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BRAKE SYSTEM SECTION BR CONTENTS PRECAUTIONS .....4 Supplemental Restraint System (SRS) ‘‘AIR

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BRAKE SYSTEM GI

BR MA

SECTION

CONTENTS

PRECAUTIONS ...............................................................4 Supplemental Restraint System (SRS) ``AIR BAG'' and ``SEAT BELT PRE-TENSIONER''...............4 Precautions for Brake System.....................................4 Wiring Diagrams and Trouble Diagnosis.....................5
PREPARATION ...............................................................6 Commercial Service Tools ...........................................6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................7
NVH Troubleshooting Chart.........................................7 ON-VEHICLE SERVICE ..................................................8
Checking Brake Fluid Level.........................................8 Checking Brake Line ...................................................8 Changing Brake Fluid ..................................................8 Brake Burnishing Procedure........................................8 Bleeding Brake System ...............................................9 BRAKE HYDRAULIC LINE ...........................................10 Hydraulic Circuit.........................................................10 Removal.....................................................................10 Inspection................................................................... 11 Installation .................................................................. 11 DUAL PROPORTIONING VALVE.................................12 Inspection...................................................................12 BRAKE PEDAL AND BRACKET..................................13 Removal and Installation ...........................................13 Inspection...................................................................13 Adjustment .................................................................13 MASTER CYLINDER (TOKICO) ...................................15 Removal.....................................................................15 Disassembly...............................................................16 Inspection...................................................................16 Assembly ...................................................................16 Installation..................................................................17 MASTER CYLINDER (NABCO) ....................................18 Removal.....................................................................18 Disassembly...............................................................18 Inspection...................................................................19 Assembly ...................................................................19 Installation..................................................................20

CL
BRAKE BOOSTER........................................................21

On-vehicle Service.....................................................21

OPERATING CHECK ...............................................21 MT
AIRTIGHT CHECK ...................................................21

Removal.....................................................................21

Inspection...................................................................21 AT

OUTPUT ROD LENGTH CHECK ..............................21

Installation..................................................................22
VACUUM HOSE.............................................................23 AX

Removal and Installation ...........................................23

Inspection...................................................................23 HOSES AND CONNECTORS ...................................23

CHECK VALVE ........................................................23

FRONT DISC BRAKE ...................................................24

Component ................................................................24

Pad Replacement ......................................................24

Removal.....................................................................25 ST

Disassembly...............................................................25

Inspection...................................................................26
CALIPER.................................................................26 RS

ROTOR ...................................................................26

Assembly ...................................................................27 Installation..................................................................27

REAR DISC BRAKE......................................................28

Component ................................................................28 HA
Pad Replacement ......................................................28

Removal.....................................................................30

Disassembly...............................................................31 SC

Inspection...................................................................32

CALIPER.................................................................32
ROTOR...................................................................32 EL

Assembly ...................................................................33

Installation..................................................................35 PARKING BRAKE CONTROL ......................................37

IDX

Components...............................................................37

Removal and Installation ...........................................37

Inspection...................................................................37

Adjustment .................................................................38

CONTENTS (Cont'd)

ABS
DESCRIPTION ...............................................................39 Purpose......................................................................39 ABS (Anti-Lock Brake System) Operation ................39 ABS Hydraulic Circuit ................................................39 System Components .................................................40 System Description....................................................40 SENSOR .................................................................40 CONTROL UNIT ......................................................40 ABS ACTUATOR AND ELECTRIC UNIT ....................40 Component Parts and Harness Connector Location .....................................................................42 Schematic ..................................................................43 Wiring Diagram -- ABS -- ........................................44
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................48
Self-diagnosis ............................................................48 FUNCTION ..............................................................48 SELF-DIAGNOSIS PROCEDURE..............................48 HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) ........................................48 HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) ........................................49
CONSULT-II ...............................................................50 CONSULT-II APPLICATION TO ABS..........................50 ECU (ABS CONTROL UNIT) PART NUMBER MODE.....................................................................50
CONSULT-II Inspection Procedure............................50 SELF-DIAGNOSIS PROCEDURE..............................50 SELF-DIAGNOSTIC RESULTS MODE.......................52 DATA MONITOR PROCEDURE ................................53 ACTIVE TEST PROCEDURE ....................................54 DATA MONITOR MODE...........................................55 ACTIVE TEST MODE ...............................................55
TROUBLE DIAGNOSIS -- INTRODUCTION ...............56 How to Perform Trouble Diagnoses for Quick and Accurate Repair ..................................................56 INTRODUCTION......................................................56
TROUBLE DIAGNOSIS -- BASIC INSPECTION.........57 Preliminary Check......................................................57 Ground Circuit Check ................................................60 ABS ACTUATOR AND ELECTRIC UNIT GROUND.....60
TROUBLE DIAGNOSIS -- GENERAL DESCRIPTION ...............................................................61
Malfunction Code/Symptom Chart.............................61 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS.............................................................................62
Wheel Sensor or Rotor..............................................62 DIAGNOSTIC PROCEDURE.....................................62
ABS Actuator Solenoid Valve or Solenoid Valve Relay..........................................................................65
DIAGNOSTIC PROCEDURE.....................................65 Motor Relay or Motor.................................................68
DIAGNOSTIC PROCEDURE.....................................68

Low Voltage ...............................................................70 DIAGNOSTIC PROCEDURE.....................................70
Control Unit................................................................72 DIAGNOSTIC PROCEDURE.....................................72
TROUBLE DIAGNOSES FOR SYMPTOMS .................73 1. ABS Works Frequently ..........................................73 2. Unexpected Pedal Action ......................................73 3. Long Stopping Distance ........................................74 4. ABS Does Not Work..............................................75 5. Pedal Vibration and Noise.....................................76 6. ABS Warning Lamp Does Not Come On When Ignition Switch Is Turned On...........................77 7. ABS Warning Lamp Stays On When Ignition Switch Is Turned On ..................................................79
TCS
DESCRIPTION ...............................................................81 Purpose......................................................................81 ABS (Anti-Lock Brake System) Operation ................81 ABS Hydraulic Circuit ................................................81 TCS (Traction Control System) Operation ................82 System Components .................................................82 System Description....................................................82 SENSOR .................................................................82 CONTROL UNIT ......................................................83 ACTUATOR.............................................................83 Component Parts and Harness Connector Location .....................................................................84 Schematic ..................................................................85 Wiring Diagram -- TCS -- ........................................86
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................91
Self-diagnosis ............................................................91 FUNCTION ..............................................................91 SELF-DIAGNOSIS PROCEDURE..............................91 HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) ........................................92 HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) ........................................92
CONSULT-II ...............................................................93 CONSULT-II APPLICATION TO TCS .........................93 ECU (ABS/TCS CONTROL UNIT) PART NUMBER MODE.....................................................................93
CONSULT-II Inspection Procedure............................94 SELF-DIAGNOSIS PROCEDURE..............................94 SELF-DIAGNOSTIC RESULTS MODE.......................95 DATA MONITOR PROCEDURE ................................96 ACTIVE TEST PROCEDURE ....................................97 DATA MONITOR MODE...........................................98 ACTIVE TEST MODE ...............................................99
TROUBLE DIAGNOSIS -- INTRODUCTION .............100 How to Perform Trouble Diagnoses for Quick and Accurate Repair ................................................100

BR-2

CONTENTS (Cont'd)

INTRODUCTION....................................................100 TROUBLE DIAGNOSIS -- BASIC INSPECTION.......101
Preliminary Check....................................................101 Ground Circuit Check ..............................................104
ACTUATOR MOTOR GROUND ..............................104 CONTROL UNIT GROUND.....................................104 ABS SOLENOID VALVE RELAY GROUND ..............104 TROUBLE DIAGNOSIS -- GENERAL DESCRIPTION .............................................................105 Malfunction Code/Symptom Chart...........................105 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS...........................................................................107 Wheel Sensor or Rotor............................................107 DIAGNOSTIC PROCEDURE...................................107 ABS Actuator Solenoid Valve ..................................110 DIAGNOSTIC PROCEDURE...................................110 Solenoid Valve Relay...............................................114 DIAGNOSTIC PROCEDURE...................................114 Motor Relay or Motor...............................................120 DIAGNOSTIC PROCEDURE...................................120 Low Voltage .............................................................126 DIAGNOSTIC PROCEDURE...................................126 Control Unit..............................................................128 DIAGNOSTIC PROCEDURE...................................128 ENGINE CHECK SIGNAL -- Engine System.........129 DIAGNOSTIC PROCEDURE...................................129 ENG SPEED SIG -- Engine Speed Signal ............129 DIAGNOSTIC PROCEDURE...................................129 LAN SIGNAL 1 -- LAN Monitoring..........................131 DIAGNOSTIC PROCEDURE...................................131 LAN SIGNAL 2 -- LAN Communication Start Procedures Incomplete............................................132 DIAGNOSTIC PROCEDURE...................................132 LAN CIRCUITS 1, LAN CIRCUITS 2 -- LAN Communication System Failure...............................133 DIAGNOSTIC PROCEDURE...................................133 LAN SIGNAL 3 -- Continued Reception After LAN Communication Starts .....................................135 DIAGNOSTIC PROCEDURE...................................135

TROUBLE DIAGNOSES FOR SYMPTOMS ...............136 GI
1. ABS Works Frequently ........................................136
2. Unexpected Pedal Action ....................................136
3. Long Stopping Distance ......................................137 MA

4. ABS Does Not Work............................................138

5. Pedal Vibration and Noise...................................139 6. ABS Warning Lamp Does Not Come On

When Ignition Switch Is Turned On.........................140

7. ABS Warning Lamp Stays On When Ignition

Switch Is Turned On ................................................143

8. SLIP Indicator Lamp Does Not Come On
When Ignition Switch Is Turned On.........................148 EC

9. TCS OFF Indicator Lamp Does Not Come On

When Ignition Switch Is Turned On.........................149 10. TCS OFF Switch Is Inoperative ........................151

11. Poor Acceleration...............................................154

CL
ABS/TCS

REMOVAL AND INSTALLATION ...............................155 MT
Wheel Sensors ........................................................155
Sensor Rotor............................................................155
REMOVAL.............................................................155 AT
INSTALLATION......................................................156
Control Unit (With TCS Models)..............................156
Actuator....................................................................156 AX
REMOVAL.............................................................156 INSTALLATION......................................................156
SU
SERVICE DATA AND SPECIFICATIONS (SDS) .......157
General Specifications.............................................157
Disc Brake ...............................................................157
Brake Pedal .............................................................157
Parking Brake ..........................................................157 ST
Control Valve ...........................................................157
Brake Booster ..........................................................158
ABS Wheel Sensor..................................................158 RS

IDX

BR-3

PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
NFBR0127
The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER" used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to NISSAN MODEL A33 is as follows:
¼ For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, warning lamp, wiring harness and spiral cable.
¼ For a side collision The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING: ¼ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.
¼ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section.
¼ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified with yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors).

SBR686C

Precautions for Brake System
¼ Recommended fluid is brake fluid "DOT 3".

NFBR0002

¼ Never reuse drained brake fluid.

¼ Be careful not to splash brake fluid on painted areas.

¼ To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid.

¼ Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.

¼ Use flare nut wrench when removing and installing brake tube.

¼ Always torque brake lines when installing.

¼ Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to "Brake Burnishing Procedure", "ON-VEHICLE SERVICE", BR-8.

WARNING: ¼ Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.

BR-4

PRECAUTIONS

Wiring Diagrams and Trouble Diagnosis

Wiring Diagrams and Trouble Diagnosis
When you read wiring diagrams, refer to the following: ¼ "HOW TO READ WIRING DIAGRAMS" in GI section

NFBR0003
GI

¼ "POWER SUPPLY ROUTING" for power distribution circuit in EL section

When you perform trouble diagnosis, refer to the following:

¼ "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES" in GI section

¼ ¼

"HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT" in GI section For trouble diagnoses of models with ABS, refer to the trouble diagnoses for models with ABS. Refer to

BR-39.

¼ For trouble diagnoses of models with TCS, refer to the trouble diagnoses for models with TCS even when LC
the diagnostic items are related to the ABS system. Refer to BR-81.

ST RS BT HA SC EL IDX

BR-5

Commercial Service Tools

Tool name
1 Flare nut crowfoot 2 Torque wrench

Description

Brake fluid pressure gauge

NT360

PREPARATION Commercial Service Tools

NFBR0004

Removing and installing each brake piping a: 10 mm (0.39 in)

Measuring brake fluid pressure

NT151

BR-6

NFBR0005
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
NVH Troubleshooting Chart NFBR0005S01
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
GI

NVH in SU section NVH in ST section

NVH in SU section

NVH in AX section

BR-27, 33

BR-26, 32

BR-24, 28

MA
Reference page
EM

ROAD WHEEL STEERING

SUSPENSION

DRIVE SHAFT

Rotor thickness variation

TIRES

AXLE

Rotor rust

Rotor deflection

Rotor deformation

Rotor runout

Rotor damage

Rotor imbalance

Shims damaged

Pads - uneven wear

Pads - damaged

Possible cause and

SUSPECTED PARTS

Noise Symptom BRAKE Shake
Shimmy, Judder X: Applicable

XXX

X X X X X X CL

X X X X XX

X X X XXX X

X X X X X MT

ST RS BT HA SC EL IDX

BR-7

Checking Brake Fluid Level

ON-VEHICLE SERVICE
Checking Brake Fluid Level NFBR0006
¼ Check fluid level in reservoir tank. It should be between Max and Min lines on reservoir tank.
¼ If fluid level is extremely low, check brake system for leaks. ¼ Release parking brake lever and see if brake warning lamp
goes off. If not, check brake system for leaks.

SBR451D

Checking Brake Line
CAUTION:

NFBR0007

If leakage occurs around joints, retighten or, if necessary,

replace damaged parts.

1. Check brake lines (tubes and hoses) for cracks, deterioration

or other damage. Replace any damaged parts.

2. Check for oil leakage by fully depressing brake pedal while

engine is running.

SBR389C SBR419C

Changing Brake Fluid
CAUTION: ¼ Refill with new brake fluid "DOT 3".

NFBR0008

¼ Always keep fluid level higher than minimum line on res-

ervoir tank.

¼ Never reuse drained brake fluid.

¼ Be careful not to splash brake fluid on painted areas; it

may cause paint damage. If brake fluid is splashed on

painted 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. Drain brake fluid from each air bleeder valve by depressing

brake pedal.

4. Refill until brake fluid comes out of each air bleeder valve.

Use same procedure as in bleeding hydraulic system to refill

brake fluid. Refer to "Bleeding Brake System", BR-9.

Brake Burnishing Procedure NFBR0036
Burnish the brake contact surfaces according to the following procedure after refinishing or replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION: Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
BR-8

ON-VEHICLE SERVICE

Brake Burnishing Procedure (Cont'd)

pressure such that vehicle stopping time equals 3 to 5 sec-

onds.

3. To cool the brake system, drive the vehicle at 50 km/h (31 GI

MPH) for 1 minute without stopping.

4. Repeat steps 1 to 3, 10 times or more to complete the burnish-

ing procedure.

SBR995 SBR419C

Bleeding Brake System

NFBR0009

CAUTION:

¼ Carefully monitor brake fluid level at master cylinder dur-

ing bleeding operation.

¼ Fill reservoir with new brake fluid "DOT 3". Make sure it is FE

full at all times while bleeding air out of system.

¼ Place a container under master cylinder to avoid spillage

of brake fluid.

¼ For models with ABS, turn ignition switch OFF and dis-
connect ABS actuator connectors or battery ground cable. MT

¼ Bleed air in the following order.
Right rear brake , Left front brake , Left rear brake , Right AT
front brake

1. 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 release

air.

4. Close air bleeder valve.

5. Release brake pedal slowly.

6. Repeat steps 2. through 5. until clear brake fluid comes out of

air bleeder valve.

IDX

BR-9

Hydraulic Circuit

BRAKE HYDRAULIC LINE Hydraulic Circuit

NFBR0010

SBR661E

MBR151AB

SBR992

Removal

CAUTION:

NFBR0011

¼ Be careful not to splash brake fluid on painted areas; it

may cause paint damage. If brake fluid is splashed on

painted areas, wash it away with water immediately.

¼ All hoses must be free from excessive bending, twisting and pulling.

1. Connect vinyl tube to air bleeder valve.

2. Drain brake fluid from each air bleeder valve by depressing

brake pedal.

BR-10

BRAKE HYDRAULIC LINE

Removal (Cont'd)

3. Remove flare nut connecting brake tube and hose, then withdraw lock spring.
4. Cover openings to prevent entrance of dirt whenever discon- GI
necting brake line.

LC Inspection
NFBR0012
Check brake lines (tubes and hoses) for cracks, deterioration or EC
other damage. Replace any damaged parts.
FE

SBR686C

Installation
CAUTION: ¼ Refill with new brake fluid "DOT 3".

AT NFBR0013

¼ Never reuse drained brake fluid.

1. Tighten all flare nuts and connecting bolts.

Specification:

Flare nut

15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

Connecting bolt

17 - 20 N·m (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-9.

IDX

BR-11

Inspection

DUAL PROPORTIONING VALVE

SBR822BA

Inspection

CAUTION:

NFBR0014

¼ Carefully monitor brake fluid level at master cylinder.

¼ Use new brake fluid "DOT 3".

¼ Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on

paint areas, wash it away with water immediately.

1. Connect Tool to air bleeders of front and rear brakes on either

LH and RH side.

2. Bleed air from the Tool.

3. Check fluid pressure by depressing brake pedal.
Unit: kPa (kg/cm2, psi)

Applied pressure (Front brake)

7,355 (75, 1,067)

Output pressure (Rear brake)

5,100 - 5,492 (52 - 56, 739 - 796)

If output pressure is out of specification, replace dual proportioning valve.
4. Bleed air after disconnecting the Tool. Refer to "Bleeding Brake System", BR-9.

SBR823BA

BR-12

BRAKE PEDAL AND BRACKET Removal and Installation

Removal and Installation
NFBR0015
GI

Inspection
Check brake pedal for following items. ¼ Brake pedal bend ¼ Clevis pin deformation ¼ Crack of any welded portion ¼ Crack or deformation of clevis pin stopper

CL
SBR525EB
MT
AT NFBR0016
AX
SU

SBR997

Adjustment

ST NFBR0017

Check brake pedal free height from metal panel. Adjust if neces-

sary.

H: Free height

Refer to SDS, BR-157.

C1, C2: Clearance between pedal stopper and threaded end of stop lamp switch and ASCD switch

0.74 - 1.96 mm (0.0291 - 0.0772 in)

D: Depressed height

A/T models: 82.5 mm (3.248 in)

M/T models: 75.3 mm (2.965 in)
Under force of 490 N (50 kg, 110 lb) with engine run- SC
ning.

IDX

SBR526E

BR-13

Adjustment (Cont'd)

BRAKE PEDAL AND BRACKET
1. Loosen lock nut and adjust pedal free height by turning brake booster input rod. Then tighten lock nut.
2. Check pedal free play. Make sure that stop lamps go off when pedal is released.
3. Check brake pedal's depressed height while engine is running. If lower than specification, check brake system for leaks, accumulation of air or any damage to components (master cylinder, wheel cylinder, etc.); then make necessary repairs.
SBR229E

BR-14

1. Reservoir cap 2. Oil filter 3. Reservoir tank 4. Seal

MASTER CYLINDER (TOKICO) Removal

Removal
NFBR0018
GI

5. Cylinder body 6. O-ring 7. Piston stopper

SU
SBR554E

8. Secondary piston assembly

9. Primary piston assembly

10. Stopper cap

RS
CAUTION:

Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted BT

areas, wash it away with water immediately.

1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brake HA

pedal to empty fluid from master cylinder.

3. Remove brake pipe flare nuts.

4. Remove master cylinder mounting nuts.

IDX

BR-15

Disassembly

MASTER CYLINDER (TOKICO)
Disassembly NFBR0019
1. Bend claws of stopper cap outward and remove stopper cap.

SBR938A

2. Remove valve stopper while piston is pushed into cylinder.
3. Remove piston assemblies. If it is difficult to remove secondary piston assembly, gradually apply compressed air through fluid outlet.
4. Draw out reservoir tank.

SBR231C

Inspection
Check for the following items. Replace any part if damaged. Master cylinder: ¼ Pin holes or scratches on inner wall.
Piston: ¼ Deformation of or scratches on piston cups.

NFBR0020

Assembly NFBR0021
1. Insert secondary piston assembly. Then insert primary piston assembly.
¼ Pay attention to alignment of secondary piston slit with valve stopper mounting hole of cylinder body.

SBR354C

2. Install stopper cap. Before installing stopper cap, ensure that claws are bent inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.

SBR940A

BR-16

MASTER CYLINDER (TOKICO)

Assembly (Cont'd)

5. Install valve stopper while piston is pushed into cylinder.

SBR222B SBR704C

Installation
CAUTION: ¼ Refill with new brake fluid "DOT 3".

NFBR0022
EC

¼ Never reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount- FE
ing nuts lightly.

2. Torque mounting nuts. : 12 - 15 N·m (1.2 - 1.5 kg-m, 9 - 11 ft-lb)

3. Fill up reservoir tank with new brake fluid.

4. Plug all ports on master cylinder with fingers to prevent air MT
suction while releasing brake pedal.

5. Have driver depress brake pedal slowly several times until no

air comes out of master cylinder.

6. Fit brake lines to master cylinder.

7. Tighten flare nuts.

: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

8. Bleed air from brake system. Refer to "Bleeding Brake

System", BR-9.

ST RS BT HA SC EL IDX

BR-17

Removal

MASTER CYLINDER (NABCO) Removal

NFBR0095

1. Reservoir cap 2. Oil filter 3. Float 4. Reservoir tank

5. Seal 6. Cylinder body 7. Spring pin 8. Piston stopper pin

SBR555E
9. Secondary piston assembly 10. Primary piston assembly 11. Stopper cap

CAUTION: Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brake pedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.

Disassembly NFBR0096
1. Bend claws of stopper cap outward and remove stopper cap.

SBR234E

BR-18

MASTER CYLINDER (NABCO)
2. Drive out spring pin from cylinder body. 3. Draw out reservoir tank and seals.

Disassembly (Cont'd)
GI

SBR231E

4. Remove piston stopper pin while piston is pushed into cylinder.

Remove piston assemblies. If it is difficult to remove secondary piston assembly,

gradually apply compressed air through fluid outlet.

SBR232E

Inspection
Check for the following items. Replace any part if damaged. Master cylinder: ¼ Pin holes or scratches on inner wall.
Piston: ¼ Deformation of or scratches on piston cups.

MT AT NFBR0097
AX SU

Assembly

ST NFBR0098

1. Insert secondary piston assembly. Then insert primary piston

assembly.

¼ Pay attention to alignment of secondary piston slit with RS

valve stopper mounting hole of cylinder body.

SBR233E

HA
2. Install piston stopper pin while piston is pushed into cylinder. SC
3. Push reservoir tank seals and reservoir tank into cylinder body. 4. Install spring pin.
EL

IDX

SBR232E

BR-19

Assembly (Cont'd)

MASTER CYLINDER (NABCO)
5. Install stopper cap. Before installing stopper cap, ensure that claws are bent inward.

SBR235E SBR236E

Installation
CAUTION: ¼ Refill with new brake fluid "DOT 3".

NFBR0099

¼ Never reuse drained brake fluid.

1. Place master cylinder onto brake booster and secure mounting nuts lightly.

2. Torque mounting nuts.

: 12 - 15 N·m (1.2 - 1.5 kg-m, 9 - 11 ft-lb)

3. Fill up reservoir tank with new brake fluid.

4. Plug all ports on master cylinder with fingers to prevent air suction while releasing brake pedal.

5. Have driver depress brake pedal slowly several times until no air comes out of master cylinder.

6. Fit brake lines to master cylinder.

7. Tighten flare nuts.

: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

8. Bleed air from brake system.

BR-20

BRAKE BOOSTER

On-vehicle Service

NFBR0023

OPERATING CHECK NFBR0023S01
1. Stop engine and depress brake pedal several times. Check

that pedal stroke does not change.

2. Depress brake pedal, then start engine. If pedal goes down MA
slightly, operation is normal.

SBR002A

AIRTIGHT CHECK

EM NFBR0023S02

1. Start engine, and stop it after one or two minutes. Depress

brake pedal several times slowly. The pedal should go further

down the first time, and then it should gradually rise thereaf- LC
ter.

2. Depress brake pedal while engine is running, and stop engine

with pedal depressed. The pedal stroke should not change EC
after holding pedal down for 30 seconds.

SBR365AA

Removal
CAUTION:

AT NFBR0024

¼ Be careful not to splash brake fluid on painted areas; it

may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately.

¼ Be careful not to deform or bend brake pipes, during

removal of booster.

SBR232CB SBR208E

Inspection

ST NFBR0025

OUTPUT ROD LENGTH CHECK

NFBR0025S01

1. Apply vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg) to

brake 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)
HA

IDX

BR-21

Installation

BRAKE BOOSTER

SBR237EB

Installation

CAUTION:

NFBR0026

¼ Be careful not to deform or bend brake pipes, during

installation of booster.

¼ Replace clevis pin if damaged.

¼ Refill with new brake fluid "DOT 3".

¼ Never reuse drained brake fluid.

¼ Take care not to damage brake booster mounting bolt thread when installing. Due to the acute angle of installation, the threads can be damaged with the dash panel.

1. Before fitting booster, temporarily adjust clevis to dimension shown.

2. Fit booster, then secure mounting nuts (brake pedal bracket to

master cylinder) lightly.

3. Connect brake pedal and booster input rod with clevis pin.

4. Secure mounting nuts.

Specification:

13 - 16 N·m (1.3 - 1.6 kg-m, 9 - 12 ft-lb)

5. Install master cylinder. Refer to "Installation" in "MASTER CYLINDER", BR-17 or BR-20.

6. Bleed air. Refer to "Bleeding Brake System", BR-9.

BR-22

VACUUM HOSE

Removal and Installation

NFBR0027

CAUTION: When installing vacuum hoses, pay attention to the following

points.

Do not apply any oil or lubricants to vacuum hose and check valve.

¼ Insert vacuum tube into vacuum hose as shown.

¼ Install check valve, paying attention to its direction.

SBR225B

Inspection

NFBR0028

HOSES AND CONNECTORS

NFBR0028S01

Check vacuum lines, connections and check valve for airtightness,

improper attachment chafing and deterioration.
FE

CHECK VALVE Check vacuum with a vacuum pump.

AT NFBR0028S02

Connect to booster side Connect to engine side

Vacuum should exist.

Vacuum should not exist.

SBR844B
ST RS BT HA SC EL IDX

BR-23

Component

FRONT DISC BRAKE Component

NFBR0030

1. Main pin 2. Pin boot 3. Torque member fixing bolt 4. Torque member 5. Shim cover 6. Inner shim 7. Inner pad

8. Pad retainer 9. Outer pad 10. Outer shim 11. Shim cover 12. Connecting bolt 13. Copper washer

14. Main pin bolt 15. Bleed valve 16. Cylinder body 17. Piston seal 18. Piston 19. Piston boot

SBR527EA

Pad Replacement

WARNING:

NFBR0029

Clean brake pads with a vacuum dust collector to minimize the

hazard of airborne particles or other materials.

CAUTION: ¼ When cylinder body is open, do not depress brake pedal
because piston will pop out.

¼ Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads.

¼ If shims are rusted or show peeling of the rubber coat, replace them with new shims.

¼ It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose.

BR-24

FRONT DISC BRAKE

Pad Replacement (Cont'd)

SBR976B

1. Remove master cylinder reservoir cap.

2. Remove pin bolt.
3. Open cylinder body upward. Then remove pad with retainers, GI
inner and outer shims.

Standard pad thickness: 11 mm (0.43 in)

Pad wear limit:

2.0 mm (0.079 in)

Carefully monitor brake fluid level because brake fluid will

return to reservoir when pushing back piston.

SBR932C

Removal

WARNING:

AT NFBR0031

Clean brake pads with a vacuum dust collector to minimize the

hazard of airborne particles or other materials. Remove torque member fixing bolts and connecting bolt.

It is not necessary to remove connecting bolt except for dis-

assembly or replacement of caliper assembly. In this case, SU
suspend caliper assembly with wire so as not to stretch brake

hose.

SBR979B

Disassembly
WARNING: Do not place your fingers in front of piston.
CAUTION: Do not scratch or score cylinder wall. 1. Push out piston with piston boot with compressed air. 2. Remove piston seal with a suitable tool.

ST NFBR0032 RS BT

SBR772

CAUTION:

When removing the pad retainer from the torque member, lift

it up and out in the direction of the arrows in the figure.

IDX

SBR556E

BR-25

Inspection

FRONT DISC BRAKE

Inspection NFBR0033
CALIPER NFBR0033S01
Cylinder Body NFBR0033S0101
¼ Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body.
¼ Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.
CAUTION: Use brake fluid to clean. Never use mineral oil.

Piston CAUTION:

NFBR0033S0102

Piston sliding surface is plated. Do not polish with emery

paper even if rust or foreign materials are stuck to sliding

surface.

Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.

Slide Pin, Pin Bolt and Pin Boot NFBR0033S0103
Check for wear, cracks or other damage. Replace if any of the
above conditions are observed.

ROTOR Rubbing Surface Check rotor for roughness, cracks or chips.

NFBR0033S02 NFBR0033S0201

SBR219C

Runout NFBR0033S0202
1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).
2. Check runout using a dial indicator. Make sure that wheel bearing axial end play is within the specifications before measuring. Refer to AX section ("Front Wheel Bearing", "ON-VEHICLE SERVICE").
Maximum runout:
0.07 mm (0.0028 in)
3. If the runout is out of specification, find minimum runout position as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor to wheel hub with nuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position can be found.
4. If the runout is still out of specification, turn rotor with on-car brake lathe ("MAD, DL-8700", "AMMCO 700 and 705" or equivalent).

BR-26

FRONT DISC BRAKE

Inspection (Cont'd)

Thickness Thickness variation (At least 8 positions): Maximum 0.01 mm (0.0004 in)

NFBR0033S0203
GI

If thickness variation exceeds the specification, turn rotor with on-

car brake lathe.

Rotor repair limit:

24.0 mm (0.945 in)
EM

Assembly

1. Insert piston seal into groove on cylinder body.

NFBR0034
EC

2. With piston boot fitted to piston, insert piston boot into groove

on cylinder body and install piston.

3. Properly secure piston boot.

SBR574

Installation
CAUTION: ¼ Refill with new brake fluid "DOT 3". ¼ Never reuse drained brake fluid. 1. Install brake hose to caliper securely. 2. Install all parts and secure all bolts. 3. Bleed air. Refer to "Bleeding Brake System", BR-9.

MT AT NFBR0035
AX SU

SBR980B

CAUTION: The upper pad retainer is built so the pad returns to its origi-

nal position. Be careful to install the pad-return lever securely

to the pad wear sensor, as shown in the left figure.

HA
SBR557E
SC

IDX

BR-27

Component

REAR DISC BRAKE Component

NFBR0038

1. Nut 2. Washer 3. Return spring 4. Parking brake lever 5. Cam boot 6. Cam 7. Brake hose 8. Connecting bolt 9. Copper washer 10. Bleed screw 11. Pin bolt 12. Cable mounting bracket 13. Cylinder 14. Strut

15. O-ring 16. Push rod 17. Key plate 18. Ring C 19. Seat 20. Spring 21. Spring cover 22. Ring B 23. Piston seal 24. Ring A 25. Spacer 26. Wave washer 27. Spacer 28. Ball bearing

SBR558E
29. Adjust nut 30. Cup 31. Piston 32. Dust seal 33. Inner shim 34. Inner pad 35. Outer pad 36. Outer shim 37. Pin 38. Pin boot 39. Pad retainer 40. Torque member 41. Torque member fixing bolt

Pad Replacement

WARNING:

NFBR0037

Clean brake pads with a vacuum dust collector to minimize the

hazard of airborne particles or other materials.

CAUTION: ¼ When cylinder body is open, do not depress brake pedal
because piston will pop out.

¼ Be careful not to damage piston boot or get oil on rotor. Always replace shims in replacing pads.

¼ If shims are rusted or show peeling of rubber coat, replace them with new shims.

BR-28

REAR DISC BRAKE

Pad Replacement (Cont'd)

¼ It is not necessary to remove connecting bolt except for

disassembly or replacement of caliper assembly. In this

case, suspend cylinder body with wire so as not to stretch GI
brake hose.

¼ Burnish the brake contact surfaces after refinishing or
replacing drums or rotors, after replacing pads or linings, MA

or if a soft pedal occurs at very low mileage.

Refer to "Brake Burnishing Procedure", "ON-VEHICLE

SERVICE", BR-8.

SBR938C

1. Remove master cylinder reservoir cap.

2. Remove brake cable mounting bolt and lock spring.

3. Release parking brake control lever, then disconnect cable

from the caliper.

4. Remove upper pin bolt.

5. Open cylinder body downward. Then remove pad retainers,

and inner and outer shims.

Standard pad thickness:

10 mm (0.39 in)

Pad wear limit:

1.5 mm (0.059 in)

SBR916C

When installing new pads, push piston into cylinder body by gently turning piston clockwise, as shown.

Carefully monitor brake fluid level because brake fluid will

return to reservoir when pushing back piston.

HA
SBR641
SC

IDX

SBR868C

BR-29

Pad Replacement (Cont'd)

REAR DISC BRAKE
7. Adjust the piston to the right angle as shown in the figure.

SBR306E

8. As shown in the figure, align the piston's concave to the pad's convex, then install the cylinder body to the torque member.

SBR307E SBR939C

Removal

WARNING:

NFBR0039

Clean brake pads with a vacuum dust collector to minimize the

hazard of airborne particles or other materials.

1. Remove brake cable mounting bolt and lock spring.

2. Release parking brake control lever, then disconnect cable from the caliper.

3. Remove torque member fixing bolts and connecting bolt.

It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose.

BR-30

REAR DISC BRAKE

Disassembly

NFBR0040

Remove piston by turning it counterclockwise with suitable commercial service tool or long nose pliers.

SBR868C

SBR646

2. Pry off ring A from piston with suitable pliers and remove

adjusting nut.

SBR889

3. a.

Disassemble cylinder body. Pry off ring B with suitable pliers, then remove spring cover,

spring and seat.

b. Pry off ring C, then remove key plate, push rod and rod.

SBR088B

c. Remove piston seal.

Be careful not to damage cylinder body.

IDX

SBR656

BR-31

Disassembly (Cont'd)

REAR DISC BRAKE
4. Remove return spring, toggle lever and cable guide.

SBR877

Inspection

CALIPER CAUTION:

NFBR0041 NFBR0041S01

Use brake fluid to clean cylinder. Never use mineral oil.

Cylinder Body NFBR0041S0101
¼ Check inside surface of cylinder for score, rust, wear, damage or presence of foreign materials. If any of the above conditions are observed, replace cylinder body.
¼ Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.

Torque Member NFBR0041S0102
Check for wear, cracks or other damage. Replace if necessary.

Piston CAUTION:

NFBR0041S0103

Piston sliding surface is plated. Do not polish with emery

paper even if rust or foreign matter is stuck to sliding surface.

Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.

Pin and Pin Boot
Check for wear, cracks or other damage. Replace if any of the above conditions are observed.

NFBR0041S0104

SBR219C

ROTOR Rubbing Surface Check rotor for roughness, cracks or chips.

NFBR0041S02 NFBR0041S0201

Runout NFBR0041S0202
1. Secure rotor to wheel hub with two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that axial end play is within the specifications before measuring. Refer to AX section ("REAR WHEEL BEARING", "On-vehicle Service").

BR-32

REAR DISC BRAKE

Inspection (Cont'd)

3. Change relative positions of rotor and wheel hub so that runout

is minimized.

Maximum runout:

0.07 mm (0.0028 in)

Thickness Rotor repair limit: Standard thickness 9 mm (0.35 in) Minimum thickness 8 mm (0.31 in) Thickness variation (At least 8 portions) Maximum 0.02 mm (0.0008 in)

MA
NFBR0041S0203
EM LC EC

Assembly

NFBR0042
Insert cam with depression facing towards open end of cylin-

der.

SBR247B

Generously apply rubber grease to strut and push rod to make insertion easy.

SBR248B

HA 3. Fit push rod into square hole in key plate. Also match convex SC
portion of key plate with concave portion of cylinder.

IDX

SBR893

BR-33

Assembly (Cont'd)

REAR DISC BRAKE
4. Install ring C with a suitable tool.

SBR878

5. Install seat, spring, spring cover and ring B with suitable press and drift.

SBR869C

SBR879
6. Install cup in the specified direction.

SBR892

7. Install cup, adjuster, bearing, spacers, washers and ring A with a suitable tool.

SBR100B

BR-34

REAR DISC BRAKE

Assembly (Cont'd)

8. Insert piston seal into groove on cylinder body.
9. With piston boot fitted to piston, insert piston boot into groove
on cylinder body and fit piston by turning it clockwise with long GI
nose pilers, or suitable tool.

SBR646

SBR868C

10. Fit toggle lever, return spring and cable guide.
AT

SBR027D

11. Adjust the piston to the right angle as shown in the figure.

SBR306E SBR307E

Installation
CAUTION: ¼ Refill with new brake fluid "DOT 3". ¼ Never reuse drained brake fluid.

SC
NFBR0043
EL

1. Install caliper assembly.

¼ As shown in the figure, align the piston's concave to the pad's IDX
convex, then install the cylinder body to the torque member.

2. Install brake hose to caliper securely.

3. Install all parts and secure all bolts.

4. Bleed air. Refer to "Bleeding Brake System", BR-9.

BR-35

Installation (Cont'd)

REAR DISC BRAKE
CAUTION: The pad retainer is built so the pad returns to its original position. Be careful to install the pad so the pad-return lever is against the inner side of the pad, as shown in the left figure.
SBR559E

BR-36

PARKING BRAKE CONTROL Components

Components
NFBR0044
GI

CL
SBR550EA
MT

Removal and Installation

NFBR0045
To remove parking brake cable, first remove center console.

2. Disconnect warning switch connector.

3. Remove bolts, slacken off and remove adjusting nut.

4. Remove lock plate and disconnect cable.

SBR025D

Inspection

ST NFBR0046

1. Check control lever for wear or other damage. Replace if nec-

essary.

2. Check wires for discontinuity or deterioration. Replace if nec- RS

essary.

3. Check warning lamp and switch. Replace if necessary.
4. Check parts at each connecting portion and, if found deformed BT

or damaged, replace.

IDX

BR-37

Adjustment

PARKING BRAKE CONTROL

SBR264B

Adjustment =NFBR0047
Pay attention to the following points after adjustment.
1) There is no drag when control lever is being released.
2) Be sure that toggle lever returns to stopper when parking brake lever is released.
1. Loosen parking brake cable.
2. Depress brake pedal fully more than five times.
3. Operate control lever 10 times or more with a full stroke [203.5 mm (8.01 in)].
4. Adjust control lever or pedal by turning adjusting nut.
5. Pull control lever with specified amount of force. Check lever stroke and ensure smooth operation.
Number of notches:
10 - 11 [196 N (20 kg, 44 lb)]
6. Bend warning lamp switch plate. Warning lamp should come on when lever is pulled "A" notches. It should go off when the lever is fully released.
Number of "A" notches: 1

BR-38

DESCRIPTION

ABS
Purpose

Purpose

NFBR0100

The ABS consists of electronic and hydraulic components. It allows for control of braking force so that locking of the wheels can be avoided.

The ABS:

1) Ensures proper tracking performance through steering wheel operation.

2) Enables obstacles to be avoided through steering wheel operation.

3) Ensures vehicle stability by preventing flat spins.

ABS (Anti-Lock Brake System) Operation

¼ When the vehicle speed is less than 10 km/h (6 MPH) this system does not work.

NFBR0101

¼ The Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS warning lamp LC

for 1 second after turning the ignition switch ON. The system performs another test the first time the vehicle

reaches 6 km/h (4 MPH). A mechanical noise may be heard as the ABS performs a self-test. This is a
normal part of the self-test feature. If a malfunction is found during this check, the ABS warning lamp will EC

come on.

¼ During ABS operation, a mechanical noise may be heard. This is a normal condition.
ABS Hydraulic Circuit

FE
NFBR0102

1. Inlet solenoid valve 2. Outlet solenoid valve 3. Reservoir

4. Pump 5. Motor 6. Inlet valve

7. Outlet valve 8. Bypass check valve 9. Damper

HA
SBR984D
SC
EL

IDX

BR-39

System Components

DESCRIPTION System Components

ABS
NFBR0103

SBR644E

System Description NFBR0104
SENSOR NFBR0104S01
The sensor unit consists of a gear-shaped sensor rotor and a sen-
sor element. The element contains a bar magnet around which a
coil is wound. The sensor is installed on the back side of the brake
rotor. Sine-wave current is generated by the sensor as the wheel
rotates. The frequency and voltage increase(s) as the rotating
speed increases.

SBR124B

CONTROL UNIT NFBR0104S02
The control unit computes the wheel rotating speed by the signal current sent from the sensor. Then it supplies a DC current to the actuator solenoid valve. It also controls ON-OFF operation of the valve relay and motor relay. If any electrical malfunction should be detected in the system, the control unit causes the warning lamp to light up. In this condition, the ABS will be deactivated by the control unit, and the vehicle's brake system reverts to normal operation.

SBR588E SBR645E

ABS ACTUATOR AND ELECTRIC UNIT The ABS actuator and electric unit contains: ¼ An electric motor and pump ¼ Two relays ¼ Eight solenoid valves, each inlet and outlet for
-- LH front -- RH front -- LH rear -- RH rear ¼ ABS control unit
BR-40

NFBR0104S03

Normal brake operation

Pressure hold

ABS operation

Pressure decrease
Pressure increase

DESCRIPTION

ABS
System Description (Cont'd)

This components controls the hydraulic circuit and increases, holds

or decreases hydraulic pressure to all or individual wheels. The

ABS actuator and electric unit are not disassemble.

ABS Actuator Operation

Inlet solenoid valve

Outlet solenoid valve

NFBR0104S0301
MA

OFF (Open)

OFF (Closed)

Master cylinder brake fluid pressure is directly transmitted to caliper via the inlet solenoid valve.

ON (Closed)

OFF (Closed)

Hydraulic circuit is shut off to hold the caliper brake fluid pressure.

ON (Closed)

ON (Open)

Caliper brake fluid is sent to reservoir via the outlet

solenoid valve. Then it is pushed up to the master

cylinder by pump.

OFF (Open)

OFF (Closed)

Master cylinder brake fluid pressure is transmitted to caliper.

ST RS BT HA SC EL IDX

BR-41

DESCRIPTION
Component Parts and Harness Connector Location

ABS

Component Parts and Harness Connector

Location

NFBR0105

BR-42

SBR646EA

DESCRIPTION Schematic
BR-43

ABS
Schematic
NFBR0106
GI MA EM LC EC FE CL MT AT AX SU
ST RS BT HA SC EL IDX
MBR387A

Wiring Diagram -- ABS --

DESCRIPTION Wiring Diagram -- ABS --

ABS
NFBR0107

BR-44

MBR463A

DESCRIPTION BR-45

ABS
Wiring Diagram -- ABS -- (Cont'd)
GI MA EM LC EC FE CL MT AT AX SU
ST RS BT HA SC EL IDX
MBR450A

Wiring Diagram -- ABS -- (Cont'd)

DESCRIPTION

ABS

BR-46

MBR417A

DESCRIPTION

ABS
Wiring Diagram -- ABS -- (Cont'd)
GI MA EM LC EC FE CL MT AT
SBR650E
AX SU
ST RS BT HA SC EL IDX

BR-47

Self-diagnosis

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ABS

Self-diagnosis NFBR0108
FUNCTION NFBR0108S01
¼ When a problem occurs in the ABS, the ABS warning lamp on the instrument panel comes on. To start the self-diagnostic results mode, ground the self-diagnostic (check) terminal located on "Data link connector". The location of the malfunction is indicated by the ABS warning lamp flashing.
SELF-DIAGNOSIS PROCEDURE NFBR0108S02
1. Drive vehicle over 30 km/h (19 MPH) for at least one minute.
2. Turn ignition switch "OFF".
3. Ground terminal "8" of "Data link connector" with a suitable harness.
4. Turn ignition switch "ON" while grounding terminal "8". Do not depress brake pedal. Do not start engine.

SBR535E

5. After 3.0 seconds, the ABS warning lamp starts flashing to indicate the malfunction code No. (See NOTE.)
6. Verify the location of the malfunction with the malfunction code chart. Refer to BR-61. Then make the necessary repairs following the diagnostic procedures.
7. After the malfunctions are repaired, erase the malfunction codes stored in the control unit. Refer to BR-49.
8. Rerun the self-diagnostic results mode to verify that the malfunction codes have been erased.

SBR588E SBR535E

9. Disconnect the check terminal from the ground. The self-diagnostic results mode is now complete.
10. Check ABS warning lamp for deactivation after driving vehicle over 30 km/h (19 MPH) for at least one minute.
11. After making certain that ABS warning lamp does not come on, test the ABS SELF-DIAGNOSIS in a safe area to verify that it functions properly.
NOTE: The indication terminates after five minutes. However, when the ignition switch is turned from "OFF" to "ON", the indication starts flashing again.
HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)
NFBR0108S03
1. Determine the code No. by counting the number of times the ABS warning lamp flashes on and off.
2. When several malfunctions occur at one time, up to three code numbers can be stored; the latest malfunction will be indicated first.
3. The indication begins with the start code 12. After that a maximum of three code numbers appear in the order of the latest one first. The indication then returns to the start code 12 to repeat (the indication will stay on for five minutes at the most).

BR-48

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ABS

Self-diagnosis (Cont'd)

4. The malfunction code chart is given on the BR-61 page.

LC
SBR457D
EC

ABR256

HOW TO ERASE SELF-DIAGNOSTIC RESULTS

(MALFUNCTION CODES)

NFBR0108S04

1. Disconnect the check terminal from ground (ABS warning lamp

will stay lit).
2. Within 12.5 seconds, ground the check terminal 3 times. Each AX

terminal ground must last more than 1 second. The ABS warn-

ing lamp goes out after the erase operation has been completed.

3. Perform self-diagnosis again. Refer to BR-48. Only the start

code should appear, no malfunction codes.

IDX

BR-49

CONSULT-II

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II
CONSULT-II APPLICATION TO ABS

ITEM

SELF-DIAGNOSTIC RESULTS

DATA MONITOR

ABS
NFBR0109 NFBR0109S01
ACTIVE TEST

Front right wheel sensor

Front left wheel sensor

Rear right wheel sensor

Rear left wheel sensor

Stop lamp switch

Front right inlet solenoid valve

Front right outlet solenoid valve

Front left inlet solenoid valve

Front left outlet solenoid valve

Rear right inlet solenoid valve

Rear right outlet solenoid valve

Rear left inlet solenoid valve

Rear left outlet solenoid valve

Actuator solenoid valve relay

Actuator motor relay

(ABS MOTOR is shown on the ACTIVE TEST

screen.)

ABS warning lamp

Battery voltage

Control unit

X: Applicable --: Not applicable
ECU (ABS CONTROL UNIT) PART NUMBER MODE NFBR0109S02
Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order the ABS actuator and electric unit.

CONSULT-II Inspection Procedure
SELF-DIAGNOSIS PROCEDURE 1. Turn ignition switch OFF.

NFBR0110 NFBR0110S01

2. Connect CONSULT-II to Data Link Connector.

3. Start engine.

4. Drive vehicle over 30 km/h (19 MPH) for at least one minute.

SBR535E

BR-50

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ABS

CONSULT-II Inspection Procedure (Cont'd)

5. Stop vehicle with engine running and touch "START" on CONSULT-II screen.
GI

PBR455D

6. Touch "ABS".

PBR385C

MT
7. Touch "SELF-DIAG RESULTS".
¼ The screen shows the detected malfunction and how many AT
times the ignition switch has been turned since the malfunction.
8. Make the necessary repairs following the diagnostic proce- AX
dures.
SU

PST412B

After the malfunctions are repaired, erase the self-diagnostic results stored in the control unit by touching "ERASE".

10. Check ABS warning lamp for deactivation after driving vehicle

over 30 km/h (19 MPH) for at least one minute.

NOTE:

"SELF-DIAG RESULTS" screen shows the detected malfunction

and how many times the ignition switch has been turned since the BT
malfunction.

HA
SBR561E
SC

IDX

BR-51

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II Inspection Procedure (Cont'd)
SELF-DIAGNOSTIC RESULTS MODE

Diagnostic item
FR RH SENSOR [OPEN]*1
FR LH SENSOR [OPEN]*1
RR RH SENSOR [OPEN]*1
RR LH SENSOR [OPEN]*1
FR RH SENSOR [SHORT]*1
FR LH SENSOR [SHORT]*1
RR RH SENSOR [SHORT]*1
RR LH SENSOR [SHORT]*1
ABS SENSOR [ABNORMAL SIGNAL]
FR RH IN ABS SOL [OPEN]
FR LH IN ABS SOL [OPEN]
RR RH IN ABS SOL [OPEN]
RR LH IN ABS SOL [OPEN]
FR RH IN ABS SOL [SHORT]
FR LH IN ABS SOL [SHORT]
RR RH IN ABS SOL [SHORT]
RR LH IN ABS SOL [SHORT]
FR RH OUT ABS SOL [OPEN]
FR LH OUT ABS SOL [OPEN]
RR RH OUT ABS SOL [OPEN]
RR LH OUT ABS SOL [OPEN]
FR RH OUT ABS SOL [SHORT]
FR LH OUT ABS SOL [SHORT]

Diagnostic item is detected when ...
¼ Circuit for front right wheel sensor is open. (An abnormally high input voltage is entered.)
¼ Circuit for front left wheel sensor is open. (An abnormally high input voltage is entered.)
¼ Circuit for rear right sensor is open. (An abnormally high input voltage is entered.)
¼ Circuit for rear left sensor is open. (An abnormally high input voltage is entered.)
¼ Circuit for front right wheel sensor is shorted. (An abnormally low input voltage is entered.)
¼ Circuit for front left wheel sensor is shorted. (An abnormally low input voltage is entered.)
¼ Circuit for rear right sensor is shorted. (An abnormally low input voltage is entered.)
¼ Circuit for rear left sensor is shorted. (An abnormally low input voltage is entered.)
¼ Teeth damage on sensor rotor or improper installation of wheel sensor. (Abnormal wheel sensor signal is entered.)
¼ Circuit for front right inlet solenoid valve is open. (An abnormally low output voltage is entered.)
¼ Circuit for front left inlet solenoid valve is open. (An abnormally low output voltage is entered.)
¼ Circuit for rear right inlet solenoid valve is open. (An abnormally low output voltage is entered.)
¼ Circuit for rear left inlet solenoid valve is open. (An abnormally low output voltage is entered.)
¼ Circuit for front right inlet solenoid valve is shorted. (An abnormally high output voltage is entered.)
¼ Circuit for front left inlet solenoid valve is shorted. (An abnormally high output voltage is entered.)
¼ Circuit for rear right inlet solenoid valve is shorted. (An abnormally high output voltage is entered.)
¼ Circuit for rear left inlet solenoid valve is shorted. (An abnormally high output voltage is entered.)
¼ Circuit for front right outlet solenoid valve is open. (An abnormally low output voltage is entered.)
¼ Circuit for front left outlet solenoid valve is open. (An abnormally low output voltage is entered.)
¼ Circuit for rear right outlet solenoid valve is open. (An abnormally low output voltage is entered.)
¼ Circuit for rear left outlet solenoid valve is open. (An abnormally low output voltage is entered.)
¼ Circuit for front right outlet solenoid valve is shorted. (An abnormally high output voltage is entered.)
¼ Circuit for front left outlet solenoid valve is shorted. (An abnormally high output voltage is entered.)
BR-52

ABS
=NFBR0110S02
Reference Page BR-62 BR-62 BR-62 BR-62 BR-62 BR-62 BR-62 BR-62 BR-62 BR-65 BR-65 BR-65 BR-65 BR-65 BR-65 BR-65 BR-65 BR-65 BR-65 BR-65 BR-65 BR-65 BR-65

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ABS

CONSULT-II Inspection Procedure (Cont'd)

Diagnostic item
RR RH OUT ABS SOL [SHORT]
RR LH OUT ABS SOL [SHORT]

Diagnostic item is detected when ...
¼ Circuit for rear right outlet solenoid valve is shorted. (An abnormally high output voltage is entered.)
¼ Circuit for rear left outlet solenoid valve is shorted. (An abnormally high output voltage is entered.)

Reference

Page

BR-65

MA
BR-65

ABS ACTUATOR RELAY [ABNORMAL]

¼ Actuator solenoid valve relay is ON, even control unit sends off signal. ¼ Actuator solenoid valve relay is OFF, even control unit sends on signal.

BR-65

ABS MOTOR RELAY [ABNORMAL]

¼ Circuit for actuator motor is open or shorted. ¼ Actuator motor relay is stuck.

BR-68

BATTERY VOLT [ABNORMAL]

¼ Power source voltage supplied to ABS control unit is abnormally low.

BR-70

CONTROL UNIT*2, *3

¼ Function of calculation in ABS control unit has failed.

BR-72

FE *1: Be sure to confirm the ABS warning lamp illuminates when the ignition switch is turned ON after repairing the shorted sensor circuit,
but the lamp goes out when driving the vehicle over 30 km/h (19 MPH) for one minute in accordance with SELF-DIAGNOSIS PROCEDURE.

CL *2: When "CONTROL UNIT 5" is displayed, check to see if the ABS warning lamp is burned out, and check the circuit between the ABS
warning lamp and ABS actuator/electric unit for open or short. Then check the ABS actuator/electric unit and circuit.

*3: When "CONTROL UNIT_XX" (except "CONTROL UNIT 5") is displayed, refer to "DIAGNOSTIC PROCEDURE" in "Control Unit",

BR-72.

DATA MONITOR PROCEDURE 1. Turn ignition switch OFF. 2. Connect CONSULT-II to data link connector. 3. Turn ignition switch ON. 4. Touch "START" on CONSULT-II screen.

AT NFBR0110S03 AX

PBR455D

5. Touch "ABS".

PBR385C

6. Touch "DATA MONITOR".

7. Touch "SETTING" on "SELECT MONITOR ITEM" screen.

8. Touch "LONG TIME" on "SET RECORDING COND" screen.

9. Touch "START" on "SELECT MONITOR ITEM".

IDX

PST412B

BR-53

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II Inspection Procedure (Cont'd)

ABS

ACTIVE TEST PROCEDURE NFBR0110S04
¼ When conducting Active test, vehicle must be stationary. ¼ When ABS warning lamp stays on, never conduct Active test. 1. Turn ignition switch OFF. 2. Connect CONSULT-II to Data Link Connector. 3. Start engine. 4. Touch "START" on CONSULT-II screen.

PBR455D
5. Touch "ABS".

PBR385C
6. Touch "ACTIVE TEST".

PST412B
7. Select active test item by touching screen.

PBR976C

8. Touch "START". 9. Carry out the active test by touching screen key.

PBR934C

BR-54

MONITOR ITEM FR RH SENSOR FR LH SENSOR RR RH SENSOR RR LH SENSOR
STOP LAMP SW
FR RH IN SOL FR RH OUT SOL FR LH IN SOL FR LH OUT SOL RR IN SOL RR OUT SOL RL IN SOL RL OUT SOL
ACTUATOR RLY
MOTOR RELAY
WARNING LAMP
BATTERY VOLT

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ABS

CONSULT-II Inspection Procedure (Cont'd)

DATA MONITOR MODE

NFBR0110S05

CONDITION

SPECIFICATION

Drive vehicle. (Each wheel is rotating.)

Displays computed vehicle speed from wheel sensor signal. Almost the same speed as speedometer.

Turn ignition switch ON and Depress the pedal: ON

depress brake pedal.

Release the pedal: OFF

Ignition switch is turned ON or Operating conditions for each solenoid valve are indicated.

engine is running.

ABS is not operating: OFF

Displays ON/OFF condition of ABS actuator relay.

When turning ignition switch ON, ABS actuator relay is oper-

ated.

Ignition switch is turned ON or ABS is not operating: OFF

engine is running.

ABS is operating: ON

Warning lamp is turned on: ON Warning lamp is turned off: OFF
AT
Power supply voltage for control unit

ACTIVE TEST MODE

TEST ITEM

CONDITION

JUDGEMENT

Brake fluid pressure control operation

FR RH SOLENOID FR LH SOLENOID RR RH SOLENOID RR LH SOLENOID

Ignition switch is turned ON.

UP (Increase): KEEP (Hold):

IN SOL OFF ON

DOWN (Decrease):

ABS MOTOR

ABS actuator motor ON: Motor runs OFF: Motor stops

NOTE: Active test will automatically stop ten seconds after the test starts. (TEST IS STOPPED monitor shows ON.)

AX
NFBR0110S06
SU
OUT SOL OFF OFF
ST
ON
RS
BT

IDX

BR-55

TROUBLE DIAGNOSIS -- INTRODUCTION
How to Perform Trouble Diagnoses for Quick and Accurate Repair

ABS

SEF233G SEF234G

How to Perform Trouble Diagnoses for Quick and Accurate Repair
NFBR0111
INTRODUCTION NFBR0111S01
The ABS system has an electronic control unit to control major functions. The control unit accepts input signals from sensors and instantly drives actuator. It is essential that both kinds of signals are proper and stable. It is also important to check for conventional problems: such as air leaks in the booster or lines, lack of brake fluid, or other problems with the brake system. It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are caused by poor electric connections or faulty wiring. In this case, careful checking of suspicious circuits may help prevent the replacement of good parts. A visual check only may not find the cause of the problems, so a road test should be performed. Before undertaking actual checks, take just a few minutes to talk with a customer who approaches with a ABS complaint. The customer is a very good source of information on such problems; especially intermittent ones. Through the talks with the customer, find out what symptoms are present and under what conditions they occur. Start your diagnosis by looking for "conventional" problems first. This is one of the best ways to troubleshoot brake problems on an ABS controlled vehicle. Also check related Service Bulletins for information.

BR-56

TROUBLE DIAGNOSIS -- BASIC INSPECTION
Preliminary Check
1 CHECK BRAKE FLUID LEVEL Check brake fluid level in reservoir tank. Low fluid level may indicate brake pad wear or leakage from brake line.

ABS
Preliminary Check
NFBR0112
GI
MA

FE SBR451D
Is brake fluid filled between MAX and MIN lines on reservoir tank and/or has brake fluid been contaminated?

Yes

GO TO 2.

Repair. GO TO 2.

2 CHECK BRAKE LINE

Check brake line for leakage.
AT

SBR389C

Is leakage present at or around brake lines, tubes or hoses or are any of these parts cracked or damaged?

Yes

GO TO 3.

Repair. GO TO 3.

IDX

BR-57

TROUBLE DIAGNOSIS -- BASIC INSPECTION
Preliminary Check (Cont'd)
3 CHECK BRAKE BOOSTER OPERATION Check brake booster for operation and air tightness. Refer to BR-21.

ABS

Is brake booster airtight and functioning properly?

Yes

GO TO 4.

Replace. GO TO 4.

4 CHECK BRAKE PAD AND ROTOR
Check brake pad and rotor. Refer to BR-24, BR-26, BR-28, BR-32.

SBR058C

Are brake pads and rotors functioning properly?

Yes

GO TO 5.

Replace.

SBR059C

BR-58

TROUBLE DIAGNOSIS -- BASIC INSPECTION

ABS

Preliminary Check (Cont'd)

5 RECHECK BRAKE FLUID LEVEL

Check brake fluid level in reservoir tank again.

EC SBR451D

Is brake fluid filled between MAX and MIN lines on reservoir tank and/or has brake fluid been contaminated?

Yes

GO TO 6.

Fill up brake fluid.

CL
6 CHECK WARNING LAMP ACTIVATION

Check warning lamp activation.

Does warning lamp turn on when ignition switch is turned "ON"?

Yes

GO TO 7.

Check fuse, warning lamp bulb and warning lamp circuit.

7 CHECK WARNING LAMP DEACTIVATION

Check warning lamp for deactivation after engine is started.

Does warning lamp turn off when engine is started?

Yes

GO TO 8.

Go to Self-diagnosis. Refer to BR-48, 50.

SBR588E
ST RS BT HA

8 DRIVE VEHICLE

Drive vehicle at speeds over 30 km/h (19 MPH) for at least one minute.

Does warning lamp remain off after vehicle has been driven at 30 km/h (19 MPH) for at least one minute?

Yes

END

Go to Self-diagnosis. Refer to BR-48, 50.

IDX

BR-59

Ground Circuit Check

TROUBLE DIAGNOSIS -- BASIC INSPECTION

ABS

Ground Circuit Check NFBR0113
ABS ACTUATOR AND ELECTRIC UNIT GROUND NFBR0113S01
¼ Check continuity between ABS actuator and electric unit connector terminals and ground.
Continuity should exist.

SBR045EG

BR-60

TROUBLE DIAGNOSIS -- GENERAL DESCRIPTION

ABS

Malfunction Code/Symptom Chart

Code No. (No. of LED flashes)

Malfunction Code/Symptom Chart

Malfunctioning part

Reference page

NFBR0114
GI

Self-diagnosis could not detect any malfunctions.

Front right sensor (open-circuit)

BR-62

Front right sensor (short-circuit)

Front left sensor (open-circuit)

BR-62

Front left sensor (short-circuit)

Rear right sensor (open-circuit)

BR-62

Rear right sensor (short-circuit)

Rear left sensor (open-circuit)

BR-62
EC
BR-62

Rear left sensor (short-circuit)

Actuator front right outlet solenoid valve

BR-62
FE
BR-65

Actuator front right inlet solenoid valve

Actuator front left outlet solenoid valve

BR-65

Actuator front left inlet solenoid valve

Actuator rear right outlet solenoid valve

BR-65

Actuator rear right inlet solenoid valve

Actuator rear left outlet solenoid valve

BR-65

Actuator rear left inlet solenoid valve

57*

Power supply (Low voltage)

BR-65

BR-70

Actuator motor or motor relay

BR-68

Solenoid valve relay

BR-65

Control unit

BR-72

ABS warning lamp stays on when ignition switch is turned on.

Control unit power supply circuit Warning lamp bulb circuit Control unit or control unit connector Solenoid valve relay stuck Power supply for solenoid valve relay coil

ABS warning lamp stays on, during self-diagnosis.

Control unit

ABS warning lamp does not come on Fuse, warning lamp bulb or warning lamp circuit

when ignition switch is turned on.

Control unit

ABS warning lamp does not come on during self-diagnosis.

Control unit

BR-79

RS
--
BT
BR-77

Pedal vibration and noise

Long stopping distance

BR-76

BR-74

Unexpected pedal action

ABS does not work.

BR-73

BR-75

ABS works frequently.

BR-73

IDX

*: Under voltage that is too low, the control unit disable the ABS. It does not set the ABS in fail-safe condition. Instead, the ABS becomes a conventional brake system. After the power supply has resumed, the warning lamp goes off, making it possible for the ABS to be re-engaged.

BR-61

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

Wheel Sensor or Rotor

DIAGNOSTIC PROCEDURE

NFBR0115

NFBR0115S01
Malfunction code No. 21, 22, 25, 26, 31, 32, 35, 36 or 18

NOTE: Wheel position should be identified by code No. except code No. 18 (sensor rotor).

1 INSPECTION START

Wheel sensor inspection

GO TO 2.

SBR590EA

2 CHECK CONNECTOR

1. Disconnect connectors from control unit and wheel sensor of malfunction code No. Check terminals for damage or loose connections. Then reconnect connectors.
2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes

GO TO 3.

INSPECTION END

BR-62

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

Wheel Sensor or Rotor (Cont'd)

3 CHECK WHEEL SENSOR CIRCUIT

1. Disconnect control unit connector.

2. Check resistance between control unit connector terminals.

Code No. 21 or 22 (Front RH wheel)

Terminals 10 and 25

Code No. 25 or 26 (Front LH wheel)

Terminals 8 and 23

Code No. 31 or 32 (Rear RH wheel)

Terminals 14 and 29

Code No. 35 or 36 (Rear LH wheel)

Terminals 12 and 27 Resistance: 0.8 - 1.85 k

Is resistance 0.8 - 1.85 k?

Yes

GO TO 5.

GO TO 4.

4 CHECK WHEEL SENSOR
Check resistance of each sensor. (See NOTE.) Resistance: 0.8 - 1.85 k

MT SBR477EB AT AX SU

BT
SBR478ED

Is resistance 0.8 - 1.85 k?

Yes

Repair harness and connectors between control unit connector and wheel sensor con-

nector.

Replace wheel sensor.

5 CHECK TIRE

Check for inflation pressure, wear and size of each tire.

Are tire pressure and size correct and is tire wear within specifications?

IDX

Yes

GO TO 6.

Adjust tire pressure or replace tire(s).

BR-63

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Wheel Sensor or Rotor (Cont'd)
6 CHECK WHEEL BEARING
Check wheel bearing axial end play. Check clearance between sensor and rotor.
Clearance: Front 0.273 - 0.925 mm (0.0107 - 0.0364 in) Rear 0.385 - 0.973 mm (0.0152 - 0.0383 in)

ABS

SBR333E

SBR069CA

Is axial end play and clearance within specifications?

Yes

GO TO 7.

Clean sensor fixing portion, or replace sensor.

7 CHECK SENSOR ROTOR

Check sensor rotor for teeth damage.

Is sensor rotor free from damage?

Yes

Check control unit pin terminals for damage or the connection of control unit harness

connector. Reconnect control unit harness connector. Then retest.

Replace sensor rotor.

BR-64

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

ABS Actuator Solenoid Valve or Solenoid Valve Relay

1 INSPECTION START

ABS Actuator Solenoid Valve or Solenoid Valve

Relay

DIAGNOSTIC PROCEDURE

GI =NFBR0116

NFBR0116S01

Malfunction code No. 41, 45, 55, 42, 46, 56, 63, 51, 52

Solenoid valve relay inspection
EM

GO TO 2.

SBR591EA
ST

2 CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT

Check 40A [E] fusible link (ABS ACTR) for ABS solenoid valve relay. For fusible link layout, refer to POWER SUPPLY

ROUTING in EL section.

Is fusible link OK?

Yes

GO TO 3.

GO TO 7.

3 CHECK FUSE

Check 10A fuse No. 31. For fuse layout, refer to "POWER SUPPLY ROUTING" in EL section.

Is fuse OK?

Yes

GO TO 4.

GO TO 9.

IDX

BR-65

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
ABS Actuator Solenoid Valve or Solenoid Valve Relay (Cont'd)

ABS

4 CHECK CONNECTOR

1. Disconnect connectors from control unit and ABS actuator. Check terminals for damage or loose connection. Then reconnect connectors.
2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes

GO TO 5.

INSPECTION END

5 CHECK GROUND CIRCUIT

Refer to ABS ACTUATOR AND ELECTRIC UNIT in Ground Circuit Check, BR-60.

Is ground circuit OK?

Yes

GO TO 6.

Repair harness and connectors.

6 CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT
1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector terminal 15 and ground.

SBR592E

Does battery voltage exist?

Yes

Replace ABS actuator and electric unit.

Check the following.

¼ Harness connector E9

¼ Harness for open or short between ABS actuator and electric unit and fusible link

If NG, repair harness or connectors.

7 REPLACE FUSIBLE LINK

Replace fusible link.

Does the fusible link blow out when ignition switch is turned "ON"?

Yes

GO TO 8.

INSPECTION END

BR-66

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

ABS Actuator Solenoid Valve or Solenoid Valve Relay (Cont'd)

8 CHECK RELAY UNIT POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector.

2. Check continuity between ABS actuator and electric unit connector terminal 15 and ground.

EC
SBR592E

Does continuity exist?

Yes

Replace ABS actuator and electric unit.

Check the following.

¼ Harness connector E9

¼ Harness for open or short between ABS actuator and electric unit and fusible link

If NG, repair harness or connectors.

9 REPLACE FUSE

Replace fuse.

Does the fuse blow out when ignition switch is turned "ON"?

Yes

Check the following.

¼ Harness connector E9

¼ Harness for open or short between ABS actuator and electric unit and fuse

If NG, repair harness or connectors.

INSPECTION END

ST RS BT HA SC EL IDX

BR-67

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Motor Relay or Motor
Motor Relay or Motor
DIAGNOSTIC PROCEDURE Malfunction code No. 61
1 INSPECTION START
ABS motor relay inspection

ABS
=NFBR0117 NFBR0117S01

GO TO 2.

SBR593EA

2 CHECK MOTOR POWER SUPPLY CIRCUIT

Check 40A [D] fusible link (ABS MTR) for ABS motor relay. For fusible link layout, refer to POWER SUPPLY ROUTING in EL section.

Is fusible link OK?

Yes

GO TO 3.

GO TO 6.

3 CHECK CONNECTOR

1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connection. Then reconnect connectors.
2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes

GO TO 4.

INSPECTION END

BR-68

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

Motor Relay or Motor (Cont'd)

4 CHECK MOTOR RELAY POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector.

2. Check voltage between ABS actuator and electric unit connector terminal 1 and ground.

EC
SBR594E

Does battery voltage exist?

Yes

GO TO 5.

Check the following.

¼ Harness connector E9

¼ Harness for open or short between ABS actuator and electric unit and fusible link

If NG, repair harness or connectors.

5 CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT

Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check, BR-60.

Is ground circuit OK?

Yes

Replace ABS actuator and electric unit.

Check the following.

¼ Harness connector E9

¼ Harness for open or short between ABS actuator and electric unit and ground

If NG, repair harness or connectors.

6 REPLACE FUSIBLE LINK

Replace fusible link.

Does the fusible link blow out when ignition switch is turned "ON"?

Yes

GO TO 7.

INSPECTION END

IDX

BR-69

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Motor Relay or Motor (Cont'd)
7 CHECK ABS ACTUATOR MOTOR POWER SUPPLY CIRCUIT 1. Disconnect battery cable and ABS actuator and electric unit connector. 2. Check continuity between ABS actuator and electric unit connector terminal 1 and ground.

ABS

SBR594E

Does continuity exist?

Yes

Check ABS actuator and electric unit pin terminals for damage or the connection of ABS

actuator and electric unit harness connector. Reconnect ABS actuator and electric unit

harness connector. Then retest.

Check the following.

¼ Harness connector E9

¼ Harness for open or short between ABS actuator and electric unit and fusible link

If NG, repair harness or connectors.

Low Voltage
DIAGNOSTIC PROCEDURE Malfunction code No. 57
1 INSPECTION START
ABS actuator and electric unit power supply and ground circuit inspection

NFBR0118 NFBR0118S01

GO TO 2.
BR-70

SBR595E

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS

Low Voltage (Cont'd)

2 CHECK CONNECTOR

1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connections. Then recon-

nect connector.

2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes

GO TO 3.

INSPECTION END

3 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector terminal 17 and ground.
EC

Does battery voltage exist when ignition switch is turned ON?

SBR596E
AT

Yes

GO TO 4.

GO TO 5.

4 CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND

Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check, BR-60.

Is ground circuit OK?

Check ABS actuator and electric unit pin terminals for damage or the connection of ABS

actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.

Check the following.

¼ Harness connector E9

¼ Harness for open or short between ABS actuator and electric unit and ground

If NG, repair harness or connectors.

5 CHECK FUSE

Check 10A fuse 31 (Engine control) for control unit. Refer to POWER SUPPLY ROUTING in EL section.

Is fuse OK?

Yes

GO TO 6.

Replace fuse.

IDX

BR-71

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Low Voltage (Cont'd)

6 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

Check continuity between battery and ABS actuator and electric unit connector terminal 17.

Does continuity exist?

Yes

Check battery. Refer to BATTERY in EL section.

Check the following.

¼ Harness connector E9

¼ Harness for open or short between ABS actuator and electric unit and fuse

If NG, repair harness or connectors.

ABS

Control Unit
DIAGNOSTIC PROCEDURE Malfunction code No. 71
1 INSPECTION START
ABS actuator and electric unit power supply and ground circuit inspection

NFBR0119 NFBR0119S01

GO TO 2.

SBR597E

2 CHECK CONNECTOR

1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connections. Then reconnect connectors.
2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes

GO TO 3.

INSPECTION END

3 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

Check voltage. Refer to "3. CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT" in "Low Voltage", BR-70.

Does battery voltage exist when ignition switch is turned ON?

Yes

GO TO 4.

Repair.

4 CHECK WARNING LAMP INDICATION

Does warning lamp indicate code No. 71 again?

Yes

Replace ABS actuator and electric unit.

Inspect the system according to the code No.

BR-72

TROUBLE DIAGNOSES FOR SYMPTOMS

1. ABS Works Frequently

1 CHECK BRAKE FLUID PRESSURE

Check brake fluid pressure distribution. Refer to dual proportioning valve inspection in "DUAL PROPORTIONING VALVE", BR-12.

Is brake fluid pressure distribution normal?

Yes

GO TO 2.

Perform Preliminary Check. Refer to BR-57.

ABS
1. ABS Works Frequently
NFBR0120
GI
MA
EM

2 CHECK WHEEL SENSOR

1. Check wheel sensor connector for terminal damage or loose connections.

2. Perform wheel sensor mechanical check.

Refer to "Wheel Sensor or Rotor", BR-62.

Are wheel sensors functioning properly?

Yes

GO TO 3.

Repair.

3 CHECK FRONT AXLE
Check front and rear axles for excessive looseness. Refer to AX section, "Front Wheel Bearing", "ON-VEHICLE SERVICE" MT
and "Rear Wheel Bearing", "ON-VEHICLE SERVICE".

Is front axle installed properly?

Yes

Go to "3. CHECK WARNING LAMP INDICATION" in "2. Unexpected Pedal Action",

BR-73.

Repair.

2. Unexpected Pedal Action
1 CHECK BRAKE PEDAL STROKE Check brake pedal stroke. Is stroke excessively large?

Yes

Perform Preliminary Check. Refer to BR-57.

GO TO 2.

ST NFBR0121 RS BT HA SC
EL SBR540A IDX

BR-73

TROUBLE DIAGNOSES FOR SYMPTOMS
2. Unexpected Pedal Action (Cont'd)

2 CHECK CONNECTOR AND PERFORMANCE

1. Disconnect ABS actuator and electric unit connector. 2. Check whether brake is effective.

OK or NG

Yes

GO TO 3.

Perform Preliminary Check. Refer to BR-57.

3 CHECK WARNING LAMP INDICATION Ensure warning lamp remains off while driving.

ABS

Is warning lamp turned off?

Yes

GO TO 4.

Carry out self-diagnosis. Refer to BR-48, BR-50.

SBR588E

4 CHECK WHEEL SENSOR

1. Check wheel sensor connector for terminal damage or loose connection. 2. Perform wheel sensor mechanical check.

Is wheel sensor mechanism OK?

Yes

Check ABS actuator and electric unit pin terminals for damage or the connection of ABS

actuator and electric unit harness connector. Reconnect ABS actuator and electric unit

harness connector. Then retest.

Repair.

3. Long Stopping Distance
1 CHECK CONNECTOR AND PERFORMANCE

NFBR0122

1. Cancel ABS by disconnecting ABS actuator and electric unit connector. 2. Check whether stopping distance is still long.

OK or NG

Perform Preliminary Check and air bleeding.

Go to "3. CHECK WARNING LAMP INDICATION" in "2. Unexpected Pedal Action",

BR-73.

BR-74

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

3. Long Stopping Distance (Cont'd)

NOTE:

Stopping distance may be longer than vehicles without ABS when

road condition is slippery.

4. ABS Does Not Work
1 CHECK WARNING LAMP INDICATION

LC
NFBR0123
EC

Does the ABS warning lamp activate?

Yes

Carry out self-diagnosis. Refer to BR-48, BR-50.

Go to "3. CHECK WARNING LAMP INDICATION" in "2. Unexpected Pedal Action",

BR-73.

NOTE:
ABS does not work when vehicle speed is under 10 km/h (6 MPH). MT

ST RS BT HA SC EL IDX

BR-75

TROUBLE DIAGNOSES FOR SYMPTOMS
5. Pedal Vibration and Noise
5. Pedal Vibration and Noise
1 INSPECTION START Pedal vibration and noise inspection

ABS
=NFBR0124

GO TO 2.

SAT797A

2 CHECK SYMPTOM

1. Apply brake. 2. Start engine.

Does the symptom appear only when engine is started?

Yes

Carry out self-diagnosis. Refer to BR-48, BR-50.

GO TO 3.

3 RECHECK SYMPTOM

Does the symptom appear when electrical equipment switches (such as headlamp) are operated?

Yes

INSPECTION END

Go to "3. CHECK WARNING LAMP INDICATION" in "2. Unexpected Pedal Action",

BR-73.

NOTE: ABS may operate and cause vibration under any of the following conditions.
¼ Applying brake gradually when shifting or operating clutch. ¼ Low friction (slippery) road. ¼ High speed cornering. ¼ Driving over bumps and pot holes. ¼ Engine speed is over 5,000 rpm with vehicle stopped.

BR-76

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

6. ABS Warning Lamp Does Not Come On When Ignition Switch Is Turned On

1 INSPECTION START

6. ABS Warning Lamp Does Not Come On

When Ignition Switch Is Turned On

GI =NFBR0125

Warning lamp circuit inspection

GO TO 2.

FE SBR598E

2 CHECK FUSE

Check 10A fuse No. 30 for warning lamp. For fuse layout, refer to "POWER SUPPLY ROUTING" in EL section.

Is fuse OK?

Yes

GO TO 3.

Replace fuse.

3 CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT

1. Install 10A fuse.

2. Remove solenoid valve relay. 3. Disconnect connectors from control unit and actuator.

4. Check voltage between control unit connector terminal 2 and ground after turning ignition switch "ON".

BT
SBR599E

Does battery voltage exist after turning ignition switch "ON"?

Yes

GO TO 5.

GO TO 4.

IDX

BR-77

TROUBLE DIAGNOSES FOR SYMPTOMS
6. ABS Warning Lamp Does Not Come On When Ignition Switch Is Turned On (Cont'd)
4 CHECK WARNING LAMP INDICATION Disconnect ABS actuator and electric unit connector.

ABS

Does the ABS warning lamp activate?

Yes

GO TO 6.

GO TO 5.

5 CHECK HARNESS FOR SHORT
1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector terminal 2 and ground.

SBR588E

SBR600E

Does battery voltage exist?

Yes

Check combination meter. Refer to WARNING LAMPS in EL section.

Repair harness and connectors between fuse and ABS actuator and electric unit connec-

tor terminal 2.

6 CHECK HARNESS CONNECTOR

Check ABS actuator and electric unit pin terminals for damage or connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then reset.

INSPECTION END

Replace ABS actuator and electric unit.

BR-78

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

7. ABS Warning Lamp Stays On When Ignition Switch Is Turned On

1 INSPECTION START

7. ABS Warning Lamp Stays On When Ignition

Switch Is Turned On

GI =NFBR0126

ABS control unit inspection

GO TO 2.
2 CHECK WARNING LAMP 1. Disconnect ABS actuator and electric unit connector. 2. Connect suitable wire between ABS actuator and electric unit connector terminal 2 and ground.

EC FE SBR601E
CL MT

SBR602E

Does warning lamp activate?

Yes

GO TO 3.

Repair combination meter. Check the following.

¼ Harness connector E9

¼ Harness for open or short between ABS actuator and electric unit and fuse

If NG, repair harness or connector.

BT
3 CHECK HARNESS CONNECTOR

Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness

connector. Reconnect ABS actuator and electric unit harness connector. Then retest.

INSPECTION END

GO TO 4.

IDX

BR-79

TROUBLE DIAGNOSES FOR SYMPTOMS
7. ABS Warning Lamp Stays On When Ignition Switch Is Turned On (Cont'd)

ABS

4 CHECK ABS MOTOR GROUND

1. Turn ignition switch "OFF". 2. Check continuity between ABS motor and ground.

Does continuity exist?

Yes

Replace ABS actuator and electric unit.

Check the following.

¼ ABS motor ground harness

¼ ABS motor ground harness for open or short between ABS motor and ground

If NG, repair harness.

BR-80

DESCRIPTION

TCS
Purpose

Purpose

NFBR0048

The ABS consists of electronic and hydraulic components. It allows for control of braking force so that locking of the wheels can be avoided.

The ABS:

1) Ensures proper tracking performance through steering wheel operation.

2) Enables obstacles to be avoided through steering wheel operation.

3) Ensures vehicle stability by preventing flat spins.

ABS (Anti-Lock Brake System) Operation

¼ When the vehicle speed is less than 10 km/h (6 MPH) this system does not work.

NFBR0049

¼ The Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS warning lamp LC

for 1 second after turning the ignition switch ON. The system performs another test the first time the vehicle

come on.

¼ During ABS operation, a mechanical noise may be heard. This is a normal condition.
ABS Hydraulic Circuit

FE
NFBR0050

1. Inlet solenoid valve 2. Outlet solenoid valve 3. Reservoir

4. Pump 5. Motor 6. Inlet valve

7. Outlet valve 8. Bypass check valve 9. Damper

HA
SBR984D
SC
EL

IDX

BR-81

TCS (Traction Control System) Operation

DESCRIPTION

TCS

TCS (Traction Control System) Operation =NFBR0081
¼ This system is designed to limit wheel slip during acceleration by cutting fuel to selected cylinders and changing transmission shift schedule. The ABS/TCS control unit monitors wheel speed slips through the ABS wheel sensors and determines the desired torque reduction needed to minimize wheel spin. The torque reduction by the ABS/TCS control unit may result in a combination of fuel cutoff and change shift timing of the transmission. The torque reduction is sent from the ABS/TCS control unit through the data link to the ECM and TCM. The ECM will cut off fuel and/or TCM change shift schedule to achieve torque reduction. The TCS will be enabled when the TCS switch is in the ON position (TCS OFF indicator not illuminated), and if the catalytic converter temperature is within normal operating range.
¼ This system has a self-diagnostic function. When the ignition switch is initially turned "ON", the SLIP indicator lamp and TCS OFF indicator lamp light. If there is no problem with the ABS and TCS, both indicator lamps will go out as soon as the engine starts.
¼ The TCS OFF switch cancels the TCS function. The TCS OFF indicator lamp then lights to indicate that the TCS is not operating.
¼ This system utilizes a fuel-cut function to control drive torque. If fuel cut continues for an extended period of time during high-speed operations, the catalyst may melt and deteriorate. During continued TCS operations, the system will sometimes suspend the drive torque control function, preventing catalyst melting and deterioration.

System Components

NFBR0051

SBR342E

System Description NFBR0052
SENSOR NFBR0052S01
The sensor unit consists of a gear-shaped sensor rotor and a sen-
sor element. The element contains a bar magnet around which a
coil is wound. The sensor is installed on the back side of the brake
rotor. Sine-wave current is generated by the sensor as the wheel
rotates. The frequency and voltage increase(s) as the rotating
speed increases.

SBR124B

BR-82

Normal brake operation

Pressure hold

ABS operation

Pressure decrease
Pressure increase

DESCRIPTION

TCS
System Description (Cont'd)

CONTROL UNIT

NFBR0052S02

ABS Function

NFBR0052S0201
The control unit computes the wheel rotating speed by the signal

current sent from the sensor. Then it supplies a DC current to the

actuator solenoid valve. It also controls ON-OFF operation of the valve relay and motor relay. If any electrical malfunction should be

detected in the system, the warning lamp is turned on. In this

condition, the ABS will be deactivated, and the vehicle's brake system reverts to normal operation.

SBR655E

TCS Function

NFBR0052S0202
Drive wheel slippage is detected by the 4-wheel rotating speed

signal. When the wheel slip becomes excessive, the TCS operates,

causing the SLIP indicator lamp to flash. And, at the same time, a fuel-cut signal to be sent to the ECM and a signal requiring a

change in the shift schedule is sent to the TCM. When the TCS

OFF switch is used to cancel TCS function, the TCS OFF indicator lamp will light. (TCS does not activate.) In case of a malfunc-

tion in the TCS, both the SLIP indicator lamp and the TCS OFF

indicator lamp will light, while shutting down the TCS system operation. The vehicle will operate in the same way as a vehicle not

equipped with the TCS.

SBR530E

ACTUATOR
The actuator contains:
¼ An electric motor and pump ¼ Two relays ¼ Eight solenoid valves, each inlet and outlet for
-- LH front -- RH front -- LH rear -- RH rear

AT NFBR0052S03 AX SU

SBR531E

These components control the hydraulic circuit. The ABS control

unit directs the actuator to increase, hold or decrease hydraulic

pressure to all or individual wheels. ABS Actuator Operation

ST
NFBR0052S0301

Inlet solenoid

Outlet solenoid

valve

OFF (Open)

OFF (Closed)

Master cylinder brake fluid pressure is directly trans-

mitted to caliper via the inlet solenoid valve.

ON (Closed) ON (Closed)

OFF (Closed)

Hydraulic circuit is shut off to hold the caliper brake fluid pressure.

ON (Open)

Caliper brake fluid is sent to reservoir via the outlet

solenoid valve. Then it is pushed up to the master

cylinder by pump.

OFF (Open)

OFF (Closed)

Master cylinder brake fluid pressure is transmitted to

caliper.

IDX

BR-83

DESCRIPTION
Component Parts and Harness Connector Location

TCS

Component Parts and Harness Connector

Location

NFBR0053

BR-84

SBR534EB

DESCRIPTION Schematic
BR-85

TCS
Schematic
NFBR0054
GI MA EM LC EC FE CL MT AT AX SU
ST RS BT HA SC EL IDX
MBR418A

Wiring Diagram -- TCS --

DESCRIPTION Wiring Diagram -- TCS --

TCS
NFBR0055

BR-86

MBR424A

DESCRIPTION BR-87

TCS
Wiring Diagram -- TCS -- (Cont'd)
GI MA EM LC EC FE CL MT AT AX SU
ST RS BT HA SC EL IDX
MBR500A

Wiring Diagram -- TCS -- (Cont'd)

DESCRIPTION

TCS

BR-88

MBR425A

DESCRIPTION BR-89

TCS
Wiring Diagram -- TCS -- (Cont'd)
GI MA EM LC EC FE CL MT AT AX SU
ST RS BT HA SC EL IDX
MBR435A

Wiring Diagram -- TCS -- (Cont'd)

DESCRIPTION

TCS

BR-90

SBR641E

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

TCS
Self-diagnosis

Self-diagnosis

NFBR0056

FUNCTION NFBR0056S01
¼ When a problem occurs in the ABS, the ABS warning lamp on

the instrument panel comes on. When a problem occurs in the

TCS, the TCS OFF indicator lamp and SLIP indicator lamp on MA
the instrument panel comes on. To actuate the self-diagnostic

results mode, ground the self-diagnostic (check) terminal

located on "Data link connector". The location of the malfunc- EM
tion is indicated by the ABS warning lamp or SLIP indicator

lamp flashing.

SELF-DIAGNOSIS PROCEDURE

NFBR0056S02

1. Drive vehicle over 30 km/h (19 MPH) for at least one minute.

2. Turn ignition switch "OFF".

3. Ground terminal "9" of "Data link connector" with a suitable

harness.

4. Turn ignition switch "ON" while grounding terminal "9".

Do not depress brake pedal.

Do not start engine.

SBR535E SBR655E

After 3.0 seconds, the SLIP indicator lamp starts flashing to indicate the malfunction code No. (See NOTE.)

6. Verify the location of the malfunction with the malfunction code

chart. Refer to BR-105. Then make the necessary repairs following the diagnostic procedures.

7. After the malfunctions are repaired, erase the malfunction

codes stored in the control unit. Refer to BR-92.

8. Rerun the self-diagnostic results mode to verify that the mal-

function codes have been erased.
HA

9. Disconnect the check terminal from the ground. The self-diag- SC
nostic results mode is now complete.

10. Check ABS warning lamp, TCS OFF indicator lamp and SLIP
indicator lamp for deactivation after driving vehicle over 30 EL

km/h (19 MPH) for at least one minute.

11. After making certain that ABS warning lamp, TCS OFF indicator lamp and SLIP indicator lamp does not come on, test the

IDX

ABS/TCS SELF-DIAGNOSIS in a safe area to verify that it

functions properly.

SBR535E

BR-91

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

TCS

Self-diagnosis (Cont'd)

NOTE: The indication terminates after five minutes. However, when the ignition switch is turned from "OFF" to "ON", the SLIP indication starts flashing again. The TCS OFF indicator lamp and ABS warning lamp remain lighted.

HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)
NFBR0056S03
1. Determine the code No. by counting the number of times the ABS warning lamp or SLIP indicator lamp flashes on and off.
2. When several malfunctions occur at one time, up to three code numbers can be stored; the latest malfunction will be indicated first.
3. The indication begins with the start code 12. After that a maximum of three code numbers appear in the order of the latest one first. The indication then returns to the start code 12 to repeat (the indication will stay on for five minutes at the most).
4. The malfunction code chart is given on the BR-105 page.

SBR457D

SBR631D

HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)
NFBR0056S04
1. Under the self-diagnostic results mode, the malfunction memory erase mode starts when the check terminal is disconnected from the ground.
2. The self-diagnostic results (malfunction codes) can be erased by grounding the check terminal more than three times in succession within 12.5 seconds after the erase mode starts. (Each grounding must be longer than one second.) The ABS warning lamp or SLIP indicator lamp stays on while the self-diagnosis is in the erase mode, and goes out after the erase operation has been completed.
3. The self-diagnosis is also completed at the same time. (Refer to BR-91.)
After the erase operation is completed, it is necessary to rerun the self-diagnostic mode to verify that malfunction codes no longer appear. Only the start code (12) should be indicated when erase operation is completed and system is functioning normally.
NOTE: The TCS OFF indicator lamp and ABS warning lamp remain lighted.

BR-92

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II
CONSULT-II APPLICATION TO TCS

ITEM Front right wheel sensor

SELF-DIAGNOSTIC RESULTS
X

DATA MONITOR X

TCS
CONSULT-II
NFBR0057
GI NFBR0057S01
ACTIVE TEST
MA
--

Front left wheel sensor Rear right wheel sensor

Rear left wheel sensor ABS sensor

Stop lamp switch Front right inlet solenoid valve

Front right outlet solenoid valve Front left inlet solenoid valve Front left outlet solenoid valve

Rear right inlet solenoid valve Rear right outlet solenoid valve

Rear left inlet solenoid valve Rear left outlet solenoid valve

Actuator solenoid valve relay

Actuator motor relay

(ABS MOTOR is shown on the ACTIVE TEST

screen.) ABS warning lamp

Battery voltage

Control unit

Engine speed signal ABS motor

A/T gear position signal TCS OFF indicator lamp

SLIP indicator lamp ECM LAN signal

X: Applicable

--: Not applicable

ECU (ABS/TCS CONTROL UNIT) PART NUMBER MODE

NFBR0057S02

Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order the ECU.

IDX

BR-93

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

TCS

CONSULT-II Inspection Procedure

CONSULT-II Inspection Procedure
SELF-DIAGNOSIS PROCEDURE 1. Turn ignition switch OFF.

NFBR0058 NFBR0058S01

2. Connect CONSULT-II to Data Link Connector.

3. Start engine.

4. Drive vehicle over 30 km/h (19 MPH) for at least one minute.

SBR535E

5. Stop vehicle with engine running and touch "START" on CONSULT-II screen.

PBR455D
6. Touch "ABS".

PBR385C

7. Touch "SELF DIAGNOSIS".
¼ The screen shows the detected malfunction and how many times the ignition switch has been turned since the malfunction.
8. Make the necessary repairs following the diagnostic procedures.

PST412B

9. After the malfunctions are repaired, erase the self-diagnostic results stored in the control unit by touching "ERASE".
10. Check ABS warning lamp, SLIP indicator lamp, TCS OFF indicator lamp for deactivation after driving vehicle over 30 km/h (19 MPH) for at least one minute.
NOTE: "SELF-DIAG RESULTS" screen shows the detected malfunction and how many times the ignition switch has been turned since the malfunction.

SBR561E

BR-94

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

TCS

CONSULT-II Inspection Procedure (Cont'd)

Diagnostic item

SELF-DIAGNOSTIC RESULTS MODE
Diagnostic item is detected when ...

=NFBR0058S02

Reference

Page

FR RH SENSOR [OPEN]*1

¼ Circuit for front right wheel sensor is open. (An abnormally high input voltage is entered.)

BR-107

FR LH SENSOR [OPEN]*1
RR RH SENSOR [OPEN]*1
RR LH SENSOR [OPEN]*1
FR RH SENSOR [SHORT]*1

¼ Circuit for front left wheel sensor is open. (An abnormally high input voltage is entered.)
¼ Circuit for rear right sensor is open. (An abnormally high input voltage is entered.)
¼ Circuit for rear left sensor is open. (An abnormally high input voltage is entered.)
¼ Circuit for front right wheel sensor is shorted. (An abnormally low input voltage is entered.)

BR-107
EM
BR-107
LC
BR-107
EC
BR-107

FR LH SENSOR [SHORT]*1

¼ Circuit for front left wheel sensor is shorted. (An abnormally low input voltage is entered.)

BR-107

RR RH SENSOR [SHORT]*1

¼ Circuit for rear right sensor is shorted. (An abnormally low input voltage is entered.)

BR-107

RR LH SENSOR [SHORT]*1
ABS SENSOR [ABNORMAL SIGNAL]
FR RH IN ABS SOL [OPEN]
FR LH IN ABS SOL [OPEN]

¼ Circuit for rear left sensor is shorted. (An abnormally low input voltage is entered.)
¼ Teeth damage on sensor rotor or improper installation of wheel sensor. (Abnormal wheel sensor signal is entered.)
¼ Circuit for front right inlet solenoid valve is open. (An abnormally low output voltage is entered.)
¼ Circuit for front left inlet solenoid valve is open. (An abnormally low output voltage is entered.)

BR-107

BR-107
AT
BR-110
AX
BR-110

RR RH IN ABS SOL [OPEN]

¼ Circuit for rear right inlet solenoid valve is open. (An abnormally low output voltage is entered.)

BR-110

RR LH IN ABS SOL [OPEN]

¼ Circuit for rear left inlet solenoid valve is open. (An abnormally low output voltage is entered.)

BR-110

FR RH IN ABS SOL [SHORT]
FR LH IN ABS SOL [SHORT]
RR RH IN ABS SOL [SHORT]
RR LH IN ABS SOL [SHORT]

¼ Circuit for front right inlet solenoid valve is shorted. (An abnormally high output voltage is entered.)
¼ Circuit for front left inlet solenoid valve is shorted. (An abnormally high output voltage is entered.)
¼ Circuit for rear right inlet solenoid valve is shorted. (An abnormally high output voltage is entered.)
¼ Circuit for rear left inlet solenoid valve is shorted. (An abnormally high output voltage is entered.)

BR-110

BR-110
RS
BR-110
BT
BR-110

FR RH OUT ABS SOL [OPEN]

¼ Circuit for front right outlet solenoid valve is open. (An abnormally low output voltage is entered.)

BR-110

FR LH OUT ABS SOL [OPEN]

¼ Circuit for front left outlet solenoid valve is open. (An abnormally low output voltage is entered.)

BR-110

RR RH OUT ABS SOL [OPEN]
RR LH OUT ABS SOL [OPEN]
FR RH OUT ABS SOL [SHORT]

¼ Circuit for rear right outlet solenoid valve is open. (An abnormally low output voltage is entered.)
¼ Circuit for rear left outlet solenoid valve is open. (An abnormally low output voltage is entered.)
¼ Circuit for front right outlet solenoid valve is shorted. (An abnormally high output voltage is entered.)

BR-110

BR-110
IDX
BR-110

FR LH OUT ABS SOL [SHORT]

¼ Circuit for front left outlet solenoid valve is shorted. (An abnormally high output voltage is entered.)

BR-110

BR-95

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

TCS

CONSULT-II Inspection Procedure (Cont'd)

Diagnostic item

Diagnostic item is detected when ...

Reference Page

RR RH OUT ABS SOL [SHORT]

¼ Circuit for rear right outlet solenoid valve is shorted. (An abnormally high output voltage is entered.)

BR-110

RR LH OUT ABS SOL [SHORT]

¼ Circuit for rear left outlet solenoid valve is shorted. (An abnormally high output voltage is entered.)

BR-110

ABS ACTUATOR RELAY [ABNORMAL]

¼ Actuator solenoid valve relay is ON, even control unit sends off signal. ¼ Actuator solenoid valve relay is OFF, even control unit sends on signal.

BR-114

ABS MOTOR [ABNORMAL]

¼ Circuit for actuator motor is open or shorted. ¼ Actuator motor relay is stuck.

BR-120

BATTERY VOLTAGE [ABNORMAL]

¼ Power source voltage supplied to ABS control unit is abnormally low.

BR-126

CONTROL UNIT

¼ Function of calculation in ABS control unit has failed.

BR-128

LAN SIGNAL 1 [ABNORMAL]

¼ ECM judges that communication signal between ABS/TCS control unit and ECM is abnormal.

BR-131

LAN SIGNAL 2 [ABNORMAL]

¼ On the Local Area Network (LAN) between ABS/TCS control unit and ECM, ECM does not transmit the LAN start signal to ABS/TCS control unit.

BR-132

LAN SIGNAL 3 [ABNORMAL]

¼ The communication start signal output is not terminated and the ordinary signals are not entered to ABS/TCS control unit.

BR-135

ENGINE SPEED SIG [ABNORMAL]

¼ Engine speed signal from ECM is not entered.

BR-129

ENGINE CHECK SIGNAL

¼ Based on the signal from ECM, the ABS/TCS control unit judges that the engine control system is malfunctioning.

BR-129

LAN CIRCUIT 1 [ABNORMAL]

¼ The communication line between ABS/TCS control unit and ECM is open or shorted.

BR-133

LAN CIRCUIT 2 [ABNORMAL]

¼ An instantaneous signal interruption occurs repeatedly on the communication line between ABS/TCS control unit and ECM.

BR-133

*1: Be sure to confirm the ABS warning lamp illuminates when the ignition switch is turned ON after repairing the shorted sensor circuit, but the lamp goes out when driving the vehicle over 30 km/h (19 MPH) for one minute in accordance with SELF-DIAGNOSIS PROCEDURE.

DATA MONITOR PROCEDURE 1. Turn ignition switch OFF.

NFBR0058S03

2. Connect CONSULT-II to data link connector.

3. Turn ignition switch ON.

4. Touch "START" on CONSULT-II screen.

PBR455D
5. Touch "ABS".

PBR385C

BR-96

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

TCS

CONSULT-II Inspection Procedure (Cont'd)

6. Touch "DATA MONITOR".
7. Touch "SETTING" on "SELECT MONITOR ITEM" screen.
8. Touch "LONG TIME" on "SET RECORDING COND" screen. GI
9. Touch "START" on "SELECT MONITOR ITEM".

PST412B

ACTIVE TEST PROCEDURE

NFBR0058S04

¼ When conducting Active test, vehicle must be stationary.

¼ When ABS warning lamp or SLIP indicator lamp stays on,

never conduct Active test.

1. Turn ignition switch OFF.

2. Connect CONSULT-II to Data Link Connector.

3. Start engine. 4. Touch "START" on CONSULT-II screen.

PBR455D

5. Touch "ABS".
AT

PBR385C

6. Touch "ACTIVE TEST".

PST412B

7. Select active test item by touching screen.

IDX

PBR976C

BR-97

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT-II Inspection Procedure (Cont'd)
8. Touch "START". 9. Carry out the active test by touching screen key.

TCS

MONITOR ITEM FR RH SENSOR FR LH SENSOR RR RH SENSOR RR LH SENSOR STOP LAMP SW ENGINE SPEED FR RH IN SOL FR RH OUT SOL FR LH IN SOL FR LH OUT SOL RR IN SOL RR OUT SOL RL IN SOL RL OUT SOL
ACTUATOR RLY
MOTOR RELAY
WARNING LAMP BATTERY VOLT THRTL OPENING
TRQ RDUC SIG
GEAR
TCS SW
TCS OFF LAMP

PBR934C
DATA MONITOR MODE

CONDITION

SPECIFICATION

NFBR0058S05

Drive vehicle. (Each wheel is rotating.)

Displays computed vehicle speed from wheel sensor signal. Almost the same speed as speedometer.

Turn ignition switch ON and depress brake pedal.
Engine is running. (rpm)

Depress the pedal: ON Release the pedal: OFF
Engine speed: 0 - 8,000 (rpm)

Ignition switch is turned ON or Operating conditions for each solenoid valve are indicated.

engine is running.

ABS is not operating: OFF

Displays ON/OFF condition of ABS actuator relay. When turning ignition switch ON, ABS actuator relay is operated.

Ignition switch is turned ON or engine is running.

ABS is not operating: OFF ABS is operating: ON
Warning lamp is turned on: ON Warning lamp is turned off: OFF

Power supply voltage for control unit

The throttle valve opening rate (%)

Opening rate: 0 - 100%

The operating cylinder ratio to fuel injected, calculated and sent by ABS/TCS control unit to ECM, is displayed.

TCS is not operating: 0 TCS is operating: 0 - 6* * Displays the number of cylinders to which fuel supply is cut.

A/T gear position signal detected by TCM via ECM is displayed.

Gear position: P, N: N.P 1st: 1 2nd: 2 3rd: 3 4th: 4

ON/OFF condition of signal

TCS OFF S/W (all the time switch is pressed): ON

from TCS switch is displayed. TCS OFF S/W (released): OFF

¼ TCS OFF condition is displayed.
¼ The condition of malfunctioning TCS is displayed.

TCS OFF indicator "OFF": OFF TCS OFF indicator "ON": ON

BR-98

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

TCS

CONSULT-II Inspection Procedure (Cont'd)

MONITOR ITEM SLIP LAMP TCS OPR SIG

CONDITION
The TCS functioning state is displayed by detecting rear wheel slip.
TCS operating condition

SPECIFICATION
SLIP indicator "ON": ON SLIP indicator "OFF": OFF
TCS is not operating: OFF TCS is operating: ON

ACTIVE TEST MODE

TEST ITEM

CONDITION

JUDGEMENT

Brake fluid pressure control operation

FR RH SOLENOID FR LH SOLENOID RR RH SOLENOID RR LH SOLENOID

Ignition switch is turned ON.

UP (Increase): KEEP (Hold):

IN SOL OFF ON

DOWN (Decrease):

ABS MOTOR

ABS actuator motor ON: Motor runs OFF: Motor stops

NOTE: Active test will automatically stop ten seconds after the test starts. (TEST IS STOPPED monitor shows ON.)

EM
NFBR0058S06
LC

OUT SOL

OFF

ST RS BT HA SC EL IDX

BR-99

TROUBLE DIAGNOSIS -- INTRODUCTION
How to Perform Trouble Diagnoses for Quick and Accurate Repair

TCS

SEF233G SEF234G

How to Perform Trouble Diagnoses for Quick and Accurate Repair
NFBR0059
INTRODUCTION NFBR0059S01
The ABS/TCS system has an electronic control unit to control major functions. The control unit accepts input signals from sensors and instantly drives actuator. It is essential that both kinds of signals are proper and stable. It is also important to check for conventional problems: such as air leaks in the booster or lines, lack of brake fluid, or other problems with the brake system. It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are caused by poor electric connections or faulty wiring. In this case, careful checking of suspicious circuits may help prevent the replacement of good parts. A visual check only may not find the cause of the problems, so a road test should be performed. Before undertaking actual checks, take just a few minutes to talk with a customer who approaches with an ABS/TCS complaint. The customer is a very good source of information on such problems; especially intermittent ones. Through the talks with the customer, find out what symptoms are present and under what conditions they occur. Start your diagnosis by looking for "conventional" problems first. This is one of the best ways to troubleshoot brake problems on an ABS/TCS controlled vehicle. Also check related Service Bulletins for information.

BR-100

TROUBLE DIAGNOSIS -- BASIC INSPECTION
Preliminary Check
1 CHECK BRAKE FLUID LEVEL Check brake fluid level in reservoir tank. Low fluid level may indicate brake pad wear or leakage from brake line.

TCS
Preliminary Check
NFBR0060
GI
MA

FE SBR451D
Is brake fluid filled between MAX and MIN lines on reservoir tank and/or has brake fluid been contaminated?

Yes

GO TO 2.

Repair. GO TO 2.

2 CHECK BRAKE LINE

Check brake line for leakage.
AT

SBR389C

Is leakage present at or around brake lines, tubes or hoses or are any of these parts cracked or damaged?

Yes

GO TO 3.

Repair. GO TO 3.

IDX

BR-101

TROUBLE DIAGNOSIS -- BASIC INSPECTION
Preliminary Check (Cont'd)
3 CHECK BRAKE BOOSTER OPERATION Check brake booster for operation and air tightness. Refer to BR-21.

TCS

Is brake booster airtight and functioning properly?

Yes

GO TO 4.

Replace. GO TO 4.

4 CHECK BRAKE PAD AND ROTOR
Check brake pad and rotor. Refer to BR-24, 26, 28, 32.

SBR058C

Are brake pads and rotors functioning properly?

Yes

GO TO 5.

Replace.

SBR059C

BR-102

TROUBLE DIAGNOSIS -- BASIC INSPECTION

TCS

Preliminary Check (Cont'd)

5 RECHECK BRAKE FLUID LEVEL

Check brake fluid level in reservoir tank again.

EC SBR451D

Is brake fluid filled between MAX and MIN lines on reservoir tank and/or has brake fluid been contaminated?

Yes

GO TO 6.

Fill up brake fluid.

CL
6 CHECK WARNING LAMP ACTIVATION

Check warning lamp activation.

Does warning lamp turn on when ignition switch is turned "ON"?

Yes

GO TO 7.

Check fuse, warning lamp bulb and warning lamp circuit.

7 CHECK WARNING LAMP DEACTIVATION

Check warning lamp for deactivation after engine is started.

Does warning lamp turn off when engine is started?

Yes

GO TO 8.

Go to Self-diagnosis. Refer to BR-91, 94.

SBR655E
ST RS BT HA

8 DRIVE VEHICLE

Drive vehicle at speeds over 30 km/h (19 MPH) for at least one minute.

Does warning lamp remain off after vehicle has been driven at 30 km/h (19 MPH) for at least one minute?

Yes

END

Go to Self-diagnosis. Refer to BR-91, 94.

IDX

BR-103

Ground Circuit Check

TROUBLE DIAGNOSIS -- BASIC INSPECTION

TCS

Ground Circuit Check NFBR0061
ACTUATOR MOTOR GROUND NFBR0061S01
¼ Check resistance between actuator motor ground terminal and body ground.
Resistance: 0

SBR792D

CONTROL UNIT GROUND NFBR0061S02
¼ Check resistance between the terminals and ground. Resistance: 0

SBR714DF

ABS SOLENOID VALVE RELAY GROUND NFBR0061S03
¼ Check resistance between solenoid valve relay terminal 4 and ground.
Resistance: 0

SBR764DI

BR-104

TROUBLE DIAGNOSIS -- GENERAL DESCRIPTION

TCS

Malfunction Code/Symptom Chart

Code No. (No. of SLIP indicator flashes)

Malfunction Code/Symptom Chart

Malfunctioning part

Warning lamp
ABS

Indicator

TCS OFF

SLIP

Failsafe

NFBR0062
GI
Reference
Page MA

Self-diagnosis could not detect any malfunctions

OFF OFF OFF

Front right sensor (open-circuit)

Front right sensor (short-circuit)*2

X BR-107
X BR-107 LC

Front left sensor (open-circuit)

Front left sensor (short-circuit)*2

X BR-107
X BR-107 EC

Rear right sensor (open-circuit)

Rear right sensor (short-circuit)*2

X BR-107
X BR-107 FE

Rear left sensor (open-circuit)

Rear left sensor (short-circuit)*2

X BR-107
CL
X BR-107

Actuator front right outlet solenoid valve

Actuator front right inlet solenoid valve

X BR-110
MT
X BR-110

Actuator front left outlet solenoid valve

Actuator front left inlet solenoid valve

X BR-110
AT
X BR-110

Actuator rear right outlet solenoid valve

Actuator rear right inlet solenoid valve

X BR-110 AX
X BR-110

Actuator rear left outlet solenoid valve

Actuator rear left inlet solenoid valve

X BR-110 SU
X BR-110

Power supply (Low or high voltage)*3

ON OFF --*1 BR-126

Actuator motor or motor relay*4

X BR-120

Solenoid valve relay

Control unit

LAN communication system failure

X BR-114 ST

ON ON*5

X BR-128

OFF ON

X BR-133 RS

Engine speed signal

LAN is monitoring

OFF ON

X BR-129
X BR-131 BT

Engine parts are under fail-safe condition

OFF ON

X BR-129

LAN communication start procedures are incomplete OFF ON

X BR-132 HA

94 85 ABS works frequently.

Continued reception after LAN communication starts OFF ON

ECM determines the ABS/TCS control unit is malfunctioning.

OFF ON

X BR-135
SC
X BR-131
-- BR-136 EL

Unexpected pedal action Long stopping distance

-- BR-136

-- BR-137 IDX

ABS does not work.

-- BR-138

Pedal vibration and noise

-- BR-139

BR-105

TROUBLE DIAGNOSIS -- GENERAL DESCRIPTION

TCS

Malfunction Code/Symptom Chart (Cont'd)

Code No. (No. of SLIP indicator flashes)

Malfunctioning part

Warning lamp
ABS

Indicator

TCS OFF

SLIP

Failsafe

Reference Page

SLIP indicator stays on when engine is running

Control unit power supply circuit Warning lamp bulb circuit Control unit or control unit connector Solenoid valve relay stuck Power supply for solenoid valve relay coil

X*6

SLIP indicator does not come Fuse, warning lamp bulb or warning lamp circuit on when engine is running Control unit

Poor acceleration

TCM is the cause of the symptom.

OFF OFF OFF

-- BR-154

X: Available --: Not available
*1: Fail-safe operation does not activate. A signal from control unit suspends TCS and ABS control operation. Brakes operate conventionally. After specified power supply voltage resumes, TCS OFF indicator and ABS warning lamp go out, allowing for TCS and ABS control operation.
*2: If a wheel or wheels spin on bad or slippery road surfaces for a period of approximately 10 to 80 seconds, the ABS warning lamp and the TCS OFF indicator lamp light. But this is not a malfunction. When the ignition switch is turned "ON" after a shorted wheel sensor circuit has been repaired, the ABS warning lamp and the TCS OFF indicator lamp light. Drive the vehicle at about 30 km/h (19 MPH) to ensure these lamps go out within 1 minute.
*3: When the BATTERY VOLTAGE [ABNORMAL] code No. appears on the display, it does not indicate a malfunction related to the ABS/TCS control unit. Do not replace the ABS/TCS control unit even if the code No. appears.
*4: The BATTERY VOLTAGE [ABNORMAL] code No. can sometimes appear when the ABS motor ground circuit is loose or disconnected. When it does, always check the ground circuit for improper installation.
*5: Only the SLIP indicator lamp goes out depending on the type of ECM malfunction.
*6: If failure occurs in self-diagnostic check terminal (terminal No. 4 of data link connector) circuit and/or TCS operation (SLIP indicator) circuit, fail-safe operation will not activate.

BR-106

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

Wheel Sensor or Rotor

NFBR0064

DIAGNOSTIC PROCEDURE NFBR0064S01
Malfunction code No. 21, 22, 25, 26, 31, 32, 35, 36 or 18

NOTE:
Wheel position should be identified by code No. except code No. MA
18 (sensor rotor).

1 INSPECTION START

Wheel sensor inspection

GO TO 2.

CL
SBR769DE
MT

2 CHECK CONNECTOR

1. Disconnect connectors from control unit and wheel sensor of malfunction code No. Check terminals for damage or

loose connections. Then reconnect connectors.

2. Carry out self-diagnosis again.
AX
Does warning lamp activate again?

Yes

GO TO 3.

INSPECTION END

ST RS BT HA SC EL IDX

BR-107

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Wheel Sensor or Rotor (Cont'd)
3 CHECK WHEEL SENSOR CIRCUIT
1. Disconnect control unit connector. 2. Check resistance between control unit connector terminals.
Code No. 21 or 22 (Front RH wheel) Terminals 14 and 15 Code No. 25 or 26 (Front LH wheel) Terminals 9 and 10 Code No. 31 or 32 (Rear RH wheel) Terminals 11 and 38 Code No. 35 or 36 (Rear LH wheel) Terminals 12 and 13
Resistance: 0.8 - 1.85 k

TCS

Is resistance 0.8 - 1.85 k?

Yes

GO TO 5.

GO TO 4.

4 CHECK WHEEL SENSOR
Check resistance of each sensor. (See NOTE) Resistance: 0.8 - 1.85 k

SBR247DJ

SBR761DE

Is resistance 0.8 - 1.85 k?

Yes

Repair harness and connectors between control unit connector and wheel sensor con-

nector.

Replace wheel sensor.

5 CHECK TIRE

Check for inflation pressure, wear and size of each tire.

Are tire pressure and size correct and is tire wear within specifications?

Yes

GO TO 6.

Adjust tire pressure or replace tire(s).

BR-108

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

Wheel Sensor or Rotor (Cont'd)

6 CHECK WHEEL BEARING

Check wheel bearing axial end play.

Check clearance between sensor and rotor.

Clearance:

Front

0.273 - 0.925 mm (0.0107 - 0.0364 in)

Rear

0.387 - 0.992 mm (0.0152 - 0.0391 in)

FE CL SBR605AA

Is axial end play and clearance within specifications?

SU SBR069CA

Yes

GO TO 7.

Clean sensor fixing portion, or replace sensor.

ST
7 CHECK SENSOR ROTOR

Check sensor rotor for teeth damage.
RS
Is sensor rotor free from damage?

Yes

Check control unit pin terminals for damage or the connection of control unit harness

connector. Reconnect control unit harness connector. Then retest.

Replace sensor rotor.

IDX

BR-109

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
ABS Actuator Solenoid Valve
ABS Actuator Solenoid Valve
DIAGNOSTIC PROCEDURE Malfunction code No. 41, 45, 51, 55, 42, 46, 52, 56
1 INSPECTION START
ABS actuator solenoid valve inspection

TCS
=NFBR0063 NFBR0063S01

GO TO 2.

SBR334EB

2 CHECK CONNECTOR

1. Disconnect connectors from control unit, ABS actuator and ABS solenoid valve relay. Check terminals for damage or loose connections. Then reconnect connectors.
2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes

GO TO 3.

INSPECTION END

BR-110

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

ABS Actuator Solenoid Valve (Cont'd)

3 CHECK ABS ACTUATOR SOLENOID VALVE

1. Disconnect connectors from control unit and ABS actuator.

2. Check resistance between control unit connector terminals and ABS actuator 2-pin connector E5 (ABS actuator side)

terminals.

EC
MTBL0084
FE

Is resistance within specifications?

Yes

GO TO 6.

GO TO 4.

AT
SBR766DH
AX
SU

ST RS BT HA SC EL IDX

BR-111

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

ABS Actuator Solenoid Valve (Cont'd)

4 CHECK ABS ACTUATOR SOLENOID VALVE
1. Disconnect ABS actuator 8-pin connector. 2. Check resistance between ABS actuator 8-pin connector E7 (ABS actuator side) terminals and ABS actuator 2-pin con-
nector E5 (ABS actuator side) terminals.

MTBL0085

SBR767DH

Is resistance within specifications?

Yes

Check the following.

¼ Harness connectors E7, E5

¼ Harness for open or short between actuator connector and control unit

¼ Harness for open or short between actuator 8-pin connector and actuator 2-pin con-

nector

If NG, repair harness or connectors.

GO TO 5.

BR-112

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

ABS Actuator Solenoid Valve (Cont'd)

5 CHECK ABS ACTUATOR SOLENOID VALVE

Check resistance between solenoid valve terminals 1, 3, 5, 7, 14, 15, 16, 17.

Is resistance within specifications?

MTBL0086
FE

Yes

Check the following.

¼ Harness connectors E7, E5 ¼ Harness for open or short between actuator connector and control unit

¼ Harness for open or short between actuator 8-pin connector and actuator 2-pin con-

nector If NG, repair harness or connectors.

Replace ABS actuator.

6 CHECK ABS ACTUATOR SOLENOID VALVE RELAY

1. Remove solenoid valve relay.

2. Check continuity between ABS actuator 2-pin connector E5 (body side) terminal 19 and solenoid valve relay terminal 3.

Continuity should exist.

Does continuity exist?

SBR768DH
BT

Yes

Go to "Solenoid Valve Relay", BR-114.

Check the following.

¼ Harness connectors E33, E5

¼ Harness for open or short between actuator connector and solenoid valve relay termi-

nal (relay box side)

If NG, repair harness or connectors.

IDX

BR-113

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Solenoid Valve Relay
Solenoid Valve Relay
DIAGNOSTIC PROCEDURE Malfunction code No. 63
1 INSPECTION START
Solenoid valve relay inspection

TCS
NFBR0066 NFBR0066S01

GO TO 2.

SBR334EB

2 CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT

Check 40A [e] fusible link (ABS ACTR) for ABS solenoid valve relay. For fusible link layout, refer to POWER SUPPLY ROUTING in EL section.

Is fusible link OK?

Yes

GO TO 3.

GO TO 9.

3 CHECK FUSE

Check 10A fuse No. 30. For fuse layout, refer to "POWER SUPPLY ROUTING" in EL section.

Is fuse OK?

Yes

GO TO 4.

GO TO 13.

4 CHECK CONNECTOR

1. Disconnect connectors from control unit and ABS actuator. Check terminals for damage or loose connection. Then reconnect connectors.
2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes

GO TO 5.

INSPECTION END

BR-114

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

Solenoid Valve Relay (Cont'd)

5 CHECK GROUND CIRCUIT

Refer to CONTROL UNIT GROUND and ACTUATOR MOTOR GROUND in Ground Circuit Check, BR-104.

Is ground circuit OK?

Yes

GO TO 6.

Repair harness and connectors.

EM
6 CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Remove solenoid valve relay.

2. Check voltage between solenoid valve relay terminal 5 and ground.

MT SBR777DI

Does battery voltage exist?

Yes

GO TO 7.

Check the following.

¼ Harness connector E33 ¼ Harness for open or short between solenoid valve terminal (relay box side) and fusible

link

If NG, repair harness or connectors.
SU

ST RS BT HA SC EL IDX

BR-115

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Solenoid Valve Relay (Cont'd)
7 CHECK CIRCUIT 1. Disconnect control unit connector. 2. Check continuity between control unit connector terminals and solenoid valve relay terminals.

TCS

MTBL0089

SBR778DH

Does continuity exist?

Yes

GO TO 8.

Check the following.

¼ Harness connector E91

¼ Harness for open or short between solenoid valve relay terminal (relay box side) and

control unit

If NG, repair harness or connectors.

BR-116

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

Solenoid Valve Relay (Cont'd)

8 CHECK SOLENOID VALVE RELAY
GI

While applying battery voltage to relay terminals, insert fuse into the circuit.

LC MTBL0090 EC

Is solenoid valve relay OK?

Yes

Go to "ABS Actuator Solenoid Valve", BR-110.

Replace solenoid valve relay.

9 REPLACE FUSIBLE LINK

Replace fusible link.

Does the fusible link blow out when ignition switch is turned "ON"?

Yes

GO TO 10.

INSPECTION END

MT
SBR776D
AT AX SU
ST

IDX

BR-117

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Solenoid Valve Relay (Cont'd)
10 CHECK RELAY UNIT POWER SUPPLY CIRCUIT 1. Remove solenoid valve relay. 2. Check continuity between solenoid valve relay terminal 5 and ground.

TCS

SBR779DI

Does continuity exist?

Yes

GO TO 11.

Check the following.

¼ Harness connector E33

¼ Harness for open or short between solenoid valve terminal (relay box side) and fusible

link

If NG, repair harness or connectors.

11 CHECK ABS SOLENOID VALVE RELAY
1. Disconnect ABS actuator 2-pin connectors and control unit connector. 2. Check continuity between ABS actuator 2-pin connector E5 (body side) terminal 19 and ground.

Does continuity exist?

Yes

Replace ABS relay box.

GO TO 12.

SBR493DH

BR-118

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

Solenoid Valve Relay (Cont'd)

12 CHECK ABS SOLENOID VALVE

Check continuity between ABS actuator 2-pin connector E5 (ABS actuator side) terminal 19 and ground.

Does continuity exist?

Yes

Replace ABS actuator.

Go to "ABS Actuator Solenoid Valve", BR-110.

13 REPLACE FUSE

Replace fuse.

Does the fuse blow out when ignition switch is turned "ON"?

Yes

Check the following.

¼ Harness connector E91

¼ Harness for open or short between ABS control unit connector and fuse

If NG, repair harness or connectors.

INSPECTION END

EC SBR494DH FE CL MT AT AX SU

ST RS BT HA SC EL IDX

BR-119

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Motor Relay or Motor
Motor Relay or Motor
DIAGNOSTIC PROCEDURE Malfunction code No. 61
1 INSPECTION START
ABS motor relay inspection

TCS
=NFBR0065 NFBR0065S01

GO TO 2.

SBR335EB

2 CHECK MOTOR POWER SUPPLY CIRCUIT

Check 40A [d] fusible link (ABS MTR) for ABS motor relay. For fusible link layout, refer to POWER SUPPLY ROUTING in EL section.

Is fusible link OK?

Yes

GO TO 3.

GO TO 10.

3 CHECK CONNECTOR

1. Disconnect connectors from control unit and ABS actuator. Check terminals for damage or loose connection. Then reconnect connectors.
2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes

GO TO 4.

INSPECTION END

BR-120

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

Motor Relay or Motor (Cont'd)

4 CHECK ABS RELAY UNIT POWER SUPPLY CIRCUIT

1. Remove motor relay.

2. Check voltage between motor relay terminal 5 and ground.

EC
SBR771DI

Does battery voltage exist?

Yes

GO TO 5.

Check the following.

¼ Harness connector E29

¼ Harness for open or short between motor relay terminal (relay box side) and fusible

link

If NG, repair harness or connectors.

ST RS BT HA SC EL IDX

BR-121

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Motor Relay or Motor (Cont'd)
5 CHECK CIRCUIT 1. Disconnect control unit connector. 2. Check continuity between control unit connector terminals and motor relay terminals.

TCS

MTBL0087

SBR772DH

Does continuity exist?

Yes

GO TO 6.

Check the following.

¼ Harness connectors E29, E91

¼ Harness for open or short between motor relay terminal (relay box side) and control

unit

If NG, repair harness or connectors.

BR-122

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

Motor Relay or Motor (Cont'd)

6 CHECK MOTOR RELAY
GI

While applying battery voltage to relay terminals, insert fuse into the circuit.

LC MTBL0088 EC

Is motor relay OK?

Yes

GO TO 7.

Replace motor relay.

MT
SBR776D
AT
AX

7 CHECK ACTUATOR MOTOR GROUND CIRCUIT

Refer to ACTUATOR MOTOR GROUND in Ground Circuit Check, BR-104.

Is ground circuit OK?

Yes

GO TO 8.

Check the following.

¼ Harness connector E29

¼ Harness for open or short between solenoid valve relay terminal (relay box side) and

ground

If NG, repair harness or connectors.

IDX

BR-123

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

Motor Relay or Motor (Cont'd)

8 CHECK ABS ACTUATOR CIRCUIT
Check continuity between ABS actuator 2-pin connector E5 (ABS actuator side) terminal 21 and actuator motor ground terminal.

SBR793DF

Does continuity exist?

Yes

GO TO 9.

Check the following.

¼ Harness connector E5

¼ Harness for open or short between actuator connector and motor terminal

If NG, repair harness or connectors.

9 CHECK MOTOR
1. Remove motor relay. 2. Connect actuator connectors. 3. Connect suitable wire between motor relay connector terminals 3 and 5.
Do not connect wire for more than 5 seconds.

Does motor operate?

Yes

Go to "Low Voltage", BR-126.

Replace ABS actuator.

10 REPLACE FUSIBLE LINK

Replace fusible link.

Does the fusible link blow out when ignition switch is turned "ON"?

Yes

GO TO 11.

INSPECTION END

SBR773DI

BR-124

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

Motor Relay or Motor (Cont'd)

11 CHECK MOTOR POWER SUPPLY CIRCUIT

1. Remove motor relay.

2. Check continuity between motor relay terminal 5 and ground.

EC
SBR774DI

Does continuity exist?

Yes

GO TO 12.

Check the following.

¼ Harness connector E29

¼ Harness for open or short between motor relay terminal (relay box side) and fusible

link

If NG, repair harness or connectors.

12 CHECK ABS MOTOR RELAY

1. Disconnect control unit connector.

2. Check continuity between motor relay terminal 3 and ground.

Does continuity exist?

SBR775DJ
RS

Yes

Check the following.

¼ Harness connector E29 ¼ Harness for open or short between motor relay terminal (relay box side) and fusible

link

If NG, repair harness or connectors.

GO TO 13.

IDX

BR-125

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Motor Relay or Motor (Cont'd)
13 CHECK ABS MOTOR POWER SUPPLY CIRCUIT 1. Remove motor ground. 2. Check continuity between ABS actuator 2-pin connector E5 (ABS actuator side) terminal 21 and ground.

TCS

Does continuity exist?

Yes

Replace ABS actuator.

GO TO 14.

SBR489DH

14 CHECK MOTOR

Go to "9. CHECK MOTOR" in "Motor Relay or Motor" (preceding page).

Does motor operate?

Yes

Check control unit pin terminals for damage or the connection of control unit harness

connector. Reconnect control unit harness connector. Then retest.

Replace ABS actuator.

Low Voltage
DIAGNOSTIC PROCEDURE Malfunction code No. 57
1 INSPECTION START
ABS control unit power supply and ground circuit inspection

NFBR0067 NFBR0067S01

GO TO 2.
BR-126

SBR337EB

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

Low Voltage (Cont'd)

2 CHECK CONNECTOR

1. Disconnect control unit connectors. Check terminals for damage or loose connections. Then reconnect connectors.

2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes

GO TO 3.

INSPECTION END

3 CHECK ABS CONTROL UNIT POWER SUPPLY

1. Disconnect control unit connector.

2. Check voltage between control unit connector terminal 1 and ground.

MT
SBR726DF

Does battery voltage exist when ignition switch is turned ON?

Yes

GO TO 4.

GO TO 5.

4 CHECK CONTROL UNIT GROUND

Refer to CONTROL UNIT GROUND in Ground Circuit Check, BR-104.

Is ground circuit OK?

Check control unit pin terminals for damage or the connection of control unit harness

connector. Reconnect control unit harness connector. Then retest.

Check the following.

¼ Harness connector E91

¼ Harness for open or short between control unit and ground

If NG, repair harness or connectors.

5 CHECK FUSE

Check 10A fuse 31 (Engine control) for control unit. Refer to POWER SUPPLY ROUTING in EL section.

Is fuse OK?

Yes

GO TO 6.

Replace fuse.

6 CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT

Check continuity between battery and control unit connector terminal 1.

Does continuity exist?

Yes

Check battery. Refer to BATTERY in EL section.

IDX

Check the following.

¼ Harness connector E91

¼ Harness for open or short between control unit and fuse

If NG, repair harness or connectors.

BR-127

Control Unit

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Control Unit
DIAGNOSTIC PROCEDURE Malfunction code No. 71

1 INSPECTION START

ABS control unit power supply and ground circuit inspection

TCS
NFBR0068 NFBR0068S01

GO TO 2.

SBR337EB

2 CHECK CONNECTOR

1. Disconnect control unit connector. Check terminals for damage or loose connections. Then reconnect connectors.
2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes

GO TO 3.

INSPECTION END

3 CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT

Check voltage. Refer to "3. CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT" in "Low Voltage", BR-126.

Does battery voltage exist when ignition switch is turned ON?

Yes

GO TO 4.

Repair.

4 CHECK WARNING LAMP INDICATION

Does warning lamp indicate code No. 71 again?

Yes

Replace control unit.

Inspect the system according to the code No.

BR-128

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

ENGINE CHECK SIGNAL -- Engine System

=NFBR0082

DIAGNOSTIC PROCEDURE Malfunction code No. 87

GI NFBR0082S01

1 INSPECTION START
MA
Self-diagnostic item "ENGINE CHECK SIGNAL" appears on display.

GO TO 2.
EM

2 CHECK ENGINE SYSTEM

Perform self-diagnostic procedures for ECM.

Does any of following self-diagnostic items appear on display?

[P1335 CRANK POS SEN (REF)]*1, [P0100 MAF SEN/CIRCUIT]*1, [P0115 COOLANT T SEN/CIRC]*1, [P0125 COOL-

ANT T SEN/CIRC]*1, [P1320 IGN SIGNAL-PRIMARY]*1, [P0120 THRTL POS SEN/CIRC]*1, [P0605 ECM]*1

*1: Out of ECM diagnostic items, 7 items shown at left cause TCS to be suspended (TCS OFF indicator "ON" and SLIP

indicator "ON") and allow control unit to indicate "ENGINE CHECK SIGNAL".

Yes

Go to "TROUBLE DIAGNOSES" in EC section.

GO TO 3.

3 CHECK CONTROL UNIT TO ECM CIRCUIT

Do "ECM -- ABSTCS COMM NG" and/or "ABS-TCS C/U SIGNAL" [ECM self-diagnostic items]*2 appear on display?

*2: Items which cause TCS to be suspended (TCS OFF indicator "ON" and SLIP indicator "ON") and allow ABS/TCS con-

trol unit to indicate "ENGINE CHECK SIGNAL".

Yes

Go to "LAN monitoring", "LAN communication start procedures incomplete" and "LAN

communication system failure".

GO TO 4.

4 CHECK DIAGNOSTIC ITEMS

Does any other diagnostic items appears?

Yes

Repair or replace affected engine control system parts.

INSPECTION END

1 INSPECTION START

ENG SPEED SIG -- Engine Speed Signal ST NFBR0083
DIAGNOSTIC PROCEDURE NFBR0083S01
Malfunction code No. 81
RS

Self-diagnostic item "ENGINE SPEED SIG" appears on display.
BT

GO TO 2.

EL
SBR539E
IDX

BR-129

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

ENG SPEED SIG -- Engine Speed Signal (Cont'd)

2 CHECK ENGINE SYSTEM

Perform self-diagnostic procedures for ECM. Does [P1335 CRANK POS SEN (REF)]*1 (Self-diagnostic item) appear on display? *1: Out of ECM diagnostic item, only [P1335 CRANK POS SEN (REF)] causes TCS to be suspended (SLIP indicator lamp "ON" and TCS OFF indicator lamp "ON") and allows control unit to indicate "ENGINE SPEED SIG".

Yes

Check ECM. Refer to "TROUBLE DIAGNOSES" in EC section.

GO TO 3.

3 CHECK CONTROL UNIT TO ECM CIRCUIT

Perform self-diagnostic procedures for ECM.

Does [ECM-ABSTCS COMM NG] and [ABS-TCS C/U SIGNAL]*1 (self-diagnostic items) appears on display?

Yes

Go to "LAN monitoring", "LAN communication start procedures incomplete" and "LAN

communication system failure".

GO TO 4.

4 CHECK CONNECTOR

1. Disconnect control unit and ECM connectors, then reconnect them securely. 2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes

GO TO 5.

INSPECTION END

5 CHECK CONTROL UNIT TO ECM HARNESS CONNECTORS
1. Disconnect control unit and ECM connectors. 2. Check continuity between control unit terminal 20 and ECM terminal 25.

SBR540E

Continuity should exist?

Yes

GO TO 6.

Check the following.

¼ Harness connectors E91 and F48

¼ Harness for open or short between control unit connector and ECM connector

If NG, repair harness or connectors.

6 CHECK SELF-DIAGNOSIS

Connect connectors, then repeat self-diagnostic procedures.

Does self-diagnostic item appears on display?

Yes

Repair or replace.

INSPECTION END

BR-130

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

LAN SIGNAL 1 -- LAN Monitoring

LAN SIGNAL 1 -- LAN Monitoring
DIAGNOSTIC PROCEDURE Malfunction code No. 85

NFBR0084
GI NFBR0084S01

1 INSPECTION START
MA
Self-diagnostic item "LAN SIGNAL 1" appears on display.

GO TO 2.

2 CHECK SELF-DIAGNOSIS

Perform self-diagnostic procedures for ECM.

Does "ABS-TCS communication" (self-diagnostic item) appears on display?

Yes

Check LAN circuit. Refer to "CHECK LAN CIRCUIT", BR-133.

GO TO 3.

3 CHECK CIRCUIT

Check ECM to battery power circuits, harness and connectors.

OK or NG

¼ Repeat self-diagnostic procedures for control unit.

¼ If NG, replace control unit.

Repair or replace affected parts.

FE SBR541E CL MT AT AX SU
ST

IDX

BR-131

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

LAN SIGNAL 2 -- LAN Communication Start Procedures Incomplete

LAN SIGNAL 2 -- LAN Communication Start

Procedures Incomplete
DIAGNOSTIC PROCEDURE Malfunction code No. 92

=NFBR0085 NFBR0085S01

1 INSPECTION START

Self-diagnostic item "LAN SIGNAL 2" appears on display.

GO TO 2.

2 CHECK ENGINE SYSTEM

Is self-diagnosis for ECM able to start?

Yes

GO TO 3.

¼ Repair or replace data link connector to ECM harness and connector.

¼ Faulty ECM. (Malfunction indicator lamp remains "ON" during operation.)

3 CHECK SELF-DIAGNOSIS

Does [ECM-ABSTCS COMM NG] (self-diagnostic item) appear on display?

Yes

Check LAN circuit. Refer to "CHECK LAN CIRCUIT", BR-131.

GO TO 4.

4 CHECK STARTER SIGNAL

Is starter signal input to ECM?

Yes

¼ If other items appear on display, repair or replace affected areas.

¼ Repeat self-diagnostic procedures for control unit.

Repair or replace starter switch system.

SBR541E

BR-132

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

LAN CIRCUITS 1, LAN CIRCUITS 2 -- LAN Communication System Failure

1 INSPECTION START

LAN CIRCUITS 1, LAN CIRCUITS 2 -- LAN

Communication System Failure
DIAGNOSTIC PROCEDURE Malfunction code No. 96, 98

GI =NFBR0086
NFBR0086S01

Self-diagnostic item "LAN CIRCUITS 1" or "LAN CIRCUITS 2" appears on display.
EM

GO TO 2.

FE
SBR541E
CL

2 CHECK ENGINE SYSTEM

Perform self-diagnostic procedures for ECM.

Does self-diagnostic item [ECM-ABSTCS COMM NG] appear on display?

Yes

GO TO 6.

GO TO 3.

3 CHECK SELF-DIAGNOSIS

Does "ABS-TCS C/U SIGNAL" appear on display?

Yes

GO TO 4.

Faulty control unit

ST
4 CHECK SELF-DIAGNOSIS

Does any other control unit self-diagnostic items appears on display?

Yes

Repair or replace affected items shown on display.

GO TO 5.

5 CHECK VOLTAGE

Check if battery voltage is too low (less than 9V) or battery terminals are loose.

Repeat self-diagnostic procedures.

Faulty control unit

IDX

BR-133

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
LAN CIRCUITS 1, LAN CIRCUITS 2 -- LAN Communication System Failure (Cont'd)
6 CHECK LAN CIRCUIT Check continuity between connector terminals.

TCS

SBR542E

MTBL0320

Does continuity exist?

Yes

Repeat self-diagnostic procedures.

Check the following.

¼ Harness connectors E91, F48, F50

¼ Harness for open or short between control unit connector and TCM connector

¼ Harness for open or short between ECM connector and TCM connector

If NG, repair harness or connectors.

BR-134

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

TCS

LAN SIGNAL 3 -- Continued Reception After LAN Communication Starts

1 INSPECTION START

LAN SIGNAL 3 -- Continued Reception After

LAN Communication Starts
DIAGNOSTIC PROCEDURE Malfunction code No. 94

GI =NFBR0087
NFBR0087S01

Self-diagnostic item "LAN SIGNAL 3" appears on display.
EM

GO TO 2.

FE
SBR541E
CL

2 CHECK SELF-DIAGNOSIS

Perform self-diagnostic procedures for ECM.

Does self-diagnostic item [ECM-ABSTCS COMM NG] appear on display?

Yes

Check ECM. Refer to "TROUBLE DIAGNOSES" in EC section.

GO TO 3.

3 CHECK SELF-DIAGNOSIS

Does self-diagnostic item [ABS-TCS C/U SIGNAL] appears on display?

Yes

¼ Replace control unit.

¼ Repeat self-diagnostic procedures for control unit.

If other items appears on display, repair or replace affected areas.

IDX

BR-135

1. ABS Works Frequently

TROUBLE DIAGNOSES FOR SYMPTOMS 1. ABS Works Frequently

1 CHECK BRAKE FLUID PRESSURE

Check brake fluid pressure distribution. Refer to dual proportioning valve inspection in "DUAL PROPORTIONING VALVE", BR-12.

Is brake fluid pressure distribution normal?

Yes

GO TO 2.

Perform Preliminary Check. Refer to BR-101.

TCS
NFBR0073

2 CHECK WHEEL SENSOR

1. Check wheel sensor connector for terminal damage or loose connections. 2. Perform wheel sensor mechanical check.
Refer to "Wheel Sensor or Rotor", BR-107.

Are wheel sensors functioning properly?

Yes

GO TO 3.

Repair.

3 CHECK FRONT AXLE

Check front and rear axles for excessive looseness. Refer to AX section, "Front Wheel Bearing", "ON-VEHICLE SERVICE" and "Rear Wheel Bearing", "ON-VEHICLE SERVICE".

Is front axle installed properly?

Yes

Go to "3. CHECK WARNING LAMP INDICATION" in "2. Unexpected Pedal Action",

BR-136.

Repair.

2. Unexpected Pedal Action
1 CHECK BRAKE PEDAL STROKE Check brake pedal stroke. Is stroke excessively large?

NFBR0071

Yes

Perform Preliminary Check. Refer to BR-101.

GO TO 2.

BR-136

SBR540A

TROUBLE DIAGNOSES FOR SYMPTOMS

TCS

2. Unexpected Pedal Action (Cont'd)

2 CHECK CONNECTOR AND PERFORMANCE

1. Disconnect ABS solenoid valve relay.

2. Check whether brake is effective.

OK or NG

Yes

GO TO 3.

Perform Preliminary Check. Refer to BR-101.

3 CHECK WARNING LAMP INDICATION

Ensure warning lamp remains off while driving.

MT SBR655E

Is warning lamp turned off?

Yes

GO TO 4.

Carry out self-diagnosis. Refer to BR-91, BR-94.

4 CHECK WHEEL SENSOR

1. Check wheel sensor connector for terminal damage or loose connection.

2. Perform wheel sensor mechanical check. Refer to "Wheel Sensor Rotor", BR-107.

Is wheel sensor mechanism OK?

Yes

Check control unit pin terminals for damage or the connection of control unit harness

connector. Reconnect control unit harness connector. Then retest.

Repair.

3. Long Stopping Distance
1 CHECK CONNECTOR AND PERFORMANCE 1. Cancel ABS by disconnecting ABS solenoid valve relay. 2. Check stopping distance.

SC
NFBR0070
EL

OK or NG

IDX

Perform Preliminary Check and air bleeding.

Go to "3. CHECK WARNING LAMP INDICATION" in "2. Unexpected Pedal Action",

BR-136.

BR-137

TROUBLE DIAGNOSES FOR SYMPTOMS

TCS

3. Long Stopping Distance (Cont'd)

NOTE: Stopping distance may be longer than vehicles without ABS when road condition is slippery.

4. ABS Does Not Work
1 CHECK WARNING LAMP INDICATION

NFBR0072

Does the ABS warning lamp activate?

Yes

Carry out self-diagnosis. Refer to BR-91, 94.

Go to "3. CHECK WARNING LAMP INDICATION" in "2. Unexpected Pedal Action",

BR-136.

NOTE: ABS does not work when vehicle speed is under 10 km/h (6 MPH).

BR-138

TROUBLE DIAGNOSES FOR SYMPTOMS

TCS

5. Pedal Vibration and Noise

1 INSPECTION START Pedal vibration and noise inspection

5. Pedal Vibration and Noise

=NFBR0069
GI

GO TO 2.

2 CHECK SYMPTOM

1. Apply brake. 2. Start engine.

Does the symptom appear only when engine is started?

Yes

Carry out self-diagnosis. Refer to BR-91, 94.

GO TO 3.

EC
SAT797A
FE
CL
MT
AT

3 RECHECK SYMPTOM

Does the symptom appear when electrical equipment switches (such as headlamp) are operated?

Yes

GO TO 4.

Go to "3. CHECK WARNING LAMP INDICATION" in "2. Unexpected Pedal Action",

BR-136.

4 CHECK WHEEL SENSOR
Check wheel sensor shield ground. For location of shield ground, refer to wiring diagram and "HARNESS LAYOUT" in EL ST
section.

Is wheel sensor shield grounded properly?

Yes

Check control unit pin terminals for damage or the connection of control unit harness

connector. Reconnect control unit harness connector. Then retest.

Repair.

NOTE:
ABS may operate and cause vibration under any of the following HA

conditions.

¼ Applying brake gradually when shifting or operating clutch. ¼ Low friction (slippery) road.

¼ High speed cornering.

¼ Driving over bumps and pot holes.

¼ Engine speed is over 5,000 rpm with vehicle stopped.

IDX

BR-139

TROUBLE DIAGNOSES FOR SYMPTOMS
6. ABS Warning Lamp Does Not Come On When Ignition Switch Is Turned On

TCS

1 INSPECTION START

6. ABS Warning Lamp Does Not Come On

When Ignition Switch Is Turned On

=NFBR0074

Warning lamp circuit inspection

GO TO 2.

SBR334EB

2 CHECK FUSE

Check 10A fuse No. 30 for warning lamp. For fuse layout, refer to "POWER SUPPLY ROUTING" in EL section.

Is fuse OK?

Yes

GO TO 3.

Replace fuse.

BR-140

TROUBLE DIAGNOSES FOR SYMPTOMS

TCS

6. ABS Warning Lamp Does Not Come On When Ignition Switch Is Turned On (Cont'd)

3 CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT

1. Install 10A fuse.

2. Remove solenoid valve relay.

3. Disconnect connectors from control unit and actuator.

4. Check voltage between control unit connector terminal 30 and ground after turning ignition switch "ON".

Does battery voltage exist after turning ignition switch "ON"?

FE SBR715DD

Yes

GO TO 5.

GO TO 4.

4 CHECK WARNING LAMP

Check warning lamp bulb.

Is warning lamp bulb OK?

Yes

Repair harness and connectors between fuse and control unit connector terminal 30

(including combination meter).

Replace bulb.

ST RS BT HA SC EL IDX

BR-141

TROUBLE DIAGNOSES FOR SYMPTOMS
6. ABS Warning Lamp Does Not Come On When Ignition Switch Is Turned On (Cont'd) 5 CHECK CIRCUIT 1. Remove solenoid valve relay. 2. Check continuity between control unit terminals and solenoid valve relay terminals.
NOTE: Pay attention to tester polarity. Specifications may vary depending on the type of tester. Before performing this inspection, refer to the instruction manual of the tester.

TCS
MTBL0091

SBR105EF

Does continuity exist?

Yes

GO TO 6.

Check the following.

¼ Harness connectors E33, E91

¼ Harness for open or short between solenoid valve relay terminal (relay box side) and

control unit

6 CHECK SOLENOID VALVE RELAY

Refer to "8. CHECK SOLENOID VALVE RELAY", "Solenoid Valve Relay", BR-114.

Is solenoid valve relay OK?

Yes

Go to "Low Voltage", BR-126.

Replace solenoid valve relay.

BR-142

TROUBLE DIAGNOSES FOR SYMPTOMS

TCS

7. ABS Warning Lamp Stays On When Ignition Switch Is Turned On

1 INSPECTION START

7. ABS Warning Lamp Stays On When Ignition

Switch Is Turned On

GI =NFBR0075

ABS control unit inspection

GO TO 2.

2 CHECK FUSE

Check 10A fuse No. 31 for control unit. For fuse layout, refer to "POWER SUPPLY ROUTING" in EL section.

Is fuse OK?

Yes

GO TO 3.

GO TO 9.

AX
SBR338EB
SU
ST RS

IDX

BR-143

TROUBLE DIAGNOSES FOR SYMPTOMS
7. ABS Warning Lamp Stays On When Ignition Switch Is Turned On (Cont'd)
3 CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT 1. Disconnect connector from control unit. 2. Check voltage between control unit connector terminal 1 and ground after turning ignition switch "ON".

TCS

SBR240DG

Does battery voltage exist?

Yes

GO TO 4.

Check the following.

¼ Harness connector E91

¼ Harness for open or short between control unit and fuse

If NG, repair harness or connectors.

BR-144

TROUBLE DIAGNOSES FOR SYMPTOMS

TCS

7. ABS Warning Lamp Stays On When Ignition Switch Is Turned On (Cont'd)

4 CHECK ABS SOLENOID VALVE RELAY COIL POWER SUPPLY CIRCUIT

1. Turn ignition switch "OFF".

2. Remove solenoid valve relay.

3. Check continuity between control unit connector terminals and solenoid valve relay terminals.

EM
MTBL0092
LC

SU
SBR781DH

Does continuity exist?

Yes

GO TO 5.

Check the following.

¼ Harness connectors E33, E91

¼ Harness for open or short between solenoid valve relay terminal (relay box side) and

control unit

If NG, repair harness or connectors.

5 CHECK ABS SOLENOID VALVE RELAY

Go to "8. CHECK SOLENOID VALVE RELAY", "Solenoid Valve Relay", BR-114.

Does continuity exist?

Yes

GO TO 6.

Replace solenoid valve relay.

IDX

BR-145

TROUBLE DIAGNOSES FOR SYMPTOMS
7. ABS Warning Lamp Stays On When Ignition Switch Is Turned On (Cont'd)
6 CHECK WARNING LAMP GROUND CIRCUIT 1. Turn ignition switch "OFF". 2. Disconnect connectors from control unit and remove solenoid valve relay. 3. Check continuity between control unit connector terminal 30 and body ground.

TCS

SBR106ED

Does continuity exist?

Yes

Check the following.

¼ Harness connector E91

¼ Harness for open or short between control unit and fuse

If NG, repair harness or connectors.

GO TO 7.

7 CHECK ABS SOLENOID VALVE RELAY CIRCUIT
1. Remove 10A fuse 30 (meter) for warning lamp. For fuse layout, refer to POWER SUPPLY ROUTING in EL section. 2. Disconnect ABS actuator 2-pin connector E5. 3. Check continuity between ABS actuator 2-pin connector (body side) terminal 19 (-) and 10A fuse 11 (fuse box side)
terminal (+). NOTE: Pay attention to tester polarity. Specifications may vary depending on the type of tester. Before performing this inspection, refer to the instruction manual of the tester.

Does continuity exist?

Yes

Replace ABS relay unit.

GO TO 8.

SBR339EA

BR-146

TROUBLE DIAGNOSES FOR SYMPTOMS

TCS

7. ABS Warning Lamp Stays On When Ignition Switch Is Turned On (Cont'd)

8 CHECK ABS SOLENOID VALVE CIRCUIT

1. Disconnect ABS actuator 8-pin connector.

2. Check continuity between each ABS actuator 8-pin connector (ABS actuator side) terminal and body ground.

EC
SBR783DG

Does continuity exist?

Yes

Replace ABS actuator.

Check control unit pin terminals for damage or the connection of control unit harness

connector. Reconnect control unit harness connector. Then retest.

9 REPLACE FUSE

Replace 10A fuse No. 31.

Does the fuse blow out when ignition switch is turned "ON"?

Yes

GO TO 10.

INSPECTION END

10 CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT

1. Disconnect control unit connector.

2. Check continuity between control unit connector terminal 1 and body ground.

SBR720DF

Does continuity exist?

Yes

Check the following.

¼ Harness connector E91

¼ Harness for open or short between control unit and fuse

If NG, repair harness or connectors.

Check control unit pin terminals for damage or the connection of control unit harness connector. Reconnect control unit harness connector. Then retest.

IDX

BR-147

TROUBLE DIAGNOSES FOR SYMPTOMS
8. SLIP Indicator Lamp Does Not Come On When Ignition Switch Is Turned On

TCS

1 INSPECTION START

8. SLIP Indicator Lamp Does Not Come On

When Ignition Switch Is Turned On

=NFBR0088

Indicator lamp circuit inspection

GO TO 2.

2 CHECK FUSE

Check 10A fuse No. 30 for control unit. For fuse layout, refer to "POWER SUPPLY ROUTING" in EL section.

Is fuse OK?

Yes

GO TO 3.

Replace fuse.

3 CHECK CONTROL UNIT POWER SUPPLY CIRCUIT
1. Install 10A fuse. 2. Disconnect connector from control unit. 3. Check voltage between control unit connector terminal 32 and ground after turning ignition switch "ON".

SBR537E

Does battery voltage exist?

Yes

GO TO 5.

GO TO 4.

SBR350EA

4 CHECK INDICATOR LAMP

Check indicator lamp bulb.

Is indicator lamp bulb OK?

Yes

Repair harness and connectors between fuse and control unit connector terminal 32

(including combination meter).

Replace bulb.

BR-148

TROUBLE DIAGNOSES FOR SYMPTOMS

TCS

8. SLIP Indicator Lamp Does Not Come On When Ignition Switch Is Turned On (Cont'd)

5 CHECK CIRCUIT

1. Disconnect control unit connector.

2. Check continuity between control unit connector terminal 16 and data link connector terminal 9.

EC
SBR538E

Does continuity exist?

Yes

GO TO 6.

Check the following.

¼ Harness connectors E91, M28

¼ Harness for open or short between control unit and data link connector

MT
6 CHECK CONNECTOR

1. Disconnect connector from control unit. Check terminals for damage or loose connection. Then reconnect connector. 2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes

Check items the self-diagnosis detected as faulty.

INSPECTION END

1 INSPECTION START Indicator lamp circuit inspection

9. TCS OFF Indicator Lamp Does Not Come On When Ignition Switch Is Turned On

NFBR0089

GO TO 2.

EL
SBR352EA
IDX

BR-149

TROUBLE DIAGNOSES FOR SYMPTOMS
9. TCS OFF Indicator Lamp Does Not Come On When Ignition Switch Is Turned On (Cont'd)

2 CHECK FUSE

Check 10A fuse No. 30 for control unit. For fuse layout, refer to "POWER SUPPLY ROUTING" in EL section.

Is fuse OK?

Yes

GO TO 3.

Replace fuse.

3 CHECK CONTROL UNIT POWER SUPPLY CIRCUIT
1. Install 10A fuse. 2. Disconnect connector from control unit. 3. Check voltage between control unit connector terminal 31 and ground after turning ignition switch "ON".

TCS

Does battery voltage exist?

Yes

GO TO 5.

GO TO 4.

SBR353EA

4 CHECK INDICATOR LAMP

Check indicator lamp bulb.

Is indicator lamp bulb OK?

Yes

Repair harness and connectors between control unit connector terminal 31 and fuse box

(including combination meter).

Replace bulb.

5 CHECK CONNECTOR

1. Disconnect connector from control unit. Check terminals for damage or loose connection. Then reconnect connector. 2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes

Check items the self-diagnosis detected as faulty.

INSPECTION END

BR-150

TROUBLE DIAGNOSES FOR SYMPTOMS

TCS

10. TCS OFF Switch Is Inoperative

1 INSPECTION START Inspect TCS OFF switch.

10. TCS OFF Switch Is Inoperative

=NFBR0090
GI

GO TO 2.
2 CHECK TCS OFF SWITCH 1. Remove TCS OFF switch and disconnect TCS OFF switch connector. 2. Check continuity between terminal 2 and 3 for TCS OFF switch connector.

EC
SBR543E
FE
CL
MT

When TCS OFF switch is pressed: Continuity should exist.
When TCS OFF switch is released: Continuity should not exist.

GO TO 3.

Replace TCS OFF switch.

SU
SBR544E
ST RS

IDX

BR-151

TROUBLE DIAGNOSES FOR SYMPTOMS
10. TCS OFF Switch Is Inoperative (Cont'd)
3 CHECK TCS OFF SWITCH POWER SUPPLY CIRCUIT ¼ Disconnect connector from control unit. ¼ Check continuity between control unit connector terminal 44 and TCS OFF switch connector terminal 2.

TCS

SBR545E

Does continuity exist?

Yes

GO TO 4.

Check the following.

¼ Harness connectors E91, M45

¼ Harness for open or short between TCS OFF switch terminal (body side) and control

unit

If NG, repair harness or connectors.

4 CHECK TCS OFF SWITCH POWER SUPPLY Check continuity between TCS OFF switch connector terminal 2 and ground.

Does continuity exist?

Yes

GO TO 5.

Repair harness and connectors.

SBR546E

BR-152

TROUBLE DIAGNOSES FOR SYMPTOMS

TCS

10. TCS OFF Switch Is Inoperative (Cont'd)

5 CHECK TCS OFF SWITCH GROUND CIRCUIT

Check continuity between TCS OFF switch connector terminal 3 and ground.

Does continuity exist?

Yes

Final check

Repair harness and connectors.

EC SBR547E FE CL

ST RS BT HA SC EL IDX

BR-153

TROUBLE DIAGNOSES FOR SYMPTOMS

TCS

11. Poor Acceleration

1 INSPECTION START

11. Poor Acceleration

=NFBR0091

Engine acceleration is poor while TCS is operating. Vehicle instability is caused by unstable engine rpm operation. (Engine is shaking.)

GO TO 2.

2 CHECK PERFORMANCE

1. Cancel TCS operation using TCS OFF switch. (TCS OFF indicator lamp lights.) 2. Drive vehicle or accelerate engine.

Is engine acceleration poor or does automatic transaxle shift when TCS is not operating?

Yes

Go to "TROUBLE DIAGNOSES" in BR section.

GO TO 3.

3 CHECK SELF-DIAGNOSIS

Perform self-diagnostic procedures for TCM.

Does any of the following self-diagnostic items appear on the display?

Yes

Go to "TROUBLE DIAGNOSES" in AT section.

GO TO 4.

4 CHECK SELF-DIAGNOSIS

Perform self-diagnostic procedures for ABS/TCS.

Does any of the following self-diagnostic items appear on the display?

Yes

Go to "TROUBLE DIAGNOSES" in BR section.

GO TO 5.

5 CHECK SELF-DIAGNOSIS

Perform self-diagnostic procedures for ECM.

Does any of the following self-diagnostic items appear on the display?

Yes

Go to "TROUBLE DIAGNOSES" in EC section.

INSPECTION END

BR-154

REMOVAL AND INSTALLATION

NFBR0076
ABS/TCS

CAUTION:

Be careful not to damage sensor edge and sensor rotor teeth.

When removing the front or rear wheel hub assembly, first GI

remove the ABS wheel sensor from the assembly. Failure to

do so may result in damage to the sensor wires making the

sensor inoperative.

Wheel Sensors

NFBR0076S01
EM

AT
SBR921C
AX

Sensor Rotor

ST NFBR0076S02

REMOVAL

NFBR0076S0201

1. Remove the drive shaft and rear wheel hub. Refer to "Drive

Shaft" and "Wheel Hub" in AX section.

2. Remove the sensor rotor using suitable puller, drift and bear-

ing replacer.

HA
SBR984C
SC

IDX

SBR873CA

BR-155

Sensor Rotor (Cont'd)

REMOVAL AND INSTALLATION

ABS/TCS

INSTALLATION NFBR0076S0202
Install the sensor rotor. For front sensor rotor, use hammer and wooden block. For rear sensor rotor, use suitable drift and press.
¼ Always replace sensor rotor with new one.

SBR985C
¼ Pay attention to the dimension of rear sensor rotor as show in figure. h: 12.5 - 13.5 mm (0.492 - 0.531 in)

SBR986C
Control Unit (With TCS Models)
Location: Driver side dash side lower.

NFBR0076S03

SBR532E SBR533E

Actuator
REMOVAL 1. Disconnect battery cable.

NFBR0076S04 NFBR0076S0401

2. Drain brake fluid. Refer to "Changing Brake Fluid" (BR-8).

3. Remove air cleaner and duct.

4. Apply different colored paint to each pipe connector and actuator to prevent incorrect connection.

5. Disconnect harness connectors, brake pipes and remove fixing nuts and actuator ground cable.

INSTALLATION CAUTION:

NFBR0076S0402

After installation, refill brake fluid. Then bleed air. Refer to

"Bleeding Brake System" (BR-9).

1. Temporarily install actuator on the bracket.

2. Tighten actuator ground cable.

3. Connect brake pipes temporarily.

4. Tighten fixing nuts.

5. Tighten brake pipes.

6. Connect harness connectors and battery cable.

7. Install air cleaner and duct.

BR-156

Front brake
Rear brake Master cylinder Control valve Brake booster Recommended brake fluid

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications

Brake model

General Specifications

NFBR0077
Unit: mm (in)
GI
CLZ25VC disc brake

Cylinder bore diameter
Pad Length × width × thickness
Rotor outer diameter × thickness

57.2 (2.252)
125.6 × 46 × 11 (4.94 × 1.81 × 0.43)
280 × 26 (11.02 × 1.02)

MA EM

Brake model Cylinder bore diameter

CL9HB disc brake

33.96 (1.3370)

Pad Length × width × thickness
Rotor outer diameter × thickness

89.1 × 39.5 × 10

(3.508 × 1.555 × 0.39)

278 × 9 (10.94 × 0.35)

Cylinder bore diameter Valve model

23.81 (15/16)

Dual proportioning valve

Booster model Diaphragm diameter

Primary Secondary

M215T

230 (9.06)

205 (8.07)

DOT 3

Brake model Pad wear limit
Rotor repair limit

Disc Brake

Minimum thickness Maximum runout Minimum thickness

CLZ25VC 2.0 (0.079) 0.07 (0.0028) 24.0 (0.945)

AT
NFBR0078
Unit: mm (in)

CL9HB

1.5 (0.059)

0.07 (0.0028)

8 (0.31)

Brake Pedal
M/T Free height "H"*
A/T Clearance "C" between pedal stopper and threaded end of stop lamp switch or ASCD switch

NFBR0079
Unit: mm (in)

158 - 165 (6.22 - 6.50)

167 - 174 (6.57 - 6.85)

0.74 - 1.96 (0.0291 - 0.0772)

*: Measured from surface of dash reinforcement panel to surface of pedal pad
Parking Brake
Number of notches [under force of 196 N (20 kg, 44 lb)]

10 - 11

BT
NFBR0080
HA

Number of notches when warning lamp switch comes on

1
SC

Control Valve

EL NFBR0092
Unit: kPa (kg/cm2, psi)

Applied pressure (front) Output pressure (rear)

7,355 (75, 1,067) 5,100 - 5,492 (52 - 56, 739 - 796)

IDX

BR-157

Brake Booster
Output rod length Clevis length

SERVICE DATA AND SPECIFICATIONS (SDS)

Brake Booster

10.275 - 10.525 (0.4045 - 0.4144) 130 (5.12)

NFBR0093
Unit: mm (in)

Clearance Resistance Dimension of rear sensor rotor

ABS Wheel Sensor
Front Rear Front Rear

NFBR0094
0.273 - 0.925 mm (0.0107 - 0.0364 in) 0.385 - 0.973 mm (0.0252 - 0.0383 in)
0.8 - 1.85 0.8 - 1.85 12.5 - 13.5 mm (0.4921 - 0.5315 in)

BR-158

Acrobat Distiller 3.0J (Windows 版) Parlance Publisher 5.0/(Xyvision Postscript Formatter) 3.0 3