Daewoo Matiz (2003 year). Manual - part 138

SECTION 4F

ANTILOCK BRAKE SYSTEM

CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise
noted.

CAUTION: Don’t diagnosis the Antilock Brake System (ABS) under the vehicle moving status. Because the
ABS function will be stopped.

TABLE OF CONTENTS

Description and Operation

4F-3

. . . . . . . . . . . . . . . . . .

ABS System Components

4F-3

. . . . . . . . . . . . . . . . . .

Hydraulic Unit

4F-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EBCM (Electronic Brake Control Module)

4F-4

. . . . .

Wheel Speed Sensors and Rings

4F-5

. . . . . . . . . . . .

Electronic Brake Distribution

4F-5

. . . . . . . . . . . . . . . .

Indicator

4F-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EBCM Connector

4F-6

. . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Fluid Flow Diagrams

4F-7

. . . . . . . . . . . . . .

Normal Braking Mode

4F-7

. . . . . . . . . . . . . . . . . . . .

Isolation Mode (Pressure Maintain)

4F-8

. . . . . . . .

Dump Mode (Pressure Decrease)

4F-9

. . . . . . . . .

Reapply Mode (Pressure Increase)

4F-10

. . . . . . .

Proportioning Function

4F-11

. . . . . . . . . . . . . . . . . .

Visual Identification

4F-12

. . . . . . . . . . . . . . . . . . . . . . .

EBCM Connector Face View

4F-12

. . . . . . . . . . . . . . .

Component Locator

4F-13

. . . . . . . . . . . . . . . . . . . . . . .

ABS

4F-13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Information and Procedures

4F-16

. . . .

DTC 0354 Left Front Wheel Speed Sensor

Circuit Open or Shorted

4F-16

. . . . . . . . . . . . . . . . .

DTC 0355 Left Front Wheel Speed Sensor

Poor Air Gap or Missing Tooth Ring

4F-20

. . . . . . .

DTC 0356 Left Front Wheel Speed Sensor

Circuit Intermittent Shorted

4F-22

. . . . . . . . . . . . . .

DTC 0404 Right Front Wheel Speed Sensor

Circuit Open or Shorted

4F-24

. . . . . . . . . . . . . . . . .

DTC 0405 Right Front Wheel Speed Sensor

Poor Air Gap or Missing Tooth Ring

4F-28

. . . . . . .

DTC 0406 Right Front Wheel Speed Sensor

Circuit Intermittent Shorted

4F-30

. . . . . . . . . . . . . .

DTC 0454 Left Rear Wheel Speed Sensor

Circuit Open or Shorted

4F-32

. . . . . . . . . . . . . . . . .

DTC 0455 Left Rear Wheel Speed Sensor

Poor Air Gap or Missing Tooth Ring

4F-36

. . . . . . .

DTC 0456 Left Rear Wheel Speed Sensor

Circuit Intermittent Shorted

4F-38

. . . . . . . . . . . . . .

DTC 0504 Right Rear Wheel Speed Sensor

Circuit Open or Shorted

4F-42

. . . . . . . . . . . . . . . . .

DTC 0505 Right Rear Wheel Speed Sensor

Poor Air Gap or Missing Tooth Ring

4F-46

. . . . . . .

DTC 0506 Right Rear Wheel Speed Sensor

Circuit Intermittent Shorted

4F-48

. . . . . . . . . . . . . .

DTC 0601 Left Front Dump Shorted or

Driver Open

4F-52

. . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0602 Left Front Dump Open or

Driver Shorted

4F-54

. . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0651 Left Front Isolation Shorted or

Driver Open

4F-56

. . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0652 Left Front Isolation Open or

Driver Shorted

4F-58

. . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0701 Right Front Dump Shorted or

Driver Open

4F-60

. . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0702 Right Front Dump Open or

Driver Shorted

4F-62

. . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0751 Right Front Isolation Shorted or

Driver Open

4F-64

. . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0752 Right Front Isolation Open or

Driver Shorted

4F-66

. . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0801 Left Rear Dump Shorted or

Driver Open

4F-68

. . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0802 Left Rear Dump Open or

Driver Shorted

4F-70

. . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0851 Left Rear Isolation Shorted or

Driver Open

4F-72

. . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0852 Left Rear Isolation Open or

Driver Shorted

4F-74

. . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0901 Right Rear Dump Shorted or

Driver Open

4F-76

. . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0902 Right Rear Dump Open or

Driver Shorted

4F-78

. . . . . . . . . . . . . . . . . . . . . . . . .

4F – 2 ANTILOCK BRAKE SYSTEM

DTC 0951 Right Rear Isolation Shorted or

Driver Open

4F-80

. . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC 0952 Right Rear Isolation Open or

Driver Shorted

4F-82

. . . . . . . . . . . . . . . . . . . . . . . . .

DTC 1102 Return Pump Motor Circuit Open

4F-84

. .

DTC 1103 Return Pump Motor Relay Fault

4F-86

. . .

DTC 1104 Return Pump Motor Circuit

Shorted

4F-88

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC 1211 EBCM Main Relay Shorted

4F-90

. . . . . . .

DTC 1212 EBCM Main Relay Open

4F-92

. . . . . . . . .

DTC 1213 EBCM Main Relay Fault

4F-94

. . . . . . . . .

DTC 1610 Stoplamp Switch Circuit Open

4F-96

. . . .

DTC 2321 ABS (Amber) Indicator Shorted

to Battery

4F-100

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC 2322 ABS (Amber) Indicator Shorted

to Ground

4F-104

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC 2458 Wheel Speed Sensor

Intermittent Error

4F-107

. . . . . . . . . . . . . . . . . . . . . .

DTC 2459 Wheel Speed Sensor Excessive

Wheel Speed Variation

4F-108

. . . . . . . . . . . . . . . . .

DTC 2520 EBCM Internal Fault

4F-110

. . . . . . . . . . .

DTC 5501 Vehicle Inhibit Code

4F-112

. . . . . . . . . . . .

DTC 5502 Isolation Valve Time–Out

4F-114

. . . . . . .

DTC 5503 CPU Loop Time Error

4F-115

. . . . . . . . . .

DTC 5504 Excessive Dump Valve Time

4F-116

. . . .

DTC 5560 Inoperative External Watch–Dog

4F-117

DTC 5610 RAM/ROM Error 8 Bit

4F-118

. . . . . . . . . .

DTC 5630 ROM Error 16 Bit

4F-119

. . . . . . . . . . . . . .

DTC 5640 RAM Error 16 Bit

4F-120

. . . . . . . . . . . . . .

DTC 8001 Battery High Voltage Fault

(More Than 16V)

4F-122

. . . . . . . . . . . . . . . . . . . . . .

DTC 8002 Battery Low Voltage Fault

(Less Than 9V)

4F-124

. . . . . . . . . . . . . . . . . . . . . . .

DTC 8003 Battery Low Voltage Fault

(Less Than 9.5V)

4F-126

. . . . . . . . . . . . . . . . . . . . . .

Repair Instructions

4F-128

. . . . . . . . . . . . . . . . . . . . . . .

On-Vehicle Service

4F-128

. . . . . . . . . . . . . . . . . . . . . . . .

Service Precautions

4F-128

. . . . . . . . . . . . . . . . . . . . .

Bleeding System

4F-128

. . . . . . . . . . . . . . . . . . . . . . . .

Front Wheel Speed Sensor

4F-129

. . . . . . . . . . . . . . .

Rear Wheel Speed Sensor

4F-130

. . . . . . . . . . . . . . .

Front Wheel Speed Ring

4F-131

. . . . . . . . . . . . . . . . .

Rear Wheel Speed Ring

4F-131

. . . . . . . . . . . . . . . . . .

Hydraulic Modulator and Upper/Lower

Mounting Bracket

4F-132

. . . . . . . . . . . . . . . . . . . . . .

EBCM (Electronic Brake Control Module)

4F-134

. . .

Specifications

4F-136

. . . . . . . . . . . . . . . . . . . . . . . . . . .

General Specifications

4F-136

. . . . . . . . . . . . . . . . . . .

Fastener Tightening Specifications

4F-136

. . . . . . . . .

Special Tools and Equipment

4F-136

. . . . . . . . . . . . .

Special Tools Table

4F-136

. . . . . . . . . . . . . . . . . . . . . .

Schematic and Routing Diagrams

4F-137

. . . . . . . . .

ABS Circuit

4F-137

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ABS Block Diagram

4F-140

. . . . . . . . . . . . . . . . . . . . . .

ANTILOCK BRAKE SYSTEM 4F – 3

DESCRIPTION AND OPERATION

ABS SYSTEM COMPONENTS

The Antilock Braking System (ABS) consists of a con-
ventional hydraulic brake system plus antilock compo-
nents. The conventional brake system includes a
vacuum booster, master cylinder, front disc brakes, rear
drum brakes, interconnecting hydraulic brake pipes and
hoses, brake fluid level sensor and the BRAKE indicator.

The ABS components include a hydraulic unit, an elec-
tronic brake control module (EBCM), two system fuses,
four wheel speed sensors (one at each wheel), intercon-
necting wiring, the ABS indicator, and the rear drum
brake. See “ABS Component Locator” in this section for
the general layout of this system.

HYDRAULIC UNIT

The hydraulic unit with the attached EBCM is located
between the surge tank and the fire wall on the right side
of the vehicle. The basic hydraulic unit configuration
consists of return pump motor, return pump, four isola-
tion valves, four dump valves, two Low Pressure Accu-
mulators (LPA), two High Pressure Attenuators (HPA).
The hydraulic unit controls hydraulic pressure to the
front calipers and rear wheel cylinders by modulating hy-
draulic pressure to prevent wheel lockup.

Isolation valve

The isolation valve is placed in the brake fluid path from
the master cylinder to the relevant brake caliper and al-
lows free flow as commanded by the driver during nor-
mal braking and reapply phases.

In the isolation phase the coil moves the armature down,
which closes the normally open isolation orifice and pre-
vents any further increase of pressure in the brake. The
valve also remains closed during the dump phase.

The lip seal provides a one way return path for brake
fluid to flow through in:

1. Foot off pedal during isolation.

2. Residual LPA fluid.

D107E002

Dump Valve

The dump valve creates a flow path from the isolation
cartridge (brake side) to the low pressure accumulator
(LPA). The valve keeps this path permanently closed ex-
cept during the dump phase in the ABS mode. On ac-
tivation (dump phase), the coil moves up the armature
which opens the normally closed dump orifice and allow
to drain the pressure in the brake line with the brake fluid
flowing into the LPA.

The lip seal provides a return path for residual brake
fluid in the LPA.

D107E003

Low Pressure Accumulator (LPA)

LPA provides a variable chamber for brake fluid to be
quickly pushed in through the dump valve at the begin-
ning of a departure. This chamber then acts as a reser-
voir which buffers the pump.

D107E004

High Pressure Attenuator (HPA)

The HPA is in between the pump and the ISO valve
(master cylinder side) and uses the bulk mode of the
contained plastic damper and orifice size to dump out
the pressure oscillations from the pump to reduce the

4F – 4 ANTILOCK BRAKE SYSTEM

feed back to the master cylinder and brake pedal.

D107E005

Return Pump Motor

The motor drives two pump elements through the ec-
centric wheel on its shaft.

Return Pump

Description: Each pump element consists of a fixed
displacement piston driven by an eccentric on the end of
the eccentric motor. It has two check valves (inlet and
outlet) and is fed with fluid by the low pressure accumu-
lator.

Operation:

Compression stroke: the pump is filled via the inlet ball
seat, then the motor eccentric rotates moving the piston
to displace the fluid. After the pressure build-up closes
the inlet valve the piston displacement increases the
pressure until the outlet ball opens. The outlet pressure
will continue to increase for the rest of the piston stroke.

Return Stroke: The piston retracts, forced by its spring,
as the motor eccentric returns to its low end position.
The pressure at the inlet side of the outlet ball then de-
creases due to the displaced volume and the pressure
difference across this ball holds it closed.

The pressure at the outlet side of the inlet ball seat,
which is set to open at a certain pressure level also de-
creases until this valve opens. With the outlet ball
closed, the pump is filled with additional fluid from the
low pressure accumulator.

The pressure will continue until a stall point is reached
and compression of the piston cannot generate enough
differential pressure anymore to open the outlet ball
seat.

D17E006A

Return Pump

Return Pump
Motor

(0.12~0.16 in.)

EBCM (ELECTRONIC BRAKE
CONTROL MODULE)

Notice: There is no serviceable. The EBCM must be re-
placed as an assembly.

The EBCM is attached to the hydraulic unit in the engine
compartment. The controlling element of ABS is a mi-
croprocessor-based EBCM. Inputs to the system in-
clude the four wheel speed sensors, the stoplamp
switch, the ignition switch, and the unswitched battery
voltage. There is an output to a bi-directional serial data
link, located in pin M of the assembly line diagnostic link
(ALDL), for service diagnostic tools and assembly plat
testing.

The EBCM monitors the speed of each wheel. If any
wheel begins to approach lockup and the brake switch is
closed (brake pedal depressed), the EBCM controls the
dump valve to reduce brake pressure to the wheel ap-
proaching lockup. Once the wheel regains traction,
brake pressure is increased until the wheel again begins
to approach lockup. The cycle repeats until either the
vehicle comes to a stop, the brake pedal is released or
no wheels approach lockup.

Additionally, the EBCM monitors itself, each input (ex-
cept the serial data link), and each output for proper op-
eration. If it detects any system malfunction, the EBCM
will store a DTC in nonvolatile memory (DTCs will not
disappear if the battery is disconnected).

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