GENERAL DESCRIPTION DESCRIPTION

Transcription

1 BRAKE SYSTEM BR1

2 BR2 BRAKE SYSTEM GENERAL DESCRIPTION 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. 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.

3 BR2 BRAKE SYSTEM DESCRIPTION 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. 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.

4 BR4 BRAKE SYSTEM PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) LSPV Gauge Set Shoe Hold Down Spring Driver Brake Booster Push Rod Gauge Brake Tube Union Nut 10 x 12 mm Wrench Diagnosis Check Wire ABS Actuator Checker and Subharness ABS Actuator Checker Sheet A ABS Actuator Checker Subharness C ABS Actuator Checker Subharness I

5 BRAKE SYSTEM PREPARATION BR5 RECOMMENDED TOOLS TOYOTA Electrical Tester Set Snap Ring Pliers EQUIPMENT Torque wrench Micrometer Brake disc Dial indicator Brake disc Vernier calipers Brake drum LUBRICANT Item Brake fluid Capacity Classification SAEJ1703 or FMVSS No. 116 DOT 3

6 Noise from brakes Hard pedal but brake inefficient Brake pull Brake drag Low pedal or spongy pedal Part Name Trouble Brake system (Fluid leaks) Brake system (Air in) Brake pad or lining (Worn) Piston seal (Worn or damaged) Brake pedal (Freeplay minimal) Master cylinder (Faulty) Rear brake (Shoe clearance out of adjustment) Parking brake (Lever travel out of adjustment) Parking brake wire (Sticking) Booster push rod (Out of adjustment) Anchor or return spring (Faulty) Pad or lining (Cracked or distorted) Piston (Stuck) Pad or lining (oily) Piston (Frozen) Booster system (Vacuum leaks) Pad support plate (Loose) Installation bolt (Loose) Sliding pin (Worn) Disc (Scored) Pad or lining (Dirty) Pad or lining (Hardened) Antisqueal shim (Damaged) Holddown spring (Damaged) See page BR24,BR31 BR24 BR7 BR1 1, BR16 BR31 BR9 BR22 BR31 BR24, BR31 BR24, BR31 BR24, BR31 BR24, BR31 BR8 BR24, BR31 BR24, BR31 BR24, BR31 BR24, BR31 BR24, BR31 BR24, BR31 BR24 BR31 TROUBLESHOOTING Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. BRAKE SYSTEM TROUBLESHOOTING BR6

7 BRAKE SYSTEM CHECK AND ADJUSTMENT BR7 CHECK AND ADJUSTMENT BRAKE PEDAL CHECK AND ADJUSTMENT 1. CHECK THAT PEDAL HEIGHT IS CORRECT, AS SHOWN Pedal height from asphalt sheet: 4M/T mm ( in.) Others mm ( 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 Nm (260 kgfcm, 19 ftlbf) (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: mm ( 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 freeplay. HINT: If clearance (A) between the stop light switch and the brake pedal stopper has been adjusted correctly, 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 booster. (b) Push in the pedal by hand until the beginning of the resistance is felt, then measure the distance, as shown. Pedal freeplay: 16 mm ( in.) If incorrect, check the stop light switch clearance. And if the clearance is OK, then troubleshoot the brake system.

8 BR8 BRAKE SYSTEM CHECK AND ADJUSTMENT 4. CHECK THAT PEDAL RESERVE DISTANCE IS COR RECT, AS SHOWN Release the parking brake. With the engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 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 gradually 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 surface. 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.

9 BRAKE SYSTEM CHECK AND ADJUSTMENT BR9 (c) Block off the outer holes with your finger and release the brake pedal. (d) Repeat (b) and (c) 3 or 4 times. 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 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): 47 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 BR37 and BR38. (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.

10 BR10 BRAKE SYSTEM CHECK AND ADJUSTMENT Torque: 5.4 Nm (55 kgfcm, 48 in.lbf) (d) Install the console box.

11 BRAKE SYSTEM MASTER CYLINDER(w o ABS) BR1 1 MASTER CYLINDER (w o ABS) MASTER CYLINDER REMOVAL 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 surface. Wash it off immediately. 4. DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the master cylinder. SST REMOVE MASTER CYLINDER Remove the mounting nuts and pull out the master cylinder and gasket.

12 BR12 BRAKE SYSTEM MASTER CYLINDER(w/o ABS) COMPONENTS MASTER CYLINDER DISASSEMBLY 1. REMOVE MASTER CYLINDER BOOT Using a screwdriver, remove the master cylinder boot. 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

13 BRAKE SYSTEM MASTER CYLINDER(w/o ABS) BR13 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. 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.). 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. MASTER CYLINDER ASSEMBLY 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO RUBBER PARTS INDICATED BY ARROWS

14 BR14 BRAKE SYSTEM MASTER CYLINDER(w/o ABS) 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 Nm (100 kgfcm, 7 ftlbf) 4. INSTALL 2 GROMMETS 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 Nm (17.5 kgfcm, 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. MASTER CYLINDER INSTALLATION 1. ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD BEFORE INSTALLING MASTER CYLINDER (See BRAKE BOOSTER INSTALLATION)

15 BRAKE SYSTEM MASTER CYLINDER(w/o ABS) BR15 2. INSTALL MASTER CYLINDER Install the master cylinder and a new gasket on the brake booster with the 2 nuts. Torque: 13 Nm (130 kgfcm, 9 ftibf) 3. CONNECT BRAKE LINES Using SST, connect the 2 brake lines to the master cylinder. Torque the union nuts. SST Torque: 15 Nm (155 kgfcm, 11 ftibf) 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)

16 BR16 BRAKE SYSTEM MASTER CYLINDER(w ABS) MASTER CYLINDER (w ABS) MASTER CYLINDER REMOVAL 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 surface. Wash it off immediately. 4. DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the master cylinder and 2way. SST REMOVE MASTER CYLINDER Remove the mounting nuts and pull out the master cylinder and gasket.

17 BRAKE SYSTEM MASTER CYLINDER(w/ ABS) COMPONENTS BR17 MASTER CYLINDER DISASSEMBLY 1. REMOVE MASTER CYLINDER BOOT Using a screwdriver, remove the master cylinder boot. 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

18 BR18 BRAKE SYSTEM MASTER CYLINDER(w/ ABS) 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. 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.). 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. MASTER CYLINDER ASSEMBLY 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO RUBBER PARTS INDICATED BY ARROWS

19 BRAKE SYSTEM MASTER CYLINDER(w/ ABS) BR19 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 Nm (100 kgfcm, 7 ftlbf) 4. INSTALL 2 GROMMETS 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 Nm (17.5 kgfcm, 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 cylinder. MASTER CYLINDER INSTALLATION 1. ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD BEFORE INSTALLING MASTER CYLINDER (See BRAKE BOOSTER INSTALLATION)

20 BR20 BRAKE SYSTEM MASTER CYLINDER(w/ ABS) 2. INSTALL MASTER CYLINDER Install the master cylinder and a new gasket on the brake booster with the 3 nuts. Torque: 13 Nm (130 kgfcm, 9 ftlbf) 3. CONNECT BRAKE LINES Using SST, connect the brake lines to the master cylinder and 2way. Torque the union nuts. SST Torque: 15 Nm (155 kgfcm, 11 ftlbf) 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)

21 BRAKE SYSTEM BRAKE BOOSTER BR21 BRAKE BOOSTER BRAKE BOOSTER REMOVAL 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.

22 BR22 BRAKE SYSTEM BRAKE BOOSTER (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. 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 Nm (130 kgfcm. 8 ftlbf) (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. (g) Install the No.2 brake tube clamp to the body.

23 BRAKE SYSTEM BRAKE BOOSTER BR23 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 (c) Turn SST upside down, and set it on the booster. SST (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 Nm (260 kgfcm. 19 ftlbf) 8. PERFORM OPERATIONAL CHECK (See BRAKE BOOSTER OPERATIONAL TEST)

24 BR24 BRAKE SYSTEM FRONT BRAKE FRONT BRAKE COMPONENTS 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.

25 BRAKE SYSTEM FRONT BRAKE BR25 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace the pads if it is not within specification. Minimum thickness: 1.0 mm (0.039 in.) 3. REMOVE CALIPER FROM TORQUE PLATE (a) Remove the 2 installation bolts from the torque plate. (b) Remove the brake caliper and suspend it so the hose is not stretched. HINT: Do not disconnect the brake hose. 4. REMOVE FOLLOWING PARTS: (a) 2 brake pads (b) 3 antisqueal shims (c) Pad wear indicator plate (d) 4 pad support plates 5. CHECK DISC THICKNESS AND RUNOUT (See FRONT BRAKE COMPONENTS INSPECTION AND REPAIR) 6. INSTALL PAD SUPPORT PLATES Install the 4 pad support plates.

26 BR26 BRAKE SYSTEM FRONT BRAKE 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 antisqueal shims to the outside pad. (d) Install the antisqueal 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. 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 equivalent. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. (c) Install the brake caliper. (d) Install and torque the 2 installation bolts. Torque: 25 Nm (255 kgfcm. 18 ftlbf) 9. INSTALL FRONT WHEEL 10. CHECK THAT FLUID LEVEL IS MAX LINE 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.

27 BRAKE SYSTEM FRONT BRAKE BR27 2. REMOVE CALIPER FROM TORQUE PLATE Remove the 2 installation bolts and caliper. 3. REMOVE 2 BRAKE PADS CALIPER DISASSEMBLY 1. REMOVE FOLLOWING PARTS: (a) 2 sliding bushings (b) 4 dust boots 2. REMOVE CYLINDER BOOT SET RING AND CYLIN DER BOOT Using a screwdriver, remove the cylinder boot set ring and cylinder boot. 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. 4. REMOVE PISTON SEAL FROM BRAKE CYLINDER Using a screwdriver, remove the piston seal.

28 BR28 BRAKE SYSTEM FRONT BRAKE 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 minimum 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. 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 ( 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 section). 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 Nm (1,050 kgfcm, 76 ftlbf) Remeasure the disc runout. Make a note of the runout and the disc s position on the hub.

29 BRAKE SYSTEM FRONT BRAKE BR29 (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 ( in.), install the disc in that position and install and torque the torque plate. Torque: 88 Nm (900 kgfcm, 65 ftlbf) (e) If the minimum runout recorded in (b) and (c) is greater than 0.09 mm ( in.), replace the disc and repeat 3. (f) Install the torque plate and tighten the 2 bolts. Torque: 88 Nm (900 kgfcm, 65 ftlbf CALIPER ASSEMBLY 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO PARTS INDICATED WITH ARROWS 2. INSTALL PISTON SEAL AND PISTON IN CYLINDER 3. INSTALL CYLINDER BOOT AND SET RING

30 BR30 BRAKE SYSTEM FRONT BRAKE 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. 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 Nm (255 kgfcm, 18 ftlbf) 3. INSTALL FLEXIBLE HOSE Install the flexible hose on the brake caliper with the 2 new gaskets. Torque: 30 Nm (310 kgf. cm, 22 ftlbf) 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

31 BRAKE SYSTEM REAR BRAKE BR31 REAR BRAKE COMPONENTS 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.

32 BR32 BRAKE SYSTEM REAR BRAKE 4. REMOVE FRONT SHOE (a) Using a screwdriver, remove the return spring and clamp. (b) Using SST, remove the shoe holddown spring, cups and pin. SST (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 holddown spring, cups and pin. SST (b) Using pliers, remove the adjusting lever spring. (c) Remove the adjuster.

33 BRAKE SYSTEM REAR BRAKE BR33 (d) Using pliers, disconnect the parking brake cable from the lever and remove the rear shoe. 6. REMOVE AUTOMATIC ADJUSTING LEVER AND PARKING BRAKE LEVER (a) Remove the Ering. (b) Remove the automatic adjusting lever. (c) Remove the Cwasher. (d) Remove the parking brake lever. 7. REMOVE WHEEL CYLINDER (a) Using SST, disconnect the brake line. Use a container to catch the brake fluid. SST (b) Remove the 2 bolts and the wheel cylinder. 8. DISASSEMBLE WHEEL CYLINDER Remove the following parts from the wheel cylinder: 2 boots 2 pistons 2 piston cups Spring

34 BR34 BRAKE SYSTEM REAR BRAKE REAR BRAKE COMPONENTS INSPECTION AND REPAIR 1. INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage. 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: mm (7.087 in.) Maximum inside diameter: mm (7.126 in.) If the drum is scored or worn, the brake drum may be lathed to the maximum inside diameter. 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.

35 BRAKE SYSTEM REAR BRAKE BR35 REAR BRAKE INSTALLATION HINT: Assemble the parts in the correct direction, as shown. 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO FOLLOWING PARTS: (a) 2 piston cups (b) 2 pistons (c) 2 boots 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. 3. INSTALL WHEEL CYLINDER Install the wheel cylinder on the backing plate with the 2 bolts. Torque: 10 Nm (100 kgfcm, 7 ftibf) 4. CONNECT BRAKE LINE TO WHEEL CYLINDER Using SST, connect the brake line. SST Torque: 15 Nm (155 kgfcm, 11 ftibf)

36 BR36 BRAKE SYSTEM REAR BRAKE 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 (c) Adjusting bolt (d) Adjuster and brake shoe contact points 6. INSTALL PARKING BRAKE LEVER AND AUTOMAT IC ADJUSTING LEVER (a) Install the parking brake lever with a new Cwasher. (b) Install the automatic adjusting lever with the Ering. 7. INSTALL ADJUSTER AND REAR SHOE (a) Using pliers, connect the parking brake cable to the lever. (b) Set the adjuster. (c) Install the adjusting lever spring.

37 BRAKE SYSTEM REAR BRAKE BR37 (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 holddown spring, cups and pin. SST 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. (c) Using SST, install the shoe holddown spring, cups and pin. SST (d) Install the clamp. (e) Using a screwdriver, install the return spring. 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.

38 BR38 BRAKE SYSTEM REAR BRAKE (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. 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

39 BRAKE SYSTEM PROPORTIONING VALVE (P VALVE) BR39 PROPORTIONING VALVE (P VALVE) FLUID PRESSURE CHECK 7. INSTALL LSPV GAUGE (SST) SST BLEED AIR FROM FLUID PRESSURE GAUGE 3. RAISE FRONT BRAKE PRESSURE AND CHECK REAR WHEEL CYLINDER PRESSURE 4 M/T (w/o ABS) Others (w/o ABS) w/ ABS Front brake pressure kpa (kgf/cm 2, psi) 2,452 (25.0, 356) 7,845 (80.0, 1,138) 2,452 (25.0, 356) 7,845 (80.0, 1,138) 2,942 (30.0, 427) 7,845 (80.0, 1,138) Rear wheel cylinder pressure kpa (kgf/cm 2, psi) 2,452 (25.0, 356) 4,452 (45.4, 646) 2,452 (25.0, 356) 3,805 (38.8, 552) 2,942 (30.0, 427) 4,168 (42.5, 604) When inspecting the fluid pressure, inspect the left front and right rear together, and the right front and left rear together.

40 BR40 BRAKE SYSTEM PROPORTIONING VALVE (P VALVE) If the rear wheel cylinder pressure is incorrect, replace the P valve assembly. 4. BLEED BRAKE SYSTEM 5. CHECK FOR LEAKS

41 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) ANTILOCK BRAKE SYSTEM (ABS) BR41 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 failsafe system have been adopted for the ABS.

42 BR42 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) COMPONENTS FUNCTION Component Front Speed Sensor Rear Speed Sensor ABS Warning Light Actuator A6S ECU Function 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. Lights up to alert the driver when trouble has occurred in the AntiLock Brake System. Controls the brake fluid pressure to each brake cylinder through signals from the ECU. 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. SYSTEM PARTS LOCATION

43 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR43 WIRING DIAGRAM

44 BR44 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) CONNECTORS

45 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR45 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 combination 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 identified 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.

46 BR46 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 3. READ DIAGNOSTIC TROUBLE CODE (a) Turn the ignition switch on. (b) Disconnect the service connector. (c) Using SST, connect terminals Tc and E1 of the data link connector 1. SST (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 repaired, clear the diagnostic trouble codes stored in the ECU. HINT: If you disconnect the battery cable while repairing, 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.

47 Code No Light Pattern Open circuit in solenoid relay circuit Short circuit in solenoid relay circuit Open circuit in pump motor relay circuit Short circuit in pump motor relay circuit Open or short circuit in solenoid of front right wheel Open or short circuit in solenoid of front left wheel Open or short circuit in solenoid of rear right wheel Open or short circuit in solenoid of rear left wheel. Front right wheel speed sensor signal malfunction Front left wheel speed sensor signal malfunction Rear right wheel speed sensor signal malfunction Rear left wheel speed sensor signal malfunction Open circuit in front left or rear right wheel speed sensor Open circuit in front right or rear left wheel speed sensor Wrong both rear axle hubs Diagnosis Abnormal battery voltage (less than 9.5 V/more than 16.2 V) Actuator pump motor locked or open circuit in pump motor Trouble Part Actuator inside wire harness Control relay Wire harness and connector of solenoid relay circuit Actuator inside wire harness Control relay Wire harness and connector of pump motor relay circuit Actuator solenoid Wire harness and connector of actuator solenoid circuit Speed sensor Sensor rotor Wire harness and connector of speed sensor Rear sensor rotors Battery Voltage regulator Pump motor, relay and battery Wire harness, connector and ground bolt or actuator pump motor circuit DIAGNOSTIC TROUBLE CODE HINT: Using SST, connect the terminals Tc and E1, and disconnect the service connector. SST BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) Always on Malfunction in ECU ECU BR47

48 BR48 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 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 HINT: Keep the vehicle stationary. (c) Clear the diagnostic trouble codes stored in the ECU by depressing the brake pedal 8 or more times within 3 seconds. (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. ECU TERMINAL VALUES MEASUREMENT USING TOYOTA BREAKOUTBOX AND TOYOTA HANDHELD TESTER 1. Hook up the TOYOTA handheld tester and TOYOTA breakoutbox to the vehicle. 2. Read the ECU input/output values by following the prompts on the tester screen. HINT: TOYOTA handheld 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 breakoutbox operator s manual for further details.

49 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR49 TROUBLESHOOTING ABS warning light Brake condition Problem Always comes on after ignition switch is turned ON. Does not come on for 3 seconds after ignition switched ON. Goes on and off. Comes on while running. Brakes pull. Braking inefficient. ABS operates during normal braking. ABS operates just before stopping during normal braking. Brake pedal pulsates abnormally while ABS is operating. Skidding noise occurs while ABS operating. (ABS operates inefficiently) No. Also check the parts of the brake system (brake cylinder, pads, hydraulic line, etc.) not specifically part of the ABS.

50 BR50 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) ABS warning light comes on. Disconnect the service connector and connect terminals Tc and E 1 of data link connector 1. Does warning light show the diagnostic trouble code? (Ignition switch on) YES See diagnostic trouble code. Does warning light show the diagnostic normal code? (Ignition switch on) YES Inspect control relay, and replace if necessary. Short circuit in wire harness between service connector and control relay terminal W. Are connector of ECU properly connected? And are all terminals in the connector? YES Is there V between terminal IG1 on ECU wire harness side connector and body ground? (ignition switch on) YES Does warning light go off when both the ECU connectors and service connector are disconnected? (Ignition switch on) NO (Stays on) Faulty ECU connector. Faulty power circuit. Short circuit in wire harness between ECU terminal W and service connector or warning light. Faulty ECU YES (Goes off)

51 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR51 ABS warning light does not come on for 3 seconds after ignition switched ON. Disconnect the service connector and ground the female side connector. (Ignition switched ON) Does warning light come on? YES Bulb burned out or open circuit in wire harness between warning light and GAUGE fuse. Disconnect connectors from ECU and ground terminal W of ECU wire harness side connector. (Ignition switched ON) Does warning light come on? YES Open circuit in wire harness between ECU terminal W and warning light. With ignition switched off, disconnect control relay connectors, and check continuity between terminals W and GND on control relay. Reverse tester leads and check again. Is there one way continuity between terminals? Faulty ECU YES Short circuit in control relay inside diode. HINT: If the diode is shortcircuited, a malfunction at ECU terminal W will occur. When inspecting the terminal, 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.

52 BR52 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) ABS warning light goes on and off. Check for short circuit in wire harness between terminal Tc or Ts and E 1 of data link connector 1. Brakes pull. Braking inefficient. ABS operates during normal braking. ABS operates just before stopping during normal braking. Brake pedal pulsates abnormally while ABS is operating. Disconnect the service connector and connect terminals Tc and E 1 of data link connector 1. Does warning light show the diagnostic normal code? (Ignition switched ON) See diagnostic trouble code. YES Is each speed sensor installed in place? And is each installation bolt tightened securely? Speed sensor installation faulty. YES Try speed sensor diagnosis system. Is sensor signal level OK? Inspect speed sensor, and replace if necessary. YES Try speed sensor diagnosis system: Is sensor signal change OK? Inspect sensor rotor, and replace if necessary. YES Disconnect connectors from ECU, inspect continuity between each speed sensor terminals on wire harness side. Does any abnormal change occur in continuity when the connectors or wire harness of the speed sensor and intermediate connectors are twisted or bent? NO (No change) Continued on next page YES (Abnormal change) Faulty wire harness.

53 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR53 Continued from previous page Is there foreign material or ferric chips on the sensor tip? YES Clean chips from the speed sensor. Inspect the actuator operation. Is actuator operation OK? Replace ECU. YES NO Faulty actuator. Antilock brake system operations inefficiently. Disconnect the service connector and connect terminals Tc and E 1 of data link connector 1. Does warning light show the diagnostic normal code? (Ignition switched ON) Is there battery voltage between ECU terminal STP and body ground when depressing brake pedal? Inspect actuator. YES YES See diagnostic trouble code. Open circuit in stop light switch and/ or wire harness.

54 BR54 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 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 (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.

55 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR55 4. DRIVE VEHICLE (a) Release the parking brake. (b) Drive the vehicle faster than 45 km/h (28 mph) for several seconds. 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. (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.

56 Code No Light Pattern Diagnosis All speed sensors and sensor rotors are normal Low voltage of front right speed sensor signal Low voltage of front left speed sensor signal Low voltage of rear right speed sensor signal Low voltage of rear left speed sensor signal Abnormal change of front right speed sensor signal Abnormal change of front left speed sensor signal Abnormal change of rear right speed sensor signal Malfunctioning Part Front right speed sensor Sensor installation Front left speed sensor Sensor installation Rear right speed sensor Sensor installation Rear left speed sensor Sensor installation Front right sensor rotor Front left sensor rotor Rear right sensor rotor DIAGNOSTIC TROUBLE CODE BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR56 78 Abnormal change of rear left speed sensor signal Rear left sensor rotor

57 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR57 ABS ACTUATOR ABS ACTUATOR REMOVAL AND INSTALLATION Remove and install the parts, as shown.

58 BR58 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) MAIN POINTS OF REMOVAL AND INSTALLATION 1. DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the ABS actuator. SST REMOVE NO. 1 BRAKE TUBE W / GROMMET CLAMP 3. REMOVE POWER STEERING HOSE CLAMP 4. BLEED BRAKE SYSTEM (See BRAKE SYSTEM BLEEDING) ABS ACTUATOR INSPECTION 1. INSPECT BATTERY POSITIVE VOLTAGE Battery positive voltage: V 2. DISCONNECT CONNECTORS (a) Disconnect the 2 connectors from the control relay. (b) Disconnect the connector from the actuator.

59 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR59 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 subwire harness C and I (SST), as shown. SST , , (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 subwire harness to the battery negative () terminal or body ground. (c) Place the SHEET A (SST) on the actuator checker. SST

60 BR60 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 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 seconds. 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. (e) With your foot still applied onto the brake pedal, push the MOTOR switch and check that the brake pedal does not pulsate. (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. 5. (FOR OTHER WHEELS) (a) Turn the selector switch to FRONT LH position. (b) Repeat (c) (i) of step 4, check the actuator operation 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.

61 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR61 6. PUSH MOTOR SWITCH (a) Push and hold in the MOTOR switch for a few seconds. (b) Stop the engine. 7. DISCONNECT ACTUATOR CHECKER (SST) FROM ACTUATOR Remove the SHEET A (SST) and disconnect the actuator checker (SST) and subwire harness (SST) from the actuator, control relay and body side wire harness. 8. CONNECT CONNECTORS (a) Connect the connector to the actuator. (b) Connect the 2 connectors to the control relay. 9. CLEAR DIAGNOSTIC TROUBLE CODES (See DIAGNOSTIC TROUBLE CODES CLEARING)

62 BR62 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 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. (c) Connect the positive lead from the ohmmeter to terminal 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.

63 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR63 FRONT SPEED SENSOR COMPONENTS FRONT SPEED SENSOR INSPECTION 1. INSPECT SPEED SENSOR (a) Remove the fendershield. (b) Disconnect the speed sensor connector. (c) Measure the resistance between terminals. Resistance: k If resistance value is not as specified, replace the sensor. (d) Check that there is no continuity between each terminal and sensor body. If there is continuity, replace the sensor. (e) Connect the speed sensor connector. (f) Install the fendershield.

64 BR64 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 2. INSPECT SENSOR INSTALLATION Check that the sensor installation bolt is tightened properly. If not, tighten the bolt. Torque: 7.8 Nm (80 kgfcm, 69 in.ibf) 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 AND SENSOR ROTOR SERRATIONS INSPECTION INSPECT FRONT SPEED SENSOR AND SENSOR ROTOR SERRATIONS BY USING OSCILLOSCOPE (a) Connect an oscilloscope to the speed sensor connector. (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. FRONT SPEED SENSOR REMOVAL 1. DISCONNECT SPEED SENSOR CONNECTOR (a) Remove the fendershield. (b) Disconnect the speed sensor connector.