2004-2006 Kia Picanto Workshop Repair Service Manual
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2006 KIA PICANTO SERVICE
AND REPAIR MANUAL
G 1.1 SOHC > Brake System (ABS/ESP(~2009.12.6)) > ABS(Anti-Lock Brake System) > ABS Control Unit > Components and
Components Location
COMPONENTS
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G 1.1 SOHC > Brake System (ABS/ESP(~2009.12.6)) > ABS(Anti-Lock Brake System) > ABS Control Unit > Repair procedures
REMOVAL
1 . Turn the ignition switch OFF.
2 . Pull up the lock (A) of the ABS control unit 26P connector , then disconnect the connector.
3 . Disconnect the brake tubes from the HECU by unlocking the nuts counterclockwise with a spanner.
4 . Loosen the 3 ABS HECU bracket bolts, then remove HECU and bracket.
1.
Never attempt to disassemble the HECU.
2.
The HECU must be transported and stored in.
3.
Never shock to the HECU.
5 . Remove the 3 bolts, then remove the bracket from HECU.
INSTALLATION
1 . Installation is the reverse of removal.
2 . Tighten the HECU mounting bolts and nuts to the specified torque.
Tightening torque
HECU bracket nuts :
11 ~ 14 Nm (1.1 ~ 1.4 kgf.m, 8.1 ~ 10.3 Ib-ft)
HECU bracket mounting bolt :
16.7 ~ 25.5 Nm (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 Ib-ft)
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G 1.1 SOHC > Brake System (ABS/ESP(~2009.12.6)) > ABS(Anti-Lock Brake System) > Components and Components Location
COMPONENTS
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G 1.1 SOHC > Brake System (ABS/ESP(~2009.12.6)) > ABS(Anti-Lock Brake System) > Description and Operation
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/ESP ECU.
This unit has the functions as follows.
-
Input of signal from Pressure sensor, Steering angle sensor, Yaw ＆ Lateral G sensor,the wheel
speed sensors attached to each wheel.
-
Control of braking force / traction force / yaw moment .
-
Failsafe function.
-
Self diagnosis function.
-
Interface with the external diagnosis tester.
Installation position : engine compartment
-
Brake tube length from Master cylinder port to HECU inlet port should be max. 1m
-
The position should not be close to the engine block and not lower than the wheel.
OPERAT ION
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
-
Overvoltage
When overvoltage is detected (above 17 ± 0.5 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.
-
Undervoltage
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 ECU returns to
normal operating mode.
Pump Motor Checking
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G 1.1 SOHC > Brake System (ABS/ESP(~2009.12.6)) > ABS(Anti-Lock Brake System) > Description and Operation
The ECU performs a pump motor test at a speed of 12 km/h(7 MPH) 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 in the test line of manufactories (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 self-test 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 self-test 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
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.
Solenoid valve State Valve Passage
Pump
motor
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G 1.1 SOHC > Brake System (ABS/ESP(~2009.12.6)) > ABS(Anti-Lock Brake System) > Description and Operation
Inlet valve (NO)
Outlet valve (NC)
OFF
OFF
Open
Close
Master cylinder
⇔
Wheel
cylinder
Wheel cylinder
⇔
Reservoir
OFF
2. DUMP MODE
Under the emergency braking , if the wheels start to lock up, HECU sends a signal to the solenoid
valve to decrease the brake fluid, 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 .
Solenoid
Inlet valve (NO)
Outlet valve (NC)
State
ON
ON
Valve
Close
Open
Passage
Master cylinder
⇔
Wheel
cylinder
Wheel cylinder
⇔
Reservoir
Pump
motor
ON
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G 1.1 SOHC > Brake System (ABS/ESP(~2009.12.6)) > ABS(Anti-Lock Brake System) > Description and Operation
3. HOLD MODE
When the brake fluid pressure is maximally decreased in wheel cylinder, HECU sends a signal to
solenoid valve to keep the fluid pressure, 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.
Solenoid
Inlet valve (NO)
Outlet valve (NC)
State
ON
OFF
Valve
Close
Close
Passage
Master cylinder
⇔
Wheel
cylinder
Wheel cylinder
⇔
Reservoir
Pump
motor
OFF
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G 1.1 SOHC > Brake System (ABS/ESP(~2009.12.6)) > ABS(Anti-Lock Brake System) > Description and Operation
4. INCREASE MODE
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 .
Solenoid
Inlet valve (NO)
Outlet valve (NC)
State
OFF
OFF
Valve
Open
Close
Passage
Master cylinder
⇔
Wheel
cylinder
Wheel cylinder
⇔
Reservoir
Pump
motor
ON
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G 1.1 SOHC > Brake System (ABS/ESP(~2009.12.6)) > ABS(Anti-Lock Brake System) > Description and Operation
ABS HECU EXTERNAL DIAGRAM
HYDRAULIC SYSTEM DIAGRAM
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The 2004-2006 Kia Picanto Workshop Repair Service Manual is a comprehensive resource for both professional mechanics and DIY enthusiasts. This manual provides detailed information on the maintenance, repair, and servicing of the Kia Picanto model years 2004 to 2006.
With this manual, users can access step-by-step instructions, diagrams, and illustrations to aid in the repair and maintenance of the vehicle. It covers a wide range of topics including engine, transmission, suspension, steering, brakes, electrical systems, and more.
Whether you are tackling a simple repair or a complex overhaul, this manual equips you with the necessary information to ensure the job is done accurately and efficiently.
