamp cardiagn.com

2. Yaw rate & Lateral G sensor 7. Front wheel speed sensor
3. Parking brake/EBD warning 8. Steering angle sensor
lamp 9. Rear wheel speed sensor
4. ABS warning lamp
5. ESC function / warning lamp

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 recognizes critical driving conditions, such as panic reactions in dangerous situations, and stabilizes the vehicle
by wheel-individual braking and engine control intervention.
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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.
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.

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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

2. ESC operation
Motor TC
Solenoid valve Continuity Valve
pump 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
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ABS Warning lamp

The active ABS warning lamp indicates the self-test and failure status of the ABS .The ABS warning lamp shall be
on:
- During the initialization phase after IGN ON. (continuously 3 seconds).
- 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 when CAN module.
EBD/Parking brake warning lamp
The active EBD warning lamp indicates the self-test and failure status of the EBD. However, in case the Parking

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Brake Switch is turned on, the EBD warning lamp is always turned on regardless of EBD functions. The EBD
warning lamp shall be on:
- During the initialization phase after IGN ON. (continuously 3 seconds).
- When the Parking Brake Switch is ON or brake fluid level is low.
- When the EBD function is out of order .
- During diagnostic mode.
- When the ECU Connector is seperated from ECU.
- Cluster lamp is ON when communication is impossible when CAN module.
ESC Warning lamp (ESC system)
The ESC warning lamp indicates the self-test and failure status of the ESC.
The ESC warning lamp is turned on under the following conditions :
- During the initialization phase after IGN ON. (continuously 3 seconds).
- In the event of inhibition of ESC functions by failure.
- During diagnostic mode.
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 :
- During the initialization phase after IGN ON. (continuously 3 seconds).
- When the ESC control is operating. (Blinking - 2Hz)
ESC OFF lamp (ESC System)
- When the driver truns off the ESC function with the on/off switch.
ESC 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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Circuit Diagram - ESC (2)
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Circuit Diagram - ESC (3)
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Circuit Diagram - ESC (4)
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ESC Connector Input/Output

Connector Terminal
Specification
No Description
High level of wake up voltage :4.5V < V < 16.0V
29 IGNITION1(+) Low level of wake up voltage : V < 2.4V
Nominal current : I < 50mA
Over voltage range : 17.0 ± 0.5V
Operating voltage range : 10.0 ± 0.5V < V < 16.0 ±
0.5V
25 POS. BATTERY 1.(SOLENOID)
Low voltage range : 7.0 ± 0.5V < V < 9.5 ± 0.5V
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Nominal current : I < 40A
Max. leakage current : I < 0.25mA
Operating voltage range: 10.0 ± 0.5V < V < 16.0 ±
0.5V
1 POS. BATTERY 2.(MOTOR) Peak current : I < 110A
Nominal current : I < 40A
Max. leakage current : I < 0.25mA
Rated current : I <550mA
38 GROUND
Nominal current: I < 40A
Peak current : I < 110A
13 PUMP MOTOR GROUND
Nominal current : I < 40A
Max voltage : V_BAT1-0.8V
4 SENSOR POWER
Max current Capability : I < 250mA
11 SENSOR GROUND Rated current : I <250mA
18 SENSOR FRONT LEFT POWER
34 SENSOR FRONT RIGHT POWER Output voltage : V_BAT1-0.6V ~ V_BAT1-1.1V

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19 SENSOR REAR LEFT POWER Output current : Max. 30mA
33 SENSOR REAR RIGHT POWER
31 SENSOR FRONT LEFT SIGNAL
Input current LOW : 5.9 ~ 8.4mA
21 SENSOR FRONT RIGHT SIGNAL Input current HIGH :11.8 ~ 16.8mA
32 SENSOR REAR LEFT SIGNAL Frequency range :1 ~ 2,500Hz
Input duty : 50 ± 10%
20 SENSOR REAR RIGHT SIGNAL
23 BRAKE LIGHT SWITCH
10 ESC ON/OFF SWITCH Input voltage (Low) : V < 2V
Input voltage (High) : V > 6V
9 BRAKE SWITCH Max. input current:I < 3mA (@12.8V)
15 BACK-UP LAMP SWITCH
22 PARKING BRAKE SWITCH Input voltage (Low) : V < 2V
Input voltage (High) : V > 6V
35 CLUTCH SWITCH Max input current : I < 5mA (@12.8V)
External pull up resistance :1 KΩ < R
28 SENSOR FRONT RIGHT OUTPUT
Output duty :50 ± 20%
14 CAN BUS LINE(LOW)
26 CAN BUS LINE(HIGH)
Max. input current : I < 10mA
12 CAN SENSOR LINE (HIGH)
24 CAN SENSOR LINE (LOW)
Max. input current : I < 180mA
8 HAC RELAY DRIVE
Max. output low voltage : V < 1.2V
Input voltage (Low) : V < 2V
36 HAC RELAY STATE MONITORING Input voltage (High) : V > 6V
Max. Input current : I < 10mA (@12.8V)
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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.
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.

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Warning Lamp ON
1. ESC warning lamp turn on for 3sec after IGN ON.
2. ESC function lamp blinks when ESC Act.
3. ESC OFF lamp turn on in case of
A. ESC Switch OFF
B. 3sec after IGN ON
Standard Flow of Diagnostic Troubleshooting

Notes with regard to diagnosis

The condition listed in the following table are not abnormal.
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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.
ABS operation 1. Sound of the motor inside the ABS hydraulic unit operation (whine).
sound 2. Sound is generated along with vibration of the brake pedal (scraping).
3. When ABS operates, sound is generated from the vehicle chassis due to
repeated brake application and release
(Thump : suspension; squeak: tires)
ABS operation For road surfaces such as snow-covered and gravel roads, the braking distance for vehicles
(Long braking with ABS can sometimes be longer than that for other vehicles. Accordingly, advise the
distance) customer to drive safely on such roads by lowering the vehicle speed.
Diagnosis detection conditions can vary depending on the diagnosis code. When checking the trouble symptom
after
the diagnosis code has been erased, ensure that the requirements listed in "Comment" are met.

ABS Check sheet

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Problem symptoms table

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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 Only when 1.~4. are all normal and the problem is still occurring, replace the
intermittently. 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 GDS is not 1. Power source circuit
possible. 2. CAN line
(Communication with any system is
not possible)

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Communication with GDS is not 1. Power source circuit
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 1. ABS warning lamp circuit
ABS 2. HECU
warning lamp remains ON.

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 DTC - Faulty wheel speed sensor circuit
is displayed, check the following probable cause. When the problem - Faulty hydraulic circuit for leakage
is still occurring, replace the ABS control module. - Faulty HECU

Inspection procedures
DTC Inspection
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1. Connect the GDS with the data link connector and turn the ignition switch ON.
2. Verify that the normal code is output.
3. Is the normal code output?
Check the power source circuit.
Erase the DTC and recheck using GDS.

Check the power source circuit

1. Disconnect the connector from the ABS control module.
2. Turn the ignition switch ON, measure the voltage between terminal 29 of the ABS control module harness side
connector and body ground.

Specification: approximately B+

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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 ABS control module. Repair if necessary.

Check the ground circuit

1. Disconnect the connector from the ABS control module.
2. Check for continuity between terminals 13, 38 of the ABS 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.
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2. Is it normal?
Check the hydraulic circuit for leakage.
Repair or replace the wheel speed
sensor.

Check the hydraulic circuit for leakage

1. Refer to the hydraulic lines.
2. Inspect leakage of the hydraulic lines.
3. Is it normal?
The problem is still occurring, replace the ABS control
module.
Repair the hydraulic lines for leakage.

Detecting condition

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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 DTC - Faulty wheel speed sensor circuit
is displayed, check the following probable cause. When the problem - Faulty hydraulic circuit for leakage
is still occurring, replace the ABS control module. - Faulty HECU

Inspection procedures
DTC Inspection
1. Connect the GDS with the data link connector and turn the ignition switch ON.
2. Verify that the normal code is output.
3. Is the normal code output?
Check the wheel speed sensor circuit.
Erase the DTC and recheck using GDS.

Check the wheel speed sensor circuit

1. Refer to the DTC troubleshooting procedures.
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.
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2. Measure the voltage between terminal 23 of the ABS control module harness side connector and body ground
when brake pedal is depressed.

Specification : approximately B+

3. 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 control module
and the stop lamp switch.

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Check the hydraulic circuit for leakage
1. Refer to the hydraulic lines.
2. Inspection leakage of the hydraulic lines.
3. Is it normal?
The problem is still occurring, replace the ABS control
module.
Repair the hydraulic lines for leakage.

Detecting condition
Trouble Symptoms Possible Cause
Possible defect in the power supply system (including ground) for - An open in the wire
the diagnosis line. - Poor ground
- Faulty power source circuit

Inspection procedures
Check The Power Supply Circuit For The Diagnosis
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1. Measure the voltage between terminal 16 of the data link connector and body ground.

Specification : approximately B+

2. 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
1. Check for continuity between terminal 4 of the data link connector and body ground.

2. Is there continuity?
Repair an open in the wire between terminal 4 of the data link connector and
ground point.

Detecting condition
Trouble Symptoms Possible Cause
When communication with GDS is not possible, the cause may be - An open in the wire
probably an open in the HECU power circuit or an open in the - Faulty HECU
diagnosis output circuit. - Faulty power source circuit

Inspection procedures
Check for Continuity in the Diagnosis Line
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1. Disconnect the connector from the ABS control module.
2. Check for continuity between terminals 30 of the ABS control module connector and 8 of the data link
connector.
3. Is there continuity?
Check the power source of ABS control
module.
Repair an open in the wire.

Check the power source of ABS control module

1. Disconnect the connector from the ABS control module.
2. Turn the ignition switch ON, measure the voltage between terminal 29 of the ABS control module harness side
connector and body ground.

Specification : approximately B+

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3. Is voltage within specification?
Check for poor ground.
Check the harness or connector between the fuse (10A) in the engine compartment junction
block and the ABS control module. Repair if necessary.

Check for poor ground

1. Check for continuity between terminal 4 of the data link connector and ground point.

Replace the ABS control module and recheck.

Repair an open in the wire or poor ground.
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Detecting condition
Trouble Symptoms Possible Cause
When current flows in the HECU the ABS warning lamp turns from - Faulty ABS warning lamp bulb
ON - Blown fuse is related to ABS in the
to OFF as the initial check. Therefore if the lamp does not light up, engine compartment junction block
the - Faulty ABS warning lamp module
cause may be an open in the lamp power supply circuit, a blown - Faulty HECU
bulb,
an open in the both circuits between the ABS warning lamp and the
HECU, and the faulty HECU.

Inspection procedures
Problem verification
1. Disconnect the connector from the ABS control module and turn the ignition switch ON.
2. Does the ABS warning lamp light up?
Inspect again after replacing the ABS HECU.
Check the power source for the ABS warning

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lamp.

Check the power source for the ABS warning lamp

1. Disconnect the instrument cluster connector (M01) and turn the ignition switch ON.
2. Measure the voltage between terminal (M01) 40 of the cluster harness side connector and body ground.

Specification : approximately B+

3. Is voltage within specification?

Check the CAN circuit resistance for ABS warning
lamp.
Check for blown fuse.

Check the CAN circuit resistance for ABS warning lamp

1. Turn the ignition switch OFF. Disconnect the instrument cluster connector (M01).
 Page 70 of 87
2. Measure the resistance between terminal (M01) 35 and 36 of the cluster harness side connector.

Specification : 60Ω

3. Is resistance within specification?

Repair ABS warning lamp bulb or instrument cluster assembly.
Check the CAN circuit wiring for ABS warning lamp.

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Check the CAN circuit wiring for ABS warning lamp
1. Turn the ignition switch OFF. Disconnect the instrument cluster connector (M01) and ABS HECU connector.
2. Check for continuity between terminal (M01) 35 of the cluster harness side connector and terminal 26 of ABS
HECU harness side.
Check for continuity between terminal (M01) 36 of the cluster harness side connector and terminal 14 of ABS
HECU harness side.

Specification : Below 1Ω

3. Is resistance within specification?

Repair short circuit wiring between terminal 26, 14 of ABS HECU harness connector and ABS
warning lamp module.
Repair open circuit wiring between terminal 26, 14 of ABS HECU harness connector and ABS
warning lamp module.

Detecting condition
Trouble Symptoms Possible Cause
If the HECU detects trouble, it lights the ABS warning lamp and at - An open in the wire
the - Faulty instrument cluster assembly
same time prohibits ABS control. The HECU then records a - Faulty ABS warning lamp module
DTC in memory. If the ABS warning lamp remains ON, even after - Faulty HECU
the problem with the DTC is repaired and cleared, then the cause
may be an open or short in the ABS warning lamp circuit.

Inspection procedures
Check DTC Output
1. Connect the GDS to the 16P data link connector located behind the driver's side kick panel.
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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. Turn the ignition OFF. Disconnect the instrument cluster connector (M01).
2. Measure the resistance between terminal (M01) 35 and 36 of the cluster harness side connector.

Specification : 60Ω

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3. Is resistance within specification?
Repair ABS warning lamp bulb or instrument cluster
assembly.
Check the CAN circuit wiring for ABS warning lamp.

Check the CAN circuit wiring for ABS warning lamp

1. Turn the ignition switch OFF. Disconnect the instrument cluster connector (M01) and ABS HECU connector.
2. Check for continuity between terminal (M01) 35 of the cluster harness side connector and terminal 26 of ABS
HECU harness side.
Check for continuity between terminal (M01) 36 of the cluster harness side connector and terminal 14 of ABS
HECU harness side.

Specification : Below 1Ω

3. Is there continuity?
Repair short circuit wiring between terminal 26, 14 of ABS HECU harness connector and
ABS warning lamp module.If no trouble in wiring, inspect again after replacing the ABS
HECU.
Repair short circuit wiring between terminal 26, 14 of ABS HECU harness connector and
ABS warning lamp module.If no trouble in wiring, inspect again after replacing the ABS
HECU.

Bleeding of Brake System

This procedure should be followed to ensure adequate bleeding of air and filling of the ABS unit, brake lines and
master cylinder with brake fluid.
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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 ABS motor with the GDS to prevent the motor pump from burning.

(1) Select vehicle name.

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(2) Select Anti-Lock Brake system.
(3) Select HCU air bleeding mode.
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(4) Press "OK" to operate motor pump and solenoid valve.

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(5) Wait 60 sec. before operating the air bleeding. (If not, you may damage the motor.)
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(6) Perform the air bleeding.
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5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without
bubbles. Then close the bleeder screw(A).
Front

Rear
 Page 76 of 87

6. Repeat step 5 until there are no more bubbles in the fluid for each wheel.

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7. Tighten the bleeder screw.

Bleed screw tightening torque:

6.9 ~ 12.7N.m (0.7 ~ 1.3kgf.m, 5.1 ~ 9.4lb-ft)

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
Maximum braking effectiveness 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 77 of 87

Brake System > ESC(Electronic Stability Control) System > ESC Control Module > Components and
Components Location
Components

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 Page 78 of 87

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1. Front-left tube 5. MC2
2. Rear -right tube 6. MC1
3. Rear-left tube 7. ESC control module
4. Front-right tube (HECU)
8. Bracket

Brake System > ESC(Electronic Stability Control) System > ESC Control Module > Repair procedures
Removal
1. Turn the ignition switch OFF and disconnect the negative (-) battery cable.
2. Pull up the lock of the ABS control unit connector, then disconnect the connector.
 Page 79 of 87
3. Disconnect the brake tubes from the HECU by unlocking the nuts counterclockwise with a spanner.

Tightening torque:
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)

4. Loosen the HECU bracket bolts and nut, then remove HECU and bracket.

Tightening torque:
16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft)

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1. Never attempt to disassemble the HECU.
2. The HECU must be transported and stored in.
3. Never shock to the HECU.

5. Remove the bolts, then remove the bracket from HECU.

Tightening torque:
10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)

Installation
1. Installation is the reverse of removal.
2. Tighten the HECU mounting bolts and nuts to the specified torque.

Brake System > ESC(Electronic Stability Control) System > Front Wheel Speed Sensor > Components
and Components Location
 Page 80 of 87
Components

1. Front wheel speed sensor cable

2. Front wheel speed sensor
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Brake System > ESC(Electronic Stability Control) System > Front Wheel Speed Sensor > Repair
procedures
Removal
 Page 81 of 87
1. Remove the front wheel speed sensor mounting bolt (A).

Tightening torque:
6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)

2. Remove the front wheel guard.

3. Disconnect the front wheel speed sensor connector. And remove the front wheel speed sensor.
4. Installation is the reverse of removal.

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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 100 Ω resister must be used
as shown.
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2. Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage
as shown below.

V_low : 0.59V ~ 0.84V

V_high : 1.18V ~ 1.68V
Frequency range : 1 ~ 2,500Hz

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Brake System > ESC(Electronic Stability Control) System > Rear Wheel Speed Sensor > Components
and Components Location
Components
 Page 83 of 87

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1. Rear wheel speed sensor cable
2. Rear wheel speed sensor

Brake System > ESC(Electronic Stability Control) System > Rear Wheel Speed Sensor > Repair
procedures
Removal
 Page 84 of 87
1. Remove the connector after(A) removing the rear wheel speed sensor clip.

2. Remove the rear wheel speed sensor. (Refer to Driveshaft and axle group - Rear axle assembly)
3. Installation is the reverse of removal.

Inspection
1. Measure the output voltage between the terminal of the wheel speed sensor and the body ground.

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In order to protect the wheel speed sensor, when measuring output voltage, a 100 Ω 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.

V_low : 0.59V ~ 0.84V

V_high : 1.18V ~ 1.68V
Frequency range : 1 ~ 2,500Hz
 Page 85 of 87
Brake System > ESC(Electronic Stability Control) System > Yaw-rate and Lateral G Sensor >
Description and Operation
Description
When the vehicle is turning with respect to a vertical axis the yaw rate sensor detects the yaw rate electronically by
the vibration change of plate fork inside the yaw rate sensor.
If yaw velocity reaches the specific velocity after it detects the vehicle' yawing, the ESC control is reactivated.
The later G sensor senses vehicle's lateral G. A small element inside the sensor is attached to a deflectable lever arm
by later G.
Direction and magnitude of lateral G loaded to vehicle can be known with electrostatic capacity changing according
to lateral G.
It interchanges signals with HECU through extra CAN line which only used for communication between HECU and
sensor.

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Specifications
Description Specification Remarks
Operating voltage 10 ~ 16V
Output signal CAN Interface
Operating temperature -40 ~ 85°C(-40 ~ 185°F)
Measurement
-75 ~ 75°/sec
Yaw-rate range
sensor Frequency
18 ~ 22Hz
response
Measurement
-1.5 ~ 1.5g
Lateral G range
sensor Frequency
50Hz±60%
response

External Diagram
 Page 86 of 87

Brake System > ESC(Electronic Stability Control) System > Yaw-rate and Lateral G Sensor > Repair
procedures
Removal

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1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the passenger seat assembly.
(Refer to the Body group - "Seat")
3. Clear away the floor mat.
4. Disconnect the yaw rate & lateral G sensor connector.
5. Remove the mounting bolts (A).

Tightening torque:
7.9 ~ 10.8N.m (0.8 ~ 1.1kgf.m, 5.8 ~ 8.0Ib-ft)

6. Installation is the reverse of removal.

Brake System > ESC(Electronic Stability Control) System > ESC OFF Switch > Description and
Operation
Description
1. The ESC OFF switch is for the user to 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
 Page 87 of 87
Inspection
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the lower crash pad switch assembly by using the scraper and then disconnect the connectors.

3. Check the continuity between the switch terminals as the ESC OFF switch is engaged.

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Brake System > ESC(Electronic Stability Control) System > Steering Wheel Angle Sensor >
Description and Operation
Description
The Steering Angle Sensor (SAS) is installed in MDPS (Motor Driven Power Steering) and it sends messages to
HECU through CAN communication line.
The SAS is used to determine turning direction and speed of the steering wheel.
The HECU uses the signals from the SAS when performing ESC-related calculations.
Components (Steering Angle Sensor, Torque Sensor, Failsafe relay, etc.) of the EPS system are located inside the
steering column & EPS unit assembly and the steering column. EPS unit assembly must not be disassemble to be
inspected. They must be replaced. (Refer to “ST (Steering system) Gr.”)