Hyundai Santa Fe (TM): Brake System - Brake SystemHyundai Santa Fe (TM): Brake System

Repair procedures

Inspection
Operation and Leakage Check

1.
Brake Booster (A)
(1)
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.
2.
Piston cup and pressure cup inspection (B)
(1)
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.
(2)
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.
3.
Brake hoses (C)
(1)
Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it is damaged or leaking.
4.
Caliper piston seal and piston boots
(1)
Check brake operation by applying the brakes.
(2)
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 (Judder Inspection)

Brake Booster. Components and components location

Components

1. Reservoir cap
2. Reservoir
3. Brake booster
4. Master cylinder
5. Push rod

Brake Booster. Repair procedures

Brake Booster Operating Test
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.
3.
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 and battery tray.
(Refer to Engine Electrical System - "Battery")
3.
Remove the master cylinder.
(Refer to Brake System - "Brake Master Cylinder")
4.
Remove the fixing clip and the vacuum hose (A) from the brake booster.

5.
Disconnect the brake booster vacuum pressure sensor connector (A).

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

7.
Remove the brake booster (B) after loosening the mounting nuts (A).
Tightening torque :
16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

Inspection
1.
Inspect the vacuum hose.
2.
Check the boot for damage.
Installation
1.
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 installation, bleed the brake system.
(Refer to Brake System - "Brake System Bleeding")
(Refer to Brake System - "ESP System Bleeding)
3.
Check the brake oil leakage and pedal operating condition.

Master Cylinder. Components and components location

Components

1. Reservoir cap
2. Reservoir
3. Reservoir pin
4. Grommet
5. Master cylinder

Master Cylinder. Repair procedures

Removal
1.
Turm ignition switch OFF and disconnect the negative (-) battery cable.
2.
Remove the battery.
(Refer to Engine Electrical System - "Battery")
3.
Disconnect the brake fluid level sensor connector (A).

4.
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.
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
5.
Separate the brake tube (A) from the master cylinder after loosening the tube flare nut.
Tightening torque :
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)

6.
Remove the master cylinder (A) after loosening the master cylinder nuts.
Tightening torque :
12.7 - 16.7 N.m (1.3 - 1.7 kgf.m, 9.4 - 12.3 lb-ft)

7.
Separate the reservoir from the master cylinder after removing the screw (A).

Installation
1.
To install, reverse the removal procedures.
  
Before installing the pin, apply the grease to the joint pin.
Use a new snap pin whenever installing.
2.
After installation, bleed the brake system.
(Refer to Brake System - "Brake System Bleeding")
(Refer to Brake System - "ESP System Bleeding)
3.
Check the brake oil leakage and pedal operating condition.

Vacuum Pump. Repair procedures

Removal
[G 2.5 T-GDI THETA III (Only)]
1.
Disconnect the batter ( - ) cable.
2.
Remove the retaining clip then remove the vacuum pump hose (A).

3.
Remove the vacuum pump connector (A).

4.
Remove the bolts, then remove the vacuum pump assembly (A).
Tightening torque :
19.6 - 24.5 N·m (2.0 - 2.5 kgf·m, 14.5 - 18.1 lb·ft)

Installation
1.
Install in the reverse order of removal

Brake Line. Components and components location

Components

Brake Line. Repair procedures

Removal
  
Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift.
(Refer to General Information - "Lift and Support Points")
Brake Tube [Engine Room]
1.
Disconnect the brake fiuid level switch connector, and remove the reservoir cap.
2.
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.
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
3.
Remove the brake tube after loosening the flare nuts from the ESP, master cylinder and brake tube connector.
Tightenning torque
ESP : 18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
Master cylinder :
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
Brake tube connector :
13.7 - 16.7 N.m (1.4 - 1.7 kgf.m, 10.1 - 12.3 lb-ft)
Brake Hose
1.
Disconnect the brake fluid level sensor connector (A).

2.
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.
3.
Remove the wheel & tire.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

4.
Remove the tube flare nut (A) and brake hose bracket bolt (B).
Tightenning torque
(A) : 13.7 - 16.7 N.m (1.4 - 1.7 kgf.m, 10.1 - 12.3 lb-ft)
(B) : 19.6 - 29.4 N.m (2.0 - 3.0 kgf.m, 14.5 - 21.7 lb-ft)
[Front]

[Rear]

5.
Remove the hose after loosening the brake hose bolt (A) from the caliper.
Tightening torque :
24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7)
[Front]

[Rear]

Inspection
1.
Check the brake tubes for cracks, crimps and corrosion.
2.
Check the brake tube flare nuts for damage and fluid leakage.
Installation
1.
To install, reverse the removal procedures.
  
Use a new washer (A) whenever installing.
[Front]

[Rear]

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

Brake oil. Specifications

Specification

Fluid Type
DOT 4

Reservoir Quantity (cc)
MAX LEVEL
A + B + C + D
493 ± 20
ON LEVEL
B + C + D
206 ± 20
MIN LEVEL
-
167
PARTIAL LEVEL
C
Pri : 63
D
Sec : 49
CLUTCH LEVEL
E
-

Brake oil. Repair procedures

Replacement
  
Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift.
(Refer to General Information - "Lift and Support Points")
1.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
2.
Disconnect the brake fluid level sensor connector (A).

3.
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.
Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
4.
Loosen the bleed screw (A) and depress the brake pedal repeatedly several times until the brake fluid reaches the caliper cylinder.
[Front]

[Rear]

  
Work from rear right, front left, rear left to front right.
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.
5.
Retighten the bleed screw and then make sure the brake fluid in the reservoir is at the MAX (upper) level line.
6.
Loosen the right-rear brake bleed screw (A) to allow air to escape from the system. Then tighten the bleed screw securely.
[Front]

[Rear]

  
Work from rear right, front left, rear left to front right.
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.
Make sure the brake fluid in the reservoir is at the MAX (upper) level line.
7.
Re-tighten the bleed screw.
8.
Have an assistant press the brake pedal several times to pressurize it and keep it pressed.
9.
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.
[Front]

[Rear]

  
Work from rear right, front left, rear left to front right.
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.
Make sure the brake fluid in the reservoir is at the MAX (upper) level line.
10.
Repeat the procedure for wheel in the sequence until air bubbles no longer appear in the fluid.
11.
Connect the negative (-) cable.
12.
Connect the brake fluid level sensor.

Brake Pedal. Components and components location

Components

1. Brake member assembly
2. Stop lamp switch
3. Brake pedal arm assembly
4. Brake pedal pad

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 Lower Panel")
3.
Disconnect the stop lamp switch connector (A).

4.
Separate the snap pin (A) and clevis pin (B).

5.
Remove the brake pedal assembly after loosening the mounting bolts (B) and nuts (A).
Tightening torque :
16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 lb-ft)

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.
(Refer to Brake System - "Stop Lamp Switch")
Installation
1.
To install, reverse the removal procedures.
  
When installing the clevis pin, apply the grease.
Use a new snap pin whenever installing.

Front Disc Brake. Components and components location

Components

1. Caliper body
2. Caliper carrier
3. Pad inner shim
4. Brake pad
5. Pad retainer

Front Disc Brake. Repair procedures

Removal
  
Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift.
(Refer to General Information - "Lift and Support Points")
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the front wheel and tire (A) from the 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).

3.
Loosen the brake hose bolt (A) from the caliper seperate the brake hose.
Tightening torque :
24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)

4.
Remove the caliper body (A) by loosening the guided rod bolt.
Tightening torque :
37.3 - 41.2 N.m (3.8 - 4.2 kgf.m, 27.5 - 30.4 lb-ft)

5.
Remove the brake pad (A).

6.
Remove the pad pad liner (A).

7.
Remove the caliper carrier (A) by loosening the caliper mouniting bolts.
Tightening torque :
98.1 - 117.7 N.m (10.0 - 12.0 kgf.m, 72.3 - 86.8 lb-ft)

8.
Remove the front brake disc (A) by loosening the screws.
Tightening torque :
4.9 - 5.8 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 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.
3.
Remove all rust and contamination from the surface, and measure the disc thickness at 24 points, at least, of same distance 5 mm (0.20 in) from the brake disc outer circle.
Front brake disc thickness
- Standard : 30 mm (1.18 in)
- Service Limit : 28 mm (1.10 in)
Difference in thickness of each measuring part :
Less than 0.015 mm (0.0002 in) (Circumferential direction), 0.015 mm (0.0004 in) (Radial)

4.
If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
Front Brake Disc Runout Check
1.
Place a dial gauge about 10 mm (0.20 in) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout
Limit : 0.050 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 meet the limit specification, remove the disc, turn it 180° and reinstall. 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.
2.
Use a SST (09581-11000) when installing the brake caliper assembly.

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

Rear Disc Brake. Components and components location

Components

1. EPB actuator
2. Caliper body
3. Caliper carrier
4. Pad retainer
5. Brake pad

Rear Disc Brake. Repair procedures

Removal
  
Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift.
(Refer to General Information - "Lift and Support Points")
1.
Before removing the rear caliper, perform “Brake Pad Replacement Mode” using the self-diagnosis.
Raise the vehicle, and make sure it is securely supported.

2.
Select C2 (Release) on the screen below.

3.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
4.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
5.
Remove the rear wheel and tire (A) from the rear 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).

6.
Disconnect the EPB actuator connetor (A).

7.
Remove the hose after loosening the brake hose bolt (A) from the caliper.
Tightening torque :
24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)

8.
Remove the caliper body (A) after loosening the guide rod bolt.
Tightening torque :
37.3 - 41.2 N.m (3.8 - 4.2 kgf.m, 27.5 - 30.4 lb-ft)

9.
Remove the brake pad (A).

10.
Remove the pad liner (A).

11.
Remove the caliper carrier (A) after loosening the caliper mounting bolt.
Tightening torque :
98.1 - 117.6 N.m (10.0 - 12.0 kgf.m, 72.3 - 86.8 lb-ft)

12.
Remove the rear brake disc (A) after loosening the screw.
Tightening torque :
4.9 - 5.9 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

Inspection
Rear Brake Disc Thickness Check
1.
Check the brake disc for damage and cracks.
2.
Remove all rust and contamination from the surface, and measure the disc thickness at 24 points, at least, of same distance 5 mm (0.20 in) from the brake disc outer circle.
Rear brake disc thickness
- Standard (Solid disc) : 11 mm (0.43 in) (16 inch)
- Service Limit : 9 mm (0.35 in) (16 inch)
- Standard (Ventilated disc) : 20 mm (0.78 in) (17 inch)
- Service Limit : 18 mm (0.70 in) (17 inch)
Difference in thickness of each measuring part :
Less than 0.015 mm (0.0002 in) (Circumferential direction), 0.015 mm (0.0004 in) (Radial)

3.
If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
Rear Brake Disc Runout Check
1.
Place a dial gauge about 10 mm (0.20 in) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout
Limit : 0.055 mm (0.0020 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 cannot be corrected by changing the position of the brake disc, replace the brake disc.
Installation
1.
Install in the reverse order of removal.
2.
When istalling, press and rotate the piston into the caliper body until it is fully retracted.

3.
After installation, bleed the brake system.
(Refer to Brake system - "Brake Bleeding Procedures")
4.
After installing the rear caliper, perform “Brake Pad Replacement Mode” using the self-diagnosis.

5.
Select C1 (Apply) on the screen below.

6.
After replacing the rear caliper, make sure that the caliper is installed correctly by performing "Check assembling (ECU replaced)" from the option

Brake Pad. Repair procedures

Replacement
  
Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift.
(Refer to General Information - "Lift and Support Points")
Front Brake Pad
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the front wheel and tire (A) from front hub.
  
Be careful not to damage the hub bolts when removing the front wheel and tire (A).

3.
Up the brake caliper body (A) by loosening the guided rod bolt.
Tightening torque :
37.3 - 41.2 N.m (3.8 - 4.2 kgf.m, 27.5 - 30.4 lb-ft)

4.
Remove the brake pad (A).

5.
Replace the pad liner (A) with a new one.

  
Brake apply a small amount of grease to the areas marked with "X" on both ends of the new product.
(Be careful as excessive coating may cause noise due to contamination on the disk or friction material.)

6.
Replace the brake pad (A) with a new one.

  
When installing, use a new one return spring (A), pad retainer (B), inner shim (C).

7.
Use a SST (09581-11000) when installing the brake caliper assembly.

8.
Install the caliper body (A) then tighten the guide rod bolt.
Tightening torque :
37.3 - 41.2 N.m (3.8 - 4.2 kgf.m, 27.5 - 30.4 lb-ft)

9.
Install the front wheel and tire (A).
Tightening torque :
107.8 - 127.4 N.m (11.0 - 13.0 kgf.m, 79.5 - 94.0 lb-ft)

Rear Brake Pad
1.
 Before removing the rear caliper, perform "Brake Pad Replacement Mode" using the self-diagnosis.

2.
Select C2 (Release) on the screen below.

3.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
4.
Remove the rear wheel and tire (A) from the rear hub.
  
Be careful not to damage the hub bolts when removing the rear wheel and tire (A).

5.
Disconnect the EPB actuator connector (A).

6.
Remove the caliper body (A) after loosening the guide rod bolt.

7.
Remove the brake pad (A).

8.
Replace the pad liner (A) with a new one.

9.
Replace the brake pad (A) with a new one.

  
When installing, use a new one pad retainer (A), brake pad (B).

10.
Rotate the caliper piston and push the direction of the arrow.

11.
Install the caliper body (A) then tighten the guide rod bolt.
Tightening torque :
37.3 - 41.2 N.m (3.8 - 4.2 kgf.m, 27.5 - 30.4 lb-ft)

12.
Install the rear wheel and tire (A).
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).

13.
After replacing the brake pad (EPB applied), perform "Brake Pad Replacement Mode" using the self-diagnosis.

14.
 Select C1 (Apply) on the screen below.

  
After replacing the brake pad is complete, make sure to repeat engagement/disengagement 3 times at "Brake Pad Replacement Mode".
15.
After replacing the brake pad, make sure that the caliper is installed correctly by performing "Check assembling (ECU replaced)" from the optional function.

Inspection
Front Brake Pad Check
1.
Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Front brake disc thickness Pad thickness
- Standard : 11 mm (0.43 in)
- Service Limit : 2.0 mm (0.78 in)

2.
Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
Rear Brake Pad Check
1.
Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Pad thickness
Standard value [EPB type] : 10.0 mm (0.39 in)
Service limit [EPB type] : 2.0 mm (0.08 in)
2.
Check the damage of pad, backing metal and contamination with grease.

Stop Lamp Switch. Components and components location

Components

1. Brake member assembly
2. Stop lamp switch
3. Brake pedal arm assembly
4. Brake pedal pad

Stop Lamp Switch. Schematic diagrams

Schematic Diagram

System circuit diagram

Terminal Function

Teminal
Description
1
IGN1
2
Engine Control Module (ECM)
3
-
4
B+
5
Stop Lamp
6
Gruound

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")
3.
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. Diagnostic tool Data Analysis
1.
Analyze diagnostic tool data and confirm if there is anything wrong with the stop lamp switch.
(1)
Connect the diagnostic tool 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" diagnostic tool.
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 (A) 45° counterclockwise and remove it.

6.
Inspect a removed stop lamp switch along the below procedures.
(1)
Confirm a normal connection with terminal part
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 (Ω)
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.

3.
Confirm the gap between stop lamp switch and bracket.
Stop lamp clearance (A) : 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 (A).

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

Stop Lamp Switch. Troubleshooting

Troubleshooting
1.
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.
① A waveform inspection is performed using an oscilloscope on each part during vehicle acceleration/braking. (Refer to stop lamp switch circuit inspection procedures)

② 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.

2.
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
① Inspect waveform using an oscilloscope on each part during vehicle acceleration/braking. (Refer to stop lamp switch circuit inspection Procedures)

② 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.
Brake bleeding procedures
Brake System Bleeding Nomal Brake System    • Do not reuse the drained fluid. • Always use genuine DOT4 brake Fluid. Using a non-genuine DOT4 brake fluid can cause corrosion and decrease ...

Parking Brake System. Electronic Parking Brake (EPB)
Description and operation Description Electronic parking brake (EPB) is motor driven braking system operated by a switch instead of pulling or depressing the lever to engage the brake. Pressing the button ...

See also:

Instrument Cluster. Repair procedures
Removal 1. Disconnect the negative (-) battery terminal. 2. Remove the cluster fascia panel (A). 3. Remove the cluster (A) from the housing after removing 2 screws. 4. Disconnect the cluster connecter ...

If the engine will not start
Be sure to shift the gear to N (Neutral) or P (Park). The engine starts only when the gear is in N (Neutral) or P (Park). Turn on the interior light. If the light dims or goes out when you operate the ...

Emergency Fastening Device (EFD). Repair procedures
Removal 1. Disconnect the battery negative cable, and wait for at least three minutes before beginning work. 2. To remove the locking mechanism (A), using a (-) driver (B) turn it counter clockwise. From ...