BRAKE CONTROL SYSTEM SECTION BRC CONTENTS BRAKES BRC-1 ABS SERVICE INFORMATION... 2

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1 RS ST R R TR SYST TTS S ydraulic ircuit iagram... 6 R SRV FRT... 2 T X U RUTS... 3 recaution for Supplemental Restraint System (SRS) "R " and "ST T R-T- SR"...3 recaution for rake System...3 recaution for rake ontrol...3 SYST SRT... 5 Schematic...5 Functions...5 peration That s ot "System rror"...5 Fail-Safe Function omponent arts ocation... 7 Schematic... 8 Wiring iagram - S ontrol Unit nput/utput Signal Standard...13 SUT- Function...14 Self-iagnosis...15 ata onitor...16 ctive Test...17 Symptom hart...18 omponent nspection...18 W SSR...20 Removal and nstallation...20 TUTR TR UT (SS- Y)...21 Removal and nstallation...21 R-1

2 SRV FRT T X T X F: T tem (SUT- screen item) Reference 1101 RR R SSR RR SSR FR R SSR FR SSR RR R SSR RR SSR FR R SSR-2 R-15, "Self-iagnosis" 1108 FR SSR TTRY VT [R] 1110 TRR FUR 1111 U TR SSR 1115 S SSR [R S] F: U1000 T tem (SUT- screen item) Reference 1120 FR S S 1121 FR UT S S 1122 FR R S S 1123 FR R UT S S R-15, "Self-iagnosis" 1140 TUTR RY 1190 RR S S 1191 RR UT S S F: T tem (SUT- screen item) Reference U1000 RUT R-15, "Self-iagnosis" R-2

3 RUTS RUTS recaution for Supplemental Restraint System (SRS) "R " and "ST T R-TSR" F: The Supplemental Restraint System such as R and ST T R-TSR, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. nformation necessary to service the system safely is included in the SUT RSTRT SYST and ST TS of this Service anual. WR: 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 must be performed by an authorized SS/FT dealer. mproper 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 able and ir ag odule, see the SUT RSTRT SYST. o not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service anual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. RUTS W US WR TS (R R TR) RS WR: When working near the ir ag iagnosis Sensor Unit or other ir ag System sensors with the ignition or engine running, T use air or electric power tools or strike near the sensor(s) with a hammer. eavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury. When using air or electric power tools or hammers, always switch the ignition FF, disconnect the battery, and wait at least 3 minutes before performing any service. recaution for rake System F: WR: lean brake pads and shoes with a waste cloth, then wipe with a dust collector. nly use T 3 brake fluid. Refer to -14, "Fluids and ubricants". ever to reuse drained brake fluid. ever to spill or splash brake fluid on painted surfaces. rake fluid may seriously damage paint. Wipe it off immediately and wash with water if it gets on a painted surface. ever to use mineral oils such as gasoline or light oil. They may damage rubber parts and cause improper operation. lways loosen the brake tube flare nut with a flare nut wrench. Tighten the brake tube flare nut to the specified torque with a flare nut torque wrench (). lways conform the specified tightening torque when installing the brake pipes. rake system is an important safety part. f a brake fluid leak is detected, always disassemble the affected part. f a malfunction is detected, replace part with a new one. Turn the ignition switch FF and disconnect the S actuator and electric unit (control unit) connector or the battery negative terminal before performing the work. R recaution for rake ontrol F0061ZZ F: ust after starting vehicle after ignition switch, brake pedal may vibrate or motor operating noise may be heard from engine room. This is a normal status of operation check. Stopping distance may be longer than that of vehicles without S when vehicle drives on rough, gravel, or snow-covered (fresh, deep snow) roads. When an error is indicated by S or another warning lamp, collect all necessary information from customer (what symptoms are present under what conditions) and check for simple causes before starting diagnostic R-3

4 RUTS servicing. esides electrical system inspection, check brake booster operation, brake fluid level, and fluid leaks. f tire size and type are used in an improper combination, or brake pads are not enuine SS parts, stopping distance or steering stability may deteriorate. f there is a radio, antenna, or antenna lead-in wire (including wiring) near control module, S function may have a malfunction or error. f aftermarket parts (car stereo, player, etc.) have been installed, check for incidents such as harness pinches, open circuits, and improper wiring. R-4

5 SYST SRT Schematic SYST SRT F: R SF0136 Functions F: S The nti-ock raking System is a function that detects wheel revolution while braking, and it improves handling stability during sudden braking by electrically preventing 4 wheels lock. aneuverability is also improved for avoiding obstacles. lectrical system diagnosis by SUT- is available. lectronic rake istribution is a function that detects subtle slippages between the front and rear tire during braking, and it improves handling stability by electrically controlling the brake fluid pressure which results in reduced rear tire slippage. lectrical system diagnosis by SUT- is available. peration That s ot "System rror" F: S When starting engine or just after starting vehicle, brake pedal may vibrate or the motor operating noise may be heard from engine room. This is a normal states of the operation check. uring S operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal. Stopping distance may be longer than that of vehicles without S when vehicle drives on rough, gravel, or snow-covered (fresh, deep snow) roads. Fail-Safe Function F: S, SYST n case of electrical malfunction with S, S warning lamp will turn on. n case of electrical incidents with, brake warning lamp and S warning lamp will turn on. Simultaneously, S become one of following conditions of Fail-Safe function. 1. For S malfunction, only is activated and condition of vehicle is same condition of vehicles without S system. T: S self-diagnosis sound may be heard.that is a normal condition because a self-diagnosis for gnition switch and The first starting are being performed. 2. For malfunction, and S become inoperative, and condition of vehicle is same as condition of vehicles without S, system. R-5

6 ydraulic ircuit iagram SYST SRT F: SF3205 R-6

7 omponent arts ocation F: R SF3401 R-7

8 Schematic F: TFW0178 R-8

9 Wiring iagram - S - F: R TFW0179 R-9

10 TFW0180 R-10

11 R TFW0181 R-11

12 FW0005 R-12

13 R ontrol Unit nput/utput Signal Standard TFW0216 F: RFR VU FR SUT- UT: The display shows S actuator and electric unit (control unit) calculation data, so a normal value might be displayed even in the event the output circuit (harness) is open or short-circuited. R-13

14 onitor item FR SSR FR R SSR RR SSR RR R SSR ST SW TTRY VT FR R S FR R UT S FR S FR UT S RR S RR UT S TR RY TUTR RY S WR WR S S S F S S F S R S Wheel speed ote: onfirm tire pressure is normal. SUT- Function rake pedal operation isplay content attery voltage supplied to the S actuator and electric unit (control unit) peration status of all solenoid valve otor and motor relay operation status ctuator relay operation status S warning lamp status rake warning lamp status operation S operation System error signal status R status Vehicle stopped Vehicle running (ote) ondition rake pedal depressed rake pedal not depressed gnition switch ata monitor ctuator (solenoid valve) is active ( ctive Test with - SUT-) or actuator relay is inactive (in fail-safe mode). When the actuator (solenoid valve) is not active and actuator relay is active (ignition switch ). When the motor relay and motor are operating When the motor relay and motor are not operating When the actuator relay is operating When the actuator relay is not operating When S warning lamp is When S warning lamp is FF rake warning lamp rake warning lamp FF active not active S active S not active alfunctions condition (When system is malfunctioning) ranking ot cranking Reference value in normal operation 0 [km/h ()] early matches the speedometer display (± 10 %or less) n ff V n ff n ff n ff n ff n ff n ff n ff ff n ff F: SUT- FUT SUT- can display each self-diagnostic item using the diagnostic test modes shown following. iagnostic test mode SF- RSUTS T TR SURT TR Function Self-diagnostic results can be read and erased quickly. nput/utput data in the S actuator and electric unit (control unit) can be read. The results of transmit/receive diagnosis of communication can be read. R-14

15 iagnostic test mode TV TST FUT TST U RT UR Self-iagnosis isplay tem ist Function iagnostic Test ode in which SUT- drives some actuators apart from the S actuator and electric unit (control unit) and also shifts some parameters in a specified range. erformed by SUT- instead of a technician to determine whether each system is or. S actuator and electric unit (control unit) part number can be read. F: Self-diagnostic item alfunction detecting condition heck system RR R SSR-1 [1101] (ote 1) RR SSR-1 [1102] (ote 1) FR R SSR-1 [1103] (ote 1) FR SSR-1 [1104] (ote 1) RR R SSR-2 [1105] (ote 1) RR SSR-2 [1106] (ote 1) FR R SSR-2 [1107] (ote 1) FR SSR-2 [1108] (ote 1) TTRY VT [R] [1109] TRR FUR [1110] U TR [1111] -SSR [1113] S SSR [R S] [1115] (ote 1) ircuit of rear R wheel sensor is open, shorted or sensor power voltage is unusual. ircuit of rear wheel sensor is open, shorted or sensor power voltage is unusual. ircuit of front R wheel sensor is open, shorted or sensor power voltage is unusual. ircuit of front wheel sensor is open, shorted or sensor power voltage is unusual. When the distance between the wheel sensor and sensor rotor is too large and the sensor pulse cannot be recognized by the control unit. When the distance between the wheel sensor and sensor rotor is too large and the sensor pulse cannot be recognized by the control unit. When the distance between the wheel sensor and sensor rotor is too large and the sensor pulse cannot be recognized by the control unit. When the distance between the wheel sensor and sensor rotor is too large and the sensor pulse cannot be recognized by the control unit. S actuator and electric unit (control unit) power voltage is too low. nternal malfunction of S actuator and electric unit (control unit) uring actuator motor operation with, when actuator motor turns FF or when control line for actuator motor relay is open. uring actuator motor operation with FF, when actuator motor turns or when control line for relay is shorted to ground. nternal malfunction of S actuator and electric unit (control unit) Wheel sensor input is malfunction. heck tire heck sensor and sensor rotor heck S actuator and electric unit (control unit) heck wheel sensor circuit heck battery voltage Replace S actuator and electric unit (control unit) heck S actuator and electric unit (control unit) Replace S actuator and electric unit (control unit) heck tire heck sensor and sensor rotor heck S actuator and electric unit (control unit) heck wheel sensor circuit R R-15

16 Self-diagnostic item alfunction detecting condition heck system FR S S [1120] FR UT S S [1121] FR R S S [1122] FR R UT S S [1123] TUTR RY [1140] RR S S [1190] RR UT S S [1191] RUT [U1000] (ote 2) ote 1: fter completing repairs of shorted sensor circuit, when ignition switch is turned, S warning lamp turns on. ake sure that S warning lamp turns off while driving vehicle at 10 km/h (6 ) or more for approximately 1 minute according to self-diagnosis procedure. n addition, if wheel sensor 2 is displayed for wheels, check wheel sensor circuit and also check control unit power voltage. ote 2: When errors are detected in several systems, including communication system [U1000], troubleshoot communication circuit. ata onitor SY T ST onitor item (Unit) FR SSR [km/h ()] FR R SSR [km/h ()] RR SSR [km/h ()] RR R SSR [km/h ()] ST SW TTRY VT (V) When the control unit detects an error in the front inlet solenoid circuit. When the control unit detects an error in the front outlet solenoid circuit. When the control unit detects an error in the front R inlet solenoid circuit. When the control unit detects an error in the front R outlet solenoid circuit. When the control unit detects an error in the actuator relay circuit. When the control unit detects an error in the rear inlet solenoid circuit. When the control unit detects an error in the rear outlet solenoid circuit. When S actuator and electric unit (control unit) is not transmitting or receiving communication signal for 2 seconds or more. U UT SS ST TR T SS Wheel speed Remarks Stop lamp switch signal status heck S actuator and electric unit (control unit) heck S actuator and electric unit (control unit) heck communication line F: : pplicable : ptional item attery voltage supplied to the S actuator and electric unit (control unit) R-16

17 onitor item (Unit) FR R S FR R UT S FR S FR UT S RR R S RR R UT S RR S RR UT S TR RY TUTR RY S WR WR S S S F S S F S R S ctive Test TST T U UT SS ST TR T SS peration status of each solenoid valve otor and motor relay operation ctuator relay operation S warning lamp status rake warning lamp status operation S operation fail-safe signal S fail-safe signal ranking signal Remarks F: Solenoid valve T: The example shown is for front right wheel. The procedure for the other wheels is the same as given below. For S solenoid valve, touch U,, and W on the display screen. ake sure solenoid valve operates as shown in solenoid valve operation chart. R Solenoid Valve peration hart S solenoid valve peration U W FR R S FF FR R UT S FF FF * *: for 1 to 2 seconds after the touch, and then FF S otor R-17

18 Touch and FF on the screen. ake sure S motor relay and actuator relay operates as shown in table below. peration FF TR RY FF TUTR RY Symptom hart F: f S warning lamp turn, perform self-diagnosis. Symptom heck item rake force distribution xcessive S function operation frequency ooseness of front and rear axle Wheel sensor and sensor rotor system Unexpected pedal reaction The braking distance is long S function does not operate (ote 1) edal vibration or S operation sound occurs (ote 2) rake pedal stroke ake sure the braking force is sufficient when the S is not operating. heck stopping distance when the S in not operating. Wheel sensor Wheel sensor communication line S warning lamp indication is not normal S actuator and electric unit (control unit) ote 1: S does not operate when speed is 10 km/h (6 ) or lower. ote 2: Under the following conditions, S is activated and vibration is felt when brake pedal is lightly depressed (just place a foot on it). owever, this is normal. When shifting gears When driving on slippery road uring cornering at high speed When passing over dumps or grooves [at approximately 50 mm (1.97 in) or more] When pulling away just after starting engine [at approximately 10 km/h (6 ) or more] omponent nspection ombination meter W SSR Wheel sensor can not be inspected with circuit tester. R FU V SWT 1. Turn ignition switch FF. 2. isconnect brake fluid level switch connector. 3. heck continuity between brake fluid level switch connector terminal 1 and 2. F: rake fluid level switch ondition ontinuity When brake fluid is full in the reservoir tank 1 2 When brake fluid is empty in the reservoir tank 4. f, replace brake fluid level switch. ST SWT 1. Turn ignition switch FF. o Yes SF2966 R-18

19 2. isconnect stop lamp switch connector. 3. heck continuity between stop lamp switch connector terminal 1 and 2. Stop lamp switch ondition ontinuity f, replace stop lamp switch. R R SWT Release stop lamp switch. (When brake pedal is depressed.) ush stop lamp switch. (When brake pedal is released.) 1. Turn ignition switch FF. 2. isconnect parking brake switch harness connector. 3. perate parking brake and check continuity between parking brake switch harness connector terminal 1 and ground. arking brake switch ondition ontinuity o Yes R When parking brake operated. 1 ground When parking brake released. 4. f, replace parking brake switch. o Yes R-19

20 W SSR Removal and nstallation W SSR F: SF Front wheel sensor () 2. Rear wheel sensor (R). Front. Rear : Front Refer to -7, "omponent" for symbol marks in the figure. UT: Wheel sensor can not be separate from axle parts. R-20

21 TUTR TR UT (SSY) TUTR TR UT (SSY) Removal and nstallation F: R SF To rear 2. From master cylinder secondary 3. To front left side 4. From master cylinder primary side 5. To front right 6. S actuator and electric unit (control unit) 7. arness connector Refer to -7, "omponent" for symbol marks in the figure. UT: efore servicing, disconnect battery cables. To remove brake tube, use flare nut wrench to prevent flare nuts and brake tube from being damaged. To install, use flare nut torque wrench. o not apply excessive impact to S actuator and electric unit (control unit), such as dropping it. o not remove and install actuator by holding harness. fter work is completed, bleed air from brake tube and hose. Refer to R-8, "leeding rake System". R-21

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