Hyundai Elantra AD: Brake System

Sixth generation (AD; 2017–2020) / Hyundai Elantra AD 2017-2020 Service Manual / Brake System / Brake System

Repair procedures

Operation and Leakage Check

Check all of the following items:

Component

Procedure

Brake Booster (A)

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

Piston cup and pressure
cup inspection (B)

•	Check brake operation by applying the brakes. Look for damage or signs of fluid 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
piston boots (D)

Check brake operation by applying the brakes.
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.

Brake System Bleeding

•	Do not reuse the drained fluid.

•	Always use genuine DOT3/DOT4 brake Fluid. Using a non-genuine DOT3/DOT4 brake fluid can cause corrosion and decrease the life of the system.

•	Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.

•	Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

•	The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding procedure and checked after bleeding each brake caliper. Add fluid as required.

1.	Make sure the brake fluid in the reservoir is at the MAX(upper) level line.

2.	Have someone slowly pump the brake pedal several times, and then apply pressure.

3.	Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw securely. [Front] [Rear Disc Brake] [Rear Drum Brake]

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

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

Brake Booster Components and Components Location

Components

1. Reservoir cap
2. Reservoir
3. Booster

4. Master cylinder
5. Booster pressure sensor

Brake Booster Repair procedures

Brake Booster Operating Test

For simple checking of the brake booster operation, carry out the following tests.

1.	Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the booster is inoperative.

2.	With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is inoperative.

With the engine running, step on the brake pedal and then stop the engine.Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if the pedal rises, the booster is inoperative.

If the above three tests are okay, the booster performance can be determined as good.

Even if one of the above three tests is not okay, check the check valve, vacuum hose and booster for malfunction.

Removal

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Remove the battery. (Refer to Engine Electrical System - "Battery")

3.	Remove the ECM (A).

4.	Loosen the mounting bolts (A) and then remova the ECM bracket (B).

5.	Disconnect the brake fluid level switch connector.

6.	Remove the vacuum hose (A).

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

•	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.

8.	Remove the master cylinder. (Refer to Brake System -" Master Cylinder")

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

10.

Remove the mounting nuts (A).

Tightening torque:

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

11.	Remove the brake booster.

Inspection

1.	Inspect the vacuum hose.

2.	Check the boot for damage.

Installation

To install, reverse the removal procedure.

•	Before installing the pin, apply the grease to the joint pin.

•	Use a new snap pin whenever installing.

2.	After installing, bleed the brake system. (Refer to Brake System -"Brake System Bleeding") (Refer to Brake system - "ABS System Bleeding) (Refer to Brake system - "ESP System Bleeding)

Vacuum Pump Components and Components Location

Components

[UII 1.6]

1. Camshaft bearing cap
2. Camshaft
3. Camshaft sprocket

4. Vacuum pump
5. Vacuum pump gasket

Vacuum Pump Repair procedures

Removal

1.	Remove the cylinder head cover. (Refer to Cylinder Head Assembly - "Cylinder Head Cover")

2.	Remove the timing chain. (Refer to Timing System - "Timing Chain")

Remove the vacuum pump (A).

•	Do not disassemble the vacuum pump.

4.	To install, reverse the removal procedure.

Master Cylinder Components and Components Location

Components

1.Reservoir cap
2. Reservoir
3.Reservoir

4. Grommet
5. Master cylinder

Master Cylinder Repair procedures

Removal

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Remove the battery. (Refer to Engine Electrical System - "Battery")

3.	Remove the ECM (A).

4.	Loosen the mounting bolts (A) and then remova the ECM bracket (B).

5.	Disconnect the brake fluid level switch connector.

6.	Remove the wiring fixed clip.

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

•	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.

8.	Remove the clutch brake hose (A). [M/T Only]

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

Tightening torque:

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

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

10.

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

Tightening torque:

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

11.	Separate the reservoir by loosening the screw.

Installation

1.	To install, reverse the removal procedure.

2.	After installing, bleed the brake system. (Refer to Brake System -"Brake System Bleeding") (Refer to Brake system - "ABS System Bleeding) (Refer to Brake system - "ESP System Bleeding)

Brake Line Components and Components Location

Components

[DISC TYPE]

[DRUM TYPE]

Brake Line Repair procedures

Removal

1.	Disconnect the negative (-) battery cable.

2.	Disconnect the brake fluid level switch connector.

Remove the brake fluid from the master cylinder reservior with a syringe.

•	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.

4.	Remove the wheel & tire.

5.	Remove the brake hose clip (A).

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

Tightening torque:

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

[Front]

[Rear]

Disconnect the brake hose by loosening the bolt (A)&(B).

Tightening torque:

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

[Front]

[Rear disc]

[Rear drum]

Remove the brake hose bracket by loosening the bolt(A). [Drum brake only]

Tightening torque :

18.6 ~ 25.5 N.m (1.9 ~ 2.6 kgf.m, 13.7 ~ 18.8 lb-ft)

Inspection

1.	Check the brake tubes for cracks, crimps and corrosion.

2.	Check the brake hoses for cracks, damage and fluid leakage.

3.	Check the brake tube flare nuts for damage and fluid leakage.

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

Installation

To install, reverse the removal procedure.

•	Use a new washer (A) whenever installing.

2.	After installing, bleed the brake system. (Refer to Brake System -"Brake System Bleeding") (Refer to Brake system - "ABS System Bleeding) (Refer to Brake system - "ESP System Bleeding)

3.	Check the spilled brake oil.

Brake Pedal Components and Components Location

Components

1. Stop lamp switch
2. Brake pedal member assembly
3. Return spring

4. Bolt
5. Brake pedal arm assembly

Brake Pedal Repair procedures

Removal

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Remove the crash pad lower panel. (Refer to Body - "Crash Pad")

3.	Disconnect the stop lamp switch connector (A).

4.	Remove the wiring fixed clip from the brake pedal member.

Remove the bracket mounting nut (A).

Tightening torque:

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

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

Remove the mounting nuts (A).

Tightening torque:

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

8.	To install, reverse the removal procedure.

Inspection

1.	Check the brake pedal for bending or twisting.

2.	Check the brake pedal return spring for damage.

3.	Check the stop lamp switch.

Front Disc Brake Components and Components Location

Components

1. Caliper body
2. Bleed screw
3. Pad return spring
4. Brake pad

5. Caliper carrier
6. Pad inner shim
7. Pad retainer

Front Disc Brake Repair procedures

Removal

1.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

Remove the front wheel and tire (A) from front hub .

Tightening torque:

107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)

•	Be careful not to damage the hub bolts when removing the front wheel and tire (A).

Loosen the brake hose mounting bolt and then remove the brake hose bracket.

Tightening torque:

8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

put down the caliper body by loosening the guided rod bolt.

Tightening torque:

2.2 ~ 3.2 kgf.m

Remove the pad return spring (A).

•	Pad return springs must be replaced with new ones whenever pads are replaced.

•	Technicians should be careful not to deform pad return springs.

•	When pad return springs are deformed, it may cause improper braking, more fuel consumption.

6.	Remove the brake pad.

Separate the pad retainer. And remove the caliper carrier by loosening the caliper mounting bolts.

Tightening torque:

78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)

Remove the front brake disc by loosening the screws (A).

Tightening torque:

4.9 ~ 5.9 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)

Replacement

Loosen the brake hose mounting bolt and then remove the brake hose bracket.

Tightening torque:

8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

put down the caliper body by loosening the guided rod bolt.

Tightening torque:

2.2 ~ 3.2 kgf.m

Remove the pad return spring(A).

•	Pad return springs must be replaced with new ones whenever pads are replaced.

•	Technicians should be careful not to deform pad return springs.

•	When pad return springs are deformed, it may cause improper braking, more fuel consumption.

4.	Replace the brake pad with a new one.

Install the pad return spring(A).

•	Pad return springs must be replaced with new ones whenever pads are replaced.

•	Technicians should be careful not to deform pad return springs.

•	When pad return springs are deformed, it may cause improper braking, more fuel consumption.

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

•	Connect an air hose(B) to the SST after confirming that the valve of the SST is surely closed.

•	Input the SST in the caliper and press the caliper piston while opening the valve of the SST slowly couter clock wise.

•	Close the valve (A) of the SST and disconnect the air hose (B); then, open the valve again to get the rest of air out and remove the SST from the caliper.

Install the caliper body(A) then tighten the guide rod bolt(B).

Tightening torque :

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

Install the brake hose mounting bolt with the brake hose bracket at the shock absorber.

Tightening torque:

8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

Inspection

Front brake disc thickness check

1.	Check the brake pads for wear and fade.

2.	Check the brake disc for damage and cracks.

Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) from the brake disc outer circle.

Front brake disc thickness

- Standard : 23 mm (0.91 in)

- Service Limit : 21.4 mm (0.84 in)

Deviation: Less than 0.005 mm (0.0002 in)

4.	If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.

Front Brake Pad Check

Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.

Pad thickness

Standard value: 11 mm (0.43 in)

Service limit: 2.0 mm (0.0787 in)

2.	Check that grease is applied, to sliding contact points and the pad and backing metal for damage.

Front brake disc runout check

Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.

Brake disc runout

Limit: 0.04 mm (0.0016 in.) or less (new one)

2.	If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.

3.	If the runout does not exceed the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc again.

4.	If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.

Installation

1.	To install, reverse the removal procedure.

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

•	Connect an air hose(B) to the SST after confirming that the valve of the SST is surely closed.

•	Input the SST in the caliper and press the caliper piston while opening the valve of the SST slowly couter clock wise.

•	Close the valve (A) of the SST and disconnect the air hose (B); then, open the valve again to get the rest of air out and remove the SST from the caliper.

3.	After installing, bleed the brake system. (Refer to Brake System -"Brake System Bleeding") (Refer to Brake system - "ABS System Bleeding") (Refer to Brake system - "ESP System Bleeding")

Rear Disc Brake Components and Components Location

Components

1. Brake pad
2. Pad return spring
3. Caliper carrier
4. Pad retainer
5. Caliper body

6. Return spring
7. Stopper
8. Operating lever
9. Bleed screw

Rear Disc Brake Repair procedures

Removal

1.	Loosen the wheel nuts slightly. Raise the vehicle, and make sure it is securely supported.

Remove the rear wheel and tire (A) from front hub .

Tightening torque:

107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)

•	Be careful not to damage the hub bolts when removing the rear wheel and tire (A).

3.	Remove the parking brake cable fixed clip(A).

4.	Pull the spanner as a below arrow in order to loosen the cable. And then remove the parking cable (A).

Loosen the guide rod bolt(B) and then pivot the caliper body (A) up out of the way.

Tightening torque:

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

6.	Remove the pad return spring (A).

7.	Separate the brake pad (A) and pad retainer (B).

Loosen the caliper mounting bolts and then removethe rear caliper assembly (A).

Tightening torque:

63.7 ~ 73.5 N.m (6.5 ~ 7.5 kgf.m, 47.0 ~ 54.2 lb-ft)

Remove the rear brake disc by loosening the screws.

Tightening torque:

4.9 ~ 5.9 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)

Replacement

Brake Pad Replacement

1.	Remove the parking brake cable fixed clip(A).

2.	Pull the spanner as a below arrow in order to loosen the cable and then remove the parking cable (A).

Loosen the guide rod bolt(B) and then pivot the caliper body (A) up out of the way.

Tightening torque:

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

4.	Remove the pad return spring (A).

5.	Replace the brake pad (A) and pad retainer.

Install the pad return spring (A).

•	Pad return springs must be replaced with new ones whenever pads are replaced.

•	Technicians should be careful not to deform pad return springs.

•	When pad return springs are deformed, it may cause improper braking, more fuel consumption.

7.	Use a SST (09580-0U000) when installing the brake caliper assembly.

Install the caliper body(A) then tighten the guide rod bolt(B).

Tightening torque :

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

9.	Pull the spanner as a below arrow in order to loosen the cable and then remove the parking cable (A).

10.	Install the parking brake cable fixed clip(A).

Inspection

Rear Brake Disc Thickness Check

1.	Check the brake pads for wear and fade.

2.	Check the brake disc for damage and cracks.

Remove all rust and contamination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) from the brake disc outer circle.

Brake disc thickness

Standard: 10 mm (0.394 in)

Service limit: 8.4 mm (0.331 in)

Deviation: less than 0.005 mm (0.0002 in)

4.	If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.

Rear Brake Pad Check

Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.

Pad thickness

Standard value: 10 mm (0.394 in)

Service limit: 2.0 mm (0.0787 in)

2.	Check the damage of pad, backing metal and contamination with grease.

Rear Brake Disc Runout Check

Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.

Brake disc runout

Limit: 0.04 mm (0.0016 in.) or less (new one)

2.	If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.

3.	If the runout exceeds the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc again.

4.	If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.

Installation

1.	To install, reverse the removal procedure.

Use a SST (09580-0U000) when installing the brake caliper assembly.

•	Wind the piston into the caliper body until it is fully retracted.

•	Do not use any power assisted tools for this task.

3.	After installing, bleed the brake system. (Refer to Brake System -"Brake System Bleeding") (Refer to Brake system - "ABS System Bleeding") (Refer to Brake system - "ESP System Bleeding")

Parking Brake Adjustment

•	Re-setting of the parking brake is necessary after overhauling the caliper body, or if the brake calipers, housing, parking brake cable or brake discs have been changed.

1.	Remove the floor console to reach the adjusting nut.

2.	Loosen the parking brake cable until both operating levers rest in fully off position.

3.	Bring the brake pads in their operating position by pressing the brake pedal down several times until there is resistance.

Tension the parking brake cable by tightening the adjusting nut, until the operating levers on both calipers lift from the stop, up to a distance of (A) and (D) between operating lever (B) and stopper (C).

Distance (A+D): Max. 3 mm (0.12 in)

5.	Refit the floor console.

6.	Parking brake lever in the car must be in fully loosened position.

7.	If the handbrake cables where changed, actuate the parking brake a few times with maximum force to stretch the parking brake cables, and then control adjusting as above.

8.	Check the wheels of their free operation.

9.	Test drive.

Rear Drum Brake Components and Components Location

Components

1. Shoe hold down pin
2. Shoe adjuster
3. Upper return spring
4. Adjusting lever

5. Shoe
6. Adjusting spring
7. Lower return spring
8. Shoe hold spring

Rear Drum Brake Repair procedures

Removal

•	Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.

•	Avoid breathing dust particles.

•	Never use an air hose or brush to clean brake assemblies.

1.	Release the parking brake.

Remove the rear wheel & tire.

Tightening torque:

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

3.	Remove the rear brake drum (A).

4.	Remove the upper return spring (A).

5.	Remove the lower return spring (A).

6.	Remove the shoe hold springs (A) and shoe hold pins (B) and then remove brake shoe (C). Make sure not to damage the dust cover on the wheel cylinder.

7.	Remove the parking brake cable (A) and then remove brake shoe (B).

8.	Disconnect brake tubes (A) from the wheel cylinder (B).

9.	Remove the bolts (C) and the wheel cylinder (B) from the backing plate (D).

Installation

•	Do not spill brake fluid on the vehicle: it may damage the paint; if brake fluid does contact the paint. Wash it off immediately with water.

•	To prevent spills, cover the hose joints with rags or shop towels.

•	Use only a genuine wheel cylinder special bolt.

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

Connect the brake tubes (A) to the wheel cylinder.

Tightening torque:

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

3.	Connect the parking brake cable (A) to the brake shoe.

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

5.	Install the shoe hole down pins (B) and the shoe hole down springs (A).

6.	Clean the threaded portions of adjuster sleeve (A) and push rod female (B). Coat the threads of the adjuster assembly with grease. To shorten the clevises, turn the adjuster bolt (C).

7.	Hook the shoe adjuster lever (C), then install it to the brake shoe.

8.	Install the adjuster assembly (B) and upper return spring (A) as right direction. Be careful not to damage the wheel cylinder dust covers.

9.	Install the lower return spring (B).

10.	Apply brake cylinder grease or equivalent rubber grease to the sliding surfaces shown. Don't get grease on the brake linings.

11.	Apply brake cylinder grease or equivalent rubber grease to the brake shoe ends and opposite edges of the shoes shown. Don't get grease on the brake linings.

12.

Install the rear brake drum (A).

Tightening torque:

4.9 ~ 5.9 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)

13.	If the wheel cylinder has been removed, bleed the brake system.

14.	Depress the brake pedal several times to set the self-adjusting brake.

15.	Adjust the parking brake.

Inspection

•	Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.

•	Avoid breathing dust particles.

•	Never use an air hose or brush to clean brake assemblies.

•	Contaminated brake linings or drums reduce stopping ability.

•	Block the front wheels before jacking up the rear of the vehicle.

1.	Raise the rear of the vehicle, and make sure it is securely supported.

2.	Release the parking brake, and remove the rear brake drum.

3.	Check the wheel cylinder (A) for leakage.

4.	Check the brake linings (B) for cracking, glazing, wear, and contamination.

Measure the brake lining thickness (C).Measurement does not include brake shoe thickness.

Brake lining thickness

Standard: 4.5 mm (0.177 in)

Service limit: 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.

Measure the inside diameter of the brake drum with inside vernier calipers.

Drum inside diameter

Standard: 203.2 mm (8.0 in)

Service limit: 205.2 mm (8.079 in)

Drum roundness

Service limit: 0.06 mm (0.00236 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.

11.	Inspect the brake lining and drum for proper contact.

12.	Inspect the wheel cylinder outside for excessive wear and damage.

13.	Inspect the backing plate for wear or damage.

Stop Lamp Switch Components and Components Location

Components

1. Stop lamp switch
2. Brake pedal member assembly
3. Return spring

4. Bolt
5. Brake pedal arm assembly

Stop Lamp Switch Schematic Diagrams

Schematic Diagram

System circuit diagram

Terminal function

Teminal	Description
1	IGN1
2	Engine Control Module (ECM)
3	B+
4	Stop Lmap

Stop Lamp Switch Troubleshooting

Troubleshooting

Part diagnosis

Items

Cause

Symptom

Switch fuse

Faulty fuse connection, Damaged fuse

-	DTC Code : P0504

-	Symptom : Shifting gear trouble, Starting failure, Cruise control function cancelation trouble, EPB function cancelation trouble, Stop lamp lighting trouble, ESP OFF light illuminated.

A waveform inspection is performed using an oscilloscope on each part during vehicle acceleration/braking. (Refer to stop lamp switch circuit inspection procedures)

Refer to the relevant repair procedures of the part when something abnormal is discovered in the waveform (Refer to the repair procedures of the relevant part and if necessary replace it)

Relay fuse

Faulty fuse connection, Damaged fuse

-	DTC Code : P0504

-	Symptom : Shifting gear trouble, Starting failure, Cruise control function cancelation trouble, EPB function cancelation trouble, Stop lamp lighting trouble , ESP OFF light illuminated.

Stop lamp switch

•	Damaged wiring of each part

•	Faulty connection to connector

•	Each part is defective

-	DTC Code : P0504

-	Symptom : Shifting gear trouble, Starting failure, Cruise control function cancelation trouble, EPB function cancelation trouble, Stop lamp lighting trouble , ESP OFF light illuminated.

Stop signal electronic
module (If it applies)

-	DTC Code : P0504, C2130, C2131

-	Symptom : Shifting gear trouble, Starting failure, Cruise control function cancelation trouble, EPB function cancelation trouble, Stop lamp lighting trouble , ESP OFF light illuminated.

Engine control module(ECM)

-	DTC Code : P0504

-	Symptom :Shifting gear trouble,Cruise control function cancelation trouble

Body control module (BCM)

-	Shifting gear trouble

Shift-lock solenoid

-	Shifting gear trouble

Inhibitor switch

-	Symptom : Shifting gear trouble, Starting failure, Cruise control function cancelation trouble, EPB function cancelation trouble

Smart Key Unit(SMK)

-	Starting failure

Electronic parking brake

-	Symptom : EPB function cancelation trouble , ESP OFF light illuminated.

ABS/VDC control module
(Pressure sensor)

-	Symptom : ESP OFF light illuminated.

Symptom diagnosis

Symptom	Part that could be the cause
Trouble starting	Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, ABS/VDC control module, Each wire, Connector	Inspect waveform using an oscilloscope on each part during vehicle acceleration/braking. (Refer to stop lamp switch circuit inspection Procedures) Refer to the relevant repair procedures of the part when something abnormal is discovered in the waveform (Refer to the repair procedures of the relevant part and if necessary replace it)
Trouble shifting gears	Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, BCM, ECM, Inhibitor switch, Each wire, Connector
ESP OFF light illuminated	Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, ABS/VDC control module, Each wire, Connector
P0504	Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, ECM, Each wire, Connector
Stop lamp does notworking	Switch fuse, Relay fuse, Stop lamp switch, Stop signal electronic module, Wire/Connector disconnected
Stop lamp always turns on	Stop lamp switch, Stop signal electronic module, Wiring short circuit, Damaged fuse

3.	Stop lamp switch system diagnosis SSEM : Stop Signal Electronic Module

4.	Refer to DTC guide when the related DTC codes are displayed.

Stop Lamp Switch Repair procedures

Adjustment

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Remove the lower crash pad. (Refer to Body - "Crash Pad")

Confirm the gap between stop lamp switch and bracket.

Stop lamp clearance (A) : 1.0 ~ 2.0 mm (0.04~ 0.08 in.)

4.	If the gap between stop lamp switch and bracket is not 1.0~2.0mm(0.04~0.08in), check the mounting clip and other part of around stop lamp.

5.	If there is normal, remove the stop lamp switch and then install again.

Inspection

1. Fuse inspection

Mount the test fuse to the switch fuse and relay fuse part to confirm a normal joint fit.

2. GDS Data Analysis

Analyze GDS data and confirm if there is anything wrong with the stop lamp switch.

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

(2)	Turn the spark switch on

(3)	Step on the brake pedal.

(4)

Inspect the "brake switch" category that displays the "sensor data" GDS.)

Normal waveform : The pressure sensor signal value will change according to the brake ON/OFF switch.

3. Inspection of connector by each part

Check to see whether or not each connector has been damaged, or terminal surge, or incomplete connection has taken place

[Engine room junction box]

[ABS/VDC control module]

4. Inspect the stop lamp circuit

Connect probe to each terminal wire and confirm oscilloscope waveform.

[Stop lamp switch input/output]

[Oscilloscope waveform screen]

Removal

1.	Turn ignition switch OFF and disconnect the negative (-) battery cable.

2.	Remove the lower crash pad. (Refer to Body - "Crash Pad")

3.	Disconnect the stop lamp switch connector (A).

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

5.	Turn stop lamp switch 45° counterclockwise and remove it.

Inspect a removed stop lamp switch along the below procedures.

(1)

Confirm a normal connection with terminal part

A.	A confirmation can be made to see if the connector has been secured properly and if a connection mark is present.

(2)

Perform the inspection of parts resistance

Resistance (?)	3-4	1-2
Non rod protruded (switch turned OFF)	Infinite	0
Rod protruded (switch turned On)	0	Infinite

Installation

1.	Fix the brake pedal arm and insert fully the stop lamp switch as hiding contact part.

2.	After inserting, turn the stop switch (A) 45° clockwise, and then assemble locking plate by pushing.

Confirm the gap between stop lamp switch and bracket.

Stop lamp clearance : 1.0 ~ 2.0 mm (0.04~ 0.08 in.)

•	If the gap between stop lamp switch and bracket is not 1.0~2.0mm(0.04~0.08in), perform the above process again.

4.	Connect the stop lamp switch connector.

5.	Install the lower crash pad. (Refer to Body - "Crash Pad")

General Information

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