2007 KIA CARNIVAL warning

TIGHTENING TORQUE
ItemsNmkgf.m lb - ft
Master cylinder to booster mounting nut 8 ~ 120.8 ~ 1.2 5.8 ~ 8.7
Brake booster mounting nut 13 ~ 161.3 ~ 1.6 9.4 ~ 11.6
Bleeder screw 7 ~ 130.7 ~ 1.3 5.06 ~ 9.4
Brake tube nut, brake hose 13 ~ 171.3 ~ 1.7 9.4 ~ 12.3
Caliper guide rod bolt (Front) 22 ~ 322.2 ~ 3.215.9 ~ 23.1
Caliper guide rod bolt (Rear) 22 ~ 322.2 ~ 3.215.9 ~ 23.1
Caliper assembly to knuckle (Front) 85 ~ 1008.5 ~ 1061.5 ~ 72.3
Caliper assembly to knuckle (Rear) 50 ~ 605.0 ~ 6.036.2 ~ 43.4
Brake hose to front caliper 25 ~ 302.5 ~ 3.018.1 ~ 21.7
Brake pedal assembly bracket mounting nut 10 ~ 151.0 ~ 1.5 7.2 ~ 10.8
Brake pedal mounting nut 13 ~ 161.3 ~ 1.6 9.4 ~ 11.6
Stop lamp switch mounting nut 8 ~ 100.8 ~ 1.0 5.8 ~ 7.23
Active wheel speed sensor mounting bolt on
the brake plate 7 ~ 10
0.7 ~ 1.0 5.1 ~ 7.2
HECU mounting bracket bolt 17 ~ 261.7 ~ 2.612.3 ~ 18.8
HECU mounting nut 6 ~ 100.6 ~ 1.0 4.3 ~ 7.2
Yaw rate & lateral acceleration sensor bolt 5 ~ 80.5 ~ 0.8 3.62 ~ 5.8
SPECIFICATION (ABS)
Part ItemStandard valueRemark
HECU(Hydraulic and
Electronic Control
Unit) System
4 channel 4 sensor
(Solenoid)
·ABS system:ABS &
EBD control
Type
Motor, valve relay
intergrated type
Operating voltage 8 V ~ 16 V(DC)
Operating temperature - 40 ~ 120 °C
( - 40 ~ 248 °F)
Warning lamp Operating voltage
12 V·ABS W/L:ABS failure
·Brake W/L:Parking,
brake oil, EBD failure
Current consumption 80 mA
Acitve wheel speed
sensor Supply voltage
DC 4.5 ~ 2.0 V
Operating temperature - 40 ~ 150 °C
Output current low 5.9 ~ 8.4 mATyp.7 mA
Output current High 11.8 ~ 16.8 mATyp.14 mA
Frequency range 1 ~ 2500 HZ
Air gap Front
0.15 ~ 1.5 mm Typ.0.7 mm
Rear 0.2 ~ 1.2 mm Typ.0.7 mm
Tone wheel 48 teeth
Output duty 30~70 %
SPECIFICATION(ESP)

PartItemStandard ValueRemark
HECU(Hydraulic and
Electronic Control
Unit) System
4 channel 4
sensor(Solenoid)
·Total control(ABS,
EBD, TCS, ESP)
Type
Motor, valve relay
intergrated type
Operating voltage 8 V ~ 16 V(DC)
Operating temperature - 40 ~ 120 °C(- 40 ~
248 °F)
Warning lamp Operating voltage
12 V
·ESP Operating Lamp
·ESP Warning Lamp
Current consumption 80 mA
Active wheel speed
sensor Supply voltage
DC 4.5 ~ 20V
Operating temperature - 40 ~ 150 °C
Output current low 5.9 ~ 8.4 mA
Output current high 11.8 ~ 16.8 mA
Tone wheel 48 teeth
Frequency range 1 ~ 2500 HZ
Airgap Front
0.15 ~ 1.5 mm Typ. 0.7 mm
Rear 0.2 ~ 1.2 mm Typ. 0.7 mm
Steering Wheel Angle
Sensor Operating Voltage
8V ~ 16 V
Current Consumption Max 150 mA
Operating Angular velocity Max ± 780 °/sec
Yaw - rate & Lateral G
sensor Operating Voltage
8 V ~ 16 V
Current Consumption Max. 120 mA
Output Voltage high 4.35 V~ 4.65 VTyp. 4.5 V
Output Voltage low 0.35 ~ 0.65 VTyp. 0.5 V
Yaw Sensor Operating Range ±100 ° /s
G Sensor Operating Range ±1.8 G
Reference voltage output 2.464 ~ 2.536 VTyp. 2.5 V
LUBRICANT
Item Recommended lubricantQuantity
Brake fluid DOT 3 or DOT 4As required
Brake pedal bushing and brake pedal bolt Chassis greaseAs required
Parking brake shoe and backing plate contact surfaces Bearing greaseAs required
Caliper guide rod and boot RX - 2 grease0.8 ~ 1.3 g
Rear caliper guide rod and boot Rubber grease0.8 ~ 1.3g

18Voltage for hybrid ECU 1 A500 mA 60200
5,10,17,19 signal wheel speed sensor FL,
FR, RL,RR
6 mA
16 mA 250200 to
ground 1.5M to bat
16,9,6,8 Voltage supply for the active
wheel speed sensor FL,FR,
RL, RR 6 mA
16 mA 250200 to
ground 1.5M to bat
14,24 wheel speed sensor output
(FR, RL) 20 mA
10 mA 250200
11 Diagnostic wire K 6 mA3 mA 250200
22 ABS - warning lamp actuation 30 mA5 mA 250200
12 EBD- warning lamp actuation 30 mA5 mA 250200
20 brake light switch 10 mA5 mA 250200
15 CAN Low 30 mA20 mA 250200
26 CAN High 30 mA20 mA 250200
ABS HECU CONNECTOR Connector terminal SpecificationCondition
Number Description
1 Ground for recirculation pump Current range: Min.10A
Max.20~39A Always
4 Ground for solenoid valves and
ECU Current range: Min.2.5A
Max.5~15A Always
2 Voltage supply for pump motor
Battery voltageAlways
3 Voltage supply for solenoid valves
16 Voltage supply for the active
wheel speed sensor FL,FR, RL, RR Battery voltage
IG ON
9
6
8
5
signal wheel speed sensor FL, FR, RL,RR Voltage(High) : 0.89~1.26 V
Voltage (Low) : 0.44~0.63 V On driving
10
17
19
11
Diagnostic wire K Voltage (High)
≥ 0.8 * IG ON
Voltage (Low) ≤ 0.2 * IG ON On SCAN TOOL
communication
18 Voltage for hybrid ECU Battery voltageKEY ON/OFF
20 Brake light switch Voltage (High)
≥ 0.8 * IG ON
Voltage (Low) ≤ 0.3 * IG ON BRAKE ON/OFF
SENSOR OUTPUT ON SCAN TOOL(ABS) Description AbbreviationUnitRemarks
1 Vehicle speed sensor VEH. SPDKm/h
2 Battery voltage BATT. VOLV
3 FL Wheel speed sensor FL WHEELKm/h

4FR Wheel speed sensor FR WHEELKm/h
5 RL Wheel speed sensor RL WHEELKm/h
6 RR Wheel speed sensor RR WHEELKm/h
7 ABS Warning lamp ABS LAMP-
8 EBD Warning lamp EBD LAMP-
9 Brake Lamp B/LAMP-
10 Pump relay state PUMP RLY-
11 Valve relay state VALVE RLY-
12 Motor MOTOR-
13 Front Left valve(IN) FL INLET-
14 Front Right valve (IN) FR INLET-
15 Rear Left valve (IN) RL INLET-
16 Rear Right valve (IN) RR INLET-
17 Front Left valve (OUT) FL OUTLET-
18 Front Right valve (OUT) FR OUTLET-
19 Rear Left valve(OUT) RL OUTLET-
20 Rear Right valve (OUT) RR OUTLET-

2007 > 2.7L V6 GASOLINE >
DESCRIPTION
This specification applies to HCU(Hydraulic Control Unit) and ECU(Electronic Control Unit) of the HECU.(Hydraulic and
Electronic Control Unit)
This specification is for the wiring design and installation of ABS/TCS/ESC ECU.
This unit has the functions as follows.
a. Input of signal from Pressure sensor, Steering angle sensor, Yaw & Lateral G sensor, the wheel speed sensors
attached to each wheel.
b. Control of braking force / traction force/ yaw moment.
c. Failsafe function.
d. Self diagnosis function.
e. Interface with the external diagnosis tester.
Installation position : engine compartment a. Brake tube length from Master cylinder port to HECU inlet port should be max. 1m
b. The position should not be close to the engine block and not lower than the wheel.
OPERATION
The ECU shall be put into operation by switching on the operating voltage (IGN).
On completion of the initialization phase, the ECU shall be ready for operation.
In the operating condition, the ECU 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.
Wheel Sensor signal processing
The ECU shall receive wheel speed signal from the four active wheel sensors.
The wheel signals are converted to voltage signal by the signal conditioning circuit after receiving current signal from
active wheel sensors and given as input to the MCU.
Solenoid Valve Control
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 semiconductor circuit, the solenoid valve goes into operation.
The electrical function of the coils are always monitored by the valve test pulse under normal operation conditions.
Voltage limits
a.Overvoltage
When overvoltage is detected(above 16.8 V), the ECU 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.
b. Undervoltage
In the event of undervoltage(below 9.3 V), 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 ECU returns to normal operating
mode.
Pump Motor Checking
The ECU performs a pump motor test at a speed of 15km/h once after IGN is switched on.
Diagnostic Interface
Failures detected by the ECU are encoded on the ECU, stored in a EEPROM and read out by diagnostic equipment
when the ignition switch is turned on.
The diagnosis interface can also be used for testing the ECU during production of the ECU and for actuating the HCU
(Air - bleeding line or Roll and Brake Test line).
Warning Lamp module

1.ABS WARNING LAMP MODULE
The active ABS warning lamp module indicates the selftest and failure status of the ABS.The ABS warning lamp
shall be on:
a. During the initialization phase after IGN ON. (continuously 3 seconds).
b. In the event of inhibition of ABS functions by failure.
c. During diagnostic mode.
d. When the ECU Connector is seperated from ECU.
2. PARKING/EBD WARNING LAMP MODULE
The active EBD warning lamp module indicates the selftest and failure status 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 shall be on:
a. During the initialization phase after IGN ON. (continuously 3 seconds).
b. When the Parking Brake Switch is ON or brake fluid level is low.
c. When the EBD function is out of order.
d. During diagnostic mode.
e. When the ECU Connector is seperated from ECU.
ABS CONTROL
1.NORMAL BRAKING without ABS
Inlet valve(EV)Outlet valve(AV)Pump motor
Operation OpenCloseOFF

c.Stop lamp switch circuit.
d. Check the hydraulic circuit for leakage.
Communication with Scan tool is not possible.
(Communication with any system is not possible) a.
Power source circuit
b. Diagnosis line
Communication with Scan tool is not possible.
(Communication with ABS only is not possible) a.
Power source circuit
b. Diagnosis line
c. HECU
When ignition key is turned ON (engine OFF), the ABS
warning lamp does not light up. a.
ABS warning lamp circuit
b. HECU
Even after the engine is started, the ABS warning lamp
remains ON. a.
ABS warning lamp circuit
b. HECU
During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are
due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is
not an abnormality.
DETECTING CONDITION
Trouble Symptoms Possible Cause
Brake operation varies depending on driving conditions and road
surface conditions, so diagnosis can be difficult.However if a normal
DTC is displayed, check the following probable cause. When the
problem is still occurring, replace the ABS control module. a.
Inoperative power source circuit
b. Inoperative wheel speed sensor circuit
c. Inoperative hydraulic circuit for leakage
d. Inoperative HECU
INSPECTION PROCEDURES
DTC INSPECTION
1. Connect the Scan Tool with the data link connector and turn the ignition switch ON.
2. Verify that the system is operating to specifications.
Is the system operating to specifications ?
▶ Check the power source circuit.
▶ Erase the DTC and recheck using Scan Tool.
CHECK THE POWER SOURCE CIRCUIT.
1. Disconnect the connector from the ABS control module.
2. Turn the ignition switch ON, measure the voltage between terminal 18 of the ABS control module harness side
connector and body ground.
Specification: approximately B+
Is the voltage within specification?
▶ Check the ground circuit.
▶ Check the harness or connector between the fuse (10A) in the engine compartment junction block and the ABS
control module. Repair if necessary.

DETECTING CONDITIONTrouble Symptoms Possible Cause
When current flows in the HECU the ABS warning lamp turns from
ON to OFF as the initial check.Therefore if the lamp does not light up,
the cause may be an open in the lamp power supply circuit, a blown
bulb, an open in the both circuits between the ABS warning lamp and
the HECU, and the inoperative HECU. a.
Inoperative ABS warning lamp bulb
b. Blown No.2 fuse (10A) in the engine
compartment junction block
c. Inoperative ABS warning lamp module
d. Inoperative HECU
INSPECTION PROCEDURES
PROBLEM VERIFICATION
Disconnect the connector from the ABS control module and turn the ignition switch ON.
Does the ABS warning lamp light up?
▶ It is normal. Recheck the ABS control module.
▶ Check the power source for the ABS warning lamp.
CHECK THE POWER SOURCE FOR THE ABS WARNING LAMP
1. Disconnect the instrument cluster connector and turn the ignition switch ON.
2. Measure the voltage between terminal 8 of the cluster harness side connector and body ground.
Specification: approximately B+
Is voltage within specification?
▶ Repair bulb or instrument cluster assembly.
▶ Check for blown fuse.