SAMAND

(XU7JPL3)

Service Manual
ABS MANDO
(MGH - 25)
 Product:
Chapter: Section: SAMAND XU7JPL3
ABS MANDO MGH- 25

SAMAND
Service Manual

Foreword:

This Service Manual contains descriptions of the following categories for the
Samand:
ABS MANDO (MGH - 25)
This manual should be used as service manual and s workbook for training
instructors and technicians. We reserve the right to introduce change without
prior notice.

1
Contents

No. Section Page

no.
1 Advantages of ABS system............................................................................ 3
2 ABS system Structure..................................................................................... 4
3 ABS system Components............................................................................... 5
4 ABS system Operating Procedure ................................................................ 9
5 ABS Trouble Diagnosis .................................................................................. 11
6 ABS Trouble List............................................................................................. 12
7 ABS (HECU) Replacement Procedure........................................................... 22
8 Filling and Bleeding System After Installing A/S Type Modulator .. 26
9 Comparing Active and Passive Sensors....................................................... 27
10 ABS Schematic Diagram................................................... 28
11 ABS ECU Schematic Diagram........................................................................ 29
12 ABS ECU Block Diagram ............................................................................... 30
13 Schematic Diagram of ECU Connector Terminals....................................... 31
14 Clarifying Some Customer Complains.......................................................... 34
15 General Information About ABS.................................................................... 35

1
Mando ABS Assembly

2
1 - Advantages of ABS system.

- improved vehicle stability.

- better steering control
- reduced braking distance

Diagrammatic Illustration of ABS System Advantages

3
2 - ABS System Structure

4
3 - ABS System Components
Wheel speed sensor:
The wheel speed sensor obtains data from the
toothed wheel called exciter present on wheel
axle and transmits it to the ECU which
evaluates the wheel speed.
ECU (Electronic Control Unit):
Speed of the four wheels are evaluated
by ECU by using the signals transmitted
by wheel speed sensor and by
considering wheel slip levels it sends
action commands to the solenoid valves
and the HECU electromotor and thus
manipulates the braking pressure.

Electromotor:
When the ABS becomes active, the
ECU gives action command to ABS
electromotor to pump brake fluid
depending on the changes in wheel
speed.

HU (Hydraulic Unit):
The primary circuit of the HU is used for normal braking operations and its secondary circuit is
used for ABS action.
The hydraulic unit is composed of a group of components and controls the braking pressure
applied to each wheel. The ECU evaluates the wheel slippage condition from the incoming
sensor signals and when the ABS activation becomes necessary it analyses the situation and
immediately activates the solenoids and the pump according to the instant programs it prepares
and manipulates the braking pressure on each wheel as needed by the situation.

5
3.1 - Wheel speed sensor

- when the toothed wheel on the wheel axle starts rotating the speed sensor's
magnetic field changes and an electromotive force is created.
- the wheel speed is evaluated on the basis of the fluctuating frequencies and
voltage changes which are proportional to wheel speed.

6
3.2 - HCU (Hydraulic Control Unit)

3.2.1 - NO Solenoid valve (normally open):

When there is no electric current this solenoid remains open and the brake fluid is
allowed to flow into the calipers.
When there is electric current, this solenoid valve closes and brake fluid route to
calipers is cut off.

3.2.2 - NC Solenoid valve (normally closed):

When there is no electric current this solenoid valve remains closed and the brake fluid
path between wheel caliper and LPA is cut off. When there is electric current this
solenoid valve opens and the path between wheel caliper and LPA is established.

3.2.3 - LPA (Low Pressure Accumulator):

When the braking pressure is more than necessary and the ABS decides to reduce
braking pressure in the wheels, the NC solenoid valve opens and the extra brake fluid
passes into the LPA and from there it is transferred to the reservoir.

3.2.4 - Pump:
The extra brake fluid which is passed into the accumulator is transferred to the reservoir
by the pump.

3.2.5 - Electromotor:
It is an electromotor which makes the pump work.

7
3.3 - HECU

8
4 – System Function
4.1 - ABS Range of Action

Slip rate:

λ = vehicle speed - wheel speed * 100

Vehicle speed

Wheel locked situation λ = 100 % Brakes are not applied λ=0%

9
4.2 - EBD (Electronic Braking-pressure Distribution)

With EBD With P valve

What does EBD do?

Due to the electronic braking-pressure distribution (EBD), the front and rear wheels are
prevented from slipping and getting locked due to proper coordination of braking force.
In other words EBD is a substitute of the P-valve which is used in vehicles not having
ABS system.
Vehicles always have more braking in the front section so the rear section gets locked
before the front section and causes the vehicle to deflect from its path.
The level of braking force to be applied to rear wheels depends on the load that the
vehicle carries and the EBD balances this force.

10
5 - ABS system Trouble Diagnosis.
5.1 - Trouble Diagnosis Chart:

Warning lamps
(W/L) Trouble symptoms Trouble cause Unit
EBD ABS
locking of wheel and Incomplete
Fault in brake piping assembly
braking
OFF OFF ABS & EBD working abnormally Brake fluid leakage
Vehicle wiring
Trapped air in brake hydraulic
Reduced ABS action harness
circuit
OFF ON ABS fails to act Electromotor defective Electromotor
ON ON ABS/EBD fail to act ECU current defective
Solenoid valve current
ON ON ABS/EBD fail to act
defective
OFF ON ABS fails to act Electromotor current defective
Defect in ECU board
ON ON ABS/EBD fail to act ECU
connections
ON ON ABS/EBD fail to act ECU defective
ABS fails to act and in some Defective connection or
* ON
cases ABS/EBD fail to act continuity break in sensor.
- sensor rotor defective
- ABS malfunctioning Wheel speed
* ON - improper gap clearance
- ABS/EBD fail to act sensor
between sensor and rotor

11
5.2 - List of all ABS system faults.

1. Open circuit or short circuit in FL sensor

2. Defective FL sensor exciter

3. Improper FL sensor-exciter gap clearance

4. Open or short circuit in FR sensor

5. Defective FR sensor exciter or interference error

6. Improper FR sensor-exciter gap clearance

7. High battery voltage (above 16 V)

8. Low battery voltage (below 9.4 V)

9. Defective ECU circuit or solenoid valve winding

10. Open or short circuit in RL sensor

11. Defective RL sensor exciter or interference error

12. Improper RL sensor gap clearance

13. Open or short circuit in RR sensor

14. Defective RR sensor exciter or interference error

15. Improper RR sensor-exciter gap clearance

16. Defective electromotor or blown up electromotor fuse

17. Defective solenoid valves

12
5.3 - Method of Diagnosing Faults.
5.3.1 - Open circuit or short circuit in wheel sensor:

Take out wiring harness and sensor and

make a general check up and fit
terminals back on the connector pins.

Fit connector pin terminals in Is the problem solved?

proper position and harness its
wiring in a suitable manner.

Check wire continuity between

connector A and connector B which
connects ECU to sensor.

Find out the open circuit or Is there continuity in the wire?

short circuit and repair it or
replace wire.

Replace sensor.

Does the fault exist even

End after replacing sensor?

Note 1: Connection of the

connecters.

Replace HECU.

Note 2: Terminal numbers-

Channel Pin no.

FL 1/2
FR 19/20

RL 5/6
RR 22/23

13
5.3.2 - Defective sensor and exciter:

Remove car wheel on defective

sensor side and check sensor and
exciter wheel condition .

Measure gap clearance between

sensor and exciter

No
Is it between 0.5 to 1.5 mm?
Adjust gap clearance. (between
0.5 to 1.5 mm; best being 0.7
mm.)
Yes
Check for exciter teeth condition
and any debris sticking on teeth.

Yes
Are the teeth damaged? Replace exciter.

No
Yes
Is there debris on exciter teeth?
Remove debris.

No
Replace sensor.

No
Does the fault exist even after
replacing sensor? End

Yes

Replace HECU.

14
Note 1: If debris is sticking to exciter teeth, signal transmissions will be irregular.
Note 2: Air-gap (gap clearance) is the gap between sensor and exciter teeth.

5.3.3 - Improper sensor gap clearance:

Remove car wheel on defective

sensor side and check sensor
and exciter wheel condition.

Measure gap clearance between

sensor and exciter wheel teeth.

Is the gap between 0.5 to 1.5 No

mm?
Adjust gap clearance
(between 0.5 to 1.5
Yes mm)
Detach connectors B and C and check
wire continuity between connectors A
and B of wiring harness.

No
Does the wire have continuity? Find out the break in wire or
the short circuit and repair or
replace wire.
Yes
Replace sensor.

No
Does the fault persist even after
End
replacing sensor?

Yes
Replace HECU.

15
Note 1: Connection of the connectors-

Channel Pin no.

Note 2: Terminal numbers-
FL 1/2
FR 19/20
RL 5/6
RR 22/23

Note 3: Air-gap (gap clearance) is the gap between sensor and exciter teeth.

16
5.3.4 - Battery voltage problem:
Measure electrical
Detach wiring harness and resistance between pin
start engine and measure 4(+) of wiring harness
voltage between pin 4(+) and connector and positive
pin 8(-) and also pin 4(+) and terminal of battery.
pin 24(-).

∗
Measure voltage Check wiring
No
between +ve and -ve Is it below harness and
Is the voltage within terminals of battery. one ohm? replace if
9.4 to 17 V?
necessary.
No Yes
Is voltage below 9.4 V?
Yes Check grounding of pin
8(-) of connector and
Yes wire terminal 24(-) of the
Check for faults and wiring harness.
connect wiring harness Check and
terminals to pins 4, 8 and 24 replace battery.
of connector.

No Adjust connector Is the problem solved?

Is the problem solved? pins and connect
them properly.
Yes No
Yes
Replace HECU.
Set ground
contact properly.

Start engine and measure voltage

between pin 4(+) and pin 8(-) and
also between pin 4(+) and pin 24(-).

Start checking
Is it above 17 V? again from stage ∗
No

Replace alternator.

17
5.3.5 - Defective solenoid valve relay or fuse:

∗
Detach wiring harness and
check continuity between pin
25 of connector and ground.
Check continuity
between pin 25 of
wiring harness and
No terminal of fuse box.
Does it have continuity?

Does it have continuity?

Check wire of pin

Yes 25 and replace.

Check ABS solenoid

valve fuse in fuse box.

No Replace solenoid
Is fuse intact? valve fuse.

Yes

Check and see if pin 25 of

wiring harness is fitted
properly.
Set connector pin
No in correct position
Is the problem solved? and fit connector
properly.
No
Put HECU to work (solenoid valve relay and
electromotor).

No
Yes
Start checking again Is it possible to make it Replace HECU.
from stage ∗ work?

18
5.3.6 - Defective electromotor or electromotor fuse:
∗
Detach wiring harness and check Check continuity between pin
continuity between pin 9 and 9 of wiring harness and fuse
ground. box terminal.

Yes
Does it have Does it have continuity?
continuity?

Yes No

Check wire of
Check wire of connector pin connector pin 9 and
9 and replace if necessary. replace if necessary.

Check ABS solenoid

fuse condition in the
fuse box.

No Replace
Is fuse intact? solenoid
fuse.

Yes

Check to see whether pin 9 of wiring

harness is properly connected.

No Set connector pin in

Is the problem correct position and
solved? fit connector properly.

Yes

Put HECU to work (solenoid valve relay and electromotor).

Yes No
Starting check again from
Is it possible to make it work? Replace HECU
stage ∗

19
5.3.7 - Defective solenoid valve winding or ECU internal circuit:

Detach wiring harness and check

electrical resistance between pin 8(-)
of wiring harness and the ground, and
also between pin 24(-) of wiring
harness connector and ground.

No Check ground contact of pin

Is it below 10 ohms? 8(-) of the connector and
ground contact of terminal 24(-
) of wiring harness.
Yes

Replace HECU.

20
5.3.8 - Warning lamps turning on without reason:

Detach wiring harness and check

continuity between pin 16 of
connector and ABS module.

No Check to see whether pin

Does it have continuity? 16 of wiring harness
connector is properly
connected.
Yes
Start engine and connect pin 16 of
wiring harness connector to ground.

No
Does warning lamp turn on? Check ABS module (relay)
and replace.

Yes

Replace HECU Battery +ve

Note 1: ABS module

connections-

21
5.4 - ABS (HECU) replacement procedure
1 - While engine is off, detach the 25 pin connector from HECU.

25 pin connector of ABS, MGH-25.

22
2 - Disconnect brake pipes connected to HECU. To do this, use a 11mm spanner and open 6
nuts of size M10*1.0, by turning spanner in anti-clock wise direction.

* tightening
torque for
brake pipe
nuts is 120 to
160 kgf.cm.

* tightening
torque for
bracket bolt
and nut is 190
to 260
kgf.cm.

3 - Detach bracket by using a 12 mm spanner and removing the three bolts and nuts, by
turning spanner in anti-clock wise direction.

23
4 - After removing HECU from the vehicle along with the bracket, separate HECU from bracket
by opening the three allen screws M6×1.0 by using a 5 mm allen wrench and by turning it in
anti-clockwise direction.

5 - Use a 6 mm allen wrench to remove the six allen screws of HECU of A/S type by
turning it in anti-clockwise direction.

Note:
Two types of modulators are used in this system-
1. The dry modulator which is used when vehicle is assembled in factory.
2. The wet modulator which is used in the after sales service (A/S) program.
Since the use of dry modulator needs filling brake fluid and performing bleeding operation and
this operation is problematic outside factory assembly line, hence for after sales services the
wet modulator is used which is already filled with brake fluid and it has a different part no. from
that of the dry modulator.
When the wet modulator is used it does not need to pass the filling and bleeding tests under the
DIAG device and as such the HECU can be easily replaced and its bleeding operation is same
as the bleeding operation of the normal without ABS brake system.

24
6 - To reinstall, attach bracket to an A/S type HECU by using the three allen screws of size
M6×1.0 and tightening them in clockwise direction with a 5 mm allen wrench.

Tightening torque
for the allen screws
is 80 to 100 kgf.cm.

7 - Reinstalling procedure even for the A/S type modulator is in reverse order of removal.

25
5.5 - Filling and bleeding procedure after installing A/S type modulator.

1 - After replacing the old modulator with a new A/S type modulator (wet type), start engine and
by using DIAG device check for faults.
- if faults are reported, eliminate the faults.
- if the faults cannot be eliminated, then refer to fault diagnosing section given in this manual.

2 - Press brake pedal and remove one of the bleeding nuts and then follow the procedure for
expelling air from the system and then close the bleeding nut. Repeat this procedure for the
other wheels too until all air is expelled from system.
- see that the brake fluid in the reservoir always remains in the upper level.

3 - If air is still present in system or the brakes are not functioning well, repeat the procedure
again from phase 2.
- if even after ten times repeating of this procedure the problem is not solved then replace the
modulator and start the procedure once again from stage 1.

5.6 - Bleeding and Filling Operation Tips.

If after executing the above procedures, still you feel that the pedal is depressing too
much when the ABS is active, then do the following:

1 - Connect DIAG device and set it on bleeding mode.

2 - Press brake pedal until it gives up all pressure and then leave it off.
3 - Then immediately press pedal again and repeat this procedure until the bleeding mode is
completed.
- bleeding mode: Repeated bleeding operation by making engine to run for one minute and
activating for two seconds and deactivating for two seconds the NC solenoid valves.
- after the bleeding mode is completed, execute stages 2 and 3 of section 5.5.

26
In Mando ABS system the active type of sensors have been used, a comparison of which is
given in the following table.

Review of ECU Accommodation

Passive sensor Active sensor

Provided from battery via
Power supply N/R
ECU
Type Inductive Hall effect
Air gap 0.8 - 1.2 mm 0.5 - 1.5 mm
Voltage/Variable amplitude Current/pulse
Output (dependent on vehicle (independent of vehicle
speed) speed)

I-V conversion N/R Required

Protection circuit N/R Required

Low speed output
2 KPH Min 0.14 KPH Min
characteristics

Input/ output
characteristics of sensor

Active sensors have a semi-conductor installed in a magnetic ring and act according to the hall
effect and have a higher sensitivity compared to the passive sensors and also a longer action
range, and the other advantages of active sensors is the weaker magnet they have which does
not attract iron filings and so gives lesser trouble, when in fact the passive sensors due to their
stronger magnet easily attract iron filings to the sensors and cause interference in performance.
In this vehicle the front wheel sensors can be interchanged but the rear wheel sensors differ
from each other and cannot be interchanged. To differentiate the rear wheel sensors a red band
is used for the right wheel sensor and a blue band is used for the left wheel sensor and their
part no. also differ.
Rear wheel sensors are connected by a connector to the wiring harness of the rear lamps and
the front wheel sensors are directly connected to HECU and there is just one intermediate
connecter on the route in the region below the driver's feet.

27
28
Schematic Connections Diagram of ABS ECU Block

29
Schematic Circuit Diagram of ABS ECU Block

30
Schematic Diagram of ECU Connector Terminals

31
Feature of ECU Input and Output Signals

Connector terminal
Feature Remarks
Trml.no. Designation Description
Voltage upper limit: 16.5±0.5V<V
Operation voltage range:
9.5±0.5V<V<16.5±0.5V
Live from
Voltage lower range:
4 IGN+ ignition
8.0V<V<9.5±0.5V
switch
Minimum operation voltage:
V<7.5±0.5V
Maximum current flow: I<300mA
8 GND1 Ground Maximum current flow (for 2 Within ABS control
24 GND2 terminals):I<130.3A
Incoming voltage: V IL<0.3V BV V B: ignition voltage
V IH>0.7V BV V IL: lower incoming
DIAG Outgoing voltage: V OL<0.2V BV voltage
interface V OH<0.8V BV V IH: upper
7 DIAG socket incoming voltage
(K-line/L- V OL: lower
line) outgoing voltage
V OH: upper
outgoing voltage
Maximum current flow: 1<10ma
Wheel speed Output resistance (open
3 FR-OUT
output collector type): Above 10 k
ohms.
Input voltage (lower): -1.00<V
Brake stop
18 BRAKE IL<2.75V Input voltage (upper):
lamp input
5.00<V IH<16.00V
ABS & EBD Maximum current flow: I<200ma
ABS/EBD
16 warning Saturation voltage at I=200mA:
WLP
lamp exit Vsat<1.5V
Battery Maximum current flow (within
supply 1 ABS control): 1<30A
25 BAT 1 (supplying Maximum current flow (outside
solenoid ABS control): I<20mA
valve)
Maximum flow rush within
Battery ABS control: I<100A(t<100msec) t: electromotor
supply 2 Maximum current flow: activation time.
9 BAT 2
(supplying I<30A(t>100msec)
electromotor) With ignition switched turned off:
Dark current 1<0.5mA

32
 Feature of active and passive sensor currents

Connector terminals Feature Remarks

Trml.no. Designation Description
?
? FL+ Front left sensor signal+ Minimum sensor voltage:
FR+ Front right sensor signal+
? Vs>130mVpp
RL+ Rear left sensor signal+
? Resistance: 1100 ohms ± Sensor
? RR+ Rear right sensor signal+
50% type:
FL- Front left sensor signal-
? Input range: 30 to 2000 HZ Passive
FR- Front right sensor signal-
? Inductance: 0.7 H ± 50 %
‫ا‬ RL- Rear left sensor signal-
RR- Rear right sensor signal- Permitted offset voltage
range: 2.15V<3.5V
1 WP FL Front left sensor supply
Output voltage: V ign ± 1V
19 WP FR Front right sensor supply
Output current: Max. 50Ma
5 WP RL Rear left sensor supply
Lower outgoing current: 5.9 to
23 WP RR Rear right sensor supply
8.4 ma Sensor
2 WS FL Front left sensor signal
Upper output current: 11.8 to type:
20 WS FR Front right sensor signal
16.8 ma Active
6 WS RL Rear left sensor signal
Frequency range: 1 to 2000
22 WS RR Rear right sensor signal
HZ

33
 Clarifying Some Customer Complains

1 - Complain about ABS HECU unit noise.

- the customers complain about the noise produced after ABS activation, which is due to the
activation of solenoid valves and the electromotor.

• This noise is customary and may be heard when the ABS is working in its normal order.
The level of the noise depends on the amount of brake pressure applied to each wheel and
therefore it should be explained to the customer.
• After the vehicle starts running and its speed reaches 10 kmph, the engine ECU gets busy for
a short while to make an engine fault check up (self diagnosis), and its noise might be heard by
some sensitive customers, which however is a normal sound and is caused by the ABS
components.

2 - The customer complains that a ‘du du’ sound is heard from the rear wheels during
normal braking operations.

• This sound is created by the EBD and may be heard by some customers, but as it is just a
normal sound so there is no need to replace the HECU.

3 - Replacement of ABS HECU because of uneven braking action.

- the customer complains about uneven braking action.

• The ABS system controls every wheel individually and when there is fault in the system the
warning lamp turns on immediately. Therefore if the braking action is uneven and the warning
lamp does not turn on, the cause of fault should be investigated in other sections of the braking
system.

- a possible cause of the uneven braking action may be the brake tube assembly due to which
the ABS applies uneven braking.

4 - Replacement of ABS HECU because of ABS activation at lower vehicle speeds.

- the ABS gets active in all situations, even at speeds below 40 kmph.
• Depending on the road conditions and the amount of braking pressure on the wheel, ABS may
become active even at low speeds. But if the ABS is active all the time then the gap clearance
between sensor and exciter wheel should be checked.

34
General information about ABS.

Question 1 - Is the vehicle’s stopping distance reduced by use of ABS system.

According to the tests performed, stopping distance is lessened in most road conditions (about
5 to 20 %), but in some specific road conditions such as snowy, rough and bumpy roads, the
stopping distance may increase.

Question 2 - What is the main purpose of installing ABS?

The main purpose of installing ABS is to prevent locking up of wheels. This kind of locking up
prevention of wheels may have the following advantages:
• Preserving stability of vehicle during braking period.
• Allowing driver to have better control of vehicle during braking operation and preventing
accident.
• Maintaining braking pressure at optimum level independent of the drivers braking skill.

Question 3 - Why does the ABS warning lamp turn on?

When the driver starts the engine, the ABS warning lamp turns on as the ECU performs an
automatic self check-up operation, and goes off when no fault exists.
If the warning lamp turns on during the driving period or it does not turn off, it means that ABS
needs checking.
Even when the ABS system may have problem, the conventional braking system of the vehicle
functions normally.

Question 4 - Can the ABS system relieve you of the driving problems?
The ABS system only improves the security factor, but it cannot compensate the driver’s
mistakes or help traffic problems. Therefore the driver should take care to drive carefully and
always maintain a safe distance with the front vehicles and adjust vehicle speed with road
conditions.

35
 SAMAND Service Manuals

The intellectual property rights pertaining to the technical information in

this document are the sole property of the manufacturer. No parts of this
information mar be reproduced of distributed in any from or by any
means, without the prior written consent of the manufacturer.

This document is strictly confidential and reserved for the in-house use
of the IKCO company network.

IKCO after Sales Services Department

SAMAND building (No. 5)
14KM Karaj highway - Tehran - Iran
Tel: +98 21 48909353
Fax: +98 21 48909360
Http://Iksa.ikco.com/Export