Workshop Manual

2001 - 2006
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COMPONENTS

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REMOVAL
1. Disconnect the double lock connector (A) from the HECU.

2. Disconnect the brake tubes from the HECU.

• Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it
off immediately with water.
• Take care not to damage or deform the brake lines during removal and installation.
• To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or
equivalent material.

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3. Remove the HECU bracket mounting bolt and remove the HECU.
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[Link] attempt to disassemble the HECU.

[Link] HECU must be transported and stored in an upright position and with the ports sealed. The HECU
must not be drained.

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

Tightening torque
HECU mounting bolt:
8~10 Nm (80~100 kg·cm, 5.9~7.3 lb·ft)
HECU bracket mounting bolt:
17~26 Nm (170~260 kg·cm, 12.5~19.1 lb·ft)
Brake tube nut:
13~17 Nm (130~170 kg·cm, 9.5~12.5 lb·ft)

ABS OPERATION CHECK

WHEEL SPEED SENSOR OUTPUT VOLTAGE CHECK
1. Raise the vehicle and release the parking brake.
2. Disconnect the HECU harness connector's and measure from the harness side connector.

Be sure to remove the connector's double lock and insert the probe into the harness side (back-probe).
Inserting it into the terminal side may result in a bad connection.

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3. Rotate the wheel to be measured approximately 1/2 to 1 rotation per second, and check the output voltage
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using a circuit tester or an oscilloscope.

Wheel speed Rear

Front left Front right Rear right
sensor left

1 19 5 22
Terminal
2 20 6 23

Output voltage:
When measuring with an oscilloscope :
130mV p·p or more

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CIRCUIT DIAGRAM

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INSPECTION OF HECU TERMINALS

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Terminals No. Condition Standard Voltage (V)

25 - GND (8,24) Always 10 - 14

9 - GND (8,24) Always 10 - 14

4 - GND (8,24) Ignition switch ON 10 - 14

Ignition switch ON, ABS

16 - GND (8,24) 3-5
warning lamp ON

Stop lamp switch OFF Below 1.0

18 - GND (8,24)
Stop lamp switch ON 8 - 14

Ignition switch ON,

19 - 20 slowly turn right front AC voltage generation
wheel

Ignition switch ON,

1-2 slowly turn left front AC voltage generation
wheel

Ignition switch ON,

22 - 23 slowly turn right rear AC voltage generation
wheel

Ignition switch ON,

5-6 AC voltage generation
slowly turn left rear wheel

Ignition switch ON, TCS

14 - GND (8,24) 10 - 14
switch ON

GND (8,24) - Body ground Always Continuity

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COMPONENTS

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DESCRIPTION
This specification applies to Hydraulic and Electronic Control Unit (HECU) of the Anti lock Braking System(ABS) and
Traction Control System(TCS).
This HECU has the functions as follows:
- Input of signal from the wheel speed sensors attached to each wheel.
- Control of braking force and traction force
- Failsafe function
- Self diagnosis function
- Interface with the external diagnosis tester

Operation
The HECU shall be put into operation by switching on the operating voltage (IGN).
On completion of the initialization phase, the HECU shall be ready for operation.
In the operating condition, the HECU shall be ready, within the specified limits (voltage and temperature), to process the
signals offered by the various sensors and switches in accordance with the control algorithm defined by the software and to
control the hydraulic and electrical actuators.
The HECU shall receive wheel speed signal from the four inductive wheel sensors.
The wheel signals are converted to square wave by the signal conditioning circuit and given as input to the - processor.
The sensor connections shall be monitored for short-circuit and inter-ruption and then in the event of 2 sensor failures, the
HECU shall shut down the system.
When one side of the valve coil is connected to the positive voltage that is provided through the valve relay and the other
side is connected to the ground by the MOSFET, the solenoid valve goes into operation.
The electrical function of the valves are always monitored by the valve test pulse under normal operation conditions.
When overvoltage is detected(above 16V), the HECU switches off the valve relay and shuts down the system. When voltage
is returned to operating range, the system goes back to the normal condition after the initialization phase.
In the event of undervoltage(below 10V), ABS control shall be inhibited and the warning lamp shall be turned on.
When voltage is returned to operating range, the warning lamp is switched off and the HECU returns to normal operating
mode.
The pump motor operates when the ABS is functioning.
The HECU performs a pump motor test at a speed of 20km/h once after turned the Ignition switch on. You may hear the
motor operate at this time, but it is normal.
Malfunctions or failures detected by the HECU are encoded on the HECU, stored in a EEPROM and read out by diagnostic
equipment (hi-scan pro) when the ignition switch is turned on.

Warning lamp control

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1. ABS warning lamp module

The ABS warning lamp module indicates the operating condition of the ABS.
The ABS warning lamp is turned on under the following conditions.
[Link] the initialization phase after ignition switch ON (3 seconds).
[Link] the event of inhibition of ABS functions by failure.
[Link] the system ECU is shut down even though ignition power is applied.
[Link] diagnostic mode.
[Link] the HECU connector is disconnected.
2. EBD warning lamp module
The EBD warning lamp module indicates the operating condition of the EBD. However, in case the parking brake switch is
turned on, the EBD warning lamp is always turned on regardless of EBD functions.
The EBD warning lamp is turned on under the following conditions.
[Link] the initialization phase after ignition switch ON. (3 seconds).
[Link] the system ECU is shut down even though ignition power is applied.
[Link] the parking brake switch is ON or brake fluid is low level.
[Link] the event of inhibition of EBD functions by failure.
3. TCS lamp module
The TCS warning lamp module indicates the operating condition of the TCS.
The TCS warning lamp is turned on under the following conditions :
[Link] the initialization phase after ignition switch ON (3 seconds).
[Link] the event of inhibition of TCS functions by failure.
[Link] the TCS OFF switch is turned on.
TCS function lamp is turned on when the TCS functions are operating (Blinking-2Hz).

Diagnostic trouble code (DTC)

1. If the CPU cannot be activated or the CPU fails, the ABS indicator comes on, but the DTC is not memorized.
2. The memory can hold any number of DTCs. However, when the same DTC is detected more than once, the later one is
written over the old one.
Therefore, when the same problem is detected repeatedly, it is memorized as one DTC.
3. The DTCs are indicated in the order they occur.
4. The DTCs are memorized in the EEPROM (non - volatile memory). Therefore, the memorized DTCs cannot be canceled
by disconnecting the battery. Perform the specified procedures to erase the DTCs.

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Self-diagnosis
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1. Self diagnosis can be classified into two categories:
[Link] diagnosis:
Performed right after the engine starts and until the ABS indicator goes off.
[Link] diagnosis:
Performed right after the initial diagnosis until the ignition switch is turned OFF.
2. When a problem is detected by self-diagnosis, the system:
[Link] the solenoid valve OFF
[Link] the pump motor OFF
[Link] the ABS indicator ON

How to troubleshoot ABS DTC

1. Question the customer about the conditions when the problem occured, and try to reproduce the same conditions for
troubleshooting. Find out when the ABS indicator came on, such as during initial diagnosis, during ABS control, after ABS
control, when vehicle speed was at a certain speed, etc.
2. When the ABS indicator does not come on during the test-drive, but troubleshooting is performed based on the DTC.
check for loose connectors, poor contact of the terminals, etc. before you start troubleshooting.
3. After troubleshooting, erase the DTC and test-drive the vehicle. Be sure the ABS indicator does not come on.

HI-SCAN (PRO) CHECK

1. Turn the ignition switch OFF.
2. Connect the Hi-scan (pro) to the 16P data link connector located behind the driver's side kick panel.

3. Turn the ignition switch ON.

4. Check for diagnostic trouble codes using the Hi-scan (pro).
5. After completion of the repair or correction of the problem, erase the stored fault codes using the clear key on the Hi-scan
(pro).
6. Disconnect the Hi-scan (pro) from the 16P data link connector.

SYSTEM FUNCTION
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ABS OPERATION
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1. NORMAL BRAKING

Solenoid valve State Valve Passage Pump motor

IN (NO) OFF OPEN Master cylinder ⇔ Wheel cylinder

OFF
OUT (NC) OFF CLOSE Wheel cylinder ⇔ Reservoir

Under the normal braking, voltage is not supplied to solenoid valve, inlet valve is opened and outlet valve is closed.
When the brake is depressed, brake fluid is supplied to the wheel cylinder via solenoid valve to activate the brake.
When the brake is released, brake fluid is back to the master cylinder via inlet valve and check valve.

2. DUMP MODE

Solenoid valve State Valve Passage Pump motor

IN (NO) ON CLOSE Master cylinder ⇔ Wheel cylinder

ON
OUT (NC) ON OPEN Wheel cylinder ⇔ Reservoir

Under the emergency braking, if the wheels start to lock up, HECU sends a signal to the solenoid valve to decrease the
brakefluid, then voltage is supplied to each solenoid. At this time inlet valve is closed and brake fluid is blocked from the
master cylinder. Conversely outlet valve is opened and brake fluid passes through wheel cylinder to reservoir, resulting
in pressure decrease.

3. HOLD MODE

Solenoid valve State Valve Passage Pump motor

IN (NO) ON CLOSE Master cylinder ⇔ Wheel cylinder

ON
OUT (NC) OFF CLOSE Wheel cylinder ⇔ Reservoir

When the brake fluid pressure is maximally decreased in wheel cylinder, HECU sends a signal to solenoid valve to keep
the fluidpressure, voltage is supplied to inlet valve but it is not supplied to outlet valve. At this time inlet and outlet valves
are closed and brake fluid is kept in wheel cylinder.

4. INCREASE MODE

Solenoid valve State Valve Passage Pump motor

IN (NO) OFF OPEN Master cylinder ⇔ Wheel cylinder

ON
OUT (NC) OFF CLOSE Wheel cylinder ⇔ Reservoir

If HECU determines there's no lock-up in the wheel, HECU cuts voltage to solenoid valve. So voltage is not supplied to
each solenoid valve, brake fluid passes through the inlet valve to wheel cylinder, resulting in pressure increase.

TRACTION CONTROL SYSTEM (TCS) OPERATION

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1. NORMAL MODE
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Solenoid valve State Valve Motor pump TC valve

IN (NO) OFF OPEN

OFF OFF
OUT (NC) OFF CLOSE

• In the normal driving condition, TC valve (normally open) is the passage between the master cylinder and the each
wheel cylinder.
• When brake pedal is applied, brake pressure is delivered to the wheel cylinders via NO-TC valve and all solenoid
valves inside the hydraulic unit are deactivated.
• In case of TCS malfunction it does not affect brake operation.

2. PRESSURE INCREASE MODE

Solenoid valve State Valve Motor pump TC valve

FRONT: OFF FRONT: OPEN

IN (NO)
REAR: ON REAR: CLOSE ON ON
OUT (NC) OFF CLOSE

• If a front wheel spin is detected, TCS begins a brake control to decrease a wheel spin.
• Hydraulic shuttle valve (HSV) is opened.
Brake fluid is supplied from the master cylinder by motor operation to the spin wheel via HSV.
• TC valve is closed (ON).
Brake pressure generated from motor pump is delivered only to the front wheel.
• Inlet valve remains open to deliver the brake pressure generated from motor pump to the spinning wheels.

3. PRESSURE DUMP MODE

Solenoid valve State Valve Motor pump TC valve

IN (NO) ON CLOSE

FRONT: ON FRONT: OPEN ON ON

OUT (NC)
REAR: OFF REAR: CLOSE

• When the wheel deceleration is under the threshold and the wheel spin is reduced under a slip threshold, applied
brake pressure is reduced to get a optimum traction force.
• Outlet valve is open to release the brake pressure and inlet valve is closed to block the pressure increase from the
motor pump.
• Hydraulic shuttle valve (HSV) remains opened, TC valve is ON.
• Motor is ON, to dump the brake fluid being released from the lock-up wheel.

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4. PRESSURE HOLD MODE

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Solenoid valve State Valve Motor pump TC valve

IN (NO) ON CLOSE
ON ON
OUT (NC) OFF CLOSE

TRACTION CONTROL SYSTEM (TCS) FUNCTION

1. Main performance
[Link]: Lower vibration and higher launchability, acceleration and climbability by slip control.
[Link] and passing: Stable cornering and passing.
[Link] stability: Control traction force traverse vector prior to provide easy turning when turning the steering wheel.
2. General TCS features
[Link] drivability. Minor operation of acceleration is not necessary in launching and acceleration on slippery road.
[Link] stable cornering by stable acceleration on normal road condition.
[Link] system will compare vehicle speed received from rear wheel speed sensor and driving wheel speed from front
wheel speed sensor on slippery road condition, and provide optimum slipping rate of driving wheels.

FULL TRACTION CONTROL SYSTEM (FTCS)

1. The ABS control module (HECU) controls TCS control too.
2. HECU will compare signals from front (driving) and rear wheel speed sensors to detect driving wheels slip.
3. Upon detecting driving wheels slip, HECU will perform TCS control. The TCS control will include brake TCS (BTCS)
control.
4. HECU will transmit engine torque reduction request, fuel cut cylinder number, and TCS control request signals in
accordance with slip level to engine ECM and TCM through BUS line which will provide CAN communication for TCS
control.
5. Engine ECM will perform fuel cut as requested by HECU and retard ignition timing as per engine torque reduction request
signal.
6. TCM will hold shift position by TCS control time according to TCS operation signal. Then enhanced acceleration by kick-
down will not occur.

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BRAKE TRACTION CONTROL SYSTEM (BTCS)

1. On TCS control, only brake control will be performed. (engine and TCM control will not happen)
2. Controlled by motor pump output pressure.

EBD (ELECTRONIC BRAKE-FORCE DISTRIBUTION) OPERATION

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

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FAIL SAFE

SYSTEM WARNING LAMP

FAIL CAUSE
ABS EBD ABS EBD

None ON ON OFF OFF

1-Wheel speed sensor failure OFF ON ON OFF

Pump malfunction OFF ON ON OFF

Low voltage OFF ON ON OFF

2 or more wheel speed sensor failure

Solenoid valve failure
HECU malfunction
OFF OFF ON ON
Valve relay failure
Over voltage
Other failure

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BLEEDING OF BRAKE SYSTEM

1. Remove the reservoir cap (A) 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 (A) and insert the other end of the tube into a
half filled clear plastic bottle.

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3. Connect the hi-scan (pro) to the data link connector located underneath the dash panel.
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4. Select and operate according to the instructions on the hi-scan (Pro) screen.

You must obey the maximum operating time of the ABS motor with the hi-scan (Pro) to prevent the motor
pump from burning.
(1) Select hyundai vehicle diagnosis.

(2) Select vehicle name.

(3) Select Anti-Lock Brake system.
(4) Select air bleeding mode.

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(5) Press "YES" to operate motor pump and solenoid valve.

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(6) Wait 60 sec. before operating the air bleeding.

(If not, you may damage the motor.)

5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without
bubbles. Then close the bleeder screw.

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

Bleed screw tightening torque:

7 ~ 13 Nm (70 ~130 kg·cm, 5.1 ~ 9.5 lb·ft)

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HYDRAULIC SYSTEM DIAGRAM

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CIRCUIT DIAGRAM Ebay User ID: reveleus1

CIRCUIT DIAGRAM (1)

CIRCUIT DIAGRAM (2)

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TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING

NOTES WITH REGARD TO DIAGNOSIS

Phenomenon Explanation

System check sound When starting the engine, a thudding sound can sometimes be heard coming from
inside the engine compartment. This is because the system operation check is
being performed.

ABS operation sound [Link] of the motor inside the ABS hydraulic unit operation (whine).
[Link] is generated along with vibration of the brake pedal (scraping).
[Link] ABS operates, sound is generated from the vehicle chassis due
torepeated brake application and release
(Thump : suspension; squeak: tires)

ABS operation (Long braking For road surfaces such as snow-covered and gravel roads, the braking distance
distance) for vehicles with ABS can sometimes be longer than that for other vehicles.
Accordingly, advise the customer to drive safely on such roads by lowering the
vehicle speed.

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Pedal kick back Pedal kick back is normal operation.

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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

PROBLEM SYMPTOMS TABLE

Symptom Suspect Area See page

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ABS does not operate. Only when

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User ID: -4. are all normal and the
problem is still occurring, replace the HECU.
[Link] the DTC reconfirming that the
normal code is output. BR - 59
[Link] source circuit.
[Link] sensor circuit.
[Link] the hydraulic circuit for leakage.

ABS does not operate intermittently. Only when 1. -4. are all normal and the
problem is still occurring, replace the ABS
actuator assembly.
[Link] the DTC reconfirming that the
BR - 61
normal code is output.
[Link] speed sensor circuit.
[Link] lamp switch circuit.
[Link] the hydraulic circuit for leakage.

Communication with Hi-scan (pro) is not [Link] source circuit

possible. [Link] line BR - 63
(Communication with any system is not
possible)

Communication with Hi-scan (pro) is not [Link] source circuit

possible. [Link] line BR - 64
(Communication with ABS only is not possible) [Link]

When ignition key is turned ON (engine OFF), [Link] warning lamp circuit
BR - 66
the ABS warning lamp does not light up. [Link]

Even after the engine is started, the ABS [Link] warning lamp circuit
BR - 68
warning lamp remains ON. [Link]

Brake warning lamp is abnormal. [Link] oil level sensor

[Link] brake switch BR - 70
[Link] warning lamp circuit

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.

DIAGNOSTIC TROUBLE CODE CHART

DTC No. Detection Item MIL* Memory See page

C1101 Battery voltage over volt: 18V or more BR-

C1102 Battery voltage low volt: 9.5V or less BR-

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C1200 FL wheel sensor: open or short to ground

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BR-

C1201 - Range/Performance: speed jump or damaged exciter BR-

C1202 - No signal: air-gap error or wrong excite BR-

C1203 FR wheel sensor: open or short to ground BR-

C1204 - Range/Performance: speed jump or damaged exciter BR-

C1205 - No signal excite: air-gap error or wrong excite BR-

C1206 RL wheel sensor: open or short to ground BR-

C1207 - Range/Performance: speed jump or damaged exciter BR-

C1208 - No signal excite: air-gap error or wrong excite BR-

C1209 RR wheel sensor: open or short to ground BR-

C1210 - Range/Performance: speed jump or damaged exciter BR-

C1211 - No signal: air-gap error or wrong excite BR-

C1604 ECU hardware: ECU internal or valve failure BR-

C2112 Valve relay: valve relay or fuse failure BR-

Motor-Electrical: open or short to battery, motor relay, fuse or

C2402 BR-
motor lock fail

C1503 TCS switch failure × BR-

C1605 CAN Hardware failure ∆ BR-

C1610 CAN Bus off failure ∆ BR-

C1611 EMS Time-out failure ∆ BR-

C1612 TCM Time-out failure ∆ BR-

C1613 TCM Un-matching failure ∆ BR-

C2227 Brake disc overheat ∆ BR-

*MIL: Malfunction Indication Lamp

: ABS warning lamp
∆: TCS warning lamp

DETECTING CONDITION

Trouble Symptoms Possible Cause

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Brake operation varies depending on driving conditions and road

Ebay User ID: reveleus1 - Faulty power source circuit
surface conditions, so diagnosis can be difficult. - Faulty wheel speed sensor circuit
However if a normal DTC is displayed, check the following probable - Faulty hydraulic circuit for leakage
cause. When the problem is still occurring, replace the ABS control
- Faulty HECU
module.

INSPECTION PROCEDURES

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DETECTING CONDITION

Trouble Symptoms Possible Cause

Brake operation varies depending on driving conditions and road - Faulty wheel speed sensor circuit
surface conditions, so diagnosis can be difficult. - Faulty stop lamp switch circuit
However if a normal DTC is displayed, check the following probable - Faulty hydraulic circuit for leakage
cause. When the problem is still occurring, replace the ABS control
- Faulty HECU
module.

INSPECTION PROCEDURES

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DETECTING CONDITION

Trouble Symptoms Possible Cause

Possible defect in the power supply system (including ground) for the - An open in the wire
diagnosis line. - Poor ground (G14)

INSPECTION PROCEDURES

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DETECTING CONDITION

Trouble Symptoms Possible Cause

When communication with Hi-Scan (pro) is not possible, the cause - An open in the wire
may be probably an open in the HECU power circuit or an open in the - Blown No.11 fuse (10A) in the passenger
diagnosis output circuit. compartment junction block
- Faulty HECU

INSPECTION PROCEDURES

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DETECTING CONDITION

Trouble Symptoms Possible Cause

When current flows in the HECU the ABS warning lamp turns from ON - Blown No.2 fuse (10A) in the passenger
to OFF as the initial check. compartment junction block
Therefore if the lamp does not light up, the cause may be an open in - An open in the wire
the lamp power supply circuit, a blown bulb, an open in the both - Faulty ABS warning lamp bulb
circuits between the ABS warning lamp and the HECU, and the faulty
- Faulty ABS warning lamp module
HECU.
- Faulty HECU

INSPECTION PROCEDURES

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DETECTING CONDITION

Trouble Symptoms Possible Cause

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If the HECU detects trouble, it lights the ABS warning lamp while at the
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same time prohibiting ABS control. At this time, the HECU records a - Faulty instrument cluster assembly
DTC in memory. - Faulty HECU
Even though the normal code is output, the ABS warning lamp
remains ON, then the cause may be probably an open or short in the
ABS warning lamp circuit.

INSPECTION PROCEDURES

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DETECTING CONDITION

Trouble Symptoms Possible Cause

The brake warning lamp lights up when the brake oil is insufficient, - Faulty brake oil level sensor
parking brake is applied or EBD is defective. - Faulty parking brake switch
- Faulty instrument cluster
- Faulty HECU

INSPECTION PROCEDURES

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C1101 Ebay User ID: reveleus1

(Over Voltage)
DTC Battery Voltage out of Range (Low or Over Voltage)
C1102
(Low Voltage)

DESCRIPTION

The voltage of the HECU power supply drops lower than or rises higher than the specified value. If the voltage returns
to the specified value, this code is no longer output.

If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to the
standard value, the code is no longer output. Before carrying out the following inspection, check the battery level,
and refill if necessary.

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

Detecting Condition for Over Voltage:

[Link] Vign>17V is continued for 500msec.
[Link] Vign>19V is continued for 49msec.
[Link] the voltage recover normal operating range, the controller
is reset.
C1101 Detecting Condition for Low Voltage:
- An open or short in the wire
(Over Voltage) [Link] Vign<9.4V is continued for 500msec.
- Faulty power supply circuit
C1102 [Link] Vign>9.6V is continued for 500msec, the controller
- Faulty HECU
(Low Voltage) recovers to normal state.
[Link] ABS control or standstill, detection voltage = 8.4V,
recovery voltage = 8.6V.
[Link] Vign<7.2V is continued for 28msec.
[Link] Vign>7.5V is continued for 28msec, the controller
recovers to state 1).

FAILSAFE FUNCTION

Over voltage failure:

System down. both the ABS(,TCS) and the EBD function are inhibited and the ABS(,TCS) and the EBD warning lamps
is activated. In this failure, the valve relay and all solenoids are prevented from being switched on.
Low voltage failure:
[Link] the ABS control cycle : inhibit the ABS(,TCS) control of front wheels and allow the ABS control of rear
wheels, deactivating the motor, and the ABS(,TCS) warning lamp is switched on. When the voltage recover to the
normal operating range, enable ABS function and ABS(,TCS) warning lamp is switched off and erase the error code.
[Link] the ABS control cycle : inhibit ABS control of the front wheels and allow ABS control of the rear wheels,
deactivating the motor. the ABS(,TCS) warning lamp is directly switched on and the state keeps continuously. the
error code is always stored.

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INSPECTION PROCEDURES
Ebay User ID: reveleus1

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C1200 (FL)
C1203 (FR)
DTC Wheel Speed Sensor Open or Short to Ground
C1206 (RL)
C1209 (RR)

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

The wheel velocity is below 7km/h and the offset voltage of the sensor - An open or short in the
C1200 (FL)
is outside the permitted range. if this condition is continued for more wire
C1203 (FR)
than 140msec. - Faulty wheel speed
C1206 (RL)
sensor
C1209 (RR)
- Faulty HECU

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FAILSAFE FUNCTION
Ebay User ID: reveleus1
Sensor failure outside the ABS control cycle:
[Link] one wheel failure
Only the ABS(,TCS) function is inhibited. the ABS(,TCS) warning lamp is activated and the EBD warning lamp not
activated.
[Link] than two wheels failure
System down. both the ABS(,TCS) and the EBD function are inhibited and the ABS(,TCS) and the EBD warning
lamps is activated. In this failure, the valve relay and all solenoids are prevented from being switched on.
Sensor failure inside the ABS control cycle:
[Link] front wheel failure
Inhibit the ABS control of the failed-wheel and maintain the ABS control of normal wheel.
After the controller completes the ABS control, the ABS(,TCS) function is inhibited. the ABS(,TCS) warning lamp is
activated and the EBD warning lamp not activated.
[Link] rear wheel failure
Inhibit ABS control of both front wheels and the pressure of both rear wheels is decreased.
After the controller completes the ABS control, Only the ABS(,TCS) function is inhibited. the ABS(,TCS) warning
lamp is activated and the EBD warning lamp not activated.
[Link] than two wheels failure.
System down. both the ABS(,TCS) and the EBD function are inhibited and the ABS(,TCS) and the EBD warning
lamps is activated. In this failure, the valve relay and all solenoids are prevented from being switched on.

INSPECTION PROCEDURES

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C1201 (FL)
C1204 (FR) Wheel Speed Sensor Signal Malfunction
DTC
C1207 (RL) (Speed jump or damaged exciter)
C1210 (RR)

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

Detecting Condition for Speed Jump:

This monitoring is performed for the period that the velocity of each
wheel exceeds 2km/h.
[Link] counts the number of the wheel acceleration of 100g
[(25km/h) for 7ms]. When the numbers at one wheel exceed 56
times, or When the numbers at more two wheels exceed 5 times,
controller recognize the failure.
[Link] counts the number of the wheel acceleration of 40g
[(10km/h) for 7ms]. When the numbers at one wheel exceed 126
times, or When the numbers at more two wheels exceed 20 times,
controller recognize the failure. - Improper installation of
[Link] counts the number of the wheel deceleration of -100g[(- wheel speed sensor
C1201 (FL) 25km/h) for 7ms]. When the numbers at each wheel exceed 56 - An open or short in the
C1204 (FR) times, controller recognize the failure. wire
C1207 (RL) [Link] wheel deceleration of –100g[(-25km/h) for 7ms] causes the - Faulty wheel speed
C1210 (RR) controller to start monitoring this failure and to compare the wheel sensor
velocity with the vehicle velocity from next cycle. When its - Faulty rotor or wheel
difference of -100g is continued for more than 140msec, controller bearing
recognize the failure. - Faulty HECU

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[Link] case that any sensor failure at other wheel was already detected,
Ebay User ID: reveleus1
When the numbers of 100g at each wheel exceed 5 times, or When
the numbers of 40g at each wheel exceed 20 times, controller
recognize the failure.
Detecting Condition for Damaged Exciter:
[Link]. wheel velocity exceeds 20km/h and the wheel velocity is 40%
of max. wheel velocity. if this condition is lasted for 2 minutes.
[Link]. wheel velocity exceeds 40km/h and the wheel velocity is 60%
of max. wheel velocity. if this condition is lasted for 2 minutes.

FAILSAFE FUNCTION

Sensor failure outside the ABS control cycle:

[Link] one wheel failure
Only the ABS(,TCS) function is inhibited. the ABS(,TCS) warning lamp is activated and the EBD warning lamp not
activated.
[Link] than two wheels failure
System down. both the ABS(,TCS) and the EBD function are inhibited and the ABS(,TCS) and the EBD warning
lamps is activated. In this failure, the valve relay and all solenoids are prevented from being switched on.
Sensor failure inside the ABS control cycle:
[Link] front wheel failure
Inhibit the ABS control of the failed-wheel and maintain the ABS control of normal wheel.
After the controller completes the ABS control, the ABS(,TCS) function is inhibited. the ABS(,TCS) warning lamp is
activated and the EBD warning lamp not activated.
[Link] rear wheel failure
Inhibit ABS control of both front wheels and the pressure of both rear wheels is decreased.
After the controller completes the ABS control, Only the ABS(,TCS) function is inhibited. the ABS(,TCS) warning
lamp is activated and the EBD warning lamp not activated.
[Link] than two wheels failure.
System down. both the ABS(,TCS) and the EBD function are inhibited and the ABS(,TCS) and the EBD warning
lamps is activated. In this failure, the valve relay and all solenoids are prevented from being switched on.

INSPECTION PROCEDURES

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C1202 (FL)
C1205 (FR) Wheel Speed Sensor Signal Malfunction
DTC
C1208 (RL) (Air-gap error or wrong excite)
C1211 (RR)

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

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Detecting Condition for Large Air-Gap:

Ebay User ID: reveleus1
This monitoring is performed for the period that the minimum velocity
rises from 2km/h to 10km/h.
[Link] the minimum wheel velocity is 2km/h and the velocity of
other wheels exceed 10km/h with the acceleration of < 0.4g, the
controller start comparing the velocity of other wheels except the
- Improper installation of
min. wheel. if their difference below 4km/h is continued for
wheel speed sensor
140msec, Otherwise, if their difference beyond 4km/h or > 0.4g is
- An open or short in the
C1202 (FL) continued for 2 minutes.
wire
C1205 (FR) [Link] < 0.4g, when the velocity of more two wheels is 2km/h and the
- Faulty wheel speed
C1208 (RL) max. wheel velocity exceeds 10km/h, the condition is continued for
sensor
C1211 (RR) 20 sec. Otherwise, In >0.4g, the condition is 2 minutes.
- Faulty rotor or wheel
[Link] velocity of 4 wheel exceeds 10km/h, when velocity of 1 wheel
bearing
or 2 wheel is 2km/h and difference of other 2 wheel velocity is less
than 4km/h under that those velocity is more than 10km/h, if that - Faulty HECU
conditions are continued for 12 seconds.
Detecting Condition for Long Term ABS mode:
[Link] the ABS control cycle, if the wheel velocity of 2km/h is
lasted for more than 12sec.
[Link] the ABS control cycle is continued for more than 36sec.

FAILSAFE FUNCTION

Sensor failure outside the ABS control cycle:

[Link] one wheel failure
Only the ABS(,TCS) function is inhibited. the ABS(,TCS) warning lamp is activated and the EBD warning lamp not
activated.
[Link] than two wheels failure
System down. both the ABS(,TCS) and the EBD function are inhibited and the ABS(,TCS) and the EBD warning
lamps is activated. In this failure, the valve relay and all solenoids are prevented from being switched on.
Sensor failure inside the ABS control cycle:
[Link] front wheel failure
Inhibit the ABS control of the failed-wheel and maintain the ABS control of normal wheel.
After the controller completes the ABS control, the ABS(,TCS) function is inhibited. the ABS(,TCS) warning lamp is
activated and the EBD warning lamp not activated.
[Link] rear wheel failure
Inhibit ABS control of both front wheels and the pressure of both rear wheels is decreased.
After the controller completes the ABS control, Only the ABS(,TCS) function is inhibited. the ABS(,TCS) warning
lamp is activated and the EBD warning lamp not activated.
[Link] than two wheels failure.
System down. both the ABS(,TCS) and the EBD function are inhibited and the ABS(,TCS) and the EBD warning
lamps is activated. In this failure, the valve relay and all solenoids are prevented from being switched on.

INSPECTION PROCEDURES

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ECU Hardware Failure

DTC C1604
(ECU Internal or Solenoid Valve Failure)

DESCRIPTION

The HECU always monitors the solenoid valve drive circuit.

It determines that there is an open or short-circuit in the solenoid coil or in a harness even if no current flows in the
solenoid or through the HECU.

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

Detecting Condition for Solenoid Valve Open or Short:

[Link] the valve relay is switched off, the drain voltage of the
solenoid drive MOSFET is over the criterion, which is continued for
56msec.
[Link] the valve relay is switched on and a solenoid off, the drain
voltage of the solenoid drive MOSFET is under the criterion, which - An open or short in the
is continued for 56msec. solenoid valve circuit.
C1604 [Link] the valve relay and a solenoid are switched on, the drain - Leakage current in the
voltage of the solenoid drive MOSFET is over the criterion, which is solenoid valve.
continued for 56msec. - Faulty HECU.
Detecting Condition for EEPROM Failure of ECU:
When the MCU can’t erase or write a data of the EEPROM.
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Detecting Condition for MCU Failure of ECU:

Ebay User ID: reveleus1
If the master/slave processor detects abnormal operation in RAM,
status register, interrupt, timer, A/D converter and cycle time.

FAILSAFE FUNCTION

System down. both the ABS(,TCS) and the EBD function are inhibited and the ABS(,TCS) and the EBD warning lamps
is activated. In this failure, the valve relay and all solenoids are prevented from being switched on.

INSPECTION PROCEDURES

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DTC C2112 Valve Relay Failure (Valve Relay or Fuse Failure)

DESCRIPTION

When the ignition switch is turned ON, the HECU switches the valve relay on and off during its initial check. During this
time, voltage sent to the valve relay is compared to the voltage in the valve power monitor line. If no current is detected
in the valve power monitor line, the HECU determines that there is an open circuit and DTC C2112 is recorded.

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

Detecting Condition for Valve Relay Open:

When the valve relay is switched on, the reference voltage of valve
- An open or short in the
relay is under the permitted range, which is continued for 56msec.
C2112 valve relay circuit.
Detecting Condition for Valve Relay Short:
- Faulty HECU
When the valve relay is switched off, the reference voltage of valve
relay is over the criterion, which is continued for 56msec.

FAILSAFE FUNCTION

System down. both the ABS(,TCS) and the EBD function are inhibited and the ABS(,TCS) and the EBD warning lamps
is activated. In this failure, the valve relay and all solenoids are prevented from being switched on.

INSPECTION PROCEDURES

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DTC C2402 Motor Relay or Motor Electrical Failure

DESCRIPTION

The ABS motor relay supplies power to the ABS pump motor. While the ABS is activated, the HECU switches the ABS
motor relay ON and operates the ABS pump motor.

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

Detecting Condition for Motor Relay Open or Motor Short to

Battery:
When the motor relay is switched on, the reference voltage of motor is
over the criterion, which is continued for 49msec.
Detecting Condition for Motor Lock:
The controller starts monitoring the motor voltage for 84msec from the
time when the motor relay is switched off. if the motor voltage is over - An open or short in the
the criterion for 49msec after shutting off the motor, the motor is motor relay or motor
C2402 reactivated for 500msec after shutting off the motor 84msec and the circuit.
above check is performed again for a maximum of two times. When - Motor lock
the motor voltage is not normal even on the second check, the - Faulty HECU.
controller recognizes it as failure.
Detecting Condition for Fuse Open, Motor Open or Short to
Ground:
The controller starts monitoring the motor after 1.8sec from the time
when the motor relay is switched off. if the motor voltage is under the
criterion for 0.2 sec.

FAILSAFE FUNCTION

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[Link] the ABS(,TCS) function is inhibited. the ABS(,TCS) warning

Ebay User ID: lamp is activated and the EBD warning lamp not
reveleus1
activated.
[Link] error during the ABS control cycle : inhibit the ABS control of front wheels, allow ABS control of the rear
wheels, and ABS(,TCS) warning lamp is switched ON at the end of ABS control.

INSPECTION PROCEDURES

DTC C1503 TCS Switch Failure (only System with TCS)

DESCRIPTION

When the TCS switch is pressed, TCS control is deactivated and the TCS OFF indicator lights up.
The TCS OFF indicator turns "ON" when the HECU prohibit TCS controls.

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

The condition that the level of TCS switch is high is continued for 60 - An open or short in the
sec. TCS switch circuit.
C1503
- Faulty TCS switch
- Faulty HECU.

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FAILSAFE FUNCTION Ebay User ID: reveleus1

Inhibit the TCS control and allow the ABS/EBD control.

Meanwhile, stop checking the TCS switch failure under the TCS control.

INSPECTION PROCEDURES

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CAN Hardware Failure

DTC C1605
(only System with TCS)

DESCRIPTION

The CAN circuit is used to send TCS control information from the HECU to the engine ECM and TCM, and engine and
transmission control information from the engine ECM and TCM to the HECU.

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

C1605 In case that CAN has hardware failure. - Faulty CAN or bus

FAILSAFE FUNCTION

Inhibit the TCS control and allow the ABS/EBD control.

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 Purchased
from Ebay seller
Reveleus1

Thank-you for purchasing from me, it

is much appreciated.
To contact me please email
suzlever@[Link]
[Link]

DTC C1610 CANUser

Ebay BusID: Off Failure
reveleus1 (only System with TCS)

DESCRIPTION

The CAN circuit is used to send TCS control information from the HECU to the engine ECM and TCM, and engine and
transmission control information from the engine ECM and TCM to the HECU.

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

- An open or short in the

CAN bus circuit.
C1610 In case CAN BUS off state continued for more than 0.1sec.
- Faulty CAN bus
- Faulty HECU

FAILSAFE FUNCTION

Inhibit the TCS control and allow the ABS/EBD control.

INSPECTION PROCEDURES

DTC C1611 EMS Time-out Failure (only System with TCS)

DESCRIPTION

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HECU will compare signals from front (driving) and Ebay

rearUser
wheel speed sensors to detect driving wheels slip.
ID: reveleus1
Upon detecting driving wheels slip, HECU will perform TCS control.
The HECU will transmit engine torque reduction request, fuel cut cylinder number, and TCS control request signals in
accordance with slip level to engine ECM and TCM through BUS line which will provide CAN communication for TCS
control.
Engine ECM will perform fuel cut as requested by HECU and retard ignition timing as per engine torque reduction
request signal.
TCM will hold shift position by TCS control time according to TCS operation signal. Then enhanced acceleration by kick-
down will not occur.

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

- An open or short in the

[Link] case that EMS1 or EMS2 message was not received for more CAN bus circuit.
C1611 than 0.5 sec. within normal voltage condition. - Faulty CAN bus
[Link] monitoring starts 2 sec. after power up. - Faulty EMS
- Faulty HECU

FAILSAFE FUNCTION

Inhibit the TCS control and allow the ABS/EBD control.

INSPECTION PROCEDURES

DTC C1612 TCM Time-out Failure (only System with TCS)

DESCRIPTION

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HECU will compare signals from front (driving) and Ebay

rearUser
wheel speed sensors to detect driving wheels slip.
ID: reveleus1
Upon detecting driving wheels slip, HECU will perform TCS control.
The HECU will transmit engine torque reduction request, fuel cut cylinder number, and TCS control request signals in
accordance with slip level to engine ECM and TCM through BUS line which will provide CAN communication for TCS
control.
Engine ECM will perform fuel cut as requested by HECU and retard ignition timing as per engine torque reduction
request signal.
TCM will hold shift position by TCS control time according to TCS operation signal. Then enhanced acceleration by kick-
down will not occur.

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

- An open or short in the

[Link] case that TCM message was not received for more than 0.5 sec. CAN bus circuit.
C1612 within normal voltage condition. - Faulty CAN bus
[Link] monitoring starts 2 sec. after power up. - Faulty TCM
- Faulty HECU

FAILSAFE FUNCTION

Inhibit the TCS control and allow the ABS/EBD control.

INSPECTION PROCEDURES

TCM Wrong-Matched Transmission Failure

DTC C1613
(only System with TCS)

DESCRIPTION
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HECU will compare signals from front (driving) and Ebay

rearUser
wheel speed sensors to detect driving wheels slip.
ID: reveleus1
Upon detecting driving wheels slip, HECU will perform TCS control.
The HECU will transmit engine torque reduction request, fuel cut cylinder number, and TCS control request signals in
accordance with slip level to engine ECM and TCM through BUS line which will provide CAN communication for TCS
control.
Engine ECM will perform fuel cut as requested by HECU and retard ignition timing as per engine torque reduction
request signal.
TCM will hold shift position by TCS control time according to TCS operation signal. Then enhanced acceleration by kick-
down will not occur.

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

[Link] case that the information about transmission is different in the

- Faulty CAN bus
C1613 EMS message and TCM message within normal voltage condition.
- Faulty EMS or TCM
[Link] monitoring starts 2 sec. after power up.

FAILSAFE FUNCTION

Inhibit the TCS control and allow the ABS/EBD control.

DTC C2227 Brake Disc Overheat (only System with TCS)

DESCRIPTION

On TCS control, brake control will be performed by motor pump output pressure.
This brake traction control cause the brake disc to overheat.

DTC DETECTING CONDITION

DTC No Detecting Condition Possible Cause

[Link] the calculated temperature of disc is higher than predefined

value.
C2227 - Brake disc is overheating
[Link] the calculated temperature reach to predefined value, the
controller recovers to normal state.

FAILSAFE FUNCTION

Inhibit the TCS control and allow the ABS/EBD control.

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Operation and Leakage Check

Check all of the following items:

Component Procedure

Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes do not
work properly, check the brake booster. Replace the brake booster as an assembly if it
does not work properly or if there are signs of leakage.

Piston cup and pressure • Check brake operation by applying the brakes. Look for damage or signs of fluid
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.

Wheel cylinder piston cup Check brake operation by applying the brakes.
and dust cover (E) Look for damage or signs of fluid leakage. If the pedal does not work properly, the brakes
drag, or there is damage or signs of fluid leakage, replace the wheel cylinder.

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Ebay User ID: reveleus1

Operation and Leakage Check

Check all of the following items:

Component Procedure

Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes do not
work properly, check the brake booster. Replace the brake booster as an assembly if it
does not work properly or if there are signs of leakage.

Piston cup and pressure • Check brake operation by applying the brakes. Look for damage or signs of fluid
cup inspection (B) leakage. Replace the master cylinder as an assembly if the pedal does not work
properly or if there is damage or signs of fluid leakage.
• Check for a difference in brake pedal stroke between quick and slow brake
applications. Replace the master cylinder if there is a difference in pedal stroke.

Brake hoses (C ) Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it is
damaged or leaking.

Caliper piston seal and Check brake operation by applying the brakes.
piston boots (D) Look for damage or signs of fluid leakage. If the pedal does not work properly, the brakes
drag, or there is damage or signs of fluid leakage, disassemble and inspect the brake
caliper. Replace the boots and seals with new ones whenever the brake caliper is
disassembled.

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Wheel cylinder piston cup Check brake operation byUser

Ebay applying the brakes.
ID: reveleus1
and dust cover (E) Look for damage or signs of fluid leakage. If the pedal does not work properly, the brakes
drag, or there is damage or signs of fluid leakage, replace the wheel cylinder.

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COMPONENTS

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[Link]

COMPONENTS Ebay User ID: reveleus1

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REPLACEMENT
1. Remove the master cylinder (see page BR-20).
2. Disconnect the vacuum hose (A) from the brake booster (B).

3. Remove the snap pin (A) clevis pin (B) and washer (C).

4. Remove the for booster mounting nuts (D).

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5. Remove the brake booster (A) from the engine compartment.

Ebay User ID: reveleus1

6. Install the brake booster in the reverse order of removal, and note these items:
[Link] installation, adjust brake pedal height and brake pedal free play (see page BR-9).
[Link] new snap pin and clevis pin whenever installing.
[Link] grease to both sides of the snap pin and the clevis pin.

REPLACEMENT
1. Remove the master cylinder (see page BR-20).
2. Disconnect the vacuum hose (A) from the brake booster (B).

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3. Remove the snap pin (A) clevis pin (B) and washer (C).
Ebay User ID: reveleus1

4. Remove the for booster mounting nuts (D).

5. Remove the brake booster (A) from the engine compartment.

6. Install the brake booster in the reverse order of removal, and note these items:
[Link] installation, adjust brake pedal height and brake pedal free play (see page BR-9).
[Link] new snap pin and clevis pin whenever installing.
[Link] grease to both sides of the snap pin and the clevis pin.

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[Link]

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TESTS
Functional test
1. With the engine stopped, depress the brake pedal several times to deplete the vacuum reservoir, then depress
the pedal hard and hold it for 15 seconds. If the pedal sinks, either the master cylinder is bypassing internally,
or the brake system (master cylinder, lines, proportioning valve, or caliper) is leaking.
2. Start the engine with the pedal depressed. If the pedal sinks slightly, the vacuum booster is operating
normally. If the pedal height does not vary, the booster or check valve is faulty

Leak test
1. Depress the brake pedal with the engine running, then stop the engine. If the pedal height does not vary while
depressed for 30 seconds, the vacuum booster is OK. If the pedal rises, the booster is faulty.
2. With the engine stopped, depress the brake pedal several times using normal pressure. When the pedal is first
depressed, it should be low. On consecutive application, the pedal height should gradually rise. If the pedal
position does not vary, check the booster check valve.

Check valve test

1. Disconnect the brake booster vacuum hose (check valve built in) (A) at the booster (B).

2. Start the engine and let it idle. There should be vacuum available. If no vacuum is available, the check valve is
not working properly. Replace the brake booster vacuum hose and check valve and retest.

TESTS
Functional test
1. With the engine stopped, depress the brake pedal several times to deplete the vacuum reservoir, then depress
the pedal hard and hold it for 15 seconds. If the pedal sinks, either the master cylinder is bypassing internally,
or the brake system (master cylinder, lines, proportioning valve, or caliper) is leaking.
2. Start the engine with the pedal depressed. If the pedal sinks slightly, the vacuum booster is operating
normally. If the pedal height does not vary, the booster or check valve is faulty
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Leak test Ebay User ID: reveleus1

1. Depress the brake pedal with the engine running, then stop the engine. If the pedal height does not vary while
depressed for 30 seconds, the vacuum booster is OK. If the pedal rises, the booster is faulty.
2. With the engine stopped, depress the brake pedal several times using normal pressure. When the pedal is first
depressed, it should be low. On consecutive application, the pedal height should gradually rise. If the pedal
position does not vary, check the booster check valve.

Check valve test

1. Disconnect the brake booster vacuum hose (check valve built in) (A) at the booster (B).

2. Start the engine and let it idle. There should be vacuum available. If no vacuum is available, the check valve is
not working properly. Replace the brake booster vacuum hose and check valve and retest.

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Component Location

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Component Location Ebay User ID: reveleus1

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Inspection
1. Inspect the brake hoses, for damage, deterioration, leaks, interference and twisting.
2. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines.
3. Check for leaks at hose and line joints or connections, and retighten if necessary.
4. Check the master cylinder for damage and leakage.

Replace the brake hose clip whenever the brake hose is serviced.

Replacement

• Before reassembling, check that all parts are free of dust and other foreign particles.
• Replace parts with new ones whenever specified to do so.
• Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off
immediately with water.
1. Replace the brake hose (A) if the hose is twisted, cracked, or if it leaks.

2. Disconnect the brake hose from the brake line (B) using a 10mm flare-nut wrench (C).

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3. Remove and discard the brake hose clip (A) from the brake hose (B).
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4. Remove the connector bolt (C), and disconnect the brake hose from the caliper.
5. Remove the brake hose from the knuckle.
6. Install the brake hose (A) on the knuckle with 12mm flange bolt (B) first, then connect the brake hose to the
caliper with the connector bolt (C) and new sealing washers (D).

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7. Install the brake hose (A) on the upper brake hose bracket (B) with a new brake hose clip (C).
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8. Connect the brake line (D) to the brake hose

9. After installing the brake hose, bleed the brake system. (see page BR-12)
10. Perform the following checks.
[Link] the brake hose and line joint for leaks, and tighten if necessary.
[Link] the brake hoses for interference and twisting.

Inspection
1. Inspect the brake hoses, for damage, deterioration, leaks, interference and twisting.
2. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines.
3. Check for leaks at hose and line joints or connections, and retighten if necessary.
4. Check the master cylinder for damage and leakage.

Replace the brake hose clip whenever the brake hose is serviced.

Replacement

• Before reassembling, check that all parts are free of dust and other foreign particles.
• Replace parts with new ones whenever specified to do so.
• Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off
immediately with water.

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1. Replace the brake hose (A) if the hose is twisted, cracked, or if it leaks.
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2. Disconnect the brake hose from the brake line (B) using a 10mm flare-nut wrench (C).
3. Remove and discard the brake hose clip (A) from the brake hose (B).

4. Remove the connector bolt (C), and disconnect the brake hose from the caliper.
5. Remove the brake hose from the knuckle.

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6. Install the brake hose (A) on the knuckle with 12mm flange bolt (B) first, then connect the brake hose to the
Ebay User ID: reveleus1
caliper with the connector bolt (C) and new sealing washers (D).

7. Install the brake hose (A) on the upper brake hose bracket (B) with a new brake hose clip (C).

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

9. After installing the brake hose, bleed the brake system. (see page BR-12)
10. Perform the following checks.
[Link] the brake hose and line joint for leaks, and tighten if necessary.
[Link] the brake hoses for interference and twisting.

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COMPONENTS

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COMPONENTS Ebay User ID: reveleus1

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Component Locating Index

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Component Locating Index Ebay User ID: reveleus1

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COMPONENTS

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COMPONENTS

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[Link] (2 of 4)14/03/2009 3:01:31 PM

[Link]

Ebay User ID: reveleus1

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[Link]

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General information

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.

Remove, disassemble, inspect, reassemble, and install the caliper and note these items:
• Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off
immediately with water.
• To prevent dripping, cover disconnected hose joints with rags or shop towels.
• Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
• Before reassembling, check that all parts are free of dirt and other foreign particles.
• Replace parts with new ones as specified in the illustration.
• Make sure no dirt or other foreign matter gets into the brake fluid.
• Make sure no grease or oil gets on the brake discs or pads.
• When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency.
• Do not reuse drained brake fluid.
• Always use Genuine DOT 3 or DOT 4 brake fluid. Non Genuine DOT 3 or DOT 4 brake fluid can cause
corrosion and shorten the life of the system.
• Coat the piston, piston seal groove, and caliper bore with clean brake fluid.
• Replace all rubber parts with new ones.
• After installing the caliper, check the brake hose and line for leaks, interference, and twisting.

General information

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.
Remove, disassemble, inspect, reassemble, and install the caliper and note these items:
• Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off
immediately with water.
• To prevent dripping, cover disconnected hose joints with rags or shop towels.
• Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
• Before reassembling, check that all parts are free of dirt and other foreign particles.
• Replace parts with new ones as specified in the illustration.
• Make sure no dirt or other foreign matter gets into the brake fluid.
• Make sure no grease or oil gets on the brake discs or pads.

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• When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency.
Ebay User ID: reveleus1
• Do not reuse drained brake fluid.
• Always use Genuine DOT 3 or DOT 4 brake fluid. Non Genuine DOT 3 or DOT 4 brake fluid can cause
corrosion and shorten the life of the system.
• Coat the piston, piston seal groove, and caliper bore with clean brake fluid.
• Replace all rubber parts with new ones.
• After installing the caliper, check the brake hose and line for leaks, interference, and twisting.

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REPLACEMENT

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

1. Loosen the front wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported.
Remove the front wheels.
2. Remove the brake hose mounting bolts (A) from the knuckle.

3. Remove guide rod (B) and the caliper (C) up out of the way. Check the hoses and pin boots for damage and
deterioration.
4. Remove the pad shims (A), pad retainers (B) and pads (C).

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5. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include
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pad backing plate (A) thickness.

Brake pad thickness:

11mm (0.43 in.)
2mm (0.079 in.)

6. If the brake pad thickness is less than service limit, replace the front pads as a set.
7. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
8. Check the brake disc for damage and cracks.
9. Install the pad retainers (A).

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10. Check the foreign material at the pad shims (A) and the back of the pads (B).
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Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.

11. Install the brake pads (B) and pad shims (A) correctly. Install the pad with the wear indicator (C) on the inside.
If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary
loss of braking efficiency.
12. Push in the piston (A) so that the caliper will fit over the pads. Make sure that the piston boot is in position to
prevent damaging it when pivoting the caliper down.
13. Pivot the caliper down into position. Being careful not to damage the pin boot, install the guide rod bolt (B)
and torque it to proper specification.

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Insert the piston in the cylinder using the special tool (09581-11000).

14. Install the brake hose on to the knuckle.

15. Depress the brake pedal several times to make sure the brakes work, then test-drive.

Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been
replaced as a set. Several applications of the brake will restore the normal pedal stroke.
16. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.

INSPECTION
Runout
1. Loosen the front wheel nuts slightly, then raise the vehicle and make sure it is securely supported.
Remove the front wheels.
2. Remove the brake pads (see page BR-27).
3. Inspect the disc surface for damage and cracks.
Clean the disc thoroughly and remove all rust.
4. Use wheel nuts and suitable flat washers (A) to hold the disc securely against the hub, then mount a dial
indicator as shown, and measure the runout at 10 mm (0.4 in.) from the outer edge of the disc.

Brake disc runout:

0.10 mm (0.004 in.)

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5. If the disc is beyond the service limit, refinish the brake disc with an on-car brake lathe.

22.4 mm (0.882 in.)

• If the brake disc is beyond the service limit for refinishing, replace it (see page BR-27).
• A new disc should be refinished if its runout is greater than 0.10 mm (0.004 in.).

Thickness and parallelism

1. Loosen the front wheel nuts slightly, then raise the vehicle and make sure it is securely supported.
Remove the front wheels.
2. Remove the brake pads (see page BR-27)
3. Using measure disc thickness at eight points, approximately 45° apart and 10 mm (0.4 in.) in from the outer
edge of the disc. Replace the brake disc of the smallest measurement is less than the max. refinishing limit.

Brake disc thickness:

24 mm (0.945 in.)
22.4 mm (0.882 in.)
Max. 0.015 mm (0.0006 in.)

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This is the maximum allowable difference between the thickness measurements.

4. If the disc is beyond the service limit for parallelism, refinish the brake disc with an on-car brake lathe.

If the brake disc is beyond the service limit for refinishing, replace it (see DS group-front axle).

REPLACEMENT

Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
• Avoid breathing dust particles.
• Never use on air hose or brush to clean brake assemblies.
1. Loosen the front wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported.
Remove the front wheels.
2. Remove the brake hose mounting bolts (A) from the knuckle.

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[Link]

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3. Remove guide rod (B) and the caliper (C) up out of the way. Check the hoses and pin boots for damage and
deterioration.
4. Remove the pad shims (A), pad retainers (B) and pads (C).

5. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include
pad backing plate (A) thickness.

Brake pad thickness:

11mm (0.43 in.)
2mm (0.079 in.)

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6. If the brake pad thickness is less than service limit, replace the front pads as a set.
7. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
8. Check the brake disc for damage and cracks.
9. Install the pad retainers (A).

10. Check the foreign material at the pad shims (A) and the back of the pads (B).
Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.

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11. Install the brake pads (B) and pad shims (A) correctly. Install the pad with the wear indicator (C) on the inside.
If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary
loss of braking efficiency.
12. Push in the piston (A) so that the caliper will fit over the pads. Make sure that the piston boot is in position to
prevent damaging it when pivoting the caliper down.
13. Pivot the caliper down into position. Being careful not to damage the pin boot, install the guide rod bolt (B)
and torque it to proper specification.

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Insert the piston in the cylinder using the special tool (09581-11000).

14. Install the brake hose on to the knuckle.

15. Depress the brake pedal several times to make sure the brakes work, then test-drive.

Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been
replaced as a set. Several applications of the brake will restore the normal pedal stroke.
16. After installation, check for leaks at hose and line joints or connections, and retighten if necessary.

INSPECTION
Runout
1. Loosen the front wheel nuts slightly, then raise the vehicle and make sure it is securely supported.
Remove the front wheels.
2. Remove the brake pads (see page BR-27).
3. Inspect the disc surface for damage and cracks.
Clean the disc thoroughly and remove all rust.
4. Use wheel nuts and suitable flat washers (A) to hold the disc securely against the hub, then mount a dial
indicator as shown, and measure the runout at 10 mm (0.4 in.) from the outer edge of the disc.

Brake disc runout:

0.10 mm (0.004 in.)

Email: suzlever@[Link]

[Link] (10 of 12)14/03/2009 3:01:46 PM

[Link]

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5. If the disc is beyond the service limit, refinish the brake disc with an on-car brake lathe.

22.4 mm (0.882 in.)

• If the brake disc is beyond the service limit for refinishing, replace it (see page BR-27).
• A new disc should be refinished if its runout is greater than 0.10 mm (0.004 in.).

Thickness and parallelism

1. Loosen the front wheel nuts slightly, then raise the vehicle and make sure it is securely supported.
Remove the front wheels.
2. Remove the brake pads (see page BR-27)
3. Using measure disc thickness at eight points, approximately 45° apart and 10 mm (0.4 in.) in from the outer
edge of the disc. Replace the brake disc of the smallest measurement is less than the max. refinishing limit.

Brake disc thickness:

24 mm (0.945 in.)
22.4 mm (0.882 in.)
Max. 0.015 mm (0.0006 in.)

Email: suzlever@[Link]

[Link] (11 of 12)14/03/2009 3:01:46 PM

[Link]

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This is the maximum allowable difference between the thickness measurements.

4. If the disc is beyond the service limit for parallelism, refinish the brake disc with an on-car brake lathe.

If the brake disc is beyond the service limit for refinishing, replace it (see DS group-front axle).

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COMPONENTS

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[Link] 3:05:50 PM
 Purchased
from Ebay seller
Reveleus1

Thank-you for purchasing from me, it

is much appreciated.
To contact me please email
suzlever@[Link]
[Link]

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REMOVAL
FRONT WHEEL SPEED SENSOR
1. Remove the front wheel speed sensor mounting bolt (A).

2. Remove the front wheel guard (A).

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3. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector (A).
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REAR WHEEL SPEED SENSOR

1. Remove the rear wheel speed sensor mounting bolt (A).

2. Remove the rear seat side pad then disconnect the rear wheel speed sensor connector (A).

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INSPECTION
1. Connect an ohmmeter between the wheel speed sensor terminals and measure the resistance.

Service standard
Front : 1275 ~ 1495
Rear : 1275 ~ 1495

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2. Connect a voltmeter between the wheel speed sensor terminals and measure the voltage by turning the wheel.
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Set the voltmeter to measure AC voltage.

Service standard: AC voltage detected.

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PRECAUTION
• Care must be taken to replace each part properly as it could affect the performance of the brake system and
result in a driving hazard. Replace the parts with parts of the same part number or equivalent.
• It is very important to keep parts and the area clean when repairing the brake system.

PRECAUTION
• Care must be taken to replace each part properly as it could affect the performance of the brake system and
result in a driving hazard. Replace the parts with parts of the same part number or equivalent.
• It is very important to keep parts and the area clean when repairing the brake system.

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COMPONENTS

COMPONENTS

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[Link]

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Replacement

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.
1. Remove the air cleaner cover (A), air filter (B), air cleaner mounting bolts (C) and air cleaner body (D) from the
air cleaner mounting bracket (E).

2. Disconnect the brake fluid level switch connectors(A), and remove the reservoir cap(B).

3. Remove the brake fluid from the master cylinder reservoir(C) with a syringe.

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4. Disconnect the brake lines(A) from the master cylinder. To prevent spills, cover the hose joints with rags or
Ebay User ID: reveleus1
shop towels.

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

6. Remove the master cylinder(C) from the brake booster(D). Be careful not to bend or damage the brake lines
when removing the master cylinder.
7. Install the master cylinder in the reverse order of removal, and note these items:
[Link] all rubber parts with new ones whenever, removed.

INSPECTION

• Before reassembling, check that all parts are free of dust and other foreign particles.
• Do not try to disassemble the master cylinder assembly. Replace the master cylinder assembly with a new
part if necessary.
• Do not allow dirt or foreign matter to contaminate the brake fluid.

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[Link]

Ebay User ID: reveleus1

Replacement

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.
1. Remove the air cleaner cover (A), air filter (B), air cleaner mounting bolts (C) and air cleaner body (D) from the
air cleaner mounting bracket (E).

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[Link]

2. Disconnect the brake fluid level switch connectors(A), and remove the reservoir cap(B).
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3. Remove the brake fluid from the master cylinder reservoir(C) with a syringe.
4. Disconnect the brake lines(A) from the master cylinder. To prevent spills, cover the hose joints with rags or
shop towels.

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

6. Remove the master cylinder(C) from the brake booster(D). Be careful not to bend or damage the brake lines
when removing the master cylinder.
7. Install the master cylinder in the reverse order of removal, and note these items:
[Link] all rubber parts with new ones whenever, removed.

INSPECTION

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Ebay User ID: reveleus1

• Before reassembling, check that all parts are free of dust and other foreign particles.
• Do not try to disassemble the master cylinder assembly. Replace the master cylinder assembly with a new
part if necessary.
• Do not allow dirt or foreign matter to contaminate the brake fluid.

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COMPONENTS

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[Link] (1 of 2)14/03/2009 3:03:14 PM

[Link]

COMPONENTS Ebay User ID: reveleus1

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REMOVAL

• The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature
failure.
• Refer to the component as needed during this procedure.

Rear disc brake

1. Release the parking brake lever fully, and remove the parking cable clip (A) from the parking brake cable.

2. Disconnect the parking brake cable (B) from the lever (C).

Rear drum brake

1. Remove the brake shoe assembly (see page BR-39).
2. Remove the parking brake cable retaining (B), from the parking brake cable (A).

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3. Remove the parking brake cable (A) from the backing plate (B).

REMOVAL

• The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature
failure.
• Refer to the component as needed during this procedure.

Rear disc brake

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[Link]

1. Release the parking brake lever fully, and remove the parking cable clip (A) from the parking brake cable.
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2. Disconnect the parking brake cable (B) from the lever (C).

Rear drum brake

1. Remove the brake shoe assembly (see page BR-39).
2. Remove the parking brake cable retaining (B), from the parking brake cable (A).

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3. Remove the parking brake cable (A) from the backing plate (B).
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Email: suzlever@[Link]

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Ebay User ID: reveleus1

COMPONENT

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Ebay User ID: reveleus1

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Ebay User ID: reveleus1

General information

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.

Remove, disassemble, inspect, reassemble, and install the caliper and note these items:
• Do not spill brake fluid on the vehicle; it may damage the paint; If brake fluid gets on the paint, wash it off
immediately with water.
• Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
• Before reassembling, check that all parts are free of dirt and other foreign particles.
• Replace parts with new ones as specified in the illustration.
• Make sure no dirt or other foreign matter gets into the brake fluid.
• Make sure no grease or oil gets on the brake discs or pads.
• When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency.
• Do not reuse drained brake fluid.
• Always use Genuine DOT 3 or DOT 4 brake fluid. Non Genuine DOT 3 or DOT 4 brake fluid cause corrosion
and shorten the life of the system.
• Coat the piston, piston seal groove, and caliper bore with clean brake fluid.
• Replace all rubber parts with new ones.
• After installing the caliper, check the brake hose and line for leaks, interference, interference, and twisting.

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REPLACEMENT

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.

1. Raise the rear of the vehicle and make sure it is securely supported. Remove the rear wheel.
2. Release the parking brake.
3. Remove the brake hose (A) from the suspension arm by removing the brake hose clip (B).
Thoroughly clean the outside of the caliper to prevent dust and dirt from entering inside.
Support the caliper with a piece of wire so that it does not hang from the brake hose.

4. Remove the two guide rods (C) and caliper (D) from the bracket.
5. Remove the pad shim (A) and brake pads (B).

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6. Using vernier calipers, measure the thickness of each brake pad lining. Measurement does not include pad
backing plate (A) thickness.

Brake pad thickness:

9 mm (0.35 in.)
2 mm (0.08 in.)

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7. Remove the pad retainers.

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8. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
9. Check the brake disc for damage and cracks.
10. Install the pad retainers.
11. Check the foreign material at the pad shim (A) and the back of the pads (B).
Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.

12. Install the brake pads (B) and pad shim (A) on the caliper bracket. Install the inner pad with its wear indicator
(C) facing down ward.
If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary
loss of braking efficiency.

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13. Rotate the caliper piston (A) clockwise into the cylinder, the align the cutout (B) in the piston with the tab (C)
Ebay User ID: reveleus1
on the inner pad by turning the piston back. Lubricate the boot with rubber grease to avoid twisting the piston
boot. If the piston boot is twisted, back it out so it is positioned properly.

14. Install the brake caliper (D).

15. Install and torque the guide rods (E) to proper specification.
16. Install the brake hose (F) onto the suspension arm with the brake hose clip (G).
17. After installation, check for leaks at hose and line joints and connections, and retighten if necessary.
18. Depress the brake pedal several times to make sure the brakes work, then test-drive.

Engagement of the brake may require a greater pedal stroke immediately after the brake pads have been
replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke.

INSPECTION
Runout
1. Raise the rear or the vehicle, and make sure it is securely supported.
2. Remove the brake pads (see page BR-33).
3. Inspect the disc surface for damage and cracks clean the disc thoroughly and remove all rust.

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4. Use wheel nuts and suitable flat washers (A) to hold the disc securely against the hub, then mount a dial
Ebay User ID: reveleus1
indicator (B) as shown, and measure the runout at 10 mm (0.4 in.) from the outer edge of the disc.

5. If the disc is beyond the service limit, refinish the brake disc.

8.0 mm (0.315 in.)

A new disc should be refinished if its runout is greater than 0.10 mm (0.004 in.)

Thickness and parallelism

1. Loosen the rear wheel nuts slightly, then raise the vehicle, and make sure it is securely supported.
Remove the rear wheels.
2. Remove the brak pads (see page BR-33).
3. Using a micrometer (A), measure disc thickness at eight points, approximately 45 apart and 10 mm (0.4 in.) in
from the outer edge of the disc. Replace the brake disc if the smallest measurement is less than the max.
refinishing limit.

Brake disc thickness:

10 mm (0.4 in.)
8.0 mm (0.315 in.)
Max. 0.015 mm (0.0006 in.)

This is the maximum allowable difference between the thickness measurements.

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4. If the disc is beyond the service limit for parallelism, refinish the brake disc.

If the brake disc is beyond the service limit for refinishing, replace it (see DS group-rear axle).

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COMPONENTS

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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.
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 (see page BR-39).
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 doe not include brake shoe thickness.

Brake lining thickness:

4.5 mm (0.177 in.)
1.0 mm (0.039 in.)

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.

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8. Measure the inside diameter of the brake drum with inside vernier [Link] inside diameter:
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Drum inside diameter:

203.2 mm (8 in.)
205.2 mm (8.079 in.)

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.

REPLACEMENT
Rear brake shoes

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 bean brake assemblies.
1. Disengage the upper return spring (A).

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2. Remove the shoe hole down pins (B) by pushing the shoe hole down washer (C) and turning them.
3. 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.

4. Disconnect the parking brake cable from the parking brake lever.
5. Remove the brake shoe assembly.
6. Remove the upper return spring (C), self-adjuster lever (D) and self-adjuster spring (E), and separate the
brake shoes.
7. Connect the parking brake cable to the parking brake lever.

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8. Clean the threaded portions of adjuster sleeve (A) and push rod female (B). Coat the threads of the adjuster
Ebay User ID: reveleus1
assembly with grease (Castrol grease K764).
To shorten the clevises, turn the adjuster bolt (C).

9. Hook the self-adjuster spring (D) to the adjuster lever first, then to the brake shoe.
10. Install the adjuster assembly and upper return spring (E), noting the installation direction. Be careful not to
damage the wheel cylinder dust covers.
11. Install the lower return spring (F).
12. Apply brake cylinder grease or equivalent rubber grease to the sliding surfaces shown. Wipe off any excess,
Don't get grease on the brake linings.

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13. Apply Nyogel 744MS to the brake shoe ends and opposite edges of the shoes shown. Wipe off any excess.
Ebay User ID: reveleus1
Don't get grease on the brake linings.

14. Install the brake shoes (A) onto the backing plate.
Be careful not to damage the wheel cylinder dust covers.

15. Install the shoe hole down pins (B) and the shoe hole down washers (C).
16. Hook the upper return spring (D).
17. Install the brake drum.
18. If the wheel cylinder has been removed, bleed the brake system (see page BR-12).
19. Depress the brake pedal several times to set the self-adjusting brake.
20. Adjust the parking brake (see page BR-11).

Rear wheel cylinder

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• 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.
1. Remove the brake shoes (see page BR-39).
2. Disconnect the brake line (A) from the wheel cylinder (B).

3. Remove the bolt (C) and the wheel cylinder from the backing plate.
4. Apply sealant (E) between the wheel cylinder (B) and backing plate (D), and install the wheel cylinder.
5. Install the removed parts in the reverse order of removal.
6. Fill the brake reservoir up and, bleed the brake system (see page BR-12)
7. After installation, check for a leak at the line joint, and retighten if necessary.

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Brake Pedal and Brake Switch Adjustment

Pedal Height
[Link] the brake switch connector, loosen the brake switch locknut (A), and back off the brake switch (B)
until it is no longer touching the brake pedal.
[Link] up the carpet. At the insulator cutout, measure the pedal height (C) from the middle of the left-side center
of the pedal pad (D).

135 mm (5.31 in.)

[Link] the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height
from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the
pushrod depressed.

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BRAKE SWITCH CLEARANCE

Ebay User ID: reveleus1

Pedal Free Play

[Link] the engine off, inspect the pedal free play (A) on the pedal pad (B) by pushing the pedal by hand.

3~8 mm (0.11~0.31in.)

[Link] the pedal free play is out of specification, adjust the brake switch (C). If the pedal free play is insufficient, it
may result in brake drag.

Parking brake check and adjustment

Check

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[Link] the parking brake lever (A) with 196 N (20Ebay

kgf,User
44lbf) force to fully apply the parking brake. The parking
ID: reveleus1
brake lever should be locked within the specified number of clicks (B)

Lever locked clicks:

Vehicle with rear disc brakes: 8~9
Vehicle with rear drum brakes: 8

[Link] the parking brake if the lever clicks are out of specification.
ADJUSTMENT

After rear brake caliper servicing, loosen the parking brake adjusting nut, start the engine and depress the
brake pedal several times to set the self-adjusting brake before adjusting the parking brake.
[Link] the front wheels, then raise the rear of the vehicle and make sure it is securely supported.
[Link] sure the parking brake arm (A) on the rear brake caliper contacts the brake caliper pin (B).

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Ebay User ID: reveleus1

[Link] the parking brake lever up one click.

[Link] the console (See page BD).

[Link] the adjusting nut (A) until the parking brakes drag slightly when the rear wheels are turned.

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Ebay User ID: reveleus1

[Link] the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are
turned. Readjust if necessary.
[Link] sure that the parking brakes are fully applied when the parking brake lever is pulled up fully.
[Link] the console.

Brake System Bleeding

• Do not reuse the drained fluid.

• Always use Genuine DOT 3 or DOT 4 Brake Fluid. Using a non-Genuine DOT3 or DOT 4 brake fluid can
cause corrosion and decrease the life of the system.
• Make sure no dirt of 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 level in the reservoir is at the MAX (upper) level line (A).

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Ebay User ID: reveleus1

2. Have someone slowly pump the brake pedal several times, then apply steady pressure.
3. Loosen the right-rear brake bleed screw to allow air to escape from the system. Then tighten the bleed screw
securely.
4. Repeat the procedure for each wheel in the sequence shown below until air bubbles no longer appear in the
fluid.
5. Refill the master cylinder reservoir to the MAX (upper) level line.

Front disc brake:

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Ebay User ID: reveleus1

Rear disc brake:

Rear drum brake:

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Parking Brake Switch Test

1. Remove the rear console, and disconnect the connector (A) from the switch (B).

2. Check for continuity between the positive terminal and body ground:
[Link] the brake lever up, there should be continuity.
[Link] the brake lever down, there should be no continuity.

Brake Pedal and Brake Switch Adjustment

Pedal Height
[Link] the brake switch connector, loosen the brake switch locknut (A), and back off the brake switch (B)
until it is no longer touching the brake pedal.

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[Link] up the carpet. At the insulator cutout, measure the pedal height (C) from the middle of the left-side center
Ebay User ID: reveleus1
of the pedal pad (D).

135 mm (5.31 in.)

[Link] the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height
from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the
pushrod depressed.

BRAKE SWITCH CLEARANCE

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Pedal Free Play

[Link] the engine off, inspect the pedal free play (A) on the pedal pad (B) by pushing the pedal by hand.

3~8 mm (0.11~0.31in.)

[Link] the pedal free play is out of specification, adjust the brake switch (C). If the pedal free play is insufficient, it
may result in brake drag.

Parking brake check and adjustment

Check

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[Link] the parking brake lever (A) with 196 N (20Ebay

kgf,User
44lbf) force to fully apply the parking brake. The parking
ID: reveleus1
brake lever should be locked within the specified number of clicks (B)

Lever locked clicks:

Vehicle with rear disc brakes: 8~9
Vehicle with rear drum brakes: 8

[Link] the parking brake if the lever clicks are out of specification.
ADJUSTMENT

After rear brake caliper servicing, loosen the parking brake adjusting nut, start the engine and depress the
brake pedal several times to set the self-adjusting brake before adjusting the parking brake.
[Link] the front wheels, then raise the rear of the vehicle and make sure it is securely supported.
[Link] sure the parking brake arm (A) on the rear brake caliper contacts the brake caliper pin (B).

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Ebay User ID: reveleus1

[Link] the parking brake lever up one click.

[Link] the console (See page BD).

[Link] the adjusting nut (A) until the parking brakes drag slightly when the rear wheels are turned.

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 Purchased
from Ebay seller
Reveleus1

Thank-you for purchasing from me, it

is much appreciated.
To contact me please email
suzlever@[Link]
[Link]

Ebay User ID: reveleus1

[Link] the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are
turned. Readjust if necessary.
[Link] sure that the parking brakes are fully applied when the parking brake lever is pulled up fully.
[Link] the console.

Brake System Bleeding

• Do not reuse the drained fluid.

• Always use Genuine DOT 3 or DOT 4 Brake Fluid. Using a non-Genuine DOT3 or DOT 4 brake fluid can
cause corrosion and decrease the life of the system.
• Make sure no dirt of 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 level in the reservoir is at the MAX (upper) level line (A).

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Ebay User ID: reveleus1

2. Have someone slowly pump the brake pedal several times, then apply steady pressure.
3. Loosen the right-rear brake bleed screw to allow air to escape from the system. Then tighten the bleed screw
securely.
4. Repeat the procedure for each wheel in the sequence shown below until air bubbles no longer appear in the
fluid.
5. Refill the master cylinder reservoir to the MAX (upper) level line.

Front disc brake:

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Ebay User ID: reveleus1

Rear disc brake:

Rear drum brake:

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Ebay User ID: reveleus1

Parking Brake Switch Test

1. Remove the rear console, and disconnect the connector (A) from the switch (B).

2. Check for continuity between the positive terminal and body ground:
[Link] the brake lever up, there should be continuity.
[Link] the brake lever down, there should be no continuity.

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Ebay User ID: reveleus1

SPECIAL TOOLS
Tool (Number and Name) Illustration Use

06581-11000 Spreading the front brake piston

Piston expander

09580-34000 Removal and installation of the

Rear brake piston adjuster rear brake piston

SPECIAL TOOLS
Tool (Number and Name) Illustration Use

06581-11000 Spreading the front brake piston

Piston expander

09580-34000 Removal and installation of the

Rear brake piston adjuster rear brake piston

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Ebay User ID: reveleus1

SPECIFICATIONS
Item Specification

Master cylinder Tandem type

• Type 23.81 (0.937)
• I.D. mm(in.) Provided
• Fluid level warning sensor

Brake booster Vacuum

• Type Tandem type with 7+8 in.
• Effective dia. mm(in.) 7.5 : 1
• Boosting ratio

Proportioning valve 4 DR 5 DR
• Cut-in pressure(Split point) 26 Kgf/cm² 40 Kgf/cm²
• Decompression ratio 0.27 : 1 0.32 : 1

Front brake(Disc) Floating type with ventilated disc

• Type 257 mm (10.12 in.)
• Disc O.D. 24 mm (0.94 in.)
• Disc thickness 11 mm (0.43 in.)
54 mm (2.13 in.)
• Pad thickness
• Cylinder I.D.

Rear brake(Disc) Floating type with solid disc

• Type 258 mm (10.16 in.)
• Disc O.D. 10 mm (0.39 in.)
• Disc thickness 9 mm (0.35 in.)
33.96 mm (1.34 in.)
• Pad thickness
• Cylinder I.D.

Rear brake(Drum) Leading trailing drum

• Type 203.2 mm (8 in.)
• Drum I.D. 5.2 mm (0.2 in.)
• Drum thickness 5.14 mm (0.2 in.)
Automatic
• Brake lining thickness
• Clearance adjustment

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Parking brake Mechanical

Ebay User ID:brake acting on rear wheels
reveleus1
• Actuation Lever
• Type V type
• Cable arrangement

O.D = Outer Diameter

I.D = Inner Diameter

SERVICE STANDARD
Standard value Service limit

Brake pedal height 135 mm (5.31 in.)

Brake pedal stroke 128 mm +5, 0 (5.04 in. +0.2, 0)

Stop lamp switch outer case to pedal

0.5~1.0 mm (0.02~0.04 in.)
stopper clearance

Brake pedal free play 3~8 mm (0.11~0.31 in.)

Brake pedal to floorboard clearance 61 mm (2.40 in.) or more

Booster push rod to master cylinder

0 (at 500 mmHg vacuum)
piston clearance

Parking brake lever stroke when lever

8~9 clicks: Rear Disc type
assembly is pulled with 196N (20Kg,
8 clicks: Rear Drum type
44lb force)

Front disc brake pad thickness 11 mm (0.43 in.) 2 mm (0.079 in.)

Front disc thickness (minimum) 24 mm (0.945 in.) 22.4 mm (0.882 in.)

Front disc runout 0.1 mm (0.004 in.)

Front disc parallelism 0.015 mm (0.0006 in.)

Rear drum brake lining thickness 4.5 mm (0.177 in.) 1.0 mm (0.039 in.)

Rear drum brake drum I.D. (maximum) 203.2 mm (8 in.) 205.2 mm (8.079 in.)

Rear disc brake pad thickness 9 mm (0.354 in.) 2 mm (0.079 in.)

Rear disc brake disc thickness 10 mm (0.4 in.) 8 mm (0.315 in.)

Rear disc runout 0.1 mm (0.004 in.)

Rear disc parallelism 0.015 mm (0.0006 in.)

TIGHTENING TORQUE
Nm Kgf·cm lbf·ft

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Master cylinder to booster mounting nut 8~12

Ebay User ID: reveleus1 80~120 5.9~8.9

Brake booster mounting nut 13~16 130~160 9.6~11.8

Brake booster vacuum hose fitting to surge tank 15~18 150~180 11.1~13.3

Bleeder screw 7~13 70~130 5.2~9.6

Brake tube nut, brake hose 13~17 130~170 9.6~12.5

Caliper guide rod bolt 22~32 220~320 16.2~23.6

Caliper pin bolt 35~45 350~450 25.8~33.2

Caliper assembly to knuckle 69~85 690~850 50.9~62.7

Brake hose to front caliper 25~30 250~300 18.4~22.1

Brake hub flange nut 200~260 2000~2600 147.5~191.8

Wheel cylinder mounting bolt 5~11 50~110 3.7~8.1

Replace self-locking nuts with new ones after removal.

SPECIFICATIONS
Item Specification

Master cylinder Tandem type

• Type 23.81 (0.937)
• I.D. mm(in.) Provided
• Fluid level warning sensor

Brake booster Vacuum

• Type Tandem type with 7+8 in.
• Effective dia. mm(in.) 7.5 : 1
• Boosting ratio

Proportioning valve 4 DR 5 DR
• Cut-in pressure(Split point) 26 Kgf/cm² 40 Kgf/cm²
• Decompression ratio 0.27 : 1 0.32 : 1

Front brake(Disc) Floating type with ventilated disc

• Type 257 mm (10.12 in.)
• Disc O.D. 24 mm (0.94 in.)
• Disc thickness 11 mm (0.43 in.)
54 mm (2.13 in.)
• Pad thickness
• Cylinder I.D.

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Rear brake(Disc) Floating type

Ebay User with solid disc
ID: reveleus1
• Type 258 mm (10.16 in.)
• Disc O.D. 10 mm (0.39 in.)
• Disc thickness 9 mm (0.35 in.)
33.96 mm (1.34 in.)
• Pad thickness
• Cylinder I.D.

Rear brake(Drum) Leading trailing drum

• Type 203.2 mm (8 in.)
• Drum I.D. 5.2 mm (0.2 in.)
• Drum thickness 5.14 mm (0.2 in.)
Automatic
• Brake lining thickness
• Clearance adjustment

Parking brake Mechanical brake acting on rear wheels

• Actuation Lever
• Type V type
• Cable arrangement

O.D = Outer Diameter

I.D = Inner Diameter

SERVICE STANDARD
Standard value Service limit

Brake pedal height 135 mm (5.31 in.)

Brake pedal stroke 128 mm +5, 0 (5.04 in. +0.2, 0)

Stop lamp switch outer case to pedal

0.5~1.0 mm (0.02~0.04 in.)
stopper clearance

Brake pedal free play 3~8 mm (0.11~0.31 in.)

Brake pedal to floorboard clearance 61 mm (2.40 in.) or more

Booster push rod to master cylinder

0 (at 500 mmHg vacuum)
piston clearance

Parking brake lever stroke when lever

8~9 clicks: Rear Disc type
assembly is pulled with 196N (20Kg,
8 clicks: Rear Drum type
44lb force)

Front disc brake pad thickness 11 mm (0.43 in.) 2 mm (0.079 in.)

Front disc thickness (minimum) 24 mm (0.945 in.) 22.4 mm (0.882 in.)

Front disc runout 0.1 mm (0.004 in.)

Email: suzlever@[Link]

[Link] (4 of 5)14/03/2009 2:59:02 PM

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Front disc parallelism Ebay User ID: reveleus1 0.015 mm (0.0006 in.)

Rear drum brake lining thickness 4.5 mm (0.177 in.) 1.0 mm (0.039 in.)

Rear drum brake drum I.D. (maximum) 203.2 mm (8 in.) 205.2 mm (8.079 in.)

Rear disc brake pad thickness 9 mm (0.354 in.) 2 mm (0.079 in.)

Rear disc brake disc thickness 10 mm (0.4 in.) 8 mm (0.315 in.)

Rear disc runout 0.1 mm (0.004 in.)

Rear disc parallelism 0.015 mm (0.0006 in.)

TIGHTENING TORQUE
Nm Kgf·cm lbf·ft

Master cylinder to booster mounting nut 8~12 80~120 5.9~8.9

Brake booster mounting nut 13~16 130~160 9.6~11.8

Brake booster vacuum hose fitting to surge tank 15~18 150~180 11.1~13.3

Bleeder screw 7~13 70~130 5.2~9.6

Brake tube nut, brake hose 13~17 130~170 9.6~12.5

Caliper guide rod bolt 22~32 220~320 16.2~23.6

Caliper pin bolt 35~45 350~450 25.8~33.2

Caliper assembly to knuckle 69~85 690~850 50.9~62.7

Brake hose to front caliper 25~30 250~300 18.4~22.1

Brake hub flange nut 200~260 2000~2600 147.5~191.8

Wheel cylinder mounting bolt 5~11 50~110 3.7~8.1

Replace self-locking nuts with new ones after removal.

Email: suzlever@[Link]

[Link] (5 of 5)14/03/2009 2:59:02 PM

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Ebay User ID: reveleus1

TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Symptom Suspect Area See page

Lower pedal or spongy pedal [Link] system (Fluid leaks) BR-17

[Link] system (Air in) BR-12
[Link] seals (Worn or damaged) BR-26, 32
[Link] cylinder (Faulty) BR-19

Brake drag [Link] pedal freeplay (Minimal)

BR-10
[Link] brake lever travel (Out of adjustment) BR-11
[Link] brake wire (Sticking) BR-42
[Link] or lining (Cracked or distorted) BR-27,33,39
[Link] (Stuck) BR-26,32
[Link] (Frozen) BR-26,32
[Link] spring (Faulty) BR-37
[Link] system (Vacuum leaks) BR-24
BR-19
[Link] cylinder (Faulty)

Brake pull [Link] or lining (Oily) BR-27,33,39

[Link] (Frozen) BR-26,32
[Link] (Scored) BR-25,31
[Link] or lining (Cracked or distorted) BR-27,33,39

Hard pedal but brake inefficient [Link] system (Fluid leaks)

BR-17
[Link] system (Air in) BR-12
[Link] or lining (Worn) BR-27,33,39
[Link] or lining (Cracked or distorted) BR-27,33,39
[Link] or lining (Oily) BR-27,33,39
[Link] or lining (Glazed) BR-27,33,39
[Link] (Scored) BR-25,31
BR-24
[Link] system (Vacuum leaks)

Email: suzlever@[Link]

[Link] (1 of 3)14/03/2009 2:58:36 PM

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Noise from brake [Link] or lining (Cracked

Ebay or distorted)
User ID: reveleus1
BR-27,33,39
[Link] bolt (Loosen)
BR-25,31
[Link] (Scored) BR-25,31
[Link] retainers (Loosen) BR-25,31
[Link] pin (Worn) BR-25,31
[Link] or lining (Dirty) BR-27,33,39
[Link] or lining (Glazed) BR-27,33,39
[Link] spring (Faulty) BR-37
BR-25,31
[Link] pad shim (Damage)
BR-37
[Link] hold-down spring (Damage)

TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Symptom Suspect Area See page

Lower pedal or spongy pedal [Link] system (Fluid leaks) BR-17

[Link] system (Air in) BR-12
[Link] seals (Worn or damaged) BR-26, 32
[Link] cylinder (Faulty) BR-19

Brake drag [Link] pedal freeplay (Minimal)

BR-10
[Link] brake lever travel (Out of adjustment) BR-11
[Link] brake wire (Sticking) BR-42
[Link] or lining (Cracked or distorted) BR-27,33,39
[Link] (Stuck) BR-26,32
[Link] (Frozen) BR-26,32
[Link] spring (Faulty) BR-37
[Link] system (Vacuum leaks) BR-24
BR-19
[Link] cylinder (Faulty)

Brake pull [Link] or lining (Oily) BR-27,33,39

[Link] (Frozen) BR-26,32
[Link] (Scored) BR-25,31
[Link] or lining (Cracked or distorted) BR-27,33,39

Email: suzlever@[Link]

[Link] (2 of 3)14/03/2009 2:58:36 PM

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Hard pedal but brake inefficient [Link] system

Ebay (Fluid
User ID:leaks)
reveleus1
BR-17
[Link] system (Air in) BR-12
[Link] or lining (Worn) BR-27,33,39
[Link] or lining (Cracked or distorted) BR-27,33,39
[Link] or lining (Oily) BR-27,33,39
[Link] or lining (Glazed) BR-27,33,39
[Link] (Scored) BR-25,31
BR-24
[Link] system (Vacuum leaks)

Noise from brake [Link] or lining (Cracked or distorted)

BR-27,33,39
[Link] bolt (Loosen)
BR-25,31
[Link] (Scored) BR-25,31
[Link] retainers (Loosen) BR-25,31
[Link] pin (Worn) BR-25,31
[Link] or lining (Dirty) BR-27,33,39
[Link] or lining (Glazed) BR-27,33,39
[Link] spring (Faulty) BR-37
BR-25,31
[Link] pad shim (Damage)
BR-37
[Link] hold-down spring (Damage)

Email: suzlever@[Link]

[Link] (3 of 3)14/03/2009 2:58:36 PM