Brake system

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Brake system

  1. 1. BRAKE SYSTEM BR-1
  2. 2. DESCRIPTION The service brakes consist of a foot brake which changes rotational energy to thermal energy to stop the vehicle while it is being driven and a parking brake to keep the vehicle from moving while it is parked. OPERATION FOOT BRAKE When the brake pedal is depressed, a vacuum builds up in the booster which amplifies the pedal force, pressing on the piston in the master cylinder. The piston movement raises the hydraulic pressure in the cylinder. This hydraulic pressure then acts to press the brake pads and shoes against the rotating discs and brake drums. The resulting friction converts the rotational energy to thermal energy, stopping the vehicle. GENERAL DESCRIPTION 1. Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts of the same part number or equivalent. 2. It is very important to keep parts and the area clean when repairing the brake system. 3. If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. -BRAKE SYSTEM GENERAL DESCRIPTION BR-2
  3. 3. DESCRIPTION The service brakes consist of a foot brake which changes rotational energy to thermal energy to stop the vehicle while it is being driven and a parking brake to keep the vehicle from moving while it is parked. OPERATION FOOT BRAKE When the brake pedal is depressed, a vacuum builds up in the booster which amplifies the pedal force, pressing on the piston in the master cylinder. The piston movement raises the hydraulic pressure in the cylinder. This hydraulic pressure then acts to press the brake pads and shoes against the rotating discs and brake drums. The resulting friction converts the rotational energy to thermal energy, stopping the vehicle. GENERAL DESCRIPTION 1. Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts of the same part number or equivalent. 2. It is very important to keep parts and the area clean when repairing the brake system. 3. If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. -BRAKE SYSTEM DESCRIPTION BR-2
  4. 4. PREPARATION SST (SPECIAL SERVICE TOOLS) 09990-00300 ABS Actuator Checker Sub-harness “I” 09990-00200 ABS Actuator Checker Sub-harness “C” 09751-3601 1 Brake Tube Union Nut 10 x 12 mm Wrench 09990-00150 ABS Actuator Checker and Sub-harness 09737-00010 Brake Booster Push Rod Gauge 09718-00010 Shoe Hold Down Spring Driver 09990-00163 ABS Actuator Checker Sheet ’A’ 09843-18020 Diagnosis Check Wire 09709-29017 LSPV Gauge Set -BRAKE SYSTEM PREPARATION BR-4
  5. 5. RECOMMENDED TOOLS 09082-00050 TOYOTA Electrical Tester Set SAEJ1703 or FMVSS No. 116 DOT 3 09905-00013 Snap Ring Pliers LUBRICANT EQUIPMENT Vernier calipers Torque wrench Dial indicator Micrometer Classification Brake fluid Brake drum Brake disc Brake disc CapacityItem -BRAKE SYSTEM PREPARATION BR-5
  6. 6. TROUBLESHOOTING Usethetablebelowtohelpyoufindthecauseoftheproblem.Thenumbersindicatethepriority ofthelikelycauseoftheproblem.Checkeachpartinorder.Ifnecessary,replacetheseparts. Parking brake (Lever travel out of adjustment) Rear brake (Shoe clearance out of adjustment) Booster push rod (Out of adjustment) Pad or lining (Cracked or distorted) Anchor or return spring (Faulty) Hardpedalbutbrakeinefficient Piston seal (Worn or damaged) Booster system (Vacuum leaks) Brake pedal (Freeplay minimal) Hold-down spring (Damaged) Parking brake wire (Sticking) Anti-squeal shim (Damaged) Lowpedalorspongypedal Brake pad or lining (Worn) Brake system (Fluid leaks) Pad support plate (Loose) Pad or lining (Hardened) Installation bolt (Loose) Master cylinder (Faulty) Brake system (Air in) Pad or lining (Dirty) Pad or lining (oily) Sliding pin (Worn) Noisefrombrakes Piston (Frozen) Piston (Stuck) Disc (Scored) BR-11, BR-16 Brakedrag BR-24 , BR-31 Brakepull BR-24 ,BR-31 PartName Seepage Trouble BR-31 BR-31 BR-24 BR-22 BR-31 BR-24 BR-9 BR-8 BR-7 BR-24 , BR-31 BR-24 , BR-31 BR-24 , BR-31 BR-24 , BR-31 BR-24 , BR-31 BR-24 , BR-31 BR-24 , BR-31 BR-24 , BR-31 BR-24 , BR-31 -BRAKESYSTEMTROUBLESHOOTING BR-6
  7. 7. CHECK AND ADJUSTMENT BRAKE PEDAL CHECK AND ADJUSTMENT 1. CHECK THAT PEDAL HEIGHT IS CORRECT, AS SHOWN Pedal height from asphalt sheet: 4M/T 143.0-153.0 mm (5.63-6.02 in.) Others 138.5-148.5 mm (5.45-5.85 in.) If the pedal height is incorrect, adjust it. 2. IF NECESSARY, ADJUST PEDAL HEIGHT (a) Disconnect the connector from the stop light switch. (b) Loosen the stop light switch lock nut and remove the stop light switch. (c) Loosen the push rod lock nut. (d) Adjust the pedal height by turning the pedal push rod. (e) Tighten the push rod lock nut. Torque: 25 N-m (260 kgf-cm, 19 ft-lbf) (f) Install the stop light switch and turn it until it lightly contacts the pedal stopper. (g) Turn the stop light switch back one turn. (h) Check the clearance (A) between stop light switch and pedal: Clearance: 0.5-2.4 mm (0.02-0.09 in.) (i) Tighten the stop light switch lock nut. (j) Connect the connector to the stop light switch. (k) Check that the stop lights come on when the brake pedal is depressed, and go off when the brake pedal is released: (l) After adjusting the pedal height, check the pedal free- play. HINT: If clearance (A) between the stop light switch and the brake pedal stopper has been adjusted cor- rectly, the pedal freeplay will meet the specifications. 3. CHECK THAT PEDAL FREEPLAY IS CORRECT, AS SHOWN (a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the boost- er. (b) Push in the pedal by hand until the beginning of the resistance is felt, then measure the distance, as shown. Pedal freeplay: 1-6 mm (0.04-0.24 in.) If incorrect, check the stop light switch clearance. And if the clearance is OK, then troubleshoot the brake system. -BRAKE SYSTEM CHECK AND ADJUSTMENT BR-7
  8. 8. 4. CHECK THAT PEDAL RESERVE DISTANCE IS COR- RECT, AS SHOWN Release the parking brake. With the engine running, depress the pedal and meas- ure the pedal reserve distance, as shown. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 50 mm (1.97 in.) If the reserve distance is incorrect, troubleshoot the brake system. BRAKE BOOSTER OPERATIONAL TEST 1. OPERATING CHECK (a) Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. (b) Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. 2. AIR TIGHTNESS CHECK (a) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. If the pedal goes down the furthest the 1st time, but gradu- ally rises after the 2nd or 3rd time, the booster is air tight. (b) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. (f there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is air tight. BRAKE SYSTEM BLEEDING HINT: If any work is done on the brake system or if air in the brake lines is suspected, bleed the system of air. NOTICE: Do not let brake fluid remain on a painted sur- face. Wash it off immediately. 1. FILL BRAKE RESERVOIR WITH BRAKE FLUID Fluid: SAEJ1703 or FMVSS No. 116 DOT3 2. BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Disconnect the brake lines from the master cylinder. (b) Slowly depress the brake pedal and hold it. -BRAKE SYSTEM CHECK AND ADJUSTMENT BR-8
  9. 9. PARKING BRAKE CHECK AND ADJUSTMENT 1. CHECK THAT PARKING BRAKE LEVER TRAVEL IS CORRECT Pull the parking brake lever all the way up, and count the number of clicks. Parking brake lever travel at 196 N (20 kgf, 44.1 lbf): 4-7 clicks If incorrect, adjust the parking brake. 2. IF NECESSARY, ADJUST PARKING BRAKE HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. For shoe clearance adjustment, see step 9 to 10 on pages BR-37 and BR-38 . (a) Remove the console box. (b) Loosen the lock nut and turn the adjusting nut until the lever travel is correct. (c) Tighten the lock nut. 3. BLEED BRAKE LINE (a) Connect the vinyl tube to the brake caliper. (b) Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down. (c) At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal. (d) Repeat (b) and (c) until all the air in the fluid has been bled out. (e) Repeat the above procedure to bleed the air out of the brake line for each wheel. 4. CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAEJ1703 or FMVSS No. 116 DOT3 (c) Block off the outer holes with your finger and release the brake pedal. (d) Repeat (b) and (c) 3 or 4 times. -BRAKE SYSTEM CHECK AND ADJUSTMENT BR-9
  10. 10. Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf) (d) Install the console box. -BRAKE SYSTEM CHECK AND ADJUSTMENT BR-10
  11. 11. 1. REMOVE AIR CLEANER ASSEMBLY 2. DISCONNECT LEVEL WARNING SWITCH CONNEC- TOR 3. DRAW OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted sur- face. Wash it off immediately. 4. DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the master cylinder. SST 09751 - 36011 5. REMOVE MASTER CYLINDER Remove the mounting nuts and pull out the master cylinder and gasket. MASTER CYLINDER (w o ABS) MASTER CYLINDER REMOVAL -BRAKE SYSTEM MASTER CYLINDER(w o ABS) BR-1 1
  12. 12. 2. REMOVE RESERVOIR (a) Remove the set screw and pull out the reservoir. (b) Remove the cap and strainer from the reservoir. 3. REMOVE 2 GROMMETS 4. PLACE CYLINDER IN VISE MASTER CYLINDER DISASSEMBLY 1. REMOVE MASTER CYLINDER BOOT Using a screwdriver, remove the master cylinder boot. COMPONENTS -BRAKE SYSTEM MASTER CYLINDER(w/o ABS) BR-12
  13. 13. MASTER CYLINDER COMPONENTS INSPECTION HINT: Clean the disassembled parts with compressed air. 1. INSPECT CYLINDER BORE FOR RUST OR SCORING 2. INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. 6. REMOVE PISTONS (a) Push in the piston with a screwdriver and remove the snap ring with snap ring pliers. (b) Remove the No.1 piston and spring by hand, pulling straight out, not at an angle. NOTICE: If pulled out at an angle, there is a possibility that the cylinder bore could be damaged. MASTER CYLINDER ASSEMBLY 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO RUBBER PARTS INDICATED BY ARROWS (c) Place a rag and 2 wooden blocks on the work table and lightly tap the cylinder flange against the block edges until the No.2 piston drops out of the cylinder. HINT: Make sure the distance (A) from the rag to the top of the blocks is at least 100mm (3.94in.). 5. REMOVE PISTON STOPPER BOLT Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket. HINT: Tape the screwdriver tip before use. -BRAKE SYSTEM MASTER CYLINDER(w/o ABS) BR-13
  14. 14. 2. INSTALL PISTONS NOTICE: Be careful not to damage the rubber lips an the pistons. (a) Insert the 2 pistons straight in, not at an angle. NOTICE: If inserted at an angle, there is a possibility that the cylinder bore could be damaged. (b) Push in the piston with a screwdriver and install the snap ring with snap ring pliers. HINT: Tape the screwdriver tip before use. 3. INSTALL PISTON STOPPER BOLT Using a screwdriver, push the piston in all the way and install the piston stopper bolt over a new gasket. Torque the bolt. Torque: 10 N-m (100 kgf-cm, 7 ft-lbf) 4. INSTALL 2 GROMMETS MASTER CYLINDER INSTALLATION 1. ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD BEFORE INSTALLING MASTER CYLINDER (See BRAKE BOOSTER INSTALLATION) 5. INSTALL RESERVOIR (a) Install the cap and strainer to the reservoir. (b) Push the reservoir onto the cylinder. (c) Install the set screw while pushing on the reservoir. Torque: 1.7 N-m (17.5 kgf-cm, 15.2 in.-lbf) 6. INSTALL MASTER CYLINDER BOOT Align the grooves on the master cylinder boot and master cylinder flange as shown, install the cylinder boot on the master cylinder. -BRAKE SYSTEM MASTER CYLINDER(w/o ABS) BR-14
  15. 15. 3. CONNECT BRAKE LINES Using SST, connect the 2 brake lines to the master cylinder. Torque the union nuts. SST 09751-36011 Torque: 15 N-m (155 kgf-cm, 11 ft-Ibf) 4. CONNECT LEVEL WARNING SWITCH CONNECTOR 5. INSTALL AIR CLEANER ASSEMBLY 6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See BRAKE SYSTEM BLEEDING) 7. CHECK FOR LEAKS 8. CHECK AND ADJUST BRAKE PEDAL (See BRAKE PEDAL CHECK AND ADJUSTMENT) 2. INSTALL MASTER CYLINDER Install the master cylinder and a new gasket on the brake booster with the 2 nuts. Torque: 13 N-m (130 kgf-cm, 9 ft-Ibf) -BRAKE SYSTEM MASTER CYLINDER(w/o ABS) BR-15
  16. 16. 1. REMOVE AIR CLEANER ASSEMBLY 2. DISCONNECT LEVEL WARNING SWITCH CONNEC- TOR 3. DRAW OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted sur- face. Wash it off immediately. 4. DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the master cylinder and 2-way. SST 09751- 36011 5. REMOVE MASTER CYLINDER Remove the mounting nuts and pull out the master cylinder and gasket. MASTER CYLINDER (w ABS) MASTER CYLINDER REMOVAL -BRAKE SYSTEM MASTER CYLINDER(w ABS) BR-16
  17. 17. 2. REMOVE RESERVOIR (a) Remove the set screw and pull out the reservoir. (b) Remove the cap and strainer from the reservoir. 3. REMOVE 2 GROMMETS 4. PLACE CYLINDER IN VISE MASTER CYLINDER DISASSEMBLY 1. REMOVE MASTER CYLINDER BOOT Using a screwdriver, remove the master cylinder boot. COMPONENTS -BRAKE SYSTEM MASTER CYLINDER(w/ ABS) BR-17
  18. 18. MASTER CYLINDER COMPONENTS INSPECTION HINT: Clean the disassembled parts with compressed air. 1. INSPECT CYLINDER BORE FOR RUST OR SCORING 2. INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. 6. REMOVE PISTONS (a) Push in the piston with a screwdriver and remove the snap ring with snap ring pliers. (b) Remove the No.1 piston and spring by hand, pulling straight out, not at an angle. NOTICE: If pulled out at an angle, there is a possibility that the cylinder bore could be damaged. (c) Place a rag and 2 wooden blocks on the work table and lightly tap the cylinder flange against the block edges until the No.2 piston drops out of the cylinder. HINT: Make sure the distance (A) from the rag to the top of the blocks is at least 100mm (3.94in.). 5. REMOVE PISTON STOPPER BOLT Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket. HINT: Tape the screwdriver tip before use. MASTER CYLINDER ASSEMBLY 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO RUBBER PARTS INDICATED BY ARROWS -BRAKE SYSTEM MASTER CYLINDER(w/ ABS) BR-18
  19. 19. 2. INSTALL PISTONS NOTICE: Be careful not to damage the rubber lips on the pistons. (a) Insert the 2 pistons straight in, not at an angle. NOTICE: If inserted at an angle, there is a possibility that the cylinder bore could be damaged. (b) Push in the piston with a screwdriver and install the snap ring with snap ring pliers. HINT: Tape the screwdriver tip before use. 3. INSTALL PISTON STOPPER BOLT Using a screwdriver, push the piston in all the way and install the piston stopper bolt over a new gasket. Torque the bolt. Torque: 10 N-m (100 kgf-cm, 7 ft-lbf) 4. INSTALL 2 GROMMETS MASTER CYLINDER INSTALLATION 1. ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD BEFORE INSTALLING MASTER CYLINDER (See BRAKE BOOSTER INSTALLATION) 5. INSTALL RESERVOIR (a) Install the cap and strainer to the reservoir. (b) Push the reservoir onto the cylinder. (c) Install the set screw while pushing on the reservoir. Torque: 1.7 N-m (17.5 kgf-cm, 15.2 in.-lbf) 6. INSTALL MASTER CYLINDER BOOT With the UP mark on the master cylinder boot facing upwards, install the cylinder boot on the master cylin- der. -BRAKE SYSTEM MASTER CYLINDER(w/ ABS) BR-19
  20. 20. 3. CONNECT BRAKE LINES Using SST, connect the brake lines to the master cylinder and 2-way. Torque the union nuts. SST 09751-36011 Torque: 15 N-m (155 kgf-cm, 11 ft-lbf) 4. CONNECT LEVEL WARNING SWITCH CONNECTOR 5. INSTALL AIR CLEANER ASSEMBLY 6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See BRAKE SYSTEM BLEEDING) 7. CHECK FOR LEAKS 8. CHECK AND ADJUST BRAKE PEDAL (See BRAKE PEDAL CHECK AND ADJUSTMENT) 2. INSTALL MASTER CYLINDER Install the master cylinder and a new gasket on the brake booster with the 3 nuts. Torque: 13 N-m (130 kgf-cm, 9 ft-lbf) -BRAKE SYSTEM MASTER CYLINDER(w/ ABS) BR-20
  21. 21. 1. REMOVE MASTER CYLINDER (See MASTER CYLINDER REMOVAL) 2. DISCONNECT VACUUM HOSE FROM BRAKE BOO- STER 3. REMOVE PEDAL RETURN SPRING 4. REMOVE CLIP AND CLEVIS PIN 5. REMOVE BRAKE BOOSTER (a) Remove the No.1 brake tube clamp, as shown in the illustration. BRAKE BOOSTER BRAKE BOOSTER REMOVAL -BRAKE SYSTEM BRAKE BOOSTER BR-21
  22. 22. BRAKE BOOSTER INSTALLATION 1. INSTALL BRAKE BOOSTER (a) Install the booster and a new gasket. (b) Install the clevis to the operating rod. (c) Install and torque the booster installation nuts. Torque: 13 N-m (130 kgf-cm. 8 ft-lbf) (d) Insert the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin. (e) Install the pedal return spring. (f) Install the No.1 brake tube clamp to the body. (b) Remove the No.2 brake tube clamp, as shown in the illustration. (c) Remove the 4 nuts. (d) Pull out the brake booster and gasket. (g) Install the No.2 brake tube clamp to the body. -BRAKE SYSTEM BRAKE BOOSTER BR-22
  23. 23. (c) Turn SST upside down, and set it on the booster. SST 09737-00010 (d) Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 in.) (e) Adjust the booster push rod length until the push rod slightly touches the pin head. HINT: When loosening the push rod nut, depress the brake pedal enough so that the push rod sticks out. 3. INSTALL MASTER CYLINDER 4. CONNECT VACUUM HOSE TO BRAKE BOOSTER 5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See BRAKE SYSTEM BLEEDING) 6. CHECK FOR LEAKS 7. CHECK AND ADJUST BRAKE PEDAL (See BRAKE PEDAL CHECK AND ADJUSTMENT) Check and adjust the brake pedal, then tighten the clevis lock nut. Torque: 25 N-m (260 kgf-cm. 19 ft-lbf) 8. PERFORM OPERATIONAL CHECK (See BRAKE BOOSTER OPERATIONAL TEST) 2. ADJUST LENGTH OF BOOSTER PUSH ROD (a) Install the gasket on the master cylinder. (b) Set SST on the gasket, and lower the pin until its tip slightly touches the piston. SST 09737-00010 -BRAKE SYSTEM BRAKE BOOSTER BR-23
  24. 24. BRAKE PADS REPLACEMENT HINT: If a squealing noise is made by the front brakes while driving, check the pad wear indicator. If there is evidence of the indicator contacting the disc, the brake pad should be replaced as a set. 1. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts. FRONT BRAKE COMPONENTS -BRAKE SYSTEM FRONT BRAKE BR-24
  25. 25. 4. REMOVE FOLLOWING PARTS: (a) 2 brake pads (b) 3 anti-squeal shims (c) Pad wear indicator plate (d) 4 pad support plates 5. CHECK DISC THICKNESS AND RUNOUT (See FRONT BRAKE COMPONENTS INSPECTION AND REPAIR) 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspec- tion hole and replace the pads if it is not within specification. Minimum thickness: 1.0 mm (0.039 in.) (b) Remove the brake caliper and suspend it so the hose is not stretched. HINT: Do not disconnect the brake hose. 3. REMOVE CALIPER FROM TORQUE PLATE (a) Remove the 2 installation bolts from the torque plate. 6. INSTALL PAD SUPPORT PLATES Install the 4 pad support plates. -BRAKE SYSTEM FRONT BRAKE BR-25
  26. 26. 8. INSTALL CALIPER (a) Draw out a small amount of brake fluid from the reservoir. (b) Press in the piston with a hammer handle or an equiv- alent. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. CALIPER REMOVAL 1. DISCONNECT FLEXIBLE HOSE (a) Remove the union bolt and 2 gaskets from the brake caliper, then disconnect the flexible hose from the brake caliper. (b) Use a container to catch the brake fluid as it drains out. 7. INSTALL NEW PADS (a) Install a pad wear indicator plate on the inside pad. (b) Apply disc brake grease to both sides of the inner anti -squeal shim. (c) Install the 2 anti-squeal shims to the outside pad. (d) Install the anti-squeal shim to the inside pad. (e) Install the inside pad with the pad wear indicator plate facing upward. (f) Install the outside pad. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or disc. (c) Install the brake caliper. (d) Install and torque the 2 installation bolts. Torque: 25 N-m (255 kgf-cm. 18 ft-lbf) 9. INSTALL FRONT WHEEL 10. CHECK THAT FLUID LEVEL IS MAX LINE -BRAKE SYSTEM FRONT BRAKE BR-26
  27. 27. 3. REMOVE PISTON FROM CYLINDER (a) Put a piece of cloth or equivalent between the piston and the caliper. (b) Use compressed air to remove the piston from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. 2. REMOVE CYLINDER BOOT SET RING AND CYLIN- DER BOOT Using a screwdriver, remove the cylinder boot set ring and cylinder boot. CALIPER DISASSEMBLY 1. REMOVE FOLLOWING PARTS: (a) 2 sliding bushings (b) 4 dust boots 2. REMOVE CALIPER FROM TORQUE PLATE Remove the 2 installation bolts and caliper. 3. REMOVE 2 BRAKE PADS 4. REMOVE PISTON SEAL FROM BRAKE CYLINDER Using a screwdriver, remove the piston seal. -BRAKE SYSTEM FRONT BRAKE BR-27
  28. 28. 3. MEASURE DISC RUNOUT Measure disc runout 10 mm (0.39 in.) from the outer edge of the disc. Maximum disc runout: 0.09 mm (0.0035 in.) If runout greater than maximum, attempt to adjust to below this maximum figure. HINT: Before measuring the runout, confirm that the front bearing play is within specification (See SA sec- tion). 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the torque plate from the knuckle. (b) Remove the 4 hub nuts and the disc. Reinstall the disc 1/4 of a turn round from its original position on the hub. lnstall and torque the 4 hub nuts. Torque: 103 N-m (1,050 kgf-cm, 76 ft-lbf) Remeasure the disc runout. Make a note of the runout and the disc’s position on the hub. FRONT BRAKE COMPONENTS INSPECTION AND REPAIR 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 10.0 mm (0.39 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad’s thickness is at the mini- mum thickness or less, or if the pad has excessively uneven wear. 2. MEASURE DISC THICKNESS Standard thickness: 18.0 mm (0.709 in.) Minimum thickness: 17.0 mm (0.669 in.) Replace the disc if the thickness of the disc is at the minimum thickness or less. Replace the disc or grind it on a lathe if it is scored or is worn unevenly. -BRAKE SYSTEM FRONT BRAKE BR-28
  29. 29. (c) Repeat (b) until the disc has been installed on the 2 remaining hub positions. (d) If the minimum runout recorded in (b) and (c) is less than 0.09 mm (0.0035 in.), install the disc in that position and install and torque the torque plate. Torque: 88 N-m (900 kgf-cm, 65 ft-lbf) (e) If the minimum runout recorded in (b) and (c) is greater than 0.09 mm (0.0035 in.), replace the disc and repeat 3. 2. INSTALL PISTON SEAL AND PISTON IN CYLINDER CALIPER ASSEMBLY 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO PARTS INDICATED WITH ARROWS 3. INSTALL CYLINDER BOOT AND SET RING (f) Install the torque plate and tighten the 2 bolts. Torque: 88 N-m (900 kgf-cm, 65 ft-lbf -BRAKE SYSTEM FRONT BRAKE BR-29
  30. 30. 3. INSTALL FLEXIBLE HOSE Install the flexible hose on the brake caliper with the 2 new gaskets. Torque: 30 N-m (310 kgf. cm, 22 ft-lbf) HINT: Insert the flexible hose lock pin securely in the lock hole on the brake caliper. 4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See BRAKE SYSTEM BLEEDING) 5. CHECK FOR LEAKS CALIPER INSTALLATION 1. INSTALL BRAKE PADS Install the inside and outside 2 pads. 2. INSTALL CALIPER (a) Install the brake caliper. (b) Install and torque the 2 installation bolts. Torque: 25 N-m (255 kgf-cm, 18 ft-lbf) 4. INSTALL DUST BOOTS AND SLIDING BUSHINGS (a) Install the dust boots onto the brake caliper. (b) Insure that the boots is secured firmly to the brake caliper grooves. (c) Install the bushing into the boots. (d) Insure that the boots is secured firmly to the bushing grooves. -BRAKE SYSTEM FRONT BRAKE BR-30
  31. 31. REAR BRAKE REMOVAL 1. INSPECT SHOE LINING THICKNESS Remove the inspection hole plug, and check the shoe lining thickness through the hole. If less than minimum, replace the shoes. Minimum thickness: 1.0 mm (0.039 in.) 2. REMOVE REAR WHEEL 3. REMOVE BRAKE DRUM HINT: If the brake drum cannot be removed easily, perform the following steps. (a) Insert a screwdriver through the hole in the backing plate, and hold the automatic adjusting lever away from the adjuster. (b) Using another screwdriver, reduce the brake shoe adjuster by turning the adjusting wheel. REAR BRAKE COMPONENTS -BRAKE SYSTEM REAR BRAKE BR-31
  32. 32. (b) Using SST, remove the shoe hold-down spring, cups and pin. SST 09718-00010 (c) Disconnect the anchor spring from the front shoe and remove the front shoe. (d) Remove the anchor spring from the rear shoe. 5. REMOVE REAR SHOE (a) Using SST, remove the shoe hold-down spring, cups and pin. SST 09718-00010 4. REMOVE FRONT SHOE (a) Using a screwdriver, remove the return spring and clamp. (b) Using pliers, remove the adjusting lever spring. (c) Remove the adjuster. -BRAKE SYSTEM REAR BRAKE BR-32
  33. 33. 6. REMOVE AUTOMATIC ADJUSTING LEVER AND PARKING BRAKE LEVER (a) Remove the E-ring. (b) Remove the automatic adjusting lever. (c) Remove the C-washer. (d) Remove the parking brake lever. 8. DISASSEMBLE WHEEL CYLINDER Remove the following parts from the wheel cylinder: • 2 boots • 2 pistons • 2 piston cups • Spring 7. REMOVE WHEEL CYLINDER (a) Using SST, disconnect the brake line. Use a container to catch the brake fluid. SST 09751-36011 (b) Remove the 2 bolts and the wheel cylinder. (d) Using pliers, disconnect the parking brake cable from the lever and remove the rear shoe. -BRAKE SYSTEM REAR BRAKE BR-33
  34. 34. 2. MEASURE BRAKE SHOE LINING THICKNESS Standard thickness: 4.0 mm (0.157 in.) Minimum thickness: 1.0 mm (0.039 in.) If the shoe lining is less than minimum or shows signs of uneven wear, replace the brake shoes. HINT: If any of the brake shoes have to be replaced, replace all of the rear shoes in order to maintain even braking. 3. MEASURE BRAKE DRUM INSIDE DIAMETER Standard inside diameter: 180.0 mm (7.087 in.) Maximum inside diameter: 181.0 mm (7.126 in.) If the drum is scored or worn, the brake drum may be lathed to the maximum inside diameter. REAR BRAKE COMPONENTS INSPECTION AND REPAIR 1. INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage. 4. INSPECT REAR BRAKE LINING AND DRUM FOR PROPER CONTACT If the contact between the brake lining and drum is improper, repair the lining with a brake shoe grinder, or replace the brake shoe assembly. -BRAKE SYSTEM REAR BRAKE BR-34
  35. 35. 3. INSTALL WHEEL CYLINDER Install the wheel cylinder on the backing plate with the 2 bolts. Torque: 10 N-m (100 kgf-cm, 7 ft-Ibf) 4. CONNECT BRAKE LINE TO WHEEL CYLINDER Using SST, connect the brake line. SST 09751- 36011 Torque: 15 N-m (155 kgf-cm, 11 ft-Ibf) 2. ASSEMBLE WHEEL CYLINDER (a) Install 2 piston cups to the pistons. (b) Install the spring and 2 pistons into the wheel cylinder. Check that the flanges of the piston are pointed inward. (c) Install the 2 boots. 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO FOLLOWING PARTS: (a) 2 piston cups (b) 2 pistons (c) 2 boots REAR BRAKE INSTALLATION HINT: Assemble the parts in the correct direction, as shown. -BRAKE SYSTEM REAR BRAKE BR-35
  36. 36. 5. APPLY HIGH TEMPERATURE GREASE TO FOL- LOWING PARTS: (a) Backing plate and brake shoe contact points (b) Anchor plate and brake shoe contact points 6. INSTALL PARKING BRAKE LEVER AND AUTOMAT- IC ADJUSTING LEVER (a) Install the parking brake lever with a new C-washer. (b) Install the automatic adjusting lever with the E-ring. 7. INSTALL ADJUSTER AND REAR SHOE (a) Using pliers, connect the parking brake cable to the lever. (c) Adjusting bolt (d) Adjuster and brake shoe contact points (b) Set the adjuster. (c) Install the adjusting lever spring. -BRAKE SYSTEM REAR BRAKE BR-36
  37. 37. (d) Set the rear shoe in place with the end of the shoe installed in the wheel cylinder and the other end in the anchor plate. (e) Using SST, install the shoe hold-down spring, cups and pin. SST 09718-00010 NOTICE: Do not allow oil or grease to get on the rubbing face. 8. INSTALL FRONT SHOE (a) Install the anchor spring between the front and rear shoes. (b) Set the front shoe in place with the end of the shoe installed in the wheel cylinder and the adjuster in place. NOTICE: Do not allow oil or grease to get on the rubbing face. 9. CHECK OPERATION OF AUTOMATIC ADJUSTING MECHANISM (a) Move the parking brake lever of the rear shoe back and forth, as shown. Check that the adjuster turns. If the adjuster does not turn, check for incorrect installation of the rear brake. (c) Using SST, install the shoe hold-down spring, cups and pin. SST 09718 - 00010 (d) Install the clamp. (e) Using a screwdriver, install the return spring. -BRAKE SYSTEM REAR BRAKE BR-37
  38. 38. 10. CHECK CLEARANCE BETWEEN BRAKE SHOES AND DRUM (a) Remove the brake drum. (b) Measure the brake drum inside diameter and diameter of the brake shoes. Check that the difference between the diameters is the correct shoe clearance. Shoe clearance: 0.6 mm (0.024 in.) If incorrect, check the parking brake system. 11. INSTALL BRAKE DRUM 12. INSTALL REAR WHEEL 13. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See BRAKE SYSTEM BLEEDING) 14. CHECK FOR LEAKS (b) Adjust the adjuster length to the shortest possible amount. (c) Install the brake drum. (d) Pull the parking brake lever all the way up until a clicking sound can no longer be heard. -BRAKE SYSTEM REAR BRAKE BR-38
  39. 39. PROPORTIONING VALVE (P VALVE) FLUID PRESSURE CHECK 7. INSTALL LSPV GAUGE (SST) SST 09709-29017 2. BLEED AIR FROM FLUID PRESSURE GAUGE 3. RAISE FRONT BRAKE PRESSURE AND CHECK REAR WHEEL CYLINDER PRESSURE When inspecting the fluid pressure, inspect the left front and right rear together, and the right front and left rear together. Rear wheel cylinder pressure kPa (kgf/cm2, psi)Front brake pressure kPa (kgf/cm2, psi) 2,942 (30.0, 427) 7,845 (80.0, 1,138) 2,452 (25.0, 356) 7,845 (80.0, 1,138) 2,452 (25.0, 356) 7,845 (80.0, 1,138) 2,452 (25.0, 356) 4,452 (45.4, 646) 2,942 (30.0, 427) 4,168 (42.5, 604) 2,452 (25.0, 356) 3,805 (38.8, 552) 4 M/T (w/o ABS) Others (w/o ABS) w/ ABS -BRAKE SYSTEM PROPORTIONING VALVE (P VALVE) BR-39
  40. 40. If the rear wheel cylinder pressure is incorrect, replace the P valve assembly. 4. BLEED BRAKE SYSTEM 5. CHECK FOR LEAKS -BRAKE SYSTEM PROPORTIONING VALVE (P VALVE) BR-40
  41. 41. DESCRIPTION • ABS is a brake system which controls the brake cylinder hydraulic pressure to all 4 wheels during sudden braking and braking on slippery road surface, preventing the wheels from locking. ABS provides the following benefits: (1) Steering round an obstacle with a greater degree of certainty even when panic braking. (2) Stopping during panic braking while keeping the effect upon stability and steerability to a minimum, even on curves. • In case a malfunction occurs, a diagnosis function and fail-safe system have been adopted for the ABS. ANTI-LOCK BRAKE SYSTEM (ABS) -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-41
  42. 42. From the wheel speed signals from each sensor, it calculates acceleration, deceleration and slip values and sends signals to the actuator to control brake fluid pressure. Lights up to alert the driver when trouble has occurred in the Anti-Lock Brake System. Controls the brake fluid pressure to each brake cylinder through signals from the ECU. Detect the wheel speed of each of the left and right front wheels. Detect the wheel speed of each of the left and right rear wheels. COMPONENTS FUNCTION SYSTEM PARTS LOCATION ABS Warning Light Front Speed Sensor Rear Speed Sensor Component A6S ECU Function Actuator -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-42
  43. 43. WIRING DIAGRAM -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-43
  44. 44. CONNECTORS -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-44
  45. 45. DIAGNOSIS SYSTEM DESCRIPTION If a malfunction occurs, the system will identify the problem and the ECU will store the diagnostic trouble codes for the trouble items. At the same time, the system informs the driver of a malfunction via the ”ABS” warning light in the combi- nation meter. By turning on the ignition switch, disconnecting the service connector and use SST to connect Tc and E1 of the data link connector 1, the trouble can be ident- ified by the number of blinks (diagnostic trouble code) of the warning light. In the event of 2 codes, that having the smallest numbered code will be identified 1st. HINT: The warning light does not show the diagnostic trouble codes while the vehicle is running. DIAGNOSIS SYSTEM INSPECTION 1. INSPECT BATTERY POSITIVE VOLTAGE Inspect that the battery positive voltage is about 12 V. 2. CHECK THAT WARNING LIGHT TURNS ON (a) Turn the ignition switch on. (b) Check that the ”ABS” warning light turns on for 3 seconds. If not, inspect and repair or replace the fuse, bulb and wire harness. -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-45
  46. 46. (d) In event of a malfunction, 4 seconds later the warning light will begin to blink. Read the number of blinks. (See DIAGNOSTIC TROUBLE CODE) HINT: The 1st number of blinks will equal the 1st digit of a 2 digit diagnostic trouble code. After a 1.5 second pause, the 2nd number of blinks will equal the 2nd number of a 2 digit code. If there are 2 or more codes, there will be a 2.5 second pause between each, and indication will begin after 4.0 second pause from the smaller value and continue in order to larger. (e) If the system is operating normally (no malfunction), the warning light will blink once every 0.5 seconds. (f) Repair the system. (g) After the malfunctioning components has been repai- red, clear the diagnostic trouble codes stored in the ECU. HINT: If you disconnect the battery cable while repair- ing, all diagnostic trouble codes in the ECU will erased. (h) Remove the SST from terminals Tc and E1 of the data link connector 1. (i) Connect the service connector. (j) Turn the ignition switch on, and check that the ”ABS” warning light goes off after the warning light goes on for 3 seconds. (c) Using SST, connect terminals Tc and E1 of the data link connector 1. SST 09843-18020 3. READ DIAGNOSTIC TROUBLE CODE (a) Turn the ignition switch on. (b) Disconnect the service connector. -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-46
  47. 47. DIAGNOSTICTROUBLECODE HINT:UsingSST,connecttheterminalsTcandE1,anddisconnecttheserviceconnector. SST09843-18020 S Pump motor, relay and battery S Wire harness, connector and ground bolt or actuator pump motor circuit S Actuator inside wire harness S Control relay S Wire harness and connector of pump motor relay circuit S Actuator inside wire harness S Control relay S Wire harness and connector of solenoid relay circuit S Speed sensor S Sensor rotor S Wire harness and connector of speed sensor Abnormal battery voltage (less than 9.5 V/more than 16.2 V) Open or short circuit in solenoid of front left wheel Open or short circuit in solenoid of rear left wheel Open circuit in front left or rear right wheel speed sensor Open circuit in front right or rear left wheel speed sensor S Actuator solenoid S Wire harness and connector of actuator solenoid circuit Rear left wheel speed sensor signal malfunction Actuator pump motor locked or open circuit in pump motor Open or short circuit in solenoid of rear right wheel . Front right wheel speed sensor signal malfunction Rear right wheel speed sensor signal malfunction Open or short circuit in solenoid of front right wheel Front left wheel speed sensor signal malfunction Short circuit in pump motor relay circuit Short circuit in solenoid relay circuit Open circuit in pump motor relay circuit Open circuit in solenoid relay circuit Wrong both rear axle hubs S Battery S Voltage regulator Light Pattern Diagnosis S Rear sensor rotors Malfunction in ECU Trouble PartCode No. Always on 24 S ECU 33 32 37 34 36 35 23 22 -BRAKESYSTEMANTI-LOCKBRAKESYSTEM(ABS) BR-47
  48. 48. ECU TERMINAL VALUES MEASUREMENT USING TOYOTA BREAK-OUT-BOX AND TOYOTA HAND-HELD TESTER 1. Hook up the TOYOTA hand-held tester and TOYOTA break-out-box to the vehicle. 2. Read the ECU input/output values by following the prompts on the tester screen. HINT: TOYOTA hand-held tester has a ”Snapshot” function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the TOYOTA hand - held tester / TOYOTA break-out-box operator’s manual for fur- ther details. DIAGNOSTIC TROUBLE CODES CLEARING CLEAR DIAGNOSTIC TROUBLE CODES (a) Turn the ignition switch on. (b) Using SST, connect terminals Tc and E1 of the data link connector 1. SST 09843-18020 HINT: Keep the vehicle stationary. (d) Check that the warning light shows the normal code. (e) Remove the SST from terminals Tc and E1 of the data link connector 1. (f) Check that the warning light goes off. (c) Clear the diagnostic trouble codes stored in the ECU by depressing the brake pedal 8 or more times within 3 seconds. -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-48
  49. 49. h Also check the parts of the brake system (brake cylinder, pads, hydraulic line, etc.) not specifically part of the ABS. Skidding noise occurs while ABS operating. (ABS operates inefficiently) Does not come on for 3 seconds after ignition switched ON. ABS operates just before stopping during normal braking. Brake pedal pulsates abnormally while ABS is operating. Always comes on after ignition switch is turned ON. ABS operates during normal braking. TROUBLESHOOTING Comes on while running. Braking inefficient. h ”ABS” warning light Goes on and off. Brakes pull. h Brake condition Problem No. -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-49
  50. 50. Is there 10 - 14 V between terminal IG1 on ECU wire harness side connector and body ground? (ignition switch on) Does warning light go off when both the ECU connectors and service connector are disconnected? (Ignition switch on) S Inspect control relay, and replace if necessary. S Short circuit in wire harness between service connector and control relay terminal W. Does warning light show the diagnostic trouble code? (Ignition switch on) Does warning light show the diagnostic normal code? (Ignition switch on) Short circuit in wire harness between ECU terminal W and service connector or warning light. Disconnect the service connector and connect terminals Tc and E1 of data link connector 1. Are connector of ECU properly connected? And are all terminals in the connector? ”ABS” warning light comes on. See diagnostic trouble code. Faulty ECU connector. Faulty power circuit. YES (Goes off) NO (Stays on) Faulty ECU YES YES YES YES -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-50
  51. 51. HINT: If the diode is short-circuited, a malfunction at ECU terminal W will occur. When inspecting the termi- nal, connect the ECU connector, and disconnect the service connector. Then turn the ignition switched ON, and check that the warning light goes on. If it does, the ECU terminal is OK. Disconnect connectors from ECU and ground terminal W of ECU wire harness side connector. (Ignition switched ON) With ignition switched off, disconnect control relay connectors, and check continuity between terminals W and GND on control relay. Disconnect the service connector and ground the female side connector. (Ignition switched ON) ”ABS” warning light does not come on for 3 seconds after ignition switched ON. Bulb burned out or open circuit in wire harness between warning light and GAUGE fuse. Reverse tester leads and check again. Is there one way continuity between terminals? Open circuit in wire harness between ECU terminal W and warning light. Short circuit in control relay inside diode. Does warning light come on? Does warning light come on? Faulty ECU YES YES YES -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-51
  52. 52. S Brakes pull. S Braking inefficient. S ABS operates during normal braking. S ABS operates just before stopping during normal braking. S Brake pedal pulsates abnormally while ABS is operating. Does any abnormal change occur in continuity when the connectors or wire harness of the speed sensor and intermediate connectors are twisted or bent? Disconnect connectors from ECU, inspect continuity between each speed sensor terminals on wire harness side. S Check for short circuit in wire harness between terminal Tc or Ts and E1 of data link connector 1. Disconnect the service connector and connect terminals Tc and E1 of data link connector 1. Does warning light show the diagnostic normal code? (Ignition switched ON) Try speed sensor diagnosis system: Is sensor signal change OK? Try speed sensor diagnosis system. Is sensor signal level OK? Is each speed sensor installed in place? And is each installation bolt tightened securely? NO (No change) Continued on next page Inspect speed sensor, and replace if necessary. Inspect sensor rotor, and replace if necessary. ”ABS” warning light goes on and off. Speed sensor installation faulty. YES (Abnormal change) See diagnostic trouble code. Faulty wire harness. YES YES YES YES -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-52
  53. 53. Is there battery voltage between ECU terminal STP and body ground when depressing brake pedal? Disconnect the service connector and connect terminals Tc and E1 of data link connector 1. Does warning light show the diagnostic normal code? (Ignition switched ON) Open circuit in stop light switch and/ or wire harness. Is there foreign material or ferric chips on the sensor tip? Anti-lock brake system operations inefficiently. Clean chips from the speed sensor. Inspect the actuator operation. Continued from previous page See diagnostic trouble code. Is actuator operation OK? Inspect actuator. Faulty actuator. Replace ECU. NO YES YES YES YES -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-53
  54. 54. SPEED SENSOR DIAGNOSIS SYSTEM DIAGNOSIS SYSTEM INSPECTION PRECAUTION While checking the speed sensor diagnosis system. ABS does not operate and brake system operates as a normal brake system. 1. INSPECT BATTERY POSITIVE VOLTAGE Inspect that the battery positive voltage is about 12 V. 2. CHECK THAT WARNING LIGHT TURNS ON (a) Turn the ignition switch on. (b) Check that the ”ABS” warning light turns on for 3 seconds. If not inspect and repair or replace the fuse, bulb and wire harness. (c) Check that the ”ABS” warning light turns off. (d) Turn the ignition switch off. 3. PERFORM FOLLOWING STEPS (a) Using SST, connect terminals Ts and E1 of the data link connector 1 in the engine room. SST 09843-18020 (b) Pull the parking brake lever up, and start the engine. (c) Check that the warning light blinks about 4 times every 1 second, as shown. -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-54
  55. 55. (c) Read the number of blinks of the ”ABS” warning light. (See DIAGNOSTIC TROUBLE CODE) HINT: If normal, the warning light blinks 2 times every 1 second. If 2 or more malfunctions are indicated at the same time, the smallest numbered code will be displayed 1st. 6. REPAIR MALFUNCTIONING PARTS Repair or replace the malfunctioning parts. HINT: When repairing or replacing parts, turn the ignition switch to OFF. 7. REMOVE SST Remove the SST from terminals Ts, Tc and E1 of the data link connector 1. 5. READ DIAGNOSTIC TROUBLE CODE (a) Stop the vehicle, and warning light will begin to blink. (b) Using SST, connect the terminals Tc and E1 of the data link connector 1. HINT: Do not disconnect Ts and E1. 4. DRIVE VEHICLE (a) Release the parking brake. (b) Drive the vehicle faster than 45 km/h (28 mph) for several seconds. -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-55
  56. 56. DIAGNOSTICTROUBLECODE Low voltage of front right speed sensor signal Abnormal change of rear right speed sensor signal Abnormal change of front right speed sensor signal Abnormal change of front left speed sensor signal Abnormal change of rear left speed sensor signal All speed sensors and sensor rotors are normal Low voltage of rear right speed sensor signal Low voltage of front left speed sensor signal Low voltage of rear left speed sensor signal Rear right speed sensor Sensor installation Rear left speed sensor Sensor installation Front left speed sensor Sensor installation Front right speed sensor Sensor installation Front right sensor rotor Rear right sensor rotor Front left sensor rotor Rear left sensor rotor Malfunctioning PartLight Pattern Diagnosis Code No. 72 74 78 77 73 75 76 -BRAKESYSTEMANTI-LOCKBRAKESYSTEM(ABS) BR-56
  57. 57. ABS ACTUATOR ABS ACTUATOR REMOVAL AND INSTALLATION Remove and install the parts, as shown. -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-57
  58. 58. MAIN POINTS OF REMOVAL AND INSTALLATION 1. DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the ABS actuator. SST 09751 -36011 ABS ACTUATOR INSPECTION 1. INSPECT BATTERY POSITIVE VOLTAGE Battery positive voltage: 10-14.5 V 2. DISCONNECT CONNECTORS (a) Disconnect the 2 connectors from the control relay. 3. REMOVE POWER STEERING HOSE CLAMP 4. BLEED BRAKE SYSTEM (See BRAKE SYSTEM BLEEDING) 2. REMOVE NO. 1 BRAKE TUBE W / GROMMET CLAMP (b) Disconnect the connector from the actuator. -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-58
  59. 59. 3. CONNECT ACTUATOR CHECKER (SST) TO ACTUA- TOR (a) Connect the actuator checker (SST) to the actuator, control relay and body side wire harness through the sub-wire harness C and I (SST), as shown. SST 09990-00150, 09990-00200, 09990-00300 (b) Connect the red cable of the checker to the battery positive (+) terminal and black cable to the negative (-) terminal. Connect the black cable of the sub-wire harness to the battery negative (-) terminal or body ground. (c) Place the ”SHEET A” (SST) on the actuator checker. SST 09990-00163 -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-59
  60. 60. 4. INSPECT BRAKE ACTUATOR OPERATION (a) Start the engine, and run it at idle. (b) Turn the selector switch of the actuator checker to ”FRONT RH” position. (c) Push and hold in the MOTOR switch for a few sec- onds. Make sure that you can hear the motor run. (d) Depress the brake pedal and hold it for about 15 seconds, and check that the pedal does not go down. 5. (FOR OTHER WHEELS) (a) Turn the selector switch to ”FRONT LH” position. (b) Repeat (c) - (i) of step 4, check the actuator opera- tion as before. (c) Similarly, inspect ”REAR RH” and ”REAR LH” position HINT: When inspecting ”REAR LH” position, push the REAR LH switch instead of the POWER SWITCH, and you can inspect in any selector switch position. (f) Depress the brake pedal and hold it. As you hold the pedal down, push and hold in the POWER SWITCH for a few seconds. Check that the pedal does not go down. (g) With your foot still applied onto the brake pedal, release the POWER SWITCH and check that the pedal goes down. (h) With your foot still applied on the brake pedal, push the MOTOR switch and check that the brake pedal pulsates. (i) Release the brake pedal. (e) With your foot still applied onto the brake pedal, push the MOTOR switch and check that the brake pedal does not pulsate. -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-60
  61. 61. 6. PUSH MOTOR SWITCH (a) Push and hold in the MOTOR switch for a few sec- onds. (b) Stop the engine. 7. DISCONNECT ACTUATOR CHECKER (SST) FROM ACTUATOR Remove the ”SHEET A” (SST) and disconnect the actuator checker (SST) and sub-wire harness (SST) from the actuator, control relay and body side wire harness. 8. CONNECT CONNECTORS (a) Connect the connector to the actuator. 9. CLEAR DIAGNOSTIC TROUBLE CODES (See DIAGNOSTIC TROUBLE CODES CLEARING) (b) Connect the 2 connectors to the control relay. -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-61
  62. 62. (c) Connect the positive lead from the ohmmeter to ter- minal 4 and connect negative lead to terminal 5. (d) Check that there is continuity between terminals. (e) Connect the 2 leads in reverse, and check that there is no continuity between terminals. If continuity is not as specified, replace the relay. HINT: For the different type ohmmeter, there is no continuity for step (d), and there is continuity for step (e). 4. INSPECT OPERATION OF SOLENOID RELAY CIR- CUIT (a) Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 9. (b) Check that there is continuity between terminals 2 and 5. (c) Check that there is no continuity between terminals 2 and 6. If operation is not as specified, replace the relay. CONTROL RELAY CONTROL RELAY INSPECTION 1. INSPECT CONTINUITY OF MOTOR RELAY CIRCUIT (a) Check that there is continuity between terminals 9 and 10. (b) Check that there is no continuity between terminals 7 and 8. If continuity is not as specified, replace the relay. 2. INSPECT OPERATION OF MOTOR RELAY CIRCUIT (a) Connect the positive (+) lead from the battery to terminal 10 and negative (-) lead to terminal 9. (b) Check that there is continuity between terminals 7 and 8. If operation is not as specified, replace the relay. 3. INSPECT CONTINUITY OF SOLENOID RELAY CIR- CUIT (a) Check that there is continuity between terminals 1 and 9. (b) Check that there is no continuity between terminals 2 and 5. -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-62
  63. 63. (c) Measure the resistance between terminals. Resistance: 0.92-1.22 kW If resistance value is not as specified, replace the sensor. (d) Check that there is no continuity between each termi- nal and sensor body. If there is continuity, replace the sensor. (e) Connect the speed sensor connector. (f) Install the fendershield. FRONT SPEED SENSOR INSPECTION 1. INSPECT SPEED SENSOR (a) Remove the fendershield. (b) Disconnect the speed sensor connector. FRONT SPEED SENSOR COMPONENTS -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-63
  64. 64. FRONT SPEED SENSOR AND SENSOR ROTOR SERRATIONS INSPECTION INSPECT FRONT SPEED SENSOR AND SENSOR ROTOR SERRATIONS BY USING OSCILLOSCOPE (a) Connect an oscilloscope to the speed sensor connec- tor. (b) Run the vehicle at 20 km/h (12.4 mph), and inspect speed sensor output wave. (c) Check that C is 0.5 V or more. If not as specified, replace the speed sensor. (d) Check that B is 30% or more of A. If not as specified, replace the sensor rotor. 3. VISUALLY INSPECT SENSOR ROTOR SERRATIONS (a) Remove the drive shaft. (See SA section) (b) Inspect the sensor rotor serrations for scratches, cracks, warping or missing teeth. (c) Install the drive shaft. (See SA section) NOTICE: To prevent damage to the serrations, do not strike the drive shaft. FRONT SPEED SENSOR REMOVAL 1. DISCONNECT SPEED SENSOR CONNECTOR (a) Remove the fendershield. (b) Disconnect the speed sensor connector. 2. INSPECT SENSOR INSTALLATION Check that the sensor installation bolt is tightened properly. If not, tighten the bolt. Torque: 7.8 N-m (80 kgf-cm, 69 in.-Ibf) -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-64
  65. 65. FRONT SPEED SENSOR INSTALLATION 1. INSTALL SPEED SENSOR Install the speed sensor to the steering knuckle. Torque: 7.8 N-m (80 kgf-cm, 69 in.-lbf) 2. REMOVE SPEED SENSOR (a) Remove the 2 clamp bolts and a clip holding the sensor harness to the body and shock absorber. 2. CONNECT SPEED SENSOR CONNECTOR (a) Install the sensor harness. Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf) (b) Connect the speed sensor connector. (c) Install the fendershield. (b) Remove the speed sensor from the steering knuckle. -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-65
  66. 66. (d) Check that there is no continuity between each termi- nal and sensor body. If there is continuity, replace the sensor. (e) Connect the speed sensor connector. (f) Install the seat cushion. (c) Measure the resistance between terminals. Resistance: 0.9 -1.3 kW If resistance value is not as specified, replace the sensor. REAR SPEED SENSOR INSPECTION 1. INSPECT SPEED SENSOR (a) Remove the seat cushion. (b) Disconnect the speed sensor connector. REAR SPEED SENSOR COMPONENTS -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-66
  67. 67. REAR SPEED SENSOR AND SENSOR ROTOR SERRATIONS INSPECTION INSPECT REAR SPEED SENSOR AND SENSOR ROTOR SERRATIONS BY USING OSCILLOSCOPE (a) Connect an oscilloscope to the speed sensor connec- tor. (b) Run the vehicle at 20 km/h (12.4 mph), and inspect speed sensor output wave. (c) Check that C is 0.5 V or more. If not as specified, replace the speed sensor. (d) Check that B is 30% or more of A. If not as specified, replace the brake drum. 3. VISUALLY INSPECT SENSOR ROTOR SERRATIONS (a) Remove the brake drum. (See SA section) (b) Inspect the sensor rotor serrations for scratches, cracks, warping or missing teeth. (c) Install the brake drum. (See SA section) REAR SPEED SENSOR REMOVAL 1. DISCONNECT SPEED SENSOR CONNECTOR (a) Remove the seat cushion. (b) Disconnect the speed sensor connector, and pull out the sensor wire harness with the grommet. 2. INSPECT SENSOR INSTALLATION Check that the sensor installation bolt is tightened properly. If not, tighten the bolt. Torque: 7.8 N-m (80 kgf-cm, 69 in.-Ibf) -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-67
  68. 68. REAR SPEED SENSOR INSTALLATION 1. INSTALL SPEED SENSOR Install the speed sensor to the axle beam. Torque: 7.8 N-m (80 kgf-cm, 69 in.-lbf) 2. CONNECT SPEED SENSOR CONNECTOR (a) Pass the sensor harness through the body panel, and connect the connector. (c) Remove the 3 clamp bolts holding the sensor wire harness to the suspension arm. 2. REMOVE SPEED SENSOR Remove the speed sensor from the axle beam. (b) Install the grommet securely. -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-68
  69. 69. (c) Install the sensor harness. Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf) -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-69
  70. 70. ANTI-LOCK BRAKE SYSTEM CIRCUIT SYSTEM CIRCUIT INSPECTION 1. INSPECT SYSTEM CIRCUIT WITH CONNECTOR CONNECTED (a) Remove the ABS ECU. (b) Using a voltmeter with high impedance (10 kW/V minimum), measure the voltage at each terminal and body ground. IG switch on and ”ABS” warning light goes off IG switch on and ”ABS” warning light goes off IG switch on and ”ABS” warning light goes off IG switch on and ”ABS” warning light goes off IG switch on and ”ABS” warning light goes off IG switch on and ”ABS” warning light goes off IG switch on and ”ABS” warning light goes on IG switch on and ”ABS” warning light goes on IG switch on and DLC1 Ts-E 1 not connected IG switch on and DLC1 Tc-E 1 not connected lG switch on and DLC1 Ts-E 1 connected IG switch off and brake pedal depressed Engine running and PKB lever returned IG switch on and DLC1 Tc-E 1 connected IG switch off and brake pedal returned Engine running and PKB lever pulled Parking lever switch Level warning switch Stop light switch Stop light Tester Connection Specified Value Trouble Part IG switch off IG switch off I G switch off lG switch off !G switch off ECU-IG Fuse IG switch on Check Item 10 - 14.5 V 10 - 14.5 V 10-14.5 V 10 - 14.5 V 10 - 14.5 V 10 - 14.5 V 10 - 14.5 V 10-14.5 V 10 - 14.5 V 10 - 14.5 V 10 - 14.5 V DOME Fuse 10 - 14.5 V Continuity Continuity Continuity Continuity Condition Continuity Continuity Continuity Continuity Continuity Continuity About 0 V About 0 V About 0 V About 0 V About 0 V ABS ECU ABS ECU Voltage Voltage Voltage Voltage Voltage Actuator Actuator Voltage Voltage Voltage Voltage Voltage Voltage Voltage SRRH SRRR SFLR SFLH PKB BAT STP FSS FR- IG1 FL- ?? TC TS SR W R- -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-70
  71. 71. If the circuit is not as specified, check and repair or replace the trouble part in the table above. IG switch on and ”ABS” warning light goes off IG switch on and ”ABS” warning light goes off IG switch on and ”ABS” warning light goes off IG switch on and ”ABS” warning light goes off Tester Connection Specified Value Trouble Part IG switch off IG switch off Check Item 10-14.5 V 10 - 14.5 V 10 - 14.5 V 10 - 14.5 V Continuity Continuity Condition Continuity Continuity ABS ECU Actuator ABS ECU Actuator Voltage Voltage Voltage Voltage RR- RL- SRLH SRLR SFRH SFRR -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-71
  72. 72. 2. INSPECT SYSTEM CIRCUIT WITH CONNECTOR DISCONNECTED (a) Disconnect the connectors from the ECU, inspect at the wire harness side connector. If the circuit is not as specified, check and repair or replace the trouble part in the table above. (b) Connect the connectors, and install the ECU in place. SRLR↔Body Ground SRRH↔Body Ground SRLH↔Body Ground SFRH↔Body Ground SRRR↔Body Ground SFRR↔Body Ground SFLH↔Body Ground SFLR↔Body Ground Front LH speed sensor Rear LH speed sensor Rear RH speed sensor Front RH speed sensor Tester Connection Tester Connection Specified Value Specified Value 0.92-1.22 kW 0.92-1.22 kWControl relay Control relay 0.9 - 1.3 kW About 5.0W 0.9 - 1.3 kW About 5.0W Check Item About 5.0 W About 2.2W About 5.0 W Trouble Part About 2.2 W About 2.2 W Trouble Part About 2.2 W FL + ↔ FL-Resistance RL + ↔ RL- Resistance Check Item 56 -68 W Resistance Resistance 72 - 88 W RR + ↔ RR- Resistance Resistance Resistance FR + ↔ FR- Continuity Resistance Resistance Resistance Resistance Continuity Resistance Resistance Resistance Actuator Actuator Actuator Actuator Actuator MR↔ R- Actuator Actuator Actuator Actuator R- ↔ SR MT↔ Body Ground -BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS) BR-72
  73. 73. SERVICE SPECIFICATIONS SERVICE DATA Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf) Brake booster push rod to piston clearance (W/SST) Parking brake lever travel at 196 N (20 kgf, 44.1 lbf) TORQUE SPECIFICATIONS Front disc brake torque plate x Steering knuckle Rear drum brake wheel cylinder x Backing plate ABS actuator x ABS actuator No. 1 bracket Brake pedal height (from asphalt sheet) Front disc brake caliper installation bolt Brake pedal height (from asphalt sheet) Front disc brake caliper x Flexible hose Master cylinder x Piston stopper bolt ABS actuator installation bolt and nut Front speed sensor installation bolt Rear speed sensor installation bolt 143.0-153.0 mm (5.63-6.02 in.) 138.5-148.5 mm (5.45-5.85 in.) Rear brake drum to shoe clearance Master cylinder x Brake booster Rear brake drum inside diameter Rear brake drum inside diameter Brake booster x pedal bracket More than 50 mm (1.97 in.) Brake booster clevis lock nut Master cylinder x Reservoir Rear brake lining thickness Rear brake lining thickness Front brake pad thickness 1-6 mm (0.04-0.24 in.) Front brake pad thickness Front brake disc thickness Front brake disc thickness Front brake disc runout 0.09 mm (0.0035 in.) Brake pedal freeplay 10.0 mm (0.394 in.) 18.0 mm (0.709 in.) 17.0 mm (0.669 in.) Brake tube union nut 181 mm (7.126 in.) 180 mm (7.087 in.) 4.0 mm (0.157 in.) 1.0 mm (0.039 in.) 0.6 mm (0.024 in.) 1.0 mm (0.039 in.) Part tightened 0 mm (0 in.) Bleeder plug 4 - 7 clicks 15.2 in.-lbf 48 in.-lbf 74 in.-lbf 69 in.-lbf 69 in.-lbf kgf-cm Others 4M/T Limit Limit Limit Limit ft-lbf Limit 17.5 STD STD 310 900 260 100 130 100 130 155 195 STD STD 255 5.4 7.8 N-m 7.8 8.3 -BRAKE SYSTEM SERVICE SPECIFICATIONS BR-73

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