Sistema Frenos

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SPORTAGE(AL) > 2002 > G 2.0 DOHC > Brake System

Brake System > General Information > Description and Operation DESCRIPTION
BRAKING SYSTEM The Sportage is equipped with a vacuum assisted, hydraulic, antilock brake system (ABS). When the brake pedal is depressed, a piston is moved in the master cylinder. This piston forces hydraulic fluid into the brake system lines, applying pressure to the wheel cylinders. As the wheel cylinders extend, they clamp the disc brakes against a brake rotor and extend brake shoes against a brake drum. The primary brake system consists of the following components: a master cylinder, a vacuum booster, a proportioning valve, an ABS solenoid, brake lines, rear brake drums, and front disc brake assemblies. All components are replaceable, or serviceable, with regular maintenance schedules. The parking brake system is a mechanical system used to hold the vehicle when parked.
MASTER CYLINDER
The master cylinder produces the pressure needed to actuate the wheel cylinders. The unit consists of a hydraulic fluidreservoir and a dual piston assembly. When the brake pedal is depressed, a mechanical linkage pushes on the dual piston forcing fluid out of two side ports. The front port sends fluid to the front disc brakes while the rear port sends fluid to the rear drum brakes. By using this method, a failure in one of the pistons will only affect half of the brakesystem.
VACUUM BOOSTER
The vacuum booster is a diaphragm mounted between the brake pedal and the master cylinder. A vacuum hose connecting thisunit to the engine intake manifold draws air out from between the diaphragm and the master cylinder piston. With atmospheric pressure only on the brake pedal side of the diaphragm, any pressure applied to this pedal is increased by 1 atmosphere as a form of power brakes.
PROPORTIONING VALVE
Because disc brakes need higher line pressures to produce the same amount of braking force as a drum brake, a proportioning valve has been placed in the brake lines. Its function is to keep the rear brake line pressure lower than the front brake lines, producing balanced braking.
BRAKE LINES
The brake lines connect the master cylinder with the front and rear brake assemblies.
DRUM BRAKE ASSEMBLY

The Sportage has rear wheel drum brake assemblies each consisting of a dual-servo wheel cylinder, primary and secondarybrake shoes, a self adjusting mechanism, a drum, and the backing plate. In the Sportage drum brakes, there is no difference in size between the primary shoe and the secondary shoe. The self-adjusters adjust when the brakes are applied against either forward or rearward motion.
DISC BRAKE ASSEMBLY

The Sportage has front wheel disc brakes, each consisting of a floating caliper assembly, a piston, brake pad and a ventilated disc. This system produces equal force on both sides of the front wheel disc, producing equal pad wear.
Brake System > General Information > Troubleshooting DIAGNOSIS

Problem Long pedal movement Possible Cause Air in the brake system Self-adjusters not functioning Leak in wheel cylinder or piston seal Leak in brake line or hose Internal master cylinder seal leak Uneven wear or damage to lining Drum or disc out of specification Action Bleed air from the brake system Check/replace self-adjusters Replace cylinder or seal Tighten/replace line or hose Replace M/C piston assembly Replace linings Repair/replace drum or disc
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Improper vacuum booster to master cylinder length Pedal creeps down Internal master cylinder seal leak Leaking wheel cylinder or piston seal Leaking brake line or hose Damage to vacuum booster check valve Pedal pulses Drum or disc out of specification Worn out or unevenly wearing brake linings Wheel bearings are worn out Damaged suspension components Hard pedal Leaking or damaged vacuum booster check valve Leaking or damaged vacuum booster Restriction or hole in vacuum line Glazed brake linings Damage to disc or drum surface Crimped or collapsed brake line or hose Engine intake manifold malfunction Pedal goes to floor Low fluid level or air in brake system Broken brake line or hose Cut or torn master cylinder seals Brake pedal not connected to push rod Wheel cylinder or caliper piston falls out Noise when not in use Worn linings, indicator scraping drum or disc Loos e drum brake parts Loose suspension parts Caliper interfering with rotor Bent or cracked suspension parts Drum contacting backing plate Noise when in use Linings worn, indicator scraping drum or disc Lack of lubrication on brake pedal Weak hold-down springs in drum brakes Lack of lubrication on backing plate Worn drum or rotor surface Chatters/rattles Lining contaminated by foreign substance Brake linings unevenly worn Bent or loose brake shoes
Check/adjust or replace Repair/replace master cylinder Replace wheel cylinder or seal Tighten/replace lines or hoses Replace check valve Repair/replace drum or disc Replace linings Replace wheel bearings Replace suspension parts Replace check valve Replace vacuum booster Replace vacuum line Replace linings Repair/replace drum or disc Replace brake line or hose Check engine Check, add fluid or bleed brakes Replace lines or hose Replace M/C piston assembly Check U-link and clevis pin Repair Replace linings Check/repair drum brakes Tighten or repair Check/repair if needed Repair suspension Check/repair if needed Replace linings Grease pivot bolt/return spring Replace drum brake springs Lubricate Repair/replace drum or disc Replace brake linings Replace brake linings Replace hold-down springs/shoes
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Weak or broken retractor springs
Replace drum brake springs
Loose brake cable, line or ABS wiring Check/repair Worn surface on drum or disc Drum or disc out of specification Groans (at stop) Linings worn. Incorrect or damaged lining material. Worn surface on drums or disc. Cracked or bent suspension parts. Loose suspension. Brakes pull left/right Worn pad or lining Brake fluid, oil or water on lining Hardening of pad or lining Malfunction of self-adjuster Caliper piston sticking (open or closed) Loose wheel bearings or suspension parts Worn suspension parts Loose steering or steering gear Unequal tire air pressures Front suspension out of alignment Loose or deformed back plate mounting bolt Brakes grab Contaminated brake linings Damage to drum or disc surface Drum or disc out of specification Damaged vacuum booster Brakes drag Worn or damaged drum brake return spring Parking brake not releasing Self-adjusters over adjusting Improper vacuum booster push rod length Caliper pistons stuck Brake action uneven (front-rear) Uneven wear on tires: improper inflation Lining wearing unevenly front to rear Proportioning valve not functioning properly ABS solenoid malfunctioning Fluid leak in system Worn surface on drum or rotor Brakes release slowly Worn or damaged drum brake return spring Brake pedal binding or bent Caliper piston sticking open Repair/replace drum or disc Repair/replace drum or disc Replace linings. Replace linings. Repair/replace drum or disc. Replace suspension parts. Tighten/replace parts. Replace brake linings Clean/replace Replace brake pads/lining Replace adjuster Repair/replace piston Replace bearings/tighten parts Replace worn parts Repair/replace steering parts Check tire pressure Re-align front wheels Tighten/replace Replace linings Repair/replace drums or disc Repair/replace drums or disc Replace vacuum booster Replace spring Check cable/adjustment Replace self adjusters Adjust/replace booster Repair calipers Check tire pressure Replace linings Replace proportioning valve Replace ABS solenoid Check/ repair were found Repair/replace drum or rotor Replace drum brake springs Replace brake pedal Repair caliper piston
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Worn caliper piston seals Worn or damaged master cylinder seals Long stops Discs or drums out of specification Pads or shoes not adjusting properly Worn or glazed brake linings Proportioning valve malfunctioning Caliper piston sticking closed Odor Linings have overheated Linings contaminated by foreign substance Red brake light "ON" Parking brake is on Low brake fluid level in master cylinder Improperly adjusted parking brake switch ABS light "ON" Parking brake does not hold See ABS system diagnosis Parking brake improperly adjusted Brakes not adjusting properly Linings worn out Brake cable has disconnected Brake lever bent or loose Parking brake does not release Parking brake cables binding Lever release broken or binding
Repair caliper piston Replace M/C piston assembly Repair/replace disc or drums Replace self-adjusters Replace brake linings Replace proportioning valve Repair caliper piston Check that parking brake is off Replace brake linings Release parking brake Refill master cylinder or check for leaks Check switch and harness
Adjust parking brake and cables Replace self-adjusters Replace linings Re-connect/replace cables Repair/replace lever Check parking brake cables Replace brake lever
Brake System > General Information > Repair procedures INSPECTION

BRAKE FLUID LEVEL 1. Check the fluid level in the reservoir. The level should be between "Max"and "Min"on the reservoir. If the fluid level is extremely low, check the brake system for leaks.
Fluid specification : DOT-3 or DOT-4 or SAE J1703
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Capacity : 0.55 pints (0.26 liters)
BRAKE LINES/BRAKE HOSES

Check as follows, replace parts if damaged. 1. Cracks, damage or corrosion of the brake hose. 2. Damage to the brake hose threads. 3. Scars, cracks or swelling of the flexible hose. 4. All lines for fluid leakage.
PEDAL HEIGHT
1. Check that the distance from the top center of the pedal pad to the dash panel is within specification. Pedal height: 8.90 - 9.10 in (226 - 231 mm)
INSPECTION
PEDAL FREE PLAY 1. Depress the pedal a few times to eliminate the vacuum in the system. 2. Lightly depress the pedal by hand and check the pedal play. Depress until the valve plunger contacts the stopper plate, and resistance is felt.
Pedal play : 0.16-0.28 inch (4-7 mm)
INSPECTION
PEDAL-TO-FLOOR CLEARANCE
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1. Check that the distance from the floor panel to the center of the upper surface of the pedal pad is as specified when the pedal is depressed with a force of 152 lb (69 kg, 677 N). Pedal-to-floor clearance: 4.61 inch (117 mm) min. If the distance is less than specified, check for the following: A. Air in the brake system. B. Malfunction of the automatic adjuster (for drum brakes).
PARKING BRAKE STROKE

1. Check that the stroke is within specification when the parking brake lever is pulled with a force of 22 lb (10 kg, 98 N).
Stroke: 6 -8 notches
AIR BLEEDING PROCEDURE
The fluid in the reservoir must be maintained at the 3/4 level, or higher, during air bleeding. Do not allow brake fluid to make contact with any painted surface. If any brake fluid makes contact, wash off immediately. 1. Jack up the vehicle and support it with safety stands. 2. Fill the reservoir with brake fluid. Be sure that the reservoir is at least 3/4 full at all times during the air bleeding process. 3. After removing the bleeder cap, connect one end of a transparent vinyl tube to the bleeder screw and place the
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other end in a receptacle.
Two people are required for this procedure and they should stay in voice contact with each other. Be sure the pedal remains depressed until the air bleed screw is tightened. 4. One person should depress the brake pedal a few times, and then hold it in the depressed position. 5. A second person should loosen the bleeder screw, drain out the fluid, and retighten the screw.
After tightening the bleeder screw, check that there is no fluid leakage. Be sure to clean away any spilled fluid. 6. Repeat steps 4 and 5 until no air bubbles are seen in the tube. 7. After bleeding off the air, add brake fluid to the reservoir until the "MAX" line is reached.
ADJUSTMENT
PEDAL HEIGHT 1. Disconnect the stop light switch connector. 2. Loosen lock nut "B" and turn switch "A" until it does not contact the pedal. 3. Loosen lock nut "D" and turn rod "C"to adjust the height. 4. Adjust the pedal free play and then tighten operating rod lock nut. Tighten lock nut to 21 Ib-ft (29 Nm). 5. Turn the stop light switch until it contacts the pedal and then turn an additional 1/2 turn. Then tighten lock nut.
Tighten lock nut to 11.5 Ib-ft (15.7 Nm). 6. Check that the stop lights come on when the brake pedal is depressed, and go off when the brake pedal is released.
ADJUSTMENT
PEDAL FREE PLAY 1. Loosen lock nut "D" or rod "C" and turn the rod to adjust the free play. 2. Tighten lock nut.
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REPLACEMENT
BRAKE FLUID 1. Remove the brake fluid from the reservoir using a suction pump. 2. Fill the reservoir with new brake fluid. 3. Attach a transparent vinyl tube to the bleeder screw and place the other end into a container. 4. Have an assistant apply and hold pressure to the brake pedal. 5. Loosen the bleeder screw at the wheel farthest from the brake master cylinder (right rear) and bleed brake circuit until brake pedal makes contact with the floor. 6. Tighten the bleeder screw and release the brake pedal. 7. Bleed brake circuit until fresh, clear fluid flows from the bleeder screw. 8. Repeat operation at remaining 3 wheels.
Brake System > General Information > Specifications SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS Brake Flex Hose Mounting Bolt Brake Line Nut and Bolt Brake Line-to-master Cylinder Nut Brake Pedal Pivot Bolt Nut 17 lbft (23.5 Nm) 89 lbin (10 Nm) 13 lbft (17 Nm) 17 lbft (23.5Nm)
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Front Brake Adapter Bolts Front brake Caliper Bolts Front Wheel Brake Line-to-Proportioning Valve Nut Master Cylinder Mounting Nut Master Cylinder Wheel Mounting Nut Operating Rod Lock Nut Pipe Joint Mounting Bolt Rear Wheel Backing Plate Nuts Rear Wheel Brake Line-To-ABS Solenoid Nut Rear Wheel Cylinder Bolt Reservoir Tank Bolt Stop Light Switch Lock Nut Vacuum Booster Mounting Bolt GENERAL SPECIFICATIONS Fluid Type Capacity Height Brake Pedal Play Clearance Master Vacuum System Vacuum Pedal Force System Pressure Engine OFF Engine ON Pad Min Thickness Front Disc Brake Pads Permissible Play
72 lbft (98 Nm) 13 lbft (17 Nm) 115 lbin (13 Nm) 13 lbft (17 Nm) 21 lbft (29 Nm) 89 lbin (10 Nm) 20 lbin (2.25 Nm) 73 lbft (98 Nm) 13 lbft (17 Nm) 115 lbin (13 Nm) 11 lbin (1.25 Nm) 12 lbft (15.7 Nm) 15 lbft (19.5 Nm)
DOT-3, DOT-4, or SAE J1703 8.8 fluid ounces (0.26 liters) 8.9-9.1 in (226-231 mm) 0.16-0.28 in (4-7 mm) 4.61 in (117 mm) 0.004-0.012 in (0.1-0.3 mm) 475-500 mm HG 44 lbs (196 N) 171 psi (1,177 kPa) 995 psi (6,867 kPa) 0.08 in (2.0 mm) 0.37 in (9.5 mm) 0.004 in (0.10 mm) at 4.7 in (12cm) from disc center 0.88 in (22.4 mm) 0.94 in (24 mm) 0.004 in (0.10 mm) at 4.7 in (12cm) from disc center 0.020-0.040 in (0.5-1.0 mm)
Specified Thickness Runout Pad Min Thickness
Front Disc Brake Pads
Standard Thickness Runout
Rear Brake Shoe Clearnce
Maximum Play
Brake System > Brake System > General Safety Information and Caution Safety
1. Failure trouble ratio decreases than with ABS because EBD continues to control even in the following cases among ABS failure causes. A. One wheel speed sensor failure. B. Motor pump failure. C. Failure by low voltage of battery. 2. Though there is no alarm instrument for P-valve by which driver may always be informed so that drive cannot know whetheror not of failure trouble, in which case body spin may be generated if taken a sudden braking under condition
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of failuresituation; in case of EBD failure trouble, the existing parking brake lamp is lighted to alarm EBD failure situation todriver so that driver can repair. 3. EBD fail-safe Cause of system failure None 1 Sensor failure Pump failure Low voltage of battery Failure of Plural sensors Valve failure ECU failure Other failures System ABS operate does not operate does not operate does not operate EBD operate operate operate operate ABS OFF ON ON ON Warning lamp EBD OFF OFF OFF OFF
does not operate
does not operate
ON
ON
Brake System > Brake System > General Information WARNING LAMP
1. ABS warning lamp A. It is turned on for three seconds at time of ON of ignition Key and turns off afterwards. B. It is extinguished at start of operation. C. It is lighted if system abnormality arise. D. It is lighted during self-diagnosis. E. During its lighting, ABS control is interrupted and only ordinary brake operates in same way as ABSnoninstalled vehicle. F. It is lighted when ECU connector is removed. 2. EBD(electronic brake-force distribution) warning lamp A. It is lighted at time of ON of ignition Key. B. It is extinguished at start of operation. C. It is lighted when parking brake switch is ON. D. It is lighted when brake oil is deficient E. It is lighted when EBD control is infeasible. When there is trouble at solenoid valve. When there is trouble in more than one sensor. When there is trouble in ECU.
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In case of high voltage.
Brake System > Brake System > Description and Operation PRINCIPLE
1. The principle is approximate control of brake force near the required liquid pressure distribution curve(ideal braking distribution curve)by way of adding a logic to ABS ECU instead of the existing P-valve. 2. Rear liquid pressure is controlled so that rear slip ratio will always be less than or same as that of front, having calculated the slip ratio from each wheel speed sensor at braking time. 3. Therefore rear wheel locking does not precede that of front wheel. 4. Consequently brake force improves as rear brake liquid pressure can be enlarged in amount of parts of as shown by deceleration liquid pressure in the figure below. 5. And eventually whole brake force improvement is realized as brake force can be controlled by liquid pressure distribution curves required of wheel according to friction material dispersion.
EBD OPERATION
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1. Just before rear wheel is locked precedingly to front wheel, ABS ECU lets NC valve of wheel side about to be locked be ON(OPEN) so that the brake oil pressure of wheel about to be locked be decreased and the locking be prevented. 2. If the wheel rotates as brake force is decreased, ABS ECU again lets NC valve be OFF(CLOSE) so that the brake pressure applied at MC be transmitted to clipper. 3. Motor pump does not act at this time.
EFFECT
1. Brake distance is decreased as rear brake force is enhanced in comparison with existing P-valve. 2. Stability is secured at time of rotating braking because as right and left rear wheel liquid pressures may be controlled independently from each other. 3. Brake pedal force decreases. 4. Stable braking effect can be achieved bacause front brake pad abrasion and temperature rise etc. are decreased as braking effect of rear brake is increased at braking time. 5. P-valve can be eliminated.
Brake System > Brake System > Components and Components Location COMPONENTS
The parking brake is a mechanical braking system. A cable connects the parking brake lever to mechanical extenders in the rear wheel brake drums. When the cable is pulled, these extenders push the brake shoes outward against the rear brake drum.
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Brake System > Brake System > Brake Booster > Repair procedures INSPECTION
Step 1 1. With the engine off, depress the pedal a few times. 2. With the pedal depressed, start the engine. 3. If immediately after the engine starts the pedal moves down slightly, the unit is operating.
Step 2
1. Start the engine.
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2. Stop the engine after it has run for 1 or 2 minutes. 3. Pump the pedal with the usual force. 4. If the first pedal stroke is long and becomes shorter with subsequent strokes, the unit is operating. 5. If a problem is found, inspect for damage to the check valve or vacuum hose and examine the installation. Repair if necessary, and inspect it once again.
Step 3
1. Start the engine. 2. Depress the pedal with the usual force. 3. Stop the engine. 4. Hold the pedal down for about 30 seconds. 5. If the pedal height does not change, the unit is operating. 6. If there is a problem, check for damage to the check valve or vacuum hose, and check the connection. Repair if necessary and check once again.
If the nature of the problem is still not clear after the steps above, follow the more detailed check described below:
METHOD USIING TESTER

1. Connect a pressure gauge to the master cylinder, vacuum gauge to the vacuum booster and pedal depression force gauge tothe brake pedal as shown in the figure. After bleeding the air from the pressure gauge, conduct the test as describedin the steps below. Use commercially available gauges and pedal depression force gauge.
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CHECKING FOR VACUUM LOSS

1. Unloaded condition: (1) Start the engine. (2) Depress the brake pedal with a force of 44 lb (20 kg, 196 N). (3) Stop the engine when the vacuum gauge reaches 19.7 inHg (500 mmHg). (4) Observe the vacuum gauge for 15 seconds. If the gauge shows 18.7 - 19.7 inHg (475 - 500 mmHg), the unit is operating properly.
2. Loaded condition: (1) Start the engine. (2) Depress the brake pedal with a force of 44 lb (20 kg, 196 N). (3) With the brake pedal depressed, stop the engine when the vacuum gauge reaches 19.7 inHg (500 mmHg). (4) Observe the vacuum gauge for 15 seconds. If the gauge shows 18.7 - 19.7 inHg (475 - 500 mmHg), the unit is operating.
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CHECKING FOR HYDRAULIC PRESSURE

1. With the engine off (vacuum 0 mmHg), check the fluid pressure: Pedal force 44 lb (20kg, 196N) Fluid pressure 171 psi (12kg/cm, 1,177 kPa) min
2. Start the engine. Depress the brake pedal when the vacuum reaches 19.7 inHg (500 mmHg). If the fluid pressure is within specification, the unit is operating properly. Pedal force 44 lb (20kg, 196N) Fluid pressure 995 psi (70kg/cm, 6,867 kPa) min
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CHECK VALVE
1. Disconnect the vacuum hose. 2. Check to be sure that air passes to the engine and not from the engine to the vacuum booster.
The check valve is pressed into the vacuum hose, and there is an arrow on the hose surface to indicate the installation direction.
REMOVAL
1. Remove master cylinder and bracket assembly. Refer to "Master Cylinder" in this section. 2. Disconnect vacuum hose.
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3. Remove cotter pin and clevis pin from the brake pedal.
4. From inside the car, remove the lock nuts and then remove the U-type link. 5. Remove vacuum booster.
INSTALLATION
1. Insert the vacuum booster and connect the U-Type link. 2. Attach and tighten lock nuts.
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Tighten lock nuts to 15 Ib-ft (19.5 Nm). 3. Pull brake pedal down to U-Type link. 4. Insert clevis pin and fix with new cotter pin.
5. Place the gasket onto the master cylinder. 6. Put the push rod adjuster onto the gasket and tighten the adjusting bolt until the bolt touches the bottom of the push rod hole.
7. Apply 500 mmHg vacuum with a vacuum pump.
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8. Put the master cylinder gauge (SST K95U-5200-B) onto the vacuum booster unit with the top of the adjusting bolt touching the push rod. 9. Check the clearance between the edge of the adjusting bolt and the push rod of the power brake unit. Permissible clearance: 0.004 - 0.012 inch (0.1 - 0.3 mm) If not to specification, loosen the lock nut of the push rod, and turn the push rod to make the adjustment. 10. Install master cylinder and bracket assembly.
Brake System > Brake System > Master Cylinder > Components and Components Location COMPONENTS
Secure the master cylinder flange in a vise when necessary. Replace the piston assembly, if necessary. Do not let foreign material enter the cylinder, and do not scratch the inside of the cylinder or the outer surface of the piston.
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Brake System > Brake System > Master Cylinder > Repair procedures REMOVAL
Hydraulic fluid will damage paint. If fluid gets on a painted surface, wipe off immediately. 1. Place a cloth under the master cylinder to prevent brake fluid from falling on painted surfaces. 2. Disconnect clutch fluid hose from back of master cylinder reservoir and drain reservoir. 3. Remove connector to fluid level and differential sensor.
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4. Remove the brake lines from the master cylinder to the proportioning valve using a line wrench.
5. Remove the rear wheel brake line from the right side of the ABS solenoids using a line wrench.
6. Remove the front wheel brake line from the lower left port of the proportioning valve using a line wrench.
7. Remove wire harness connector to ABS solenoids. 8. Remove wire harness connector to proportioning valve.
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9. Remove the master cylinder mounting nuts. 10. Remove bracket holding ABS solenoids and proportioning valve. 11. Remove master cylinder from vacuum booster.
INSTALLATION
1. Place a new gasket on the master cylinder and adjust the push rod length with adjuster (SST K95U-5200-B). 2. Attach proportioning valve and ABS solenoids to bracket. 3. Place master cylinder on vacuum booster unit studs. 4. Place bracket assembly on vacuum booster studs and install nuts.
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Tighten nuts to 115 Ib-in (13 Nm).
To lessen the possibility of damaging nut threads, loosen the nut at the opposite end of the brake line. This will provide greater flexibility for a proper thread start. Once both ends are properly started, tighten the nuts to specification. 5. Attach rear wheel brake line to right side port of ABS solenoid. Tighten nut to 13 Ib-ft (17 Nm). 6. Attach front wheel brake line to lower left port of proportioning valve. Tighten nut to 13 Ib-ft (17 Nm). 7. Attach brake lines to master cylinder.
Tighten nut to 13 Ib-ft (17 Nm). 8. Connect fluid level and differential sensor connector. 9. Connect ABS solenoid and proportioning valve wire harness connectors. 10. Fill reservoir tank. 11. Check for fluid leakage. 12. Check and adjust brake pedal if needed. 13. Bleed brake system.
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DISASSEMBLY
1. Unscrew the screw and remove the reservoir. 2. Remove the cap and strainer from the reservoir. 3. Remove the two bushings.
4. Push the piston in with a screwdriver and then remove the stopper bolt.
Cover the end of the screwdriver with tape to prevent any damage to the piston or cylinder bore.
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Remove the piston horizontally so as not to damage the cylinder bore. 5. Push the piston in with a screwdriver and remove the snap ring with a snap ring plier. 6. Remove the 1st piston assembly by hand.
7. Put a cloth around a wood block and then remove the 2nd piston assembly by tapping the cylinder flange lightly with the block.
INSPECTION
1. Check for abnormal wear, corrosion, or damage to the piston and inner cylinder. 2. Check for weakness or damage to the spring.
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3. Check for damage or deformation of the reservoir.
REASSEMBLY
1. Apply brake fluid to the rubber surfaces shown in the figure.
2. Insert the 2nd piston assembly and return spring horizontally.
Take care not to damage the piston rubber lip. 3. Insert the snap ring with a snap ring plier while the piston is held in with a screwdriver.
Cover the screwdriver with tape to prevent any damage. 4. Install the stopper bolt while pushing on the piston with the protected screwdriver. Tighten bolt to 17-22 Ib-in (2-2.5 Nm). 5. Ensure that the stopper bolt is in the correct position by pushing and then releasing the screwdriver.
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6. Insert the two bushings. 7. Install the cap and strainer on the reservoir. 8. Install the master cylinder on the reservoir. 9. Install the bolt while holding the reservoir.
Tighten the bolt to 9-13 Ib-in (1-1.5 Nm).
Brake System > Brake System > Proportioning Valve > Repair procedures INSPECTION
lf the valve is defective, replace the assembly. 1. Connect pressure gauges (1500 psi [10 000 kPa]) to the master cylinder and rear brake ports of proportioning bypass valve. 2. Gently depress the brake pedal to apply additional pressure to the master cylinder side fluid and rear brake side fluid.
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Fluid Pressure A 459 psi (3169 kPa) A' 430-487 psi (2972-3364 kPa) B 1422 psi (9810 kPa) B' 744-886 psi (5131-6112 kPa)
3. Reconnect brake lines to proportioning valve, ABS solenoid and master cylinder. 4. Add fluid and bleed system; check for leaks.
Brake System > Brake System > Brake Line > Repair procedures
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REMOVAL
Hydraulic fluid will damage paint. If fluid gets on a painted surface, wipe off immediately. 1. Loosen the left rear brake line flare nut at the left rear brake assembly and disconnect. 2. Loosen and remove the left rear brake line from the pipe joint. 3. Remove the two bracket bolts and then remove the left rear brake line.
4. Loosen the right rear brake line flare nut from the right rear brake assembly and disconnect. 5. Loosen and remove the right brake line from the pipe joint. 6. Remove the three bracket bolts and then remove the right rear brake line.
7. Remove the nut on the flexible hose. 8. Remove clip and then disconnect flexible hose. 9. Disconnect flexible hose from pipe joint. 10. Remove mounting bolt on pipe joint and remove pipe joint.
INSTALLATION
1. Place pipe joint in position and insert mounting bolt. Tighten bolt to 89 Ib-in (10 Nm). 2. Reconnect flexible hose to pipe joint. 3. Place flexible hose in position and insert clip.
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4. Connect flexible hose to brake line and tighten flare nut.
Tighten nut to 89 Ib-in (10 Nm). 5. Place right rear brake line in position. 6. Connect right brake line to pipe joint and hand-tighten nut. 7. Connect right brake line to right rear brake assembly and hand-tighten nut. 8. Position brake pipe clamps and insert the three mounting bolts. Tighten bolts to 89 lb-in (10 Nm). 9. Tighten brake line nuts.
Tighten nuts to 89 Ib in (10 Nm). 10. Place left rear brake line into position. 11. Connect left rear brake line to pipe joint and hand-tighten nut. 12. Connect left rear brake line to left rear brake assembly and hand-tighten nuts. 13. Position the two pipe clamps and insert mounting bolts. Tighten bolts to 89 Ib-in (10 Nm). 14. Tighten the brake line nuts. Tighten nuts to 89 Ib-in (10 Nm).
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15. Refill master cylinder and then bleed rear brakes. 16. Check for fluid leakage.
Brake System > Brake System > Brake Pedal > Repair procedures REMOVAL
1. Remove cotter pin on clevis pin and disconnect pedal from connecting rod. 2. Remove the nut and washer on the brake pedal pivot bolt. 3. Remove the pivot bolt. 4. Disconnect return spring and remove pedal.
INSTALLATION
1. Check that guide pipe, bushing, and rubber stopper are in proper position. 2. Connect the return spring to the brake pedal. 3. Position the pedal and insert pivot bolt. 4. Install washer and nut on pivot bolt. Tighten nut to 20 Ib-ft (27 Nm). 5. Push pedal down until it is in the clevis mount. 6. Insert clevis bolt and lock in place with new cotter pin.
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INSPECTION
Check the following. Replace as necessary. 1. Check bushing for wear. 2. Check pedal for deformation or bending. 3. Check pedal pad for wear. 4. Check pivot bolt for deformations. 5. Check return spring for weakness or damage.
Brake System > Brake System > Front Dinode Brake > Repair procedures REMOVAL
1. Remove the two caliper assembly bolts and pull caliper from disc.
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2. Remove the brake flex hose mounting bolt and disconnect the brake flex hose from the caliper.
Do not disassemble the brake flex hose. 3. Remove the brake pads from the adapter.
4. Remove the two adapter mounting bolts and then remove the adapter.
5. Remove the two screws and then remove the disc assembly.
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INSTALLATION
1. Place disc assembly on front axle and install the disc screws. Check the disc runout from the outer surface.
Runout: 0.004 inch (0.10 mm) at 4.7 inch (12 cm) from disc center 2. Check that anti-rattle clip is on the adapter and then install the adapter and bolts. Tighten the bolts to 17 Ib-ft (23.5 Nm). 3. Place brake pads on adapter. 4. Using a C-clamp or similar device, push the caliper piston into the caliper.
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5. Place the caliper assembly in position on the disc assembly. Tighten the bolts to 72 Ib-ft (98 Nm). 6. Reconnect the brake flex hose and tighten the mounting bolt.
Tighten the bolt to 17 Ib-ft (23.5 Nm). 7. Install the tire and bleed the brake system. 8. Pump the brake pedal three times and then check brake movement while rotating the tire.
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INSPECTION
1. Check for oil or grease on the pads or on the disc assembly. 2. Check pad lining thickness. If below minimum, replace pad.
Min. Thickness: 0.08 inch (2.0 mm) New Thickness: 0.37 inch (9.5 mm) 3. Visually check disc for damage or wear. 4. Measure disc thickness. If below minimum, replace disc assembly.
Standard: 0.94 inch (24 mm) Minimum: 0.88 inch (22.4 mm) 5. Visually check the piston seal for holes, tears, or other damage. Replace using piston repair kit.
INSPECTION
1. Check for oil or grease on the pads or on the disc assembly. 2. Check pad lining thickness. If below minimum, replace pad.
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Min. Thickness: 0.08 inch (2.0 mm) New Thickness: 0.37 inch (9.5 mm) 3. Visually check disc for damage or wear. 4. Measure disc thickness. If below minimum, replace disc assembly.
Standard: 0.94 inch (24 mm) Minimum: 0.88 inch (22.4 mm) 5. Visually check the piston seal for holes, tears, or other damage. Replace using piston repair kit.
Brake System > Brake System > Rear Drum Brake > Repair procedures REMOVAL
Hydraulic fluid will damage paint. If fluid gets on a painted surface, wipe off immediately. 1. Loosen the five wheel lug nuts. 2. Raise vehicle and support the frame. 3. Remove front wheel. 4. Set the parking brake. 5. Loosen and remove the four hub nuts and screws.
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6. Release parking brake and remove wheel drum. 7. Remove the adjuster lever spring with a spring wrench or pliers and then remove the adjuster lever.
8. Remove the return spring with a brake spring wrench or pliers.
9. Turn the adjuster star wheel clockwise to relieve tension on the shoes.
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10. Remove the adjuster assembly. 11. Turn the hold-down pins until they align with the groove in the hold-down spring clips. 12. Remove hold-down pins and spring clips.
13. Remove primary shoe and anchor spring. 14. Remove the secondary brake shoe with parking brake cable attached, then remove parking brake cable from shoe.
15. Remove control lever C-clip and lever from secondary brake shoe.
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16. Disconnect brake line from wheel cylinder. 17. Remove the two wheel cylinder mounting bolts and remove wheel cylinder.
18. Remove parking brake cable bracket bolt, then remove parking brake cable from backing plate.
19. Remove four nuts from backing plate. 20. Tap axle from behind with rubber hammer and then remove axle from housing. 21. Remove backing plate.
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INSTALLATION
1. Place backing plate on axle housing. 2. Grease axle and insert it into the axle housing. 3. Insert and tighten the four backing plate nuts.
Tighten nuts to 73 Ib-ft (98.3 Nm). 4. Install parking brake cable in backing plate, then insert and tighten the bolt in cable mounting bracket. 5. Install wheel cylinder and tighten the two mounting bolts. Tighten bolts to 115 Ib-in (13 Nm).
Apply a sealant (RTV silicone) around the wheel cylinder mounting holes. 6. Apply grease to wheel cylinder contacts points. 7. Install brake line to wheel cylinder.
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Tighten line nut to 89 Ib-in (10 Nm). 8. Install control lever on secondary shoe with new C-clip. 9. Connect the parking brake cable to secondary shoe with pliers.
10. Attach secondary shoe to backing plate with the hold down pin and spring clip. 11. Attach one end of anchor spring to secondary shoe and the other to primary shoe. 12. Position primary shoe and install hold down pin and spring clip.
13. Install adjusting assembly. 14. Install return spring with spring wrench.
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15. Install adjusting lever and adjusting lever spring.
The adjusting lever must contact the star wheel on the adjuster assembly.
16. Measure outer shoe diameter when installed on drums. 17. Measure the drum's inner diameter. 18. Calculate clearance by subtracting shoe diameter from drum diameter. Adjust by turning star wheel on adjusting assembly.
Permissible play : 0.020 - 0 .040 in ( 0.5 -1.0 mm )
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19. Install drum and set parking brake. 20. Install and tighten the three hub bolts.
21. Release parking brake and install tire and loosely tighten lug nuts. 22. Lower vehicle and then tighten lug nuts. 23. Add brake fluid and bleed brakes. 24. Check for fluid leakage.
Inspection
1. Check for cracks, scores grooves or abnormal wear on the inner surface of the drum. 2. Measure the inner diameter of the drum. Verify that the drum interior is circular. Maximum acceptable: 9.89 in (251.2 mm) 3. If damaged or out of round, but within maximum diameter, turn the drum to repair.
If you replace one set of shoes, you must replace the other set. To do otherwise will affect the uniformity of the rear brakes.
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4. Check for damage to or abnormal wear of the brake shoes. 5. Measure the thickness of the lining.
New thickness: 0.24 in (6.0 mm) Minimum thickness: 0.06 in (1.5 mm) 6. Check clearance between the drum and the ends of the brake shoes. If contact is poor, replace the shoes.
Brake System > Brake System > Specifications EBD TYPE

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Category General performance Comparison
Vehicle equipped with EBD system Ideal rear brake force distribution is feasible because control of pressure much greater than 30 bars at sudden braking time is feasible under condition of heavyvehicle (five persons boarded) and high speed. When it is transferred to ordinary brake but please drive slowly because generation of spin is worried because there is no P-valve. Abstain from behavior of taking a sudden brake; go to maintenance center at once to take measures.
At time of failure
Brake System > Parking Brake System > Parking Brake Assembly > Components and Components Location COMPONENTS
Brake System > Parking Brake System > Parking Brake Assembly > Repair procedures REMOVAL
PARKING BRAKE 1. Release parking brake. 2. Remove the six screws on the center console. 3. Remove adjuster nut and clip. 4. Disconnect the parking brake switch connector. 5. Remove the two mounting bolts. 6. Remove the parking brake switch.
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7. Remove parking brake lever.
REMOVAL
PARKING BRAKE CABLE 1. Release parking brake lever. 2. Remove the center console. 3. Loosen rear wheel lug bolts. 4. Raise vehicle and support the frame.
5. Loosen and remove the rear wheel lug nuts, then remove rear wheels. 6. Using the hydraulic brakes to hold the rear wheels, break the tension on the hub nuts.
7. Remove adjusting nut and clip from brake lever. 8. Raise vehicle higher and support the frame. 9. Remove the return spring and front cable. 10. Remove the two clips holding the front of the two rear brake cables.
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11. Remove the four brake cable bracket bolts. 12. Without removing the brake line or wheel cylinder, remove the rear drum brake shoes and disconnect the parking brake cables. Refer to "Rear Drum Brakes" in this section.
INSTALLATION
PARKING BRAKE
After reassembly, rotate the rear wheels to see if the parking brake has been set too tight. Reverse removal procedure
INSTALLATION
PARKING BRAKE CABLE 1. Reverse removal procedure. 2. Adjust parking brake cable as needed. Refer to "Parking Brake" in this section.
INSPECTION
1. Check that the stroke is within specification when the parking brake lever is pulled with a force of 22 lb (10 kg, 98 N).
Stroke : 6 - 8 notches
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ADJUSTMENT
1. Before adjustment, start the engine and depress the brake pedal several times while the vehicle is moving in reverse. 2. Stop the engine. 3. Remove the center console. 4. Remove the adjusting nut clip and turn the adjusting nut at the front of the parking cable. 5. After adjusting, check the following points: A. Turn the ignition switch "ON" pull the parking brake lever one notch, and check that the parking brake warning lamp illuminates. B. Verify that the rear brakes do not drag.
Brake System > ABS(Anti-Lock Brake System) > General Information SYSTEM OPERATION FLOW CHART
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Brake System > ABS(Anti-Lock Brake System) > Special Service Tools SPECIAL SRVICE TOOLS
ANTI-LOCK BRAKE SYSTEM (ABS) Tool (Number and name) Illustration Use
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0K2CA 089 HSP Hi-scan pro
Used to diagnose anti-lock brake system.
Brake System > ABS(Anti-Lock Brake System) > Description and Operation ELECTRONIC CONTROL UNIT (ECU)
INTRODUCTION 1. The electronics and microprocessor are integrated with the solenoid coils inside a Coil Integrated Module The ECU is mounted directly to the hydraulic control unit. The coils are used to operate the HCU valves during an ABS event. The ECU has circuits that monitor system status.
A: INLET VALVE (FR) B: INLET VALVE (FL) C: INLET VALVE (REAR) E: OUTLET VALVE (FR) F: OUTLET VALVE (FL) G: OUTLET VALVE (REAR) J: MOTOR (GND) K: MOTOR(M+)
SELF MONITORING FUNCTIONS

The ECU monitors the components of the system for faults. If a fault is detected, the ABS system will set a Diagnostic Trouble Code (DTC) and illuminate the amber ABS & EBD lamp, causing the ABS or EBD to be disabled. Although the ABS or EBD is inhibited, conventional brakes remain. When the ignition switch is placed in the run position, the ECU will perform a preliminary self check on the anti-lock electrical system indicated by an illumination of the amber ABS or EBD warning lamp in the instrument cluster.
SOLENOID VALVE CONTROL

Solenoid valve operates when one side of valve coil applies positive voltage through valve relay and the other side connects to ground by MOSFET. When valve relay turns ON and MOSFET turns ON by -processor signal, concerned solenoid valve operates.
ABS SPEED SENSORS

1. The speed sensors are a single pole, variable reluctance sensor, mounted to both rear hubs and both front half shafts. Atoothed tone ring is press fit to the rear hub assemblies and provides the signal for the rear sensor. The front tone rings are press fit to the half shaft assemblies. The signal generated is proportional to the speed of the wheels andis used by the ECU to monitor the wheel speeds.
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As the teeth of the tone ring move through the magnetic field of the sensor, an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The ECU monitors this signal to check for changes in wheel speeds. If the deceleration of one or more wheels is not within a predetermined amount, an ABS event is initiated.
HYDRAULIC CONTROL UNIT (HCU)

ABS control steps PHASE 0 PHASE 1 PHASE 2 PHASE 3 Outside of ABS Pressure decreasing condition Pressure holding condition Pressure increasing condition
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PHASE 4 PHASE 5 Basic control PHASE 0-PHASE 1 :
Pressure decreasing condition Pressure decreasing condition
When ABS ECU detects the wheel locking, ABS ECU changes PHASE 0 to PHASE 1. If wheel cylinder liquid pressure is decreased, ABS ECU changes PHASE 1 to PHASE 2. If it is judged that there is no lock phenomenon in wheel, ABS ECU changes PHASE 2 to PHASE 3. If wheel cylinder liquid pressure is cascading on the deceleration section, ABS ECU changes PHASE 2 to PHASE 4. If wheel cylinder liquid pressure is cascading on the aceleration section, ABS ECU changes PHASE 2 to PHASE 5.
PHASE 1-PHASE 2 :
PHASE 2-PHASE 3 :
PHASE 2-PHASE 4 :
PHASE 2-PHASE 5 :
ABS CONTROL FLOW
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1. WHEN ABS IS NOT OPERATED
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OPERATING CONDITION
In ordinary brakes, each solenoid valve is turned OFF when electricity is turned on from ABS ECU to the solenoid valve IN, OUT. Solenoid valve INLET OUTLET Electricity status OFF OFF Valve open-close OPEN CLOSE Open-close channel Master cylinder Wheel cylinder Wheel cylinder reservoir
As for solenoid valve at this time, IN is opened and OUT is closed by spring action. If brake pedal is pushed down, master cylinder liquid pressure passes the solenoid valve and arrives at wheel cylinder, and the brake acts. Afterwards if brake pedal is released, the liquid pressure passes IN and check valve to return to master cylinder, then brake is releassed.
2. DUMP MODE-BRAKE PRESSURE DECREASING
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OPERATING CONDITION Solenoid valve INLET OUTLET Electricity status ON ON Valve open-close CLOSE OPEN Open-close channel Master cylinder Wheel cylinder Wheel cylinder reservoir
If wheels are about to be locked at sudden braking, ABS ECU outputs the signal decreasing the liquid pressure in solenoid valve, and each solenoid valve is turned ON. At this time the solenoid valve IN is shut and interrupts the liquid channel from master cylinder. And solenoid valve OUT is opened and releases the liquid channel from wheel cylinder to the reservoir therfore the liquid pressure in wheel cylinder passes the solenoid valve OUT to arrive at reservoir solenoid valve OUT to arrive at reservoir so that pressure is decreased.
3. HOLD MODE-BRAKE PRESSURE MAINTAINED
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OPERATING CONDITION Solenoid valve INLET OUTLET Electricity status ON OFF Valve open-close CLOSE CLOSE Open-close channel Master cylinder Wheel cylinder Wheel cylinder reservoir
If wheel cylinder liquid pressure is decreased to the ultimate state, ABS ECU outputs the signal maintaining the liquid pressure in solenoid valve, so that solenoid valve IN is turned ON and OUT is turned OFF. Then wheel cylinder liquid because solenoid valve In and out are both shut so that liquid channel is interrupted.
4. RISE MODE-BRAKE PRESSURE INCREASING
OPERATING CONDITION Solenoid valve INLET OUTLET Electricity status OFF OFF Valve open-close OPEN CLOSE Open-close channel Master cylinder Wheel cylinder Wheel cylinder reservoir
If it is judged that there is no lock phenomenon in wheels, then ABSECU interrupts electricity in solenoid valve therefore each solenoid valveis turned OFF and the liquid pressure by motor pump passes the solenoid valveIN to arrive at wheelcylinder so that pressure is increased.
Fail-safe function
If failure occurred in ABS ECU system and the hydraulic, then the fail-safe circuit turns off the relay that supplies electricity to solenoid valve, stopping the control signal output, lighting the warning lamp at the same time to inform ABS failure to driver, in which case the ordinary brake function is secured under same condition as vehicles without ABS system
Brake System > ABS(Anti-Lock Brake System) > Components and Components Location STRUCTURE VIEW
Weather, road surface, and tire condition will affect vehicle performance. The MGH 10 system has been specifically
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calibrated for the vehicle to achieve the best possible balance between stopping distance, stability, and vehicle steeringcontrol. 4-wheel anti-lock brake systems are designed to provide the driver with: Enhanced steering control by enabling the vehicle to move in a driver controlled direction during braking. Enhanced braking stability by making the most of available traction (on most road surfaces).
Brake System > ABS(Anti-Lock Brake System) > ABS Control Module > Repair procedures REMOVAL (ECU)
1. Turn ignition "OFF". 2. Disconnect ECU harness connector from ECU assembly.
Do not apply a 12V power source to any terminal of the ECU connector when disconnectered.
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3. Mark the brake pipes going into and out of the HCU with tags so reinstallation of the brake lines will be correct.
Before removing the brake pipes from HCU, the HCU must be thoroughly cleaned to prevent dirt particks from falling into the ports of HCU or entering the brake pipes. 4. Remove the brake pipes from the HCU. 5. Loosen the mounting pin and grommet from HECU bracket and then remove HECU from HECU bracket. 6. Remove bolts attaching the ECU to the HCU. 7. Lift the ECU assembly straight from the HCU. 8. Clean the top of the HCU with a clean, dry cloth.
REMOVAL (HCU)
1. Turn ignition "OFF".
2. Disconnect ECU connectors from ECU assembly.
Do not apply a 12 volt power source to any terminal of the ECU connector when disconnected. 3. Mark the brake pipes going into and out of the HCU with tags so reinstallation of the brake lines will be correct.
Before removing the brake pipes from HCU, the HCU must be thoroughly cleaned to prevent dirt particles from falling into the ports of HCU or entering the brake pipes.
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4. Remove the brake pipes from the HCU. 5. Remove the bolts attaching the HECU bracket to the fender. 6. Remove HECU and bracket from vehicle. 7. Remove the mounting pin and grommet attaching the HECU to the bracket and remove HECU from bracket.
8. Remove the bolts securing the ECU to the HCU and lift the ECU carefully off the HCU. 9. Verity that the seal on the ECU is free from nicks or cracking.
REPLACEMENT (ECU)
1. Lower ECU onto the HCU and tighten its bolts to specification. Tightening torque: (1.7~1.9 Nm, 0.18~0.2 kgfm) 2. Carefully place HECU to the HECU bracket. 3. Tighten the mounting pin and grommet to the HECU bracke. Tightening torque: 5.8~7.2 lbft (7.8~9.8 Nm, 0.8~1 kgfm) 4. Reconnect brake lines. Be certain that the four outlet lines have been connected to the correct ports. Tighten the nuts to specification. Tightening torque: 9.4~15.9 lbft (12.8~21.6 Nm, 1.3~2.2 kgm)
When installing the brake pipe lines on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. 5. Connect the ECU harness connector to ECM assembly. 6. Bleed the base brakes. 7. Road test vehicle to ensure proper operation of the base and ABS systems.
REPLACEMENT (HCU)
1. Carefully replace ECU on the replacement HCU. 2. Torque the ECU bolts in the following two steps: A. Start all bolts into the HCU and hand tighten. B. Torque in the sequence shown until a final achieved for each bolt. Tightening torque: 1.3~1.4 Ibft (1.7~1.9 Nm, 0.18~0.2 kgm)
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3. Reattach bracket to the HECU mounting pin and grommet. Tightening torque: 5.8~7.2 Ibft (7.8~9.8 Nm, 0.8~1.0 kgm) 4. Reinstall bolts and nuts attaching bracket to fender. Tightening torque: 9.4~15.9 Ibft (12.8~21.6 Nm, 1.3~2.2 kgm)
When installing the brake pipe lines on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. 5. Attach brake pipes to HECU, be careful to reattach the pipes in the same positions which they were in prior to removal. Tightening torque: 9.4~15.9 Ibft (12.8~21.6 Nm, 1.3~2.2 kgm) 6. Reconnect ECU harness connectors. 7. Bleed the brakes. 8. Road test vehicle to ensure proper operation of the base and ABS systems.
Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed Sensor > Repair procedures REMOVAL
1. Remove harness connector. 2. Remove sensor bolt and remove the speed sensor.
REMOVAL
1. Wheel hub removal. Refer to "Front Axle".
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2. Remove rotor with a tool. Do not re-install a rotor once it is removed.
INSTALLATION
1. Clean speed sensor attaching surface. 2. Install speed sensor.
Tighten the bolt to : 7 lbft (9.5 Nm)
INSTALLATION
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1. Position a new sensor rotor on wheel hub as shown. 2. Press rotor onto wheel hub. 3. Reinstall wheel hub. Refer to on Front Axle.
INSPECTION
1. Measure clearance. Specified clearance: 0.0118~0.0394 in (0.3~1.0 mm) 2. Measure speed sensor resistance.
Resistance: 1385 110
INSPECTION
1. Lift and properly support front of the vehicle. 2. From backside of wheel, closely inspect sensor rotor. Rotate wheel to examine all teeth. 3. Replace rotor if teeth are missing or damaged. See Removal, this section.
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Brake System > ABS(Anti-Lock Brake System) > Rear Wheel Speed Sensor > Repair procedures REMOVAL
1. Remove the harness connector. 2. Remove the sensor bolt and remove the speed sensor.
INSTALLATION
1. Clean the speed sensor attaching surface. 2. Lubricate the sensor O-ring with motor oil. 3. Install the speed sensor.
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Tighten the bolt to : 7 Ibft (9.5 Nm).
INSPECTION
1. Check the sensor O-ring for damaged and replace if necessary.
2. Check clearance. Measure the clearance between the speed sensor and the sensor rotor teethe as follows: A. Measure the distance (A) between the sensor attaching surface and the sensor rotor teeth. B. Measure the distance (B) between the sensor attaching surface and the sensor pole piece. C. Obtain (A) - (B). Specified clearance: 0.0197~0.0394 in (0.5~1.0 mm) If the clearance is less than 0.02 inch (0.55 mm), adjust using an adjustment shim during sensor installation. If the clearance is more than specification, replace the speed sensor with a new one.
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3. Measure speed sensor resistance. Resistance :1000 50
Brake System > ABS(Anti-Lock Brake System) > Troubleshooting CYMPTOM-RELEATED DIAGNOSTIC PROCEDURES
The wheel ABS is composed of electrical and mechanical components (hydraulic unit), and components of the standard brake system. The system uses 4-sensors and 4-channels which control front wheels and rear wheels each independently. When the system detects a slip in one of the wheels, hydraulic pressure is applied to the brakes on the side where the slip is first detected .Any malfunction of the ABS electrical or mechanical components is judged by the self-diagnosis function in the ABS control unit. All malfunctions are indicated by the warning lamp in the instrument panel. In normal condition, the ABS warning lamp is on for 2~3 seconds after engine starts and goes out. If it stays on continuously, you may have malfunction with ABS system. The location of a malfunction is indicated to the technician by a diagnosis scan tool (Hi-scan pro). The self-diagnosis and indication functions must be used when diagnosing malfunctions of the ABS.
HOW TO USE DIAGNOSIS AND TROUBLESHOOTING
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SELF-DIAGNOSIS
The ABS control unit starts self-diagnostic functions after the ignition is switched ON. The ABS control unit detects failure for each circuit and component by comparing condition of the system with limited condition set inside the ABS control unit, ABS control unit stores the failure code and then outputs the four-digits of malfunction code to the diagnostic scan tool (Hi-scan pro) when the ABS terminal of the diagnostic connector is connected.
SELF-DIAGNOSIS PROCEDURES (WITH THE DIAGNOSTIC SCAN TOOL)

1. ptxtWith the ignition switch OFF, connect the diagnostic scan tool (Hi-scan pro) to the data link connector located under side of master vacuum in engine compartment.
2. Make sure the ignition switch is in the on position, and then choose correct vehicle and model, proceed to diagnostic data link menu item.
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3. Choose the inspection item after initializing the unit. 4. Press malfunction code detection No.1 and diagnostic scan tool will display any malfunction code found.
A malfunction code is a four-digits number which is continuously outputs until the failure code is erased by the diagnostic scan tool. 5. From the list of failure codes, verify the failed part and repair it according to self-diagnosis procedures. 6. After repair, erase all malfunction codes stored in the ABS control unit by selecting inspection item (No.4).
HOW TO ERASE MALFUNCTION CODE (WITH THE DIAGNOSTIC SCAN TOOL)

ABS control unit has an automatic malfunction code erasing function as below. 1. After the failures have been serviced, confirm the vehicle functions properly. 2. Press the enter key in malfunction code erase item (No.4) among the inspection items of the diagnostic scan tool (Hi-scan pro). CONNECTOR TERMINAL LIST Connector Terminal No Mark Terminal Name Over voltage range: 16.50.5V<V<20V Operating voltage range: 9.50.5V<V<16.50.5V Low voltage threshold: 9.50.5V Low voltage range: 7.00.5V<V<9.50.5V System down range: 6.00.5V<V<7.00.5V Controller off range: V<5.50.5V Max. current: I<300mA Max. current(total of 2 terminals): I<60A Input voltage(low): -1.00<V(IL)<2.75V Input voltage(high): 5.00<V(IH)<16.0V Min. sensor voltage: V(s)>150mVpp Resistance: 1100 50% Output range: 30~2000Hz Inductance: 0.7H 50% Permissible offset voltage range: 2.15V<V(offset)<3.5V Max. current: I<200mA Saturation voltage, at I=200mA: Vsat<1.5V Max. current: I<200mA Saturation voltage, at I=200mA: Vsat<1.5V Input voltage: V(IL)<0.3VBV V(IH)<0.7VBV Output voltage: V(IL)<0.2VBV V(IH)<0.8VBV VB: Ignition voltage Inside control Specification Note
IGN+
Power source via Ignition Switch terminal
2 18 24 9 23 5 8 22 4 10
GND1 GND2 BRAKE FL+ FR+ Rear+ FLFRRearABS Warning lamp
Ground terminal Brake lamp Switch input terminal
Wheel sensor Input terminal
ABS warning lamp output terminal EBD warning lamp output terminal
15
EBD Warning lamp
Diagnosis
Diagnosis interface terminal
Batt1
Battery power Max. current (inside control): I<30A Source 1 terminal Max. current (outside control): I<20mA (valve power source) Dark current: I<0.3mA
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17
Batt2
Inside control Battery power Max. rush current : I<100A(t<100msec) Source 2 terminal Max. current : I<30A(t>100msec) (Motor power source) Dark current: I<0.3mA
T: the running time of motor Not connect the chassis GND out of ECU
13
GS G-Sensor Input Terminal (In only 4WD) Input Voltage : -1.0 V 16.0V
11
GSG
THE MENAGEMENT OF FAILURE DETECTED No Description System down. Both the ABS and the EBD function are inhibited and the ABS and the EBD warning lamps is activated. In this failure, the valve relay and all solenoids are prevented from being switched on. Only the ABS function is inhibited. The ABS warning lamp is activated and the EBD warning lamp not activated. Sensor failure outside the ABS control cycle 1. Only one wheel failure: take the same action as management. 2. More than two wheels failure : take the same action as management. Sensor failure inside the ABS control cycle 1. One front wheel failure: inhibit the ABS control of the Failed-wheel and maintain the ABS control of normal wheel. Afterthe controller completes the ABS control, take the same action as the management . 2. Rear wheel failure: inhibit ABS control of both front wheels and the pressure of rear wheel is decreased. After the controller completes the ABS control, take the same action as the management . 3. More than two wheels failure: take the same action as the management. 1. Inhibit the ABS control of front wheels and allow the ABS control of rear wheel, deactivating the motor(in only motor failure). After the controller completes the ABS control, take the same action as the management 2. Low operating voltage 1. Outside the ABS control cycle: inhibit the ABS control of front wheels and allow the ABS control of rear wheel, deactivating the motor. And the ABS warning lamp is directly switched on. When the voltage recover to the normal operating range, enable ABS function and ABS function and ABS warning lamp is switched off and erase the error code of low voltage. 2. Inside the ABS control cycle: inhibit the ABS control of front wheels and allow the ABS control of rear wheel, deactivating the motor. The ABS warning lamp is directly switched on and the state keeps continuously. The error code is always stored. Motor failure inside the ABS control cycle. 1. Inhibit the ABS control of front wheels and allow the ABS control of rear wheel, deactivating the motor(in only motor failure). After the controller completes the ABS control, take the same action as the management 2.
Detect mode A: Initial check B: Outside the ABS control cycle C: Inside the ABS control cycle D: Diagnosis mode E: Failure mode DIAGNOSTIC TROUBLE CODE DESCRIPTIONS
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No
Failure Location
Failure Cause Short to GND, Short to Batt, Open
Condition for Detection The wheel velocity is below 7Km/h and the offset voltage of the sensoris outside the permitted range (2.15~3.5V). If this condition is continued for more than 140msec The wheel deceleration of [-100(-25km/h) for 7ms] causes the controllerto start monitoring this failure and to compare the wheel velocity with thevehicle velocity from next cycle. When its difference of -100g is continuedfor more than 140msec, controller recognize the failure.
Error code
Management/ Detect mode A B 3 3 3 C 4 4 4 D E 3 3 3 3 3 3
1.1
FL: C1200 FR: C1203 Rear: C1206
3 3 3
1.2
Speed Jump
FL: C1201 FR: C1204 Rear: C1207
3 3 3
4 4 4
3 3 3 3 3 3
1.3
Sensor (wiring, harness, exciter, ECU)
Large Air gap
This monitoring is performed for the period that the minimum velocityrises from 2km/h to 10km/h. 1. When the minimum wheel velocity is 2km/h and the velocity of otherwheels exceed 10km/h with the acceleration, the controller startcomparing the velocity of other wheels except the min. wheel. If FL: C1202 their differencebelow 4km/h is continued FRl C1205 for 154msec, otherwise, if their Rear: C1208 difference beyond 4km/h is contiuned for 120 seconds. 2. When the velocity of more two wheels is 2km/h and themax. Wheel velocity exceeds 10km/h, the condition is continued for 5sec. Otherwise, the condition is 120 seconds. 1. Max. wheel velocity exceeds 20km/h and the wheel velocity is 40%of max. wheel velocity. If this condition is lasted for FL: C1201 120sec. Fl C1204 2. Max. wheel velocity exceeds 40km/h and Rear: C1207 the wheel velocity is 60%of max. wheel velocity. If this condition lastes for 120sec. 1. During the ABS control cycle, if the wheel velocity of 2km/h lastsfor more than 12sec. 2. If the ABS control cycle is continued for more than 36sec. When the valve relay is switched on, the reference voltage of valverelay is outside the permitted range, which is continued for 56msec. When the valve relay is switched off, the reference voltage of valverelay is over the criterion, which is continued for 56msec. 1. When the valve relay is switched off, the drain voltage of the solenoiddrive C1604 MOSFET is over the criterion, which is continued for 56msec. FR: C1202 FR: C1205 Rear: C1208
3 3 3
3 3 3 3 3 3
1.4
Wrong Exciter
3 3 3
4 4 4
3 3 3 3 3 3
1.5
Long term ABS mode
4 4 4
2.1
2.2
Valve relay (wiring harness, ECU) Solenoid valve (ECU, wiring
Open
1 C2112 1
1 -
Short
- 1
Open, Short, Leakage Current
1 1
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harness)
2. When the valve relay is switched on and a solenoid off, the drainvoltage of the solenoid drive MOSFET is under the criterion, which is continued for 56msec. 3. When the valve relay and a solenoid are switched on, the drain voltageof the solenoid drive MOSFET is over the criterion, which is continued for 56msec. Motor relay or When the motor relay is switched on, the fuse open, reference voltage of motoris under the motor criterion, which is continued for 49msec. short to GND The controller starts monitoring the motor voltage for 84msec from thetime when the motor relay is switched off. If the motor voltage is under thecriterion for 49msec, after 1.8sec from driving the motor off, the Motor lock motor isreactivated for 1sec and the above check is performed again. In second check,when the motor voltage is under the criterion for 49msec, the controller recognizesthe failure. Motor short to BATT The controller starts monitoring the motor after 1.8sec from the time when the motor relay is switched off. If the motor voltage is over the criterionfor 200msec. The controller starts monitoring the motor after 1.8sec from the time when the motor relay is switched off. If the motor voltage is outside the permitted range for 200msec. 1. When V(IGN)<9.4V is continued for 500msec 2. If the voltage reaches to more than 9.6V, the controller recoversto normal state. 3. When V(IGN)<7.2V is detected during state 1. 4. If the voltage reaches to more than 7.5V, the controller recovers to state 1. 1. When V(IGN)>17V is continued for 500msec, or when V(IGN)>18V is continued for 49msec. 2. If the voltage recovers normal operating range, the controller isreset.
4.1
2 -
4.2
Motor relay, motor (wiring harness, ECU)
C2402
2 -
4.3
2 2
4.4
Motor open
2 2
5 C1102 1
5 5
5.1 Power supply
Low voltage
1 1
5.2
Over voltage
C1101
1 1
6.1 ECU 6.2
After the master processor writes the EEPROM pre-defined data to EEPROM, readthe data failure and compare each other. If they differ from each other. MCU failure If the master/slave processor detects abnormal operation in RAM, statusregister, interrupt, timer, A/D converter and cycle time.. The voltage of G-Sensor Signal is>4.5V or <0.6V If this condition is continued for 250 msec.
1 C1604 2
1 1
2 2
7.1
G-Sensor Short, (Only Open 4WD)
C1275
2 2
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7.2
Illegal, Sigal
When vehicle speed is>10km/h and the brake light switch is off, 0.5G is continued for 20sec.
C1274
2 2
BASIC INSPECTION
VISUAL OBSERVATION Step Inspection Yes 1 Check if parking brake is working properly. Stroke: 7~9 notches Go to next step. Repair or replace lever/cable. Inspect parking brake switch. Check operation. Turn adjusting nut. Actions
No
Check if brake fluid level in the reservoir tank is between "Max" and "Min"
Yes
Go to next step
No
Fill up brake fluids
Check if brake fluids leak on all hydraulic lines
Yes
Replace corresponding part
No
Go to next step
Check if ABS fuse is fully seated and intact - Opened or shorted - Connection Check if following component is fully seated and intact - ABS sensor
Yes No
Go to next step Replace it.
Yes
Check functions
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Hydraulic control unit (Include ECU) Brake fluids reserve tank Stop lamp switch ABS warning module EBD Warning module (Parking brake switch)
No
Connect it again Repair or replace it
CHECKING FUNCTIONALITY Step Inspection Verify if ABS warning lamp turns on for 2 to 3 seconds when ignition is switched ON. Yes Go to next step. Actions
No
Inspect warning lamp and relevant wiring harness.
- Verify if brake warning lamp turns off when parking brake is released. - Verify if brake warning lamp turns on for 2 to 3 seconds when ignition is switched ON. After parking brake is released.
Yes
Go to next step
2 No
- Check level of brake fluids. - Inspect brake pipes, hoses, wheel cylinder, seal and leak at master cylinder. - Brake warning lamp (EBD warning lamp) can turn on with ABS warning lamp at the same time when ABS is defective. - Although parking brake is released, brake warning lamp can turn on intermittently when ignition is switched on.
Retrieve malfunction codes using diagnostic tool (Hi-scan pro). Go to step 3 again after driving vehicle, and retrieve malfunction codes.
Yes No Yes
Go to corresponding detail inspection. Go to next step Go to corresponding detail inspection. - Check each connector and connections. - System OK.
No
DIAGNOSTIC TROUBLE CODE INSPECTION
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DTC C1101 C1102 C1200 C1201 C1202 C1203 C1204 C1205 C1206 C1207 C1208 C1274 C1275 C1604 C2112 C2402
Trouble location Battery voltage over volt Battery voltage low volt FL wheel sensor - Range/ Performance -No signal FR wheel sensor -Range/Performance -No signal Rear wheel sensor -Range/ Performance -No signal G-Sensor signal Range/Performance ECU hardware Valve relay, Fuse Motor- Electrical or motor lock fail > 17V < 9.4V
Symptom
Open or short to GND Speed jump or damaged exciter Air-gap error or wrong excite Open or short to GND Speed jump or damaged exciter Air-gap error or wrong excite Open or short to GND Speed jump or damaged exciter Air-gap error or wrong excite G-sensor signal fail G-Sensor openor short to ground ECU internal or valve failure Valve relay or fuse failure Open or short to battery, motor relay, fuse
WHEEL SPEED SENSOR DTC No. C1200, C1203, C1206, Wheel speed sensor open or short GND circuit [Comment] The HECU determines that an open or short circuit occurs in more than one line of wheel speed sensors. Probable cause Malfunction of wheel speed sensor Malfunction of wiring harness or connector Malfunction of HECU
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SPEED JUMP OR WRONG EXCITER DTC No. C1201, C1204, C1207, (Speed jump or wrong exciter) [Comment] A wheel speed sensor outputs an abnormal signal (other than an open short-circuit) Probable cause Improper installation of wheel speed sensor Malfunction of wheel speed sensor Malfunction of rotor Malfunction of wheel bearing Malfunction of wiring harness or connector Malfunction of HECU
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AIR GAP ERROR DTC No. C1202, C1205, C1208, (Air gap error) [Comment] A wheel speed sensor outputs an abnormal signal Probable cause alfunction of wheel speed sensor proper installation of wheel speed sensor Malfunction of rotor Malfunction of wheel bearing Malfunction of wiring harness or connector Malfunction of HECU
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VOLTAGE OUT OF RANGE DTC No. C1101, C1102 Voltage out of range (Under and over voltage) [Comment] The voltage of the HECU power supply drops lower or rises higher then specified value. If the voltage returns to the specified value, this code is no longer outpurt. Probable cause Malfunction of wiring harness or connector Malfunction of HECU
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to standard value, this code is no longer output. Before carrying out the following inspection, check the battery level,and refill it if necessary.
ECU HARDWARE DTC No. C1604 ECU Hardware (Error valve failure) Probable cause
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[Comment] The HECU always monitors the solenoid valve drive circuit. If determines that there is an open or short-circuit in the solenoid coil or in a harness : When no current flows in the solenoid even though the HECU turns on it, and vice versa. VALVE RELAY DTC No. C2112 Valve relay (Including fuse failure) [Comment] When the ignition switch is turned to ON, the HECU switches the valve relay off and on during the initial check. In thatway, the HECU compares the signals sent to the valve relay with the voltage in the valve power monitorline. That is howto check if the valve relay is operating normally. The HECU always checks if current flows in the valve power monitor line, too. It determines that there is an open circuit when no current flows. If no current flows in the valve power monitor line, this diagnosis code is output
Malfunction of wiring harness Malfunction of hydraulic unit Malfunction of HECU
Probable cause Malfunction of Malfunction of Malfunction of Malfunction of valve relay wiring harness or harness HECU hydraulic unit
Whenever reading the diagnosis codes using the ABS warning lamp, thisdiagnosis code will be output.
PUMP-MOTOR DTC No. C2402 Electrical (Pump-motor) [Comment] When the motor power line is normal but no signal is inputed to the motor monitor line when the motor power line is faulty. Probable cause Malfunction of wiring harness or harness Malfunction of hydraulic unit Malfunction of HECU
Because force-driving of the motor by means of the actuator test willdrain the battery, the engine should be started and left to run for a whileafter testing is completed.
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G-SENSOR DTC No. C1274, C1275 G-Sensor [Comment] HECU outputs G-sensor DTC as followed. Malfunction of G-sensor (putting vehicle on the flat : ON) Open between HECU and G-sensor Probable cause Malfunction of G-sensor Malfunction of Wiring harness or connector Malfunction of HECU
Brake System > ABS(Anti-Lock Brake System) > Specifications
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SPECIFICATIONS
ANTI-LOCK BRAKE SYSTEM (ABS) Items System General Type Mode Type HCU Hydraulic control method Type of pump Type of motor ECU Operation voltage Operation temperature Type Resistance () Air gap Front Rear Front Rear MGH-10 3-Sensors and 4-Channels ABS+EBD Diagonal Split Hold/ Rise/ Dump (3Mode) Radial pistons (2 pistons) 4-pole DC motor DC 10~ 16V -40 ~ 110 degree Electromagnetic induction 1385 110 1000 50 0.0118~0.0394 in (0.3~1.0 mm) 0.0197~0.0394 in (0.5~1.0 mm) Specifications
ABS sensor
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SPORTAGE(AL) > 2002 > G 2.0 DOHC > Brake System

DRUM BRAKE ASSEMBLY

DISC BRAKE ASSEMBLY

Brake System > General Information > Troubleshooting DIAGNOSIS

Weak or broken retractor springs

Replace drum brake springs

Brake System > General Information > Repair procedures INSPECTION

Fluid specification : DOT-3 or DOT-4 or SAE J1703

Capacity : 0.55 pints (0.26 liters)

BRAKE LINES/BRAKE HOSES

Pedal play : 0.16-0.28 inch (4-7 mm)

PARKING BRAKE STROKE

AIR BLEEDING PROCEDURE

other end in a receptacle.

Brake System > General Information > Specifications SPECIFICATIONS

Specified Thickness Runout Pad Min Thickness

Front Disc Brake Pads

Standard Thickness Runout

Rear Brake Shoe Clearnce

does not operate

does not operate

In case of high voltage.

METHOD USIING TESTER

CHECKING FOR VACUUM LOSS

CHECKING FOR HYDRAULIC PRESSURE

7. Apply 500 mmHg vacuum with a vacuum pump.

Tighten nuts to 115 Ib-in (13 Nm).

3. Check for damage or deformation of the reservoir.

2. Insert the 2nd piston assembly and return spring horizontally.

Tighten the bolt to 9-13 Ib-in (1-1.5 Nm).

4. Connect flexible hose to brake line and tighten flare nut.

8. Remove the return spring with a brake spring wrench or pliers.

15. Install adjusting lever and adjusting lever spring.

Permissible play : 0.020 - 0 .040 in ( 0.5 -1.0 mm )

Brake System > Brake System > Specifications EBD TYPE

Category General performance Comparison

7. Remove parking brake lever.

0K2CA 089 HSP Hi-scan pro

Used to diagnose anti-lock brake system.

SELF MONITORING FUNCTIONS

SOLENOID VALVE CONTROL

ABS SPEED SENSORS

HYDRAULIC CONTROL UNIT (HCU)

PHASE 4 PHASE 5 Basic control PHASE 0-PHASE 1 :

Pressure decreasing condition Pressure decreasing condition

ABS CONTROL FLOW

1. WHEN ABS IS NOT OPERATED

2. DUMP MODE-BRAKE PRESSURE DECREASING

3. HOLD MODE-BRAKE PRESSURE MAINTAINED

4. RISE MODE-BRAKE PRESSURE INCREASING

2. Disconnect ECU connectors from ECU assembly.

2. Remove rotor with a tool. Do not re-install a rotor once it is removed.

Tighten the bolt to : 7 lbft (9.5 Nm)

Resistance: 1385 110

Tighten the bolt to : 7 Ibft (9.5 Nm).

3. Measure speed sensor resistance. Resistance :1000 50

HOW TO USE DIAGNOSIS AND TROUBLESHOOTING

SELF-DIAGNOSIS PROCEDURES (WITH THE DIAGNOSTIC SCAN TOOL)

HOW TO ERASE MALFUNCTION CODE (WITH THE DIAGNOSTIC SCAN TOOL)

Power source via Ignition Switch terminal

GND1 GND2 BRAKE FL+ FR+ Rear+ FLFRRearABS Warning lamp

Ground terminal Brake lamp Switch input terminal