BRAKE SYSTEMSECTION BRCONTENTSPRECAUTIONS AND
PREPARATION............................3Supplemental Restraint
System (SRS)AIR BAG
...................................................................3Precautions
for Brake System.....................................4Commercial
Service Tools...........................................4NOISE,
VIBRATION AND HARSHNESS
(NVH)TROUBLESHOOTING.....................................................5NVH
Troubleshooting
Chart.........................................5ON-VEHICLE SERVICE
..................................................6Checking Brake
Fluid Level.........................................6Checking Brake
Line ...................................................6Changing
Brake Fluid..................................................6Brake
Burnishing
Procedure........................................6Bleeding Brake
System...............................................7BRAKE
HYDRAULIC LINE .........................................8BRAKE
HYDRAULIC LINE/CONTROL VALVE............10Proportioning
Valve....................................................10BRAKE
PEDAL AND BRACKET.................................. 11Removal and
Installation ...........................................
11Inspection...................................................................12Adjustment
.................................................................12MASTER
CYLINDER.....................................................13Removal
.....................................................................13Disassembly...............................................................14Inspection...................................................................14Assembly
...................................................................14Installation..................................................................15BRAKE
BOOSTER........................................................16On-vehicle
Service.....................................................16Removal
.....................................................................16Inspection...................................................................16Installation..................................................................17VACUUM
HOSE.............................................................18Removal
and Installation
...........................................18Inspection...................................................................18FRONT
DISC BRAKE ...................................................19Pad
Replacement
......................................................19Removal
.....................................................................20Disassembly...............................................................21Inspection
Caliper
.................................................21Inspection
Rotor....................................................21Assembly
...................................................................22Installation..................................................................22REAR
DRUM BRAKE
...................................................23Removal
.....................................................................24Inspection
Wheel Cylinder ....................................25Wheel Cylinder
Overhaul...........................................25Inspection
Drum....................................................25Inspection
Lining...................................................25Installation..................................................................25PARKING
BRAKE CONTROL ......................................27Removal and
Installation
...........................................28Inspection...................................................................28Adjustment
.................................................................28ANTI-LOCK
BRAKE
SYSTEM......................................29Purpose......................................................................29Operation
...................................................................29ABS
Hydraulic Circuit
................................................29System Components
.................................................30System
Description....................................................30Removal
and Installation
...........................................32TROUBLE DIAGNOSES
...............................................35How to Perform
Trouble Diagnoses for Quickand Accurate Repair
..................................................35Preliminary
Check......................................................37Component
Parts and Harness ConnectorLocation
.....................................................................38Schematic
..................................................................39Wiring
Diagram ABS
........................................40Self-diagnosis
............................................................43CONSULT..................................................................46CONSULT
Inspection Procedure...............................47Ground Circuit
Check ................................................52TROUBLE
DIAGNOSES FOR
SELF-DIAGNOSTICITEMS.............................................................................53Diagnostic
Procedure 1 (Wheel sensor or rotor) ......53Diagnostic Procedure 2
(ABS actuator solenoidvalve and solenoid valve relay)
.................................55Diagnostic Procedure 3 (Motor
relay or motor).........57Diagnostic Procedure 4 (Low voltage)
......................59GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDiagnostic
Procedure 5 (G sensor)...........................60Diagnostic
Procedure 6 (Control unit) .......................61TROUBLE
DIAGNOSES FOR SYMPTOMS.................62Diagnostic Procedure 7
(ABS works frequently.) ......62Diagnostic Procedure 8 (Unexpected
pedalaction)
........................................................................63Diagnostic
Procedure 9 (Long stopping distance) ....63Diagnostic Procedure 10
(ABS does not work.) .......64Diagnostic Procedure 11 (Pedal
vibration andnoise)
.........................................................................64Diagnostic
Procedure 12 (Warning lamp doesnot come on when ignition switch is
turned ON.) .....65Diagnostic Procedure 13 (Warning lamp stays
onwhen ignition switch is turned
ON.)...........................67Electrical Components Inspection
.............................69SERVICE DATA AND SPECIFICATIONS
(SDS) ..........70General
Specifications...............................................70Inspection
and Adjustment ........................................71When you
read wiring diagrams:GRead GI section, HOW TO READ WIRING
DIAGRAMS.GSee EL section, POWER SUPPLY ROUTING for power
distribution circuit.When you perform trouble diagnoses, read GI
section, HOW TO FOLLOW FLOW CHARTINTROUBLEDIAGNOSES
andHOWTOPERFORMEFFICIENTDIAGNOSISFORANELECTRICAL
INCIDENT.CONTENTS(Contd.)BR-2Supplemental Restraint System (SRS)AIR
BAGTheSupplemental Restraint SystemAIRBAG, usedalongwithaseat belt,
helpstoreducetheriskorseverity of injury to the driver and front
passenger in a frontal collision. The Supplemental Restraint
Systemconsists of air bag modules (located in the center of the
steering wheeland in the instrument panelon thepassenger side), a
diagnosis sensor unit, a crash zone sensor, warning lamp, wiring
harness and spiral cable.The vehicle is equipped with a passenger
air bag deactivation switch. Because no rear seat exists where
arear-facingchildrestraintcanbeplaced,theswitchisdesignedtoturnoffthepassengerairbagsothatarear-facing
child restraint can be used in the front passenger seat. The switch
is located in the center of theinstrument panel, near the ashtray.
When the switch is turned to the ON position, the passenger air bag
isenabled and could inflate in a frontal collision. When the switch
is turned to the OFF position, the passengerair bag is disabled and
will not inflate in a frontal collision. A passenger air bag OFF
indicator on the instru-ment panel lights up when the passenger air
bag is switch OFF. The driver air bag always remains enabledand is
not affected by the passenger air bag deactivation
switch.Information necessary to service the system safely is
included in the RS section of this Service Manual.WARNING:G To
avoid rendering the SRS inoperative, which could increase the risk
of personal injury or deathin the event of a collision which would
result in air bag inflation, all maintenance should be per-formed
by an authorized NISSAN dealer.G Improper maintenance, including
incorrect removal and installation of the SRS, can lead to
per-sonal injury caused by unintentional activation of the system.G
Do not use electrical test equipment on any circuit related to the
SRS unless instructed to in thisServiceManual.
SRSwiringharnessesarecoveredwithyellowinsulationeitherjustbeforetheharness
connectors or on the complete harness, for easy identification.G
The vehicle is equipped with a passenger air bag deactivation
switch which can be operated bythe customer. When the passenger air
bag is switched OFF, the passenger air bag is disabled andwill not
inflate in a frontal collision. When the passenger air bag is
switched ON, the passenger airbag is enabled and could inflate in a
frontal collision. After SRS maintenance or repair, make surethe
passenger air bag deactivation switch is in the same position (ON
or OFF) as when the vehiclearrived for
service.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPRECAUTIONS AND
PREPARATIONBR-3SBR686CPrecautions for Brake SystemG Use brake fluid
DOT 3.G Never reuse drained brake fluid.G Becareful
nottosplashbrakefluidonpaintedareas;itmaycausepaint damage. If
brakefluidissplashedonpainted areas, wash it away with water
immediately.G To clean master cylinder parts, disc brake caliper
parts orwheel cylinder parts, use clean brake fluid.G Never use
mineral oils such as gasoline or kerosene. Theywill ruin rubber
parts of the hydraulic system.G Use flare nut wrench when removing
and installing braketubes.G Always torque brake lines when
installing.G Burnishthebrakecontact surfacesafter
refinishingorreplacing drums or rotors, after replacing pads or
linings,or if asoft pedal occursat verylowmileage. Refer toBrake
Burnishing Procedure, ON-VEHICLE SERVICE,BR-6.WARNING:G Clean
brakes with a vacuum dust collector to minimize thehazard of
airborne materials.Commercial Service ToolsTool name Description1
Flare nut crowfoot2 Torque wrenchNT360Removing and installing each
brake pipinga: 10 mm (0.39 in)Brake fluid pressure
gaugeNT151Measuring brake fluid pressurePRECAUTIONS AND
PREPARATIONBR-4NVH Troubleshooting ChartUse the chart below to help
you find the cause of the symptom. If necessary, repair or replace
these parts.Reference
pageBR-19,25BR-19,25BR-23BR-20BR-21,25BR-22BR-25NVHinPDsectionNVHinPDsectionNVHinFA,RAsectionNVHinFAsectionNVHinFAsectionNVHinRAsectionNVHinSTsectionPossible
cause andSUSPECTED
PARTSLiningsorpads-damagedLiningsorpads-unevenwearReturnspringdamagedShimsdamagedRotorordrumimbalanceRotorordrumdamageRotorordrumrunoutRotorordrumdeformationRotorordrumdeflectionRotorordrumrustRotorthicknessvariationDrumoutofroundPROPELLERSHAFTDIFFERENTIALAXLEANDSUSPENSIONTIRESROADWHEELDRIVESHAFTSTEERINGSymptom
BRAKENoise X X X X X X X X X X XShake X X X X X X XShimmy, Judder X
X X X X X X X X X X XX:
ApplicableGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXNOISE, VIBRATION
AND HARSHNESS (NVH) TROUBLESHOOTINGBR-5SBR451DChecking Brake Fluid
LevelG Check fluid level in reservoir tank. It should be between
Maxand Min lines on reservoir tank.G If fluid level is extremely
low, check brake system for leaks.G
Ifthebrakewarninglampcomeson,checkbrakefluidlevelswitch and parking
brake switch.SBR389CChecking Brake LineCAUTION:If
leakageoccursaroundjoints, retightenor, if necessary,replace
damaged parts.1. Check brake lines (tubes and hoses) for cracks,
deteriorationor other damage. Replace any damaged parts.2. Checkfor
oil leakagebyfullydepressingbrakepedal whileengine is
running.SBR992Changing Brake FluidCAUTION:G Refill with new brake
fluid DOT 3.G Always keep fluid level higher than minimum line on
res-ervoir tank.G Never reuse drained brake fluid.G Becareful
nottosplashbrakefluidonpaintedareas;itmaycausepaint damage. If
brakefluidissplashedonpainted areas, wash it away with water
immediately.1. Clean inside of reservoir tank, and refill with new
brake fluid.2. Connect a vinyl tube to each air bleeder valve.3.
Drainbrakefluidfromeachairbleedervalvebydepressingbrake pedal.4.
Refill until brake fluid comes out of each air bleeder valve.Use
same procedure as in bleeding hydraulic system to refillbrake
fluid. Refer to Bleeding Brake System, BR-7.Brake Burnishing
ProcedureBurnish the brake contact surfaces according to the
following pro-cedure after refinishing or replacing drums or
rotors, after replac-ing pads or linings, or if a soft pedal occurs
at very low mileage.CAUTION:Only perform this procedure under safe
road and traffic con-ditions. Use extreme caution.1. Drive the
vehicle on a straight smooth road at 50 km/h(31 MPH).2.
Usemediumbrakepedal/foot effort tobringthevehicletoacomplete stop
from 50 km/h (31 MPH). Adjust brake pedal/footpressuresuchthat
vehiclestoppingtimeequals3to5sec-onds.3. To cool the brake system,
drive the vehicle at 50 km/h(31 MPH) for 1 minute without
stopping.4. Repeat steps 1 to 3, 10 times or more to complete the
burnish-ing procedure.ON-VEHICLE SERVICEBR-6SBR995Bleeding Brake
SystemCAUTION:G Carefully monitor brake fluid level at master
cylinder dur-ing bleeding operation.G If master cylinder is
suspected to have air inside, bleed
airfrommastercylinderfirst.RefertoInstallation,MAS-TER CYLINDER,
BR-15.G Fill reservoir with new brake fluid DOT 3. Make sure it
isfull at all times while bleeding air out of system.G Place a
container under master cylinder to avoid spillageof brake fluid.G
TurnignitionswitchOFFanddisconnect ABSactuatorand electric unit
connector or battery cable.G Bleed air in the following order.a.
Left rear brakeb. Right rear brakec. Left front braked. Right front
brakee. ABS actuator and electric unitSBR419C1. Connect a
transparent vinyl tube to air bleeder valve.2. Fully depress brake
pedal several times.3. With brake pedal depressed, open air bleeder
valve to releaseair.4. Close air bleeder valve.5. Release brake
pedal slowly.6. Repeat steps 2 through 5 until clear brake fluid
comes out ofair bleeder valve.7. Tighten air bleeder to the
specified torque.: 7 - 9 Nm (0.7 - 0.9 kg-m, 61 - 78
in-lb)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXON-VEHICLE
SERVICEBR-7ABR765BRAKE HYDRAULIC LINEBR-8SBR992REMOVALCAUTION:G
Becareful nottosplashbrakefluidonpaintedareas;itmaycausepaint
damage. If brakefluidissplashedonpainted areas, wash it away with
water immediately.G All hoses must be free from excessive bending,
twistingand pulling.1. Connect vinyl tube to air bleeder valve.2.
Drainbrakefluidfromeachairbleedervalvebydepressingbrake pedal.3.
Remove flare nut connecting brake tube and hose, then with-draw
lock spring.4. Cover openings to prevent entrance of dirt whenever
discon-necting brake
line.INSPECTIONCheckbrakelines(tubesandhoses)forcracks,
deteriorationorother damage. Replace any damaged
parts.SBR686CINSTALLATIONCAUTION:G Refill with new brake fluid DOT
3.G Never reuse drained brake fluid.1. Tighten all flare nuts and
connecting bolts.Flare nut:: 15 - 18 Nm (1.5 - 1.8 kg-m, 11 - 13
ft-lb)Connecting bolt:: 17 - 19 Nm (1.7 - 2.0 kg-m, 12 - 14
ft-lb)2. Refill until new brake fluid comes out of each air bleeder
valve.3. Bleed air. Refer to Bleeding Brake System,
BR-7.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXBRAKE HYDRAULIC
LINEBR-9ABR355Proportioning ValveABR184SBR705AAINSPECTIONCAUTION:G
Carefully monitor brake fluid level at master cylinder.G Use new
brake fluid DOT 3.G Becareful
nottosplashbrakefluidonpaintedareas;itmaycausepaint damage. If
brakefluidissplashedonpainted areas, wash it away with water
immediately.G Depress pedal slowly when raising front brake
pressure.G Checkrear brakepressure2secondsafter front brakepressure
reaches specified value.G Disconnect harnessconnector
fromABSactuator andelectric unit before checking.1. Remove front LH
tire.2. Connect tool to air bleeders on front LH brake caliper and
rearLH or RH brake wheel cylinder.3. Install front LH tire.Before
installing front LH tire, confirm the tool is not touchingthe front
LH wheel.4. Bleed air from the tool.5. Check fluid pressure by
depressing brake pedal.Unit: kPa (kg/cm2, psi)Applied pressure
(Front brake) D15884 (60, 853)Output pressure (Rear brake) D23285 -
3678(33.5 - 37.5, 476 - 533)If output pressureisout of
specification, replacemastercylinderassembly.6. Bleed air after
disconnecting the tool. Refer to Bleeding BrakeSystem, BR-7.7.
Install front LH tire.REMOVAL AND INSTALLATIONAlways replace
together with master cylinder as an assembly.G Refer to MASTER
CYLINDER, BR-13.BRAKE HYDRAULIC LINE/CONTROL VALVEBR-10Removal and
InstallationABR815GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXBRAKE
PEDAL AND BRACKETBR-11SBR997InspectionCheck brake pedal for
following items:G Brake pedal bendG Clevis pin deformationG Crack
of any welded portionG Crack or deformation of clevis pin
stopperSBR278ABAdjustmentCheck brake pedal free height from metal
floor.H: Free heightRefer to SDS, BR-71.D: Depressed heightRefer to
SDS, BR-71.Under force of 490 N (50 kg, 110 lb)with engine
runningC: Clearance between pedal stopper andthreaded end of stop
lamp switch0.3 - 1.0 mm (0.012 - 0.039 in)A: Pedal free play at
pedal pad1.0 - 3.0 mm (0.039 - 0.018 in)SBR930If necessary, adjust
brake pedal free height.1. Loosen lock nut and adjust pedal free
height by turning brakebooster input rod. Then tighten lock nut.G
Make sure that the tip of input rod stays inside.2. Loosenlock nut
andadjust clearanceC withstoplampswitch respectively, then tighten
lock nut.3. Check pedal free play.G Make sure that stop lamp is off
when pedal is released.4. Check brake pedals depressed height while
engine is running.If lowerthanspecification, checkforleaks,
airinsystem, ordamage to components (master cylinder, wheel
cylinder, etc.).Make necessary repairs.BRAKE PEDAL AND
BRACKETBR-12ABR766RemovalCAUTION:G Becareful
nottosplashbrakefluidonpaintedareas;itmaycausepaint damage. If
brakefluidissplashedonpainted areas, wash it away with water
immediately.G In the case of brake fluid leakage from the master
cylinder,disassemble the cylinder. Thencheck pistoncups
fordeformation or scratches and replace necessary parts.1. Connect
a vinyl tube to air bleeder valve.2. Drain brake fluid from each
air bleeder valve, depressing brakepedal to empty fluid from master
cylinder.3. Remove brake pipe flare nuts.4. Remove master cylinder
mounting nuts.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXMASTER
CYLINDERBR-13SBR938ADisassembly1. Bend claws of stopper cap
outward.SBR939A2. Remove piston assemblies.G If it isdifficult
toremovesecondarypistonassembly,gradually apply compressed air
through fluid outlet.3. Draw out reservoir tank.InspectionCheck
master cylinder inner wall for pin holes or scratches.Replace if
damaged.ABR767Assembly1. Insert secondary piston assembly. Then
insert primary pistonassembly.G Pay attention to direction of
piston cups in figure at left.Also, insert pistons squarely to
avoid scratches on cylin-der bore.SBR940A2. Install stopper cap.G
Before installing stopper cap, ensure that claws are bentinward.3.
Push reservoir tank seals into cylinder body.4. Push reservoir tank
into cylinder body.MASTER CYLINDERBR-14ABR190InstallationCAUTION:G
Refill with new brake fluid DOT 3.G Never reuse drained brake
fluid.1. Place master cylinder onto brake booster and secure
mount-ing nuts lightly.2. Tighten mounting nuts.: 12 - 15 Nm (1.2 -
1.5 kg-m, 9 - 11 ft-lb)3. Fill up reservoir tank with new brake
fluid.4. Plugall portsonmaster cylinder withfingerstoprevent
airsuction while releasing brake pedal.5. Have driver depress brake
pedal slowly several times until noair comes out of master
cylinder.6. Fit brake lines to master cylinder.7. Tighten flare
nuts.: 15 - 18 Nm (1.5 - 1.8 kg-m, 11 - 13 ft-lb)8. Bleed air
frombrake system. Refer to Bleeding BrakeSystem,
BR-7.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXMASTER
CYLINDERBR-15SBR002AOn-vehicle ServiceOPERATING CHECKG Depress
brake pedal several times with engine off. Afterexhaustingvacuum,
makesurethereisnochangeinpedalstroke.G Depressbrakepedal, thenstart
engine. If pedal goesdownslightly, operation is
normal.SBR365AAAIRTIGHT CHECKG Start engine, andstopit after oneor
twominutes. Depressbrakepedal several timesslowly.
Boosterisairtight if pedalstroke is less each time.G Depress brake
pedal while engine is running, and stop enginewithpedal depressed.
Thepedal strokeshouldnot changeafter holding pedal down for 30
seconds.ABR373RemovalCAUTION:G Becareful
nottosplashbrakefluidonpaintedareas;itmaycausepaint damage. If
brakefluidissplashedonpainted areas, wash it away with water
immediately.G Be careful not todeformor bendbrake pipes
duringremoval of booster.ABR749InspectionOUTPUT ROD LENGTH CHECK1.
Applyvacuumof 66.7kPa(500mmHg, 19.69inHg) tobrake booster with a
handy vacuum pump.2. Add preload of 19.6 N (2 kg, 4.4 lb) to output
rod.3. Check output rod length.Specified length:10.275 - 10.525 mm
(0.4045 - 0.4144 in)BRAKE BOOSTERBR-16SBR116BEInstallationCAUTION:G
Be careful not to deform or bend brake pipes during instal-lation
of booster.G Replace clevis pin if damaged.G Refill with new brake
fluid DOT 3.G Never reuse drained brake fluid.G Takecarenot
todamagebrakebooster mountingboltthread when installing. Due to the
narrow angle ofinstallation,
thethreadscanbedamagedbythedashpanel.A: 135 mm (5.31 in)1.
Beforefittingbooster, temporarilyadjust clevistodimensionshown.2.
Fit booster, then secure mounting nuts (brake pedal bracket tobrake
booster) lightly.3. Connect brake pedal and booster input rod with
clevis pin.4. Secure mounting nuts.: 13 - 16 Nm (1.3 - 1.6 kg-m, 9
- 12 ft-lb)5. Install master cylinder. Refer to Installation,
MASTERCYLINDER, BR-15.6. Adjust brake pedal height and free play.
Refer to BR-12.7. Secure lock nut for clevis.: 16 - 22 Nm (1.6 -
2.2 kg-m, 12 - 16 ft-lb)8. Bleed air. Refer to Bleeding Brake
System, BR-7.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXBRAKE
BOOSTERBR-17SBR225BRemoval and InstallationCAUTION:When installing
vacuum hoses, pay attention to the followingpoints.G Donot
applyanyoil orlubricantstovacuumhoseandcheck valve.G Insert vacuum
tube into vacuum hose as shown.SBR498AGInstall check valve, paying
attention to its direction.InspectionHOSES AND CONNECTORSCheck
vacuum lines and connections and check valve forairtightness,
improper attachment, chafing and deterioration.SBR943ACHECK
VALVECheck vacuum with a vacuum pump.Connect to boostersideVacuum
should exist.Connect to enginesideVacuum should not exist.VACUUM
HOSEBR-18Pad ReplacementWARNING:Clean brake pads with a vacuum dust
collector to minimize thehazard of airborne materials.CAUTION:G
When cylinder body is open, do not depress brake pedalor caliper
piston will pop out.G Be careful not to damage piston boot or get
oil on rotor.Always replace shims when replacing pads.G If
shimsarerustedorshowpeelingof therubbercoat,replace them with new
shims.G It is not necessary to remove connecting bolt except
fordisassemblyorreplacementofcaliperassembly. Inthiscase, suspend
cylinder body with wire so as not to stretchbrake hose.G
Burnishthebrakecontact surfacesafter refinishingorreplacing drums
or rotors, after replacing pads or linings,or if asoft pedal
occursat verylowmileage. Refer toBrake Burnishing Procedure,
ON-VEHICLE SERVICE,BR-6.SBR081A1. Remove master cylinder reservoir
cap.2. Remove lower pin bolt.SBR010B3. Open cylinder body upward.
Then remove pad retainers, returnspring and inner and outer
shims.Standard pad thickness:10 mm (0.39 in)Pad wear limit:2.0 mm
(0.079 in)G Carefully monitor brake fluid level because brake fluid
willreturn to reservoir when pushing back
piston.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXFRONT DISC
BRAKEBR-19SBR983DSBR083ARemovalWARNING:Clean brake pads with a
vacuum dust collector to minimize thehazard of airborne
materials.CAUTION:Suspend caliper assembly with wire so as not to
stretch brakehose.Remove torque member fixing bolts and connecting
bolt.G It is not necessary to remove connecting bolt except
fordisassemblyorreplacementofcaliperassembly. Inthiscase,
suspendcaliper assemblywithwiresoasnot tostretch brake hose.FRONT
DISC BRAKEBR-20SBR085ADisassemblyWARNING:Do not place your fingers
in front of piston.CAUTION:G Do not scratch or score cylinder
wall.G CL28VD type front disc brake uses plastic pistons.
Handlethem carefully.1. Push out pistons and dust covers with
compressed air.Use a wooden block so that both pistons come out
evenly.2. Remove piston seals with a suitable tool.Inspection
CaliperCYLINDER BODYG Check inside surface of cylinders for scores,
rust, wear, dam-age or presence of foreign objects. If any of the
above condi-tions are observed, replace cylinder body.G Minor
damage from rust or foreign objects may be eliminatedby polishing
the surface with a fine emery sandpaper. Replacecylinder body if
necessary.CAUTION:Use brake fluid to clean. Never use mineral
oil.SBR177CPISTONCAUTION:Piston sliding surface is plated. Do not
polish with emery sand-paper even if rust or foreign objects are
stuck to sliding surface.Check pistons for uneven surface, chips or
cracks. Replace if anyof these conditions are observed.SLIDE PIN,
PIN BOLT AND PIN BOOTCheck for wear, cracks or other damage.
Replace if any of theseconditions are observed.SBR089AInspection
RotorRUNOUT1. Check runout using a dial indicator.G Makesurethat
wheel bearingaxial endplayiswithinspecification before measuring.
Refer to FA section(Front Wheel Bearing, ON-VEHICLE
SERVICE).Maximum runout:0.07 mm (0.0028 in)2. If the runout is out
of specification, machine rotor with on-carbrakelathe(MAD, DL-8700,
AMMCO700and705
orequivalent).GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXFRONT DISC
BRAKEBR-21SBR090ATHICKNESSThickness variation (At least 8
positions):Maximum 0.02 mm (0.0008 in)If thickness variation
exceeds specification, machine rotor with on-car brake lathe.Rotor
repair limit:24.0 mm (0.945 in)SBR178CAssembly1. Insert piston seal
into groove on cylinder body.2. With piston boot fitted to piston,
insert piston boot into grooveon cylinder body and install
piston.3. Properly secure piston boot.CAUTION:G Secure dust seal
properly.G Lubricate with new brake fluid before installing plastic
pis-tons into cylinder body.SBR179CASBR084AInstallationCAUTION:G
Refill with new brake fluid DOT 3.G Never reuse drained brake
fluid.1. Install caliper assembly.2. Install brake hose to caliper
securely.3. Install all parts and secure all bolts.4. Bleed air.
Refer to Bleeding Brake System, BR-7.FRONT DISC BRAKEInspection
Rotor
(Contd)BR-22ABR768GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXREAR
DRUM
BRAKEBR-23RemovalWARNING:Cleanbrakeliningwithavacuumdustcollectortominimizethe
hazard of airborne materials.CAUTION:Make sure parking brake lever
is completely released.SBR280B1. Release parking brake lever fully,
then remove drum.G If drum is hard to remove, the following
procedure shouldbe carried out.a. Removeplug, thenshortenadjuster
tomakeclearancebetween brake shoe and drum.SBR093Ab. Install two
bolts as shown. Tighten the two bolts gradually.ABR3692. After
removing retainer, remove spring by rotating shoes.G Be careful not
to damage wheel cylinder piston boots.G Be careful not to damage
parking brake cable when sepa-rating it.3. Remove adjuster.4.
Disconnect parking brake cable from toggle lever.ABR4085. Remove
retainer clip with a suitable tool. Then separate togglelever and
brake shoe.REAR DRUM BRAKEBR-24ABR370Inspection Wheel CylinderG
Check wheel cylinder for leakage.G Check for wear, damage and loose
conditions.Replace if any such condition exists.SBR215BWheel
Cylinder OverhaulG Check all internal parts for wear, rust and
damage. Replace ifnecessary.G Pay attention not to scratch cylinder
when installing pistons.SBR095AInspection DrumMaximum inner
diameter (Repair limit):LT30A 296.5 mm (11.67 in)G Contact surface
should be finished with No. 120 to 150 emerysandpaper.G
Usingabrakelathe, machinebrakedrumif it showsscoremarks, partial
wear or stepped wear.G After brake drumhas been completely
reconditioned orreplaced, check drum and shoes for proper contact
pattern.SBR021AInspection LiningCheck lining thickness.Standard
lining thickness:LT30A 6.1 mm (0.240 in)Lining wear limit (A):LT30A
1.5 mm (0.059 in)ABR371InstallationG Always performshoe clearance
adjustment. Refer toBR-28.G Burnishthebrakecontact surfacesafter
refinishingorreplacing drums or rotors, after replacing pads or
linings,or if asoft pedal occursat verylowmileage. Refer toBrake
Burnishing Procedure, ON-VEHICLE SERVICE,BR-6.1. Fit toggle lever
to brake shoe with retainer clip.2. Apply brake grease to the
contact areas shown at
left.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXREAR DRUM
BRAKEBR-25ABR3963. Shorten adjuster by rotating it.G Pay attention
to direction of adjuster.Wheel ScrewLeft Left-hand threadRight
Right-hand thread4. Connect parking brake cable to toggle lever.5.
Install all parts.G Be careful not to damage wheel cylinder piston
boots.ABR3726. Check all parts are installed properly.G After
installation is completed, adjust shoe-to-drum clear-ance.7.
Install brake drum.8. When installing newwheel cylinder or
overhauling wheelcylinder, bleed air. Refer to Bleeding Brake
System, BR-7.9. Adjust parking brake. Refer to BR-28.G Install all
the parts by referring to the figure below.SBR099AGAfter installing
crank lever on back plate, make sure that thereis no play between
crank lever and back plate. If play exists,adjust boltA and lock
nutB .ABR769REAR DRUM BRAKEInstallation
(Contd)BR-26ABR770GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPARKING
BRAKE CONTROLBR-27Removal and InstallationG Be careful not to
damage cable.G Make sure there is no free play after
installation.Inspection1. Check control lever for wear or other
damage. Replace if nec-essary.2. Check wires for discontinuity or
deterioration. Replace if nec-essary.3. Check warning lamp and
switch. Correct if necessary.4. Check part at each connecting
portion and, if found deformedor damaged,
replace.ABR771AdjustmentAdjust parking brake as follows:1. Fully
release parking brake lever.2. LoosenA and rotateB until parking
brake cable loosens.3. Depressbrakepedal several timesuntil
clickingsounddoesnot occur from rear brakes.4. Adjust clearance
between rear brake shoe and drum.5. Adjust parking brake lever
stroke by rotatingB .6. Pull parking brake lever with specified
force. Check leverstroke and ensure smooth operation.7. Readjust
clearance between rear brake shoe and drum.ABR405PARKING BRAKE
CONTROLBR-28PurposeThe Anti-Lock Brake System (ABS) consists of
electronic and hydraulic components. It allows for control
ofbraking force so locking of the wheels can be avoided.The ABS:1)
Improves proper tracking performance through steering wheel
operation.2) Eases obstacle avoidance through steering wheel
operation.3) Improves vehicle stability.OperationG When the vehicle
speed is less than 10 km/h (6 MPH) this system does not work.G The
Anti-Lock Brake System (ABS) has a self-test function. The system
turns on the ABS warning lampfor 1 second each time the ignition
switch is turned ON. After the engine is started, the ABS
warninglamp turns off. The system performs a test the first time
the vehicle reaches 6 km/h (4 MPH). A mechani-cal noise may be
heard as the ABS performs this self-test. This is a normal part of
the self-test feature. Ifa malfunction is found during this check,
the ABS warning lamp will stay on.G While driving, a mechanical
noise may be heard during ABS operation. This is a normal
condition.ABS Hydraulic CircuitSBR859D1 Inlet solenoid valve2
Outlet solenoid valve3 Reservoir4 Pump5 Motor6 Inlet valve7 Outlet
valve8 Bypass check valve9
DamperGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXANTI-LOCK BRAKE
SYSTEMBR-29System ComponentsABR809System DescriptionWHEEL SENSORThe
sensor unit consists of a gear-shaped sensor rotor and a sen-sor
element. The element contains a bar magnet around which acoil is
wound. The sensor is installed on the back of the brake
rotorandthebackof therear brakedrum.Asthewheel rotates, thesensor
generates a sine-wave pattern. The frequency and voltageincrease(s)
as the rotating speed increases.ABR665CONTROL UNIT (built-in ABS
actuator and electric unit)The control unit computes the wheel
rotating speed by the signalcurrent sent from the sensor. Then it
supplies a DC current to theactuator solenoid valve. It also
controls ON-OFF operation of thevalve relay and motor relay. If any
electrical malfunction should bedetected in the system, the
controlunit causes the warning lamptolight up. Inthiscondition,
theABSwill bedeactivatedbythecontrol unit, andthevehicles
brakesystemreverts tonormaloperation. (For control unit layout,
refer to ABS ACTUATOR ANDELECTRIC UNIT, BR-31.)ANTI-LOCK BRAKE
SYSTEMBR-30G SENSORThe G sensor senses deceleration during braking
to determine whether the vehicle is being driven on a high road
(asphalt road, etc.) or a low road (snow-covered road, etc.). It
then sends a signal to the ABS con-trol unit.ABR810The reed switch
turns on when it is affected by a magnetic field. During sudden
deceleration (braking on ahigh road), the weight moves and the
magnet in the weight moves away from the reed switch. The mag-netic
field then diminishes and the reed switch turns off.SBR071EABS
ACTUATOR AND ELECTRIC UNITThe ABS actuator and electric unit
contains:G An electric motor and pumpG Two relaysG Six solenoid
valves, each inlet and outlet for LH front RH front RearG ABS
control unitThis component controls the hydraulic circuit and
increases, holdsor decreaseshydraulicpressuretoall or individual
wheels. TheABS actuator and electric unit is serviced as an
assembly.ABS actuator operationInlet solenoidvalveOutlet
solenoidvalveNormal brake operation OFF (Open) OFF (Closed)Master
cylinder brake fluid pressure is directly trans-mitted to wheel
cylinder via the inlet solenoid valve.ABS operationPressure hold ON
(Closed) OFF (Closed)Hydraulic circuit is shut off to hold the
wheel cylinderbrake fluid pressure.PressuredecreaseON (Closed) ON
(Open)Wheel cylinder brake fluid is sent to reservoir via theoutlet
solenoid valve. Then it is pushed up to themaster cylinder by
pump.PressureincreaseOFF (Open) OFF (Closed)Master cylinder brake
fluid pressure is transmitted towheel
cylinder.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXANTI-LOCK BRAKE
SYSTEMSystem Description (Contd)BR-31Removal and
InstallationCAUTION:Be careful not to damage sensor edge and sensor
rotor teeth.When removing the front wheel hub or rear axle
shaftassembly, disconnect the ABS wheel sensor from the assem-bly
and move it away.FRONT WHEEL SENSORABR686ANTI-LOCK BRAKE
SYSTEMBR-32REAR WHEEL
SENSORABR687GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXANTI-LOCK
BRAKE SYSTEMRemoval and Installation (Contd)BR-33ABR811G
SENSORAlwaysreplaceGsensorifbumpedordropped. Otherwise,performance
characteristics of Gsensor will be changed,which in turn changes
ABS control performance characteris-tics.ABS ACTUATOR AND ELECTRIC
UNITABR704Removal1. Disconnect battery cable.2. Drain brake fluid.
Refer to Changing Brake Fluid, BR-6.3. Remove mounting bracket
fixing bolts and nuts.4. Disconnect connector, brake pipes and
remove fixing nuts.InstallationCAUTION:After installation, refill
brakefluid. Thenbleedair. Refer toBleeding Brake System, BR-7.1.
Connect brake pipes temporarily.2. Tighten fixing bolts and nuts.3.
Tighten brake pipes.4. Connect connector and battery
cable.ANTI-LOCK BRAKE SYSTEMRemoval and Installation
(Contd)BR-34SEF233GSEF234GHow to Perform Trouble Diagnoses for
Quickand Accurate
RepairINTRODUCTIONTheABSsystemhasanelectroniccontrol unit tocontrol
majorfunctions. The control unit accepts input signals from sensors
andinstantly drives the actuators. It is essential that both kinds
of sig-nals are proper and stable. It is also important to check
for conven-tional problemssuchasairleaksinboosterlines, lackof
brakefluid, or other problems with the brake system.It is much more
difficult to diagnose a problem that occurs intermit-tently rather
than continuously. Most intermittent problems arecaused by poor
electric connections or faulty wiring. In this case,careful
checking of suspicious circuits may help prevent thereplacement of
good parts.A visual check only may not find the cause of the
problems, so aroad test should be performed.Before undertaking
actual checks, take a few minutes to talk witha customer who
approaches with an ABS complaint. The customeris a very good source
of information on such problems; especiallyintermittent ones.
Throughthetalkswiththecustomer, findoutwhat symptoms are present
and under what conditions they occur.Start
yourdiagnosisbylookingforconventional problemsfirst.This is one of
the best ways to troubleshoot brake problems on anABS controlled
vehicle.Also check related service bulletins for
information.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE
DIAGNOSESBR-35WORK FLOWCHECK IN Reference itemLISTEN TO CUSTOMER
COMPLAINTSINVESTIGATE ITEMS YOU SHOULD CARRY OUTRELATED TO EACH
SYMPTOM AND NOTEGo to MALFUNCTIONCODE/SYMPTOMCHART, BR-45.CHECK FOR
ANY SERVICE BULLETINS.ELIMINATE GOOD SYSTEMS AND GOOD PARTSGo to
PreliminaryCheck, BR-37.Not self-diagnostic item Self-diagnostic
itemDETERMINE MALFUNC-TIONING CIRCUIT(S) ORPART(S).Go to
Self-diagnosis,BR-43.Self-diagnosisELIMINATE GOOD PART(S),
HARNESS(ES) OR CON-NECTOR(S) THROUGH ELECTRICAL TESTINGGGo to
DiagnosticProcedure(s) 7 - 13,BR-62 - 67.GGo to ComponentParts and
HarnessConnector Location,BR-38.Malfunctioningharness(es)
andconnector(s)Malfunctioning partsINSPECTION OF EACHCOMPONENT Go
to Diagnostic Pro-cedure(s) 1 - 6, BR-53- 61REPAIRREPAIR OR
REPLACENGFINAL CHECKOKCHECK OUTTROUBLE DIAGNOSESHow to Perform
Trouble Diagnoses for Quickand Accurate Repair
(Contd)BR-36SBR451DPreliminary
CheckSBR389CSBR058CSBR059CABR665Check brake fluid level in
reservoirtank.Low fluid level may indicate brake padwear or leakage
from brake line.Check brake line for leakage.OKNGRepair.Check brake
booster for operation and airtightness. Refer to
BR-17.OKNGReplace.Check brake pads, rotors, linings anddrums. Refer
to BR-25.OKNGReplace.Check brake fluid level in reservoir
tankagain.OKNGFill up brake fluid.Check warning lamp
activation.When ignition switch is turned ON, warn-ing lamp turns
on.OKNGCheck fuse, warning lampbulb and warning lamp cir-cuit.Check
warning lamp for deactivation afterengine is started.OKNGGo to
Self-diagnosis,BR-43, 47.Drive vehicle at speeds over 30 km/h
(19MPH) for at least one minute.Ensure warning lamp remains off
whiledriving.OKNGGo to Self-diagnosis,BR-43,
47.ENDGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE
DIAGNOSESBR-37Component Parts and Harness
ConnectorLocationABR812TROUBLE
DIAGNOSESBR-38SchematicABR744GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE
DIAGNOSESBR-39Wiring Diagram ABS ABR745TROUBLE
DIAGNOSESBR-40ABR829GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE
DIAGNOSESWiring Diagram ABS (Contd)BR-41ABR747TROUBLE
DIAGNOSESWiring Diagram ABS (Contd)BR-42Self-diagnosisFUNCTIONG
When a problem occurs in the ABS, the warning lamp on theinstrument
panel comes on. To start the self-diagnostic resultsmode, ground
the self-diagnostic (check) terminallocated onData Link Connector
for CONSULT. The location of the mal-function is indicated by the
warning lamp flashing.ABR697SELF-DIAGNOSIS
PROCEDUREABR665ABR698Drive vehicle over 30 km/h (19 MPH) forat
least one minute.Turn ignition switch OFF.Ground terminal 4 of Data
link con-nector for CONSULT with a suitable har-ness.Turn ignition
switch ON while ground-ing terminal 4.Do not depress brake
pedal.After 3.0 seconds, the warning lampstarts flashing to
indicate the malfunctioncode No. (See NOTE.)Verify the location of
the malfunction withthe malfunction code chart. Refer toBR-45. Then
make the necessary repairsfollowing the diagnostic procedures.After
the malfunctions are repaired, erasethe malfunction codes stored in
the con-trol unit. Refer to BR-44.Rerun the self-diagnostic results
mode toverify that the malfunction codes havebeen erased.Disconnect
the check terminal from theground. The self-diagnostic results
modeis now complete.NOTE: The indication terminatesafter five
minutes.However, when the ignitionswitch is turned fromOFF to ON,
the indica-tion starts flashing again.A(Go to next
page.)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE
DIAGNOSESBR-43ACheck warning lamp for deactivation afterdriving
vehicle over 30 km/h (19 MPH)for at least one minute.After making
certain that warning lampdoes not come on, test the ABS in a
safearea to verify that it functions properly.HOW TO READ
SELF-DIAGNOSTIC RESULTS (Malfunction codes)G Determine the code No.
by counting the number of times the warning lamp flashes on and
off.G When severalmalfunctions occur at one time, up to three code
numbers can be stored; the latest mal-function will be indicated
first.G The indication begins with the start code 12. After that a
maximum of three code numbers appear in theorder of the latest one
first. The indication then returns to the start code 12 to repeat
(the indication willstay on for five minutes at the most).G The
malfunction code chart is on the next page.SBR457DABR256HOW TO
ERASE SELF-DIAGNOSTIC RESULTS(Malfunction codes)1. Disconnect the
check terminal from ground (ABS warning lampwill stay lit).2.
Within 12.5 seconds, ground the check terminal 3 times.
Eachterminal ground must last more than 1 second. The ABS
warn-inglampgoesout aftertheeraseoperationhasbeencom-pleted.3.
Perform self-diagnosis again. Refer to BR-43. Only the start-code
should appear, with no malfunction codes.TROUBLE
DIAGNOSESSelf-diagnosis (Contd)BR-44MALFUNCTION CODE/SYMPTOM
CHARTCode No./Symptom(No. of warning lamp flashes)Malfunctioning
part Diagnostic procedure45 Actuator front left outlet solenoid
valve 246 Actuator front left inlet solenoid valve 241 Actuator
front right outlet solenoid valve 242 Actuator front right inlet
solenoid valve 255 Actuator rear outlet solenoid valve 256 Actuator
rear inlet solenoid valve 225 1 Front left sensor (open-circuit)
126 1 Front left sensor (short-circuit) 121 1 Front right sensor
(open-circuit) 122 1 Front right sensor (short-circuit) 131 1 Rear
right sensor (open-circuit) 132 1 Rear right sensor (short-circuit)
135 1 Rear left sensor (open-circuit) 136 1 Rear left sensor
(short-circuit) 118 1 Sensor rotor 117 G sensor and circuit 561 3
Actuator motor or motor relay 363 Solenoid valve relay 257 2 Power
supply (Low voltage) 471 Control unit 6Warning lamp stays on when
ignitionswitch is turned ONControl unit power supply circuitWarning
lamp bulb circuitControl unit or control unit connectorSolenoid
valve relay stuckPower supply for solenoid valve relay
coil13Warning lamp does not come onwhen ignition switch is turned
ONFuse, warning lamp bulb or warning lamp circuitControl
unit12Pedal vibration and noise 11Long stopping distance
9Unexpected pedal action 8ABS does not work 10ABS works frequently
71: If one or more wheels spin on a rough or slippery road for 40
seconds or more, the ABS warning lamp will illuminate. This doesnot
indicate a malfunction. Only in the case of the short-circuit (Code
Nos. 26, 22, 32 and 36), after repair the ABS warning lampalso
illuminates when the ignition switch is turned ON. In this case,
drive the vehicle at speeds greater than 30 km/h (19 MPH)for
approximately 1 minute as specified in SELF-DIAGNOSIS PROCEDURE,
BR-43. Check to ensure that the ABS warninglamp goes out while the
vehicle is being driven.2: The trouble code 57, which refers to a
low power supply voltage, does not indicate that the ABS control
unit is malfunctioning.Do not replace the ABS control unit with a
new one.3: The trouble code 61 can sometimes appear when the ABS
motor is not properly grounded. If it appears, be sure to check
thecondition of the ABS motor ground circuit
connection.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE
DIAGNOSESSelf-diagnosis (Contd)BR-45CONSULTCONSULT APPLICATION TO
ABSITEMSELF-DIAGNOSTICRESULTSDATA MONITOR ACTIVE TESTFront right
wheel sensor X X Front left wheel sensor X X Rear right wheel
sensor X X Rear left wheel sensor X X G switch (G sensor) X X XStop
lamp switch X Front right inlet solenoid valve X X XFront right
outlet solenoid valve X X XFront left inlet solenoid valve X X
XFront left outlet solenoid valve X X XRear inlet solenoid valve X
X XRear outlet solenoid valve X X XActuator solenoid valve relay X
X Actuator motor relay(ABS MOTOR is shown on the Data
Monitorscreen.)X X XABS warning lamp X Battery voltage X X X:
Applicable: Not applicableECU (ABS control unit) part number
modeIgnore the ECU part number displayed in the ECU PART NUMBER
MODE. ECU (ABS control unit) is part ofthe ABS actuator and
electric unit, serviced as an assembly.TROUBLE
DIAGNOSESBR-46SEF321VCONSULT Inspection ProcedureSELF-DIAGNOSIS
PROCEDURESBR455DSBR080ESST412BSBR950C1) Turn ignition switch OFF.2)
Connect CONSULT to Data Link Con-nector for CONSULT.1) Start
engine.2) Drive vehicle over 30 km/h (19 MPH)for at least one
minute.1) Stop vehicle with engine runningand touch START on
CONSULTscreen.2) Touch ABS.3) Touch SELF-DIAG RESULTS.G The screen
shows the detected mal-function and how many times the igni-tion
switch has been turned since themalfunction.Make the necessary
repairs following thediagnostic procedures.After the malfunctions
are repaired, erasethe self-diagnostic results stored in thecontrol
unit by touching ERASE.Check warning lamp for deactivation
afterdriving vehicle over 30 km/h (19 MPH) forat least one
minute.Test the ABS in a safe area to verify that itfunctions
properly.Note: SELF-DIAG RESULTS screen shows the detected
malfunction andhow many times the ignition switch has been turned
since the
mal-function.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE
DIAGNOSESBR-47SELF-DIAGNOSTIC RESULTS MODEDiagnostic item
Diagnostic item is detected when ...DiagnosticprocedureFR RH
SENSOR[OPEN]G Circuit for front right wheel sensor is open.(An
abnormally high input voltage is entered.)1FR LH SENSOR[OPEN]G
Circuit for front left wheel sensor is open.(An abnormally high
input voltage is entered.)1RR RH SENSOR[OPEN]G Circuit for rear
right sensor is open.(An abnormally high input voltage is
entered.)1RR LH SENSOR[OPEN]G Circuit for rear left sensor is
open.(An abnormally high input voltage is entered.)1FR RH
SENSOR[SHORT]G Circuit for front right wheel sensor is shorted.(An
abnormally low input voltage is entered.)1FR LH SENSOR[SHORT]G
Circuit for front left wheel sensor is shorted.(An abnormally low
input voltage is entered.)1RR RH SENSOR[SHORT]G Circuit for rear
right sensor is shorted.(An abnormally low input voltage is
entered.)1RR LH SENSOR[SHORT]G Circuit for rear left sensor is
shorted.(An abnormally low input voltage is entered.)1ABS
SENSOR[ABNORMAL SIGNAL]G Teeth damage on sensor rotor or improper
installation of wheel sensor.(Abnormal wheel sensor signal is
entered.)1FR RH IN ABS SOL[OPEN]G Circuit for front right inlet
solenoid valve is open.(An abnormally low output voltage is
entered.)2FR LH IN ABS SOL[OPEN]G Circuit for front left inlet
solenoid valve is open.(An abnormally low output voltage is
entered.)2RR IN ABS SOL[OPEN]G Circuit for rear inlet solenoid
valve is open.(An abnormally low output voltage is entered.)2FR RH
IN ABS SOL[SHORT]G Circuit for front right inlet solenoid valve is
shorted.(An abnormally high output voltage is entered.)2FR LH IN
ABS SOL[SHORT]G Circuit for front left inlet solenoid valve is
shorted.(An abnormally high output voltage is entered.)2RR IN ABS
SOL[SHORT]G Circuit for rear inlet solenoid valve is shorted.(An
abnormally high output voltage is entered.)2FR RH OUT ABS
SOL[OPEN]G Circuit for front right outlet solenoid valve is
open.(An abnormally low output voltage is entered.)2FR LH OUT ABS
SOL[OPEN]G Circuit for front left outlet solenoid valve is open.(An
abnormally low output voltage is entered.)2RR OUT ABS SOL[OPEN]G
Circuit for rear outlet solenoid valve is open.(An abnormally low
output voltage is entered.)2FR RH OUT ABS SOL[SHORT]G Circuit for
front right outlet solenoid valve is shorted.(An abnormally high
output voltage is entered.)2FR LH OUT ABS SOL[SHORT]G Circuit for
front left outlet solenoid valve is shorted.(An abnormally high
output voltage is entered.)2RR OUT ABS SOL[SHORT]G Circuit for rear
outlet solenoid valve is shorted.(An abnormally high output voltage
is entered.)2ABS ACTUATOR RELAY[ABNORMAL]G Actuator solenoid valve
relay is ON, even if control unit sends off signal.G Actuator
solenoid valve relay is OFF, even if control unit sends on
signal.2ABS MOTOR RELAY[ABNORMAL]G Circuit for ABS motor relay is
open or shorted.G Circuit for actuator motor is open or shorted.G
Actuator motor relay is stuck.3BATTERY VOLT[VB-LOW]G Power source
voltage supplied to ABS control unit is abnormally low. 4CONTROL
UNIT G Function of calculation in ABS control unit has failed.
6G-SENSOR[ABNORMAL]G G sensor circuit is open or shorted. 5: If one
or more wheels spin on a rough or slippery road for 40 seconds or
more, the ABS warning lamp will illuminate. This doesnot indicate a
malfunction. Only in the case of the short-circuit, after repair
the ABS warning lamp also illuminates when the igni-tion switch is
turned ON. In this case, drive the vehicle at speeds greater than
30 km/h (19 MPH) for approximately 1 minute asspecified in
SELF-DIAGNOSIS PROCEDURE, BR-43. Check to ensure that the ABS
warning lamp goes out while the vehicleis being driven.TROUBLE
DIAGNOSESCONSULT Inspection Procedure (Contd)BR-48SBR455DDATA
MONITOR PROCEDURESBR080ESST412BSBR936CSBR937C1) Turn ignition
switch OFF.2) Connect CONSULT to Data Link Connector for CONSULT.3)
Turn ignition switch ON.1) Touch START on CONSULT screen.2) Touch
ABS.3) Touch DATA MONITOR.1) Touch SETTING on SELECT MONITOR ITEM
screen.2) Touch LONG TIME on SET RECORDING COND screen.3) Touch
START on SELECT MONITOR
ITEM.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE
DIAGNOSESCONSULT Inspection Procedure (Contd)BR-49SBR455DACTIVE
TEST PROCEDUREG When conducting Active test, vehicle must be
stationary.G When ABS warning lamp stays on, never conduct Active
test.SBR080ESST412BSBR857DSBR934C1) Turn ignition switch OFF.2)
Connect CONSULT to Data Link Connector for CONSULT.3) Start
engine.1) Touch START on CONSULT screen.2) Touch ABS.3) Touch
ACTIVE TEST.1) Select active test item by touching screen.2) Touch
START.Carry out the active test by touching screen key.TROUBLE
DIAGNOSESCONSULT Inspection Procedure (Contd)BR-50DATA MONITOR
MODEMONITOR ITEM CONDITION SPECIFICATIONFR RH SENSORFR LH SENSORRR
RH SENSORRR LH SENSORDrive vehicle.(Each wheel is rotating.)Wheel
speed signal(Almost the same speed as speedometer.)STOP LAMP SW
Brake is depressed.Depress the pedal: ONRelease the pedal:
OFFG-SWITCHVehicle is driven.Vehicle is stopped.Brake is
applied.During sudden braking while driving on high roads
(asphaltroads, etc.): ONWhile vehicle is stopped or during
constant-speed driving: OFFFR RH IN SOLFR RH OUT SOLFR LH IN SOLFR
LH OUT SOLRR IN SOLRR OUT SOL1. Drive vehicle at speeds over30 km/h
(19 MPH) for atleast one minute.2. Engine is running.Operating
conditions for each solenoid valve are indicated.ABS is not
operating: OFFMOTOR RELAYABS is not operating: OFFABS is operating:
ONACTUATOR RELAYIgnition switch is ON orengine is running.Ignition
switch ON (Engine stops): OFFEngine running: ONWARNING LAMPABS
warning lamp is turned on: ONABS warning lamp is turned off:
OFFBATTERY VOLT Power supply voltage for control unitACTIVE TEST
MODETEST ITEM CONDITION JUDGEMENTFR RH SOLENOIDFR LH SOLENOIDREAR
SOLENOIDEngine is running.Brake fluid pressure control operationIN
SOL OUT SOLUP (Increase):KEEP (Hold):DOWN
(Decrease):OFFONONOFFOFFONABS MOTORABS actuator motorON: Motor runs
(ABS motor relay ON)OFF: Motor stops (ABS motor relay OFF)G SWITCH
Ignition switch is ON.G SWITCH (G SENSOR),ON: Set G SWITCH MONITOR
ON(G switch circuit is closed.)OFF: Set G SWITCH MONITOR OFF(G
switch circuit is open.)Note: Active test will automatically stop
ten seconds after the test starts. (LIMIT SIGNAL monitor
showsON.)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE
DIAGNOSESCONSULT Inspection Procedure (Contd)BR-51ABR663Ground
Circuit CheckABS ACTUATOR AND ELECTRIC UNIT GROUNDG Check
resistance between ABS actuator and electric unit con-nector
terminals and ground.Resistance: approximately 0TROUBLE
DIAGNOSESBR-52ABR772Diagnostic Procedure 1 (Wheel sensor or
rotor)Malfunction code No. 21, 22, 25, 26, 31, 32, 35, 36 or
18ABR642ABR773INSPECTION START1. Disconnect connectors from ABS
actua-tor and electric unit and wheel sensorof malfunction code No.
Check termi-nals for damage or loose connections.Then reconnect
connectors.2. Carry out self-diagnosis again.Does warning lamp
activate again?YesNoInspection endCHECK WHEEL SENSOR ELECTRICAL.1.
Disconnect ABS actuator and electricunit connector.2. Check
resistance between ABS actua-tor and electric unit
connectorE39(body side) terminals.Code No. 21 or 22 (Front RH
wheel)Terminals4 and5Code No. 25 or 26 (Front LH wheel)Terminals6
and7Code No. 31 or 32 (Rear RH wheel)Terminals8 and9Code No. 35 or
36 (Rear LH wheel)Terminals1 and2Resistance: Front 1.28 - 1.92
kRear 1.28 - 1.92 kNGOKA (Go to next page.)CHECK WHEEL SENSOR.Check
each sensor for resistance.Resistance: Front 1.28 - 1.92 kRear 1.28
- 1.92 kNGOKCheck the following.G Harness connectorsE2
,E16,E39,E53,C11,C12,C102G Harness for open orshort between
wheelsensor connectors andABS actuator and elec-tric unitIf NG,
repair harness orconnectors.REPLACE.Replace wheel
sensor.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES
FOR SELF-DIAGNOSTIC ITEMSBR-53ANoteCHECK TIRE.Check for inflation
pressure, wear andsize of each tire.OKNGNoteAdjust tire pressure
orreplace tire(s).NoteCHECK WHEEL BEARING.Check wheel bearing axial
end play.OKNoteCHECK SENSOR ROTOR.Check sensor rotor for damaged
teeth.OKNGNoteReplace sensor rotor.CHECK HARNESS CONNECTOR.Check
ABS actuator and electric unit pinterminals for damage or the
connection ofABS actuator and electric unit harnessconnector.
Reconnect ABS actuator andelectric unit harness connector.
Thenretest.Note:Wheelpositionshouldbedistinguishedbycodenum-bers
except code No. 18 (sensor rotor).TROUBLE DIAGNOSES FOR
SELF-DIAGNOSTIC ITEMSDiagnostic Procedure 1 (Wheel sensor or
rotor)(Contd)BR-54ABR774Diagnostic Procedure 2 (ABS actuator
solenoidvalve and solenoid valve relay)ABR646Malfunction code Nos.
41, 42, 45, 46, 55, 56, 63CHECK FUSIBLE LINK.Check 40A fusible link
. For fusible linklayout, refer to POWER SUPPLY ROUT-ING in EL
section.OKNGA (Go to next page.)CHECK CONNECTOR.1. Disconnect ABS
actuator and electricunit connector. Check terminals fordamage or
loose connection. Thenreconnect connector.2. Carry out
self-diagnosis again.Does warning lamp activate
again?YesNoInspection endCHECK ABS ACTUATOR AND ELECTRICUNIT GROUND
CIRCUIT.Refer to ABS ACTUATOR AND ELEC-TRIC UNIT GROUND in Ground
CircuitCheck, BR-52.OKNGRepair harness and con-nector.CHECK
SOLENOID VALVE RELAYPOWER SUPPLY CIRCUIT.1. Disconnect ABS actuator
and electricunit connector.2. Check voltage between ABS actuatorand
electric unit connectorE39 (bodyside) terminal18 and ground.Battery
voltage should exist.OKNGCheck the following.G Harness
connectorE39G Harness for open orshort between ABSactuator and
electric unitand fusible linkIf NG, repair harness
orconnector.REPLACE.Replace ABS actuator and electric
unit.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR
SELF-DIAGNOSTIC ITEMSBR-55ABR647AREPLACE.Replace fusible link.Does
the fusible link blow out whenignition switch is turned
ON?YesNoInspection endCHECK SOLENOID VALVE RELAYPOWER SUPPLY
CIRCUIT FOR SHORT.1. Disconnect battery cable and ABSactuator and
electric unit connector.2. Check continuity between ABS actuatorand
electric unit connectorE39 (bodyside) terminal18 and
ground.Continuity should not exit.OKNGCheck the following.G Harness
connectorE39G Harness for open orshort between ABSactuator and
electric unitand fusible linkIf NG, repair harness
orconnector.REPLACE.Replace ABS actuator and electric unit.TROUBLE
DIAGNOSES FOR SELF-DIAGNOSTIC ITEMSDiagnostic Procedure 2 (ABS
actuator solenoidvalve and solenoid valve relay)
(Contd)BR-56ABR648Diagnostic Procedure 3 (Motor relay or
motor)Malfunction code No. 61ABR649CHECK FUSIBLE LINK.Check 40A
fusible link . For fusible linklayout, refer to POWER SUPPLY
ROUT-ING in EL section.OKNGA (Go to next page.)CHECK CONNECTOR.1.
Disconnect ABS actuator and electricunit connector. Check terminals
fordamage or loose connection. Thenreconnect connector.2. Carry out
self-diagnosis again.Does warning lamp activate
again?YesNoInspection endCHECK ABS ACTUATOR AND ELECTRICUNIT GROUND
CIRCUIT.Refer to ABS ACTUATOR AND ELEC-TRIC UNIT GROUND in Ground
CircuitCheck, BR-52.OKNGRepair harness and termi-nals.CHECK MOTOR
RELAY POWER SUP-PLY CIRCUIT.1. Disconnect ABS actuator and
electricunit connector.2. Check voltage between ABS actuatorand
electric unit connectorE39 (bodyside) terminal17 and ground.Battery
voltage should exist.OKNGCheck the following.G Harness
connectorE39G Harness for open orshort between ABSactuator and
electric unitand fusible linkIf NG, repair harness
orconnector.REPLACE.Replace ABS actuator and electric
unit.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR
SELF-DIAGNOSTIC ITEMSBR-57ABR650AREPLACE.Replace fusible link.Does
the fusible link blow out whenignition switch is turned
ON?YesNoInspection endCHECK MOTOR RELAY POWER SUP-PLY CIRCUIT FOR
SHORT.1. Disconnect battery cable and ABSactuator and electric unit
connectorE39.2. Check continuity between ABS actuatorand electric
unit connectorE39 (bodyside) terminal17 and ground.Continuity
should not exist.OKNGCheck the followingG Harness connectorE39G
Harness for open orshort between ABSactuator and electric unitand
fusible linkIf NG, repair harness orconnector.REPLACE.Replace ABS
actuator and electric unit.TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
ITEMSDiagnostic Procedure 3 (Motor relay or
motor)(Contd)BR-58ABR651Diagnostic Procedure 4 (Low
voltage)ABR652ABR775Malfunction code No. 57CHECK FUSE.Check 10A
fuse . For fuse layout,refer to POWER SUPPLY ROUTING inEL
section.OKNGACHECK CONNECTOR.1. Disconnect ABS actuator and
electricunit connector. Check terminals fordamage or loose
connection. Thenreconnect connector.2. Carry out self-diagnosis
again.Does warning lamp activate again?YesNoInspection end.CHECK
ABS ACTUATOR AND ELECTRICUNIT GROUND CIRCUIT.Refer to ABS ACTUATOR
AND ELEC-TRIC UNIT GROUND in Ground CircuitCheck, BR-52.OKNGRepair
harness and con-nector.CHECK ABS ACTUATOR AND ELEC-TRIC UNIT POWER
SUPPLY CIRCUIT.1. Disconnect ABS actuator and electricunit
connector.2. Check voltage between ABS actuatorand electric unit
connectorE39 (bodyside) terminal15 and ground.Battery voltage
should exist whenignition switch is turned ON.OKNGCheck the
following.G Harness connectorE39G Harness for open or shortbetween
ABS actuatorand electric unit and fuseREPLACE.Replace ABS actuator
and electric unit.AREPLACE.Replace fuse.Does the fuse blow out when
ignitionswitch is turned ON?YESNoInspection end.CHECK ABS ACTUATOR
AND ELEC-TRIC UNIT POWER SUPPLY CIRCUITFOR SHORT.1. Disconnect
battery cable and ABSactuator and electric unit connectorE39.2.
Check continuity between ABS actuatorand electric unit connectorE39
(bodyside) terminal15 and ground.Continuity should not
exist.OKNGCheck the following.G Harness connectorE39G Harness for
open orshort between ABSactuator and electric unitand fuseIf NG,
repair harness orconnector.REPLACE.Replace ABS actuator and
electric unit.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE
DIAGNOSES FOR SELF-DIAGNOSTIC ITEMSBR-59ABR653Diagnostic Procedure
5 (G sensor)Malfunction code No. 17ABR654ABR655CHECK CONNECTOR.1.
Disconnect ABS actuator and electricunit connector. Check terminals
fordamage or loose connection. Thenreconnect connector.2. Carry out
self-diagnosis again.Does warning lamp activate
again?YesNoInspection endCHECK G SENSOR.Refer to G SENSOR in
Electrical Compo-nents Inspection, BR-69.OKNGReplace G sensor.CHECK
G SENSOR POWER SUPPLYCIRCUIT.1. Disconnect G sensor connectors.2.
Check voltage between G sensor con-nectorM69 ,M70 (body side)
termi-nals2,15 and ground.Battery voltage should exist.OKNGCheck
the following.G Harness connectorsM69 ,M70 ,E39G Harness for open
orshort between G sensorand ABS actuator andelectric unitIf NG,
repair harness orconnectors.CHECK G SENSOR CIRCUITS.1. Disconnect
ABS actuator and electricunit connector and G sensor connec-tors.2.
Check continuity between ABS actuatorand electric unit connectorE39
(bodyside) terminals10 ,20 and G sensorconnectorsM69 ,M70 (body
side) ter-minals10 ,20 .Continuity should exist.OKNGCheck the
following.G Harness connectorsM69 ,M70 ,E39,E53G Harness for open
orshort between G sensorand ABS actuator andelectric unitIf NG,
repair harness orconnectors.REPLACE.Replace ABS actuator and
electric unit.TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
ITEMSBR-60ABR657Diagnostic Procedure 6 (Control unit)Malfunction
code No. 71CHECK CONNECTOR.1. Disconnect ABS actuator and
electricunit connector.Check terminals for damage or
looseconnections. Then reconnect connector.2. Carry out
self-diagnosis again.Does warning lamp activate
again?YesNoInspection endCHECK ABS ACTUATOR AND ELECTRICUNIT POWER
SUPPLY CIRCUIT.Check voltage. Refer to in DiagnosticProcedure 4,
BR-59.CHECK SELF-DIAGNOSTIC RESULTS.Does warning lamp indicate code
No. 71again?NoYesReplace ABS actuator andelectric
unit.INSPECTION.Inspect the system according to the
codeNo.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES
FOR SELF-DIAGNOSTIC ITEMSBR-61Diagnostic Procedure 7 (ABS
worksfrequently.)CHECK BRAKE FLUID PRESSURE.Check brake fluid
pressure distribution.Refer to Proportioning Valve,
Inspection,BR-10.OKNGRepair. Then perform Pre-liminary Check, refer
toBR-37.CHECK WHEEL SENSOR.1. Check wheel sensor connector for
ter-minal damage or loose connections.2. Perform wheel sensor
mechanicalcheck.Refer to CHECK SENSOR ROTOR inDiagnostic Procedure
1, BR-53.OKNGRepair.CHECK FRONT AXLES.Check front axles for
excessive loose-ness. Refer to FA section (Front WheelBearing,
ON-VEHICLE SERVICE).OKNGRepair.Go to in Diagnostic Procedure
8,BR-63.TROUBLE DIAGNOSES FOR SYMPTOMSBR-62SBR540ADiagnostic
Procedure 8 (Unexpected pedalaction)ABR665CHECK BRAKE PEDAL
STROKE.Check brake pedal stroke. Is strokeexcessively
large?NoYesPerform PreliminaryCheck, refer to BR-37.CHECK
MECHANICAL BRAKE SYSTEMPERFORMANCE.Disconnect ABS actuator and
electric unitconnector and check whether brake
iseffective.YesNoPerform PreliminaryCheck, refer to BR-37.CHECK
WARNING LAMP ACTIVATE.Ensure warning lamp remains off
whiledriving.OKNGCarry out self-diagnosis.Refer to BR-43, 47.CHECK
WHEEL SENSOR.1. Check wheel sensor connector for ter-minal damage
or loose connection.2. Perform wheel sensor mechanicalcheck.Refer
to CHECK SENSOR ROTOR inDiagnostic Procedure 1,
BR-53.OKNGRepair.CHECK HARNESS CONNECTOR.Check ABS actuator and
electric unit pinterminals for damage or the connection ofABS
actuator and electric unit harnessconnector.Reconnect ABS actuator
and electric unitharness connector. Then retest.Diagnostic
Procedure 9 (Long stoppingdistance)CHECK ABS PERFORMANCE.Disconnect
ABS actuator and electric unitconnector and check whether
stoppingdistance is still long.YesNoGo to in DiagnosticProcedure 8,
BR-63.Perform Preliminary Check and air bleed-ing (if
necessary).Note:StoppingdistancemaybelongerforvehicleswithoutABS
when road condition is
slippery.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES
FOR SYMPTOMSBR-63Diagnostic Procedure 10 (ABS does not work.)CHECK
WARNING LAMP ACTIVATE.Does the ABS warning lamp activate?NoYesCarry
out self-diagnosis.Refer to BR-43, 47.Go to in Diagnostic Procedure
8,BR-63.Note: ABS does not work when vehicle speed is under 10
km/h(6 MPH).SAT797ADiagnostic Procedure 11 (Pedal vibration
andnoise)INSPECTION START1. Apply brake.2. Start engine.3. Does the
symptom appear only whenengine is started?NoYesCarry out
self-diagnosis.Refer to BR-43, 47.CHECK IF SYMPTOM APPEARS.Does the
symptom appear when electricalequipment switches (such as
headlamp)are operated?YesNoGo to in DiagnosticProcedure 8,
BR-63.CHECK WHEEL SENSOR.Check wheel sensor shield ground.
Forlocation of shield ground, refer to wiringdiagram and HARNESS
LAYOUT in ELsection.OKNGRepair wheel sensor.CHECK HARNESS
CONNECTOR.Check ABS actuator and electric unit pinterminals for
damage or the connection ofABS actuator and electric unit
harnessconnector.Reconnect ABS actuator and electric unitharness
connector, then retest.TROUBLE DIAGNOSES FOR SYMPTOMSBR-64Note: ABS
may operate and cause vibration under any of thefollowing
conditions.G Applying brake gradually when shifting or
operatingclutch.G Low friction (slippery) road.G High speed
cornering.G Driving over bumps and pot holes.G Engine speed is over
5,000 rpm with vehicle stopped.ABR776ABR665ABR777ABR778Diagnostic
Procedure 12 (Warning lamp doesnot come on when ignition switch is
turnedON.)CHECK FUSE.Check 10A fuse . For fuse layout, referto
POWER SUPPLY ROUTING in EL sec-tion.OKNGReplace fuse.CHECK WARNING
LAMP ACTIVATE.Disconnect ABS actuator and electric
unitconnector.Does the warning lamp activate?NoYesA (Go to next
page.)CHECK HARNESS FOR SHORT.1. Disconnect ABS actuator and
electricunit connector and combination meterconnectorM39 .2. Check
continuity between ABS actuatorand electric unit connectorE39
(bodyside) terminal21 and ground.Continuity should not
exist.OKNGRepair harness or connec-tors.CHECK COMBINATION METER
(ABSWARNING LAMP) GROUND CIRCUIT.Check continuity between
combinationmeter connectorM39 harness terminal33 and
ground.Continuity should exist.OKNGRepair harness or
connec-tor.CHECK COMBINATION METER.Check combination meter. Refer
toWARNING LAMPS in EL
section.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES
FOR SYMPTOMSDiagnostic Procedure 11 (Pedal vibration andnoise)
(Contd)BR-65ACHECK HARNESS CONNECTOR.Check ABS actuator and
electric unit pinterminals for damage or connection ofABS actuator
and electric unit harnessconnector. Reconnect ABS actuator
andelectric unit harness connector. Thenretest.NGOKInspection
endREPLACE.Replace ABS actuator and electric unit.TROUBLE DIAGNOSES
FOR SYMPTOMSDiagnostic Procedure 12 (Warning lamp doesnot come on
when ignition switch is turnedON.) (Contd)BR-66ABR805Diagnostic
Procedure 13 (Warning lamp stayson when ignition switch is turned
ON.)ABR652ABR779CHECK FUSE.Check 10A fuse . For fuse layout,
referto POWER SUPPLY ROUTING in EL sec-tion.OKNGA (Go to next
page.)CHECK HARNESS CONNECTOR.Check ABS actuator and electric unit
pinterminals for damage or the connection ofABS actuator and
electric unit harnessconnector. Reconnect ABS actuator andelectric
unit harness connector. Thenretest.NGOKInspection endCHECK ABS
ACTUATOR AND ELECTRICUNIT GROUND CIRCUIT.Refer to ABS ACTUATOR AND
ELEC-TRIC UNIT GROUND in Ground CircuitCheck, BR-52.OKNGRepair
harness and con-nector.CHECK ABS ACTUATOR AND ELEC-TRIC UNIT POWER
SUPPLY CIRCUIT.1. Disconnect ABS actuator and electricunit
connector.2. Check voltage between ABS actuatorand electric unit
connectorE39 (bodyside) terminal15 and ground.Battery voltage
should exist whenignition switch is turned ON.OKNGCheck the
following.G Harness connectorE39G Harness for open orshort between
ABSactuator and electric unitand fuseIf NG, repair harness
orconnector.CHECK ABS WARNING LAMP SIGNALTO ABS ACTUATOR AND
ELECTRICUNIT.Check voltage between ABS actuator andelectric unit
connectorE39 (body side)terminal21 and ground.Approx. 5 volts
should exist when igni-tion switch is turned ON.OKNGB (Go to next
page.)REPLACE.Replace ABS actuator and electric
unit.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR
SYMPTOMSBR-67ABR775AREPLACE.Replace fuse.Does the fuse blow out
when ignitionswitch is turned ON?YesNoInspection endCHECK ABS
ACTUATOR AND ELEC-TRIC UNIT POWER SUPPLY CIRCUITFOR SHORT.1.
Disconnect battery cable and ABSactuator and electric unit
connectorE39.2. Check continuity between ABS actuatorand electric
unit connectorE39 (bodyside) terminal15 and ground.Continuity
should not exist.OKNGCheck the following.G Harness connectorE39G
Harness for open orshort between ABSactuator and electric unitand
fuseIf NG, repair harness orconnector.REPLACE.Replace ABS actuator
and electric unit.ABR780BCHECK ABS WARNING LAMP CON-TROL CIRCUIT.1.
Disconnect combination meter connec-torM39 .2. Check continuity
between ABS actuatorand electric unit connectorE39 (bodyside)
terminal21 and combinationmeter connectorM39 harness terminal36
.Continuity should exist.OKNGCheck the following.G Harness
connectorsE39 andM39G Harness for open orshort between ABSactuator
and electric unitand combination meterIf NG, repair harness
orconnectors.CHECK COMBINATION METER.Check combination meter. Refer
toWARNING LAMPS in EL section.TROUBLE DIAGNOSES FOR
SYMPTOMSDiagnostic Procedure 13 (Warning lamp stayson when ignition
switch is turned ON.) (Contd)BR-68ABR656Electrical Components
InspectionG
sensorCAUTION:TheGsensoriseasilydamagedifitsustainsanimpact.Becareful
not to drop or bump it.1. Measure resistance between terminals10
and15 of G sensorunit connector.G sensor conditionResistance
betweenterminals10 and15G sensor switchconditionInstalled in
vehicle 1.4 - 1.6 k ONTilted as shown in figure 4.7 - 5.5 k OFF2.
Measureresistancebetweenterminals2 and20 of theGsensor unit
connector.Resistance: 70 -
124GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR
SYMPTOMSBR-69General SpecificationsFront brakeBrake model
CL28VDCylinder bore diameter x number of pistonsmm (in)42.8 (1.685)
x 2Pad length x width x thickness mm (in) 146.6 x 48.5 x 10 (5.77 x
1.909 x 0.39)Rotor outer diameter x thickness mm (in) 277 x 26
(10.9 x 1.02)Rear brakeBrake model LT30ACylinder bore diameter mm
(in) 20.64 (13/16)Lining length x width x thicknessmm (in)296 x 50
x 6.1(11.65 x 1.97 x 0.240)Drum inner diameter mm (in) 295.0
(11.61)Master cylinderBore diameter mm (in) 25.40 (1)Control
valveValve model Proportioning valve within master cylinderSplit
point [kPa (kg/cm2, psi)] x reducing ratio 2,452 (25, 356) x
0.3Brake boosterBooster model M23TDiaphragm diametermm (in)Pri.:
230 (9.06)Sec.: 230 (9.06)Recommended brake fluid DOT 3SERVICE DATA
AND SPECIFICATIONS (SDS)BR-70Inspection and AdjustmentDISC
BRAKEUnit: mm (in)Brake model CL28VDPad wear limitMinimum thickness
2.0 (0.079)Rotor repair limitMinimum thickness 24.0 (0.945)DRUM
BRAKEUnit: mm (in)Brake model LT30ALining wear limitMinimum
thickness 1.5 (0.059)Drum repair limitMaximum innerdiameter296.5
(11.67)Out-of-round limit 0.03 (0.0012)BRAKE PEDALUnit: mm (in)Free
height H*M/T = 191 - 201 (7.52 - 7.91)A/T = 201 - 211 (7.91 -
8.31)Depressed height D[under force of 490 N (50kg, 110 lb) with
engine run-ning]M/T = 100 (3.94)A/T = 110 (4.33)Clearance C
betweenpedal stopper and threadedend of stop lamp switch orASCD
switch0.3 - 1.0 (0.012 - 0.039)Pedal free playAt pedal pad 1.0 -
3.0 (0.039 - 0.118)*: Measured from surface of dash floor panel to
pedal pad.PARKING BRAKE CONTROLControl type Stick leverLever
stroke[under force of 196 N (20 kg, 44 lb)]10 - 12Lever stroke when
warning switch comes on
1GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXSERVICE DATA AND
SPECIFICATIONS (SDS)BR-71NOTESBR-72