Page 1137 of 2643
4F – 56IANTILOCK BRAKE SYSTEM
DAEWOO V–121 BL4
J3B14F04
60A Ef230A Ef5
2
42
C107 C105
2
C110
G106
A19
A13 A1 A14
C110 C202
C202WHT LT GRN
DK
GRN LT GRN/
BLK
BLK
DK BLUDK BLU
PPL/WHT
PPL/WHT ABS
TCS Parking
Brake
Hot at all times
RED REDRED/WHT
Ignition
Switch
RED
RED
I/P Cluster
EBCM8
20
22 2216 41
1211
18 1621
1
C107
10A F410AF11
32 31
43
6 62 C201
C201 C201C201
C110 C202
Hot in Run and Start
30
4
1711
C202
15
B15
DLC
(Data Link
Connector)12
G106
BLK/WHTOil Feeding
Connector
”2” Ter.
BRNBRN BRN
BRN PNK PNK PNK
19J1
59B1
ONStart Lock
Acc
IG1
19
DIAGNOSTIC TROUBLE CODE (DTC) C0800
LOW VOLTAGE FAULT
Circuit Description
Proper operation of the electronic brake control module
(EBCM) requires a certain minimum voltage. The EBCM
monitors the ignition feed circuit to determine if the voltage
falls below a minimum level.
Diagnosis
This test checks for battery output, proper grounding,
blown fuses, faulty ignition switch, and problems in the cir-
cuitry.
Cause(s)
S The battery is defective.
S There is a defective ground connection.
S A connector is damaged.
S A wire is broken or shorted.
S A fuse is blown.
S The ignition switch is malfunctioning.
Fail Action
ABS action is disabled during the period of low voltage,and the ABS warning lamp is ON for the remainder of the
ignition cycle. If the failure is intermittent, the EBCM will
enable the system at the next ignition cycle and set a histo-
ry DTC C0800.
Test Description
The number(s) below refer to step(s) on the diagnostic
table.
1. This step determines whether there is voltage at
the battery and at the high current source.
7. This step checks for voltage at the ignition 1
source.
11. This step begins the check for voltage at the EBCM
end of the ABS harness.
15. This step checks for a defective ground connection.
16. This is a check for a defective EBCM connector.
Diagnostic Aids
It is very important to perform a thorough inspection of the
wiring and the connectors. Failure to do so may result in
misdiagnosis, causing part replacement with a reappear-
ance of the malfunction.
Page 1138 of 2643
ANTILOCK BRAKE SYSTEM 4F – 57
DAEWOO V–121 BL4
DTC C0800 – Low Voltage Fault
StepActionValue(s)YesNo
1Check the voltage at the battery.
Is the voltage within the specified value?11–14 vGo to Step 3Go to Step 2
2Charge or replace the battery as required.
Is the repair complete?–System OK–
3Check fuse EF2 in the engine fuse block.
Is the fuse blown?–Go to Step 4Go to Step 7
41. Replace fuse EF2.
2. Turn the ignition to ON.
Does the fuse blow again?–Go to Step 5Go to Step 6
51. Turn the ignition to OFF.
2. Trace the RED wires in the ABS wiring harness
from terminal 1 of C107 at the engine fuse
block to terminals 17 and 18 of the EBCM con-
nector.
3. Repair any short circuit found along this path.
Is the repair complete?–System OK–
61. Turn the ignition switch to OFF.
2. Install the scan tool.
3. Clear all DTCs.
4. Road test the vehicle.
Does DTC C0800 reset?–System OK–
7Check fuse F11 in the I/P fuse block.
Is the fuse blown?–Go to Step 8Go to Step 11
81. Replace fuse F11.
2. Turn the ignition to ON.
Does the fuse blow again?–Go to Step 9Go to Step 10
91. Turn the ignition to OFF.
2. Trace the BRN wire from fuse F11 to terminal
43 of connector C201, from terminal 62 of con-
nector C202 to terminal 6 of connector C110,
and from there to terminal 15 of the EBCM
connector.
3. Repair any short circuit found along this path.
Is the repair complete?–System OK–
101. Turn the ignition switch to OFF.
2. Install the scan tool.
3. Clear all DTCs.
4. Road test the vehicle.
Does DTC C0800 reset?–System OK–
111. Disconnect the EBCM connector from the
EBCM.
2. Turn the ignition to ON.
3. Check for the presence of battery voltage be-
tween ground and terminal 17, and between
ground and terminal 18.
Is the voltage within the specified value?11–14 vGo to Step 13Go to Step 12
Page 1139 of 2643
4F – 58IANTILOCK BRAKE SYSTEM
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
121. Turn the ignition switch to OFF.
2. Trace the orange wires between terminals 17
and 18 of the EBCM connector to terminal 1 of
connector C107 at the engine fuse block.
3. Repair the open in this circuit.
Is the repair complete?–System OK–
13Check the voltage between ground and terminal 15
of the EBCM connector.
Is the voltage within the specified value?11–14 vGo to Step 17Go to Step 14
141. Turn the ignition switch to OFF.
2. Check fuse EF5 in the engine fuse block.
Is the fuse blown?–Go to Step 15Go to Step 16
15Replace fuse EF5.
Is the repair complete?–System OK–
161. Examine circuit BRN between terminal 15 of
the EBCM connector to terminal 6 of connector
C110 to terminal 62 of C202, to F11 in the I/P
fuse block.
2. Examine the PNK wire from the I/P fuse block
to terminal 4 (IG1) of the ignition switch.
3. Examine the RED wire from terminal 2 (B1) of
the ignition switch to terminal 59 of connector
C202 to terminal 4 of connector C105 at the
engine fuse block.
4. Repair the open in the wiring or possibly bad
connector terminal, or defective ignition switch.
Is the repair complete?–System OK–
171. Turn the ignition to OFF.
2. Check the resistance between ground and ter-
minals 16 and 19 of the ABS harness EBCM
connector.
Is the resistance equal to the specified value?0 WGo to Step 18Go to Step 20
18Examine terminals 15, 16, 17, 18, and 19 of the
EBCM connector.
Is there a defective terminal?–Go to Step 19Go to Step 21
19Repair the defective terminal or replace the connec-
tor or wiring harness as required.
Is the repair complete?–System OK–
20Repair the defective ground connection.
Is the repair complete?–System OK–
211. Install the scan tool.
2. Clear all DTCs.
3. Road test the vehicle.
Does DTC C0800 set again?–Go to Step 23Go to Step 22
221. Examine the wiring harness and connectors for
causes of intermittent problems.
2. Repair any intermittent problem found.
Is the repair complete?–System OK–
23Replace the ABS unit.
Is the repair complete?–System OK–
Page 1140 of 2643
ANTILOCK BRAKE SYSTEM 4F – 59
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) C0931
OVERHEATED
DTC Description
The brake can be overheated when the TCS controls the
brake system to reduce the velocity of driving wheel. At
this moment, the EBCM calculates the brake application
time and frequency and shows the warning sign of over
heated driving wheel to the driver.Cause(s)
S EBCM show the driving wheel temperature over
400 °C.
Fail Action
TCS dose not functioning when the DTC C0931 is de-
tected.
Page 1141 of 2643
4F – 60IANTILOCK BRAKE SYSTEM
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
SERVICE PRECAUTIONS
CAUTION : Brake fluid may irritate eyes and skin. In
case of contact, take the following actions:
S Eye contact – rinse thoroughly with water.
S Skin contact – wash with soap and water.
S Ingestion – consult a physician immediately.
CAUTION : To help avoid personal injury due to poor
braking, DO NOT tap into the vehicle’s brake system
to operate a trailer brake system.
Notice : When fasteners are removed, always reinstall
them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part
number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size
and strength (or stronger) may be used. Fasteners that
are not reused, and those requiring thread–locking com-
pound will be called out. The correct torque values must
be used when installing fasteners that require them. If the
above procedures are not followed, parts or system dam-
age could result.
Notice : Use only DOT 3 equivalent hydraulic brake fluid.
The use of DOT 5 (silicone) brake fluid is not recom-
mended. Reduced brake performance or durability may
result.
Notice : Avoid spilling brake fluid on any of the vehicle’s
painted surfaces, wiring, cables, or electrical connectors.
Brake fluid will damage paint and electrical connections.
If any fluid is spilled on the vehicle, flush the area with wa-
ter to lessen the damage.
Computer System Service Precautions
Take care to avoid electronic brake control module
(EBCM) circuit overloading. In testing for opens or shorts,
do not ground or apply voltage to any circuit unless
instructed to do so by the diagnostic procedure. Test cir-
cuits only with a high–impedance multimeter. Never re-
move or apply power to any control module with the igni-
tion switch in the ON position. Always turn the ignition to
the OFF position before removing or connecting battery
cables, fuses, or connectors.
General Service Precautions
S Disconnect the EBCM connector before performing
any vehicle welding work using an electric arc weld-
er.
S Do not attempt to disassemble any component des-
ignated as nonserviceable. The hydraulic modulator
and the EBCM can be separated from each other
and replaced separately but cannot be serviced.
They have no replaceable parts, and there is no
access to the components they contain.
Page 1142 of 2643
ANTILOCK BRAKE SYSTEM 4F – 61
DAEWOO V–121 BL4
BLEEDING SYSTEM
Replacement modulators are shipped already filled and
bled. In normal procedures requiring removal of the modu-
lator, such as to replace the EBCM, air will not enter the
modulator, and normal bleeding will be all that is needed.
For this procedure, refer to Section 4A, Hydraulic Brakes.
If air enters the hydraulic modulator, or if an unfilled modu-
lator is installed, use the brake bleeding program in the
scan tool to bleed the modulator. Manual bleeding of the
hydraulic modulator is not possible.
ABS 5.3 ASSEMBLY
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the 31–pin ABS wiring harness connec-
tor from its socket on the EBCM.
3. Cover the connector and the socket with shop
cloths to protect them from brake fluid.
Notice : Take care not to allow air into the hydraulic unit
or into the brake pipes from the master cylinder. If air gets
into the hydraulic unit, it will require a bleeding procedure
using a scan tool programmed for the ABS 5.3 system. As
long as no air enters the hydraulic unit, a simple bleeding
procedure is all the system will require.
4. Remove the brake pipes from the hydraulic unit. It
may be necessary to loosen the brake pipe nuts on
the master cylinder to allow for moving those pipes
out of the way.
5. Loosen the mounting nuts on the hydraulic unit.
6. Move the brake pipes aside far enough to allow for
lifting the ABS 5.3 unit out of the mounting bracket.
7. Tighten the brake pipe nuts on the master cylinder
to avoid leaking brake fluid.
8. Cap the brake pipes.
Installation Procedure
1. Insert the ABS 5.3 hydraulic unit into its mounting
bracket and install the nuts.
Tighten
Tighten the ABS 5.3 mounting nuts to 15 NSm (11 lb–
ft).
2. Remove the screw plugs and install all of the hy-
draulic brake pipes.
Tighten
Tighten the brake pipe nuts to 22 NSm (16 lb–ft).
3. Connect the 31–pin wiring harness connector J1.
4. Connect the negative battery cable.
5. Bleed the hydraulic system. Refer to Section 4A,
Hydraulic Brakes.
Page 1143 of 2643
4F – 62IANTILOCK BRAKE SYSTEM
DAEWOO V–121 BL4
FRONT WHEEL SPEED SENSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the front wheel speed sensor electrical
connector.
3. Raise and suitably support the vehicle.
4. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
5. Turn the steering wheel to expose the speed sen-
sor. It is located at the rear of the steering knuckle
near the tie rod end.
6. Remove the bolt and the front wheel speed sensor
from the steering knuckle.
7. Free the feedthrough grommet for the speed sen-
sor harness and the hydraulic pipe from the strut
tower. Remove the speed sensor harness from it so
that the connector can pass through the hole in the
strut tower.
8. Free the sensor harness from the grommet holders
and the clamps and pull it through the fender.
Installation Procedure
1. Install the front wheel speed sensor to the steering
knuckle. Secure it with the bolt.
Tighten
Tighten the front wheel speed sensor bolt to 8 NSm
(71 lb–in).
2. Feed the sensor harness into the engine compart-
ment, insert it into the grommet, and secure the
grommet into the hole in the strut tower.
3. Secure the harness into the grommet holders and
the clamps under the fender.
4. Install the wheel. Refer to Section 2E, Tires and
Wheels.
5. Lower the vehicle.
6. Connect the front wheel speed sensor electrical
connector.
7. Connect the negative battery cable.
Page 1144 of 2643
ANTILOCK BRAKE SYSTEM 4F – 63
DAEWOO V–121 BL4
FRONT WHEEL SPEED SENSOR
JUMPER HARNESS
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect connector from the EBCM.
3. Remove the appropriate terminals from connector:
S Right–side – terminals 4 (WHT) and 5 (GRY).
S Left–side – terminals 6 (BRN) and 7 (LT BLU).
4. Both speed sensor harnesses break out of the ABS
wiring harness just beyond the ABS connector. The
right–side speed sensor harness crosses the top of
the fire wall to the right–side fender area. The left–
side speed sensor harness goes directly to the left–
side fender area.
5. Free the speed sensor harness from the wiring har-
ness.
6. Remove the front wheel speed sensor electrical
connector from the retaining clamps and disconnect
the harness from the sensor connector.
Installation Procedure
1. Install the front wheel speed sensor jumper har-
ness.
2. Connect the front wheel speed sensor electrical
connector and secure it into the clamps.
3. Replace the jumper harness into the wiring har-
ness.
4. Insert the terminals into connector as they had
been removed:
S Right–side – terminals 4 (WHT) and 5 (GRY).
S Left–side – terminals 6 (BRN) and 7 (LT BLU).
5. Connect EBCM connector.
6. Connect the negative battery cable.