BRAKE SYSTEMSECTION BRCONTENTSPRECAUTIONS AND PREPARATION............................3Supplemental Restraint System (SRS)AIR BAG ...................................................................3Precautions for Brake System.....................................4Commercial Service Tools...........................................4NOISE, VIBRATION AND HARSHNESS (NVH)TROUBLESHOOTING.....................................................5NVH Troubleshooting Chart.........................................5ON-VEHICLE SERVICE ..................................................6Checking Brake Fluid Level.........................................6Checking Brake Line ...................................................6Changing Brake Fluid..................................................6Brake Burnishing Procedure........................................6Bleeding Brake System...............................................7BRAKE HYDRAULIC LINE.............................................8CONTROL VALVE.........................................................10Load Sensing Valve (2WD) .......................................10BRAKE HYDRAULIC LINE/CONTROL VALVE............12Proportioning Valve (4WD) ........................................12BRAKE PEDAL AND BRACKET..................................13Removal and Installation ...........................................13Inspection...................................................................14Adjustment .................................................................14MASTER CYLINDER.....................................................15Removal .....................................................................15Disassembly...............................................................15Inspection...................................................................16Assembly ...................................................................16Installation..................................................................17BRAKE BOOSTER........................................................18On-vehicle Service.....................................................18Removal .....................................................................18Inspection...................................................................18Installation..................................................................19VACUUM HOSE.............................................................20Removal and Installation ...........................................20Inspection...................................................................20FRONT DISC BRAKE ...................................................21Pad Replacement ......................................................21Removal .....................................................................22Disassembly...............................................................23Inspection Caliper .................................................23Inspection Rotor....................................................23Assembly ...................................................................24Installation..................................................................24REAR DRUM BRAKE ...................................................25Removal .....................................................................26Inspection Wheel Cylinder ....................................27Wheel Cylinder Overhaul...........................................27Inspection Drum....................................................27Inspection Lining...................................................27Installation..................................................................27PARKING BRAKE CONTROL ......................................29Removal and Installation ...........................................30Inspection...................................................................30Adjustment .................................................................302WDREAR WHEEL ANTI-LOCK BRAKE SYSTEM ............31Purpose......................................................................31Operation ...................................................................31ABS Hydraulic Circuit ................................................31System Components .................................................32System Description....................................................32Removal and Installation ...........................................33TROUBLE DIAGNOSES ...............................................35How to Perform Trouble Diagnoses for Quickand Accurate Repair ..................................................35Preliminary Check......................................................37Component Parts and Harness ConnectorLocation .....................................................................38Schematic ..................................................................39Wiring Diagram ABS..............................................40Self-diagnosis ............................................................42Main Power Supply and Ground Circuit Check ........45TROUBLE DIAGNOSES FOR SELF-DIAGNOSTICITEMS.............................................................................46Diagnostic Procedure 1 .............................................46GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDiagnostic Procedure 2 .............................................46Diagnostic Procedure 3 .............................................47Diagnostic Procedure 4 .............................................48Diagnostic Procedure 5 .............................................48Diagnostic Procedure 6 .............................................48Diagnostic Procedure 7 (Warning lamp flashing5)................................................................................49TROUBLE DIAGNOSES FOR SYMPTOMS.................50Diagnostic Procedure 8 (ABS works frequently).......50Diagnostic Procedure 9 (Brake pedal stroke islarge)..........................................................................51Diagnostic Procedure 10 (Long stoppingdistance) ....................................................................51Diagnostic Procedure 11 (ABS does not work.)........52Diagnostic Procedure 12 (Pedal vibration ornoise) .........................................................................52Electrical Components Inspection .............................534WDANTI-LOCK BRAKE SYSTEM......................................54Purpose......................................................................54Operation ...................................................................54ABS Hydraulic Circuit ................................................54System Components .................................................55System Description....................................................55Removal and Installation ...........................................57TROUBLE DIAGNOSES ...............................................60How to Perform Trouble Diagnoses for Quickand Accurate Repair ..................................................60Preliminary Check......................................................62Component Parts and Harness ConnectorLocation .....................................................................63Schematic ..................................................................64Wiring Diagram ABS ........................................65Self-diagnosis ............................................................68CONSULT..................................................................71CONSULT Inspection Procedure...............................72Ground Circuit Check ................................................77TROUBLE DIAGNOSES FOR SELF-DIAGNOSTICITEMS.............................................................................78Diagnostic Procedure 1 (Wheel sensor or rotor) ......78Diagnostic Procedure 2 (ABS actuator solenoidvalve and solenoid valve relay) .................................80Diagnostic Procedure 3 (Motor relay or motor).........82Diagnostic Procedure 4 (Low voltage) ......................84Diagnostic Procedure 5 (G sensor)...........................85Diagnostic Procedure 6 (Control unit) .......................86TROUBLE DIAGNOSES FOR SYMPTOMS.................87Diagnostic Procedure 7 (ABS works frequently.) ......87Diagnostic Procedure 8 (Unexpected pedalaction) ........................................................................88Diagnostic Procedure 9 (Long stopping distance) ....88Diagnostic Procedure 10 (ABS does not work.) .......89Diagnostic Procedure 11 (Pedal vibration andnoise) .........................................................................89Diagnostic Procedure 12 (Warning lamp doesnot come on when ignition switch is turned ON.) .....90Diagnostic Procedure 13 (Warning lamp stays onwhen ignition switch is turned ON.)...........................92Electrical Components Inspection .............................94SERVICE DATA AND SPECIFICATIONS (SDS) ..........95General Specifications...............................................95Inspection and Adjustment ........................................96When you read wiring diagrams:GRead GI section, HOW TO READ WIRING DIAGRAMS.GSee EL section, POWER SUPPLY ROUTING for power distribution circuit.When you perform trouble diagnoses, read GI section, HOW TO FOLLOW FLOW CHARTINTROUBLEDIAGNOSES andHOWTOPERFORMEFFICIENTDIAGNOSISFORANELECTRICAL INCIDENT.CONTENTS(Contd.)BR-2Supplemental Restraint System (SRS)AIR BAGTheSupplemental Restraint SystemAIRBAG, usedalongwithaseat belt, helpstoreducetheriskorseverity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint Systemconsists of air bag modules (located in the center of the steering wheeland in the instrument panelon thepassenger side), a diagnosis sensor unit, a crash zone sensor (4WD models), warning lamp, wiring harnessand spiral cable.The vehicle is equipped with a passenger air bag deactivation switch. Because no rear seat exists where arear-facingchildrestraintcanbeplaced,theswitchisdesignedtoturnoffthepassengerairbagsothatarear-facing child restraint can be used in the front passenger seat. The switch is located in the center of theinstrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag isenabled and could inflate in a frontal collision. When the switch is turned to the OFF position, the passengerair bag is disabled and will not inflate in a frontal collision. A passenger air bag OFF indicator on the instru-ment panel lights up when the passenger air bag is switch OFF. The driver air bag always remains enabledand is not affected by the passenger air bag deactivation switch.Information necessary to service the system safely is included in the RS section of this Service Manual.WARNING:G To avoid rendering the SRS inoperative, which could increase the risk of personal injury or deathin the event of a collision which would result in air bag inflation, all maintenance should be per-formed by an authorized NISSAN dealer.G Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-sonal injury caused by unintentional activation of the system.G Do not use electrical test equipment on any circuit related to the SRS unless instructed to in thisServiceManual. SRSwiringharnessesarecoveredwithyellowinsulationeitherjustbeforetheharness connectors or on the complete harness, for easy identification.G The vehicle is equipped with a passenger air bag deactivation switch which can be operated bythe customer. When the passenger air bag is switched OFF, the passenger air bag is disabled andwill not inflate in a frontal collision. When the passenger air bag is switched ON, the passenger airbag is enabled and could inflate in a frontal collision. After SRS maintenance or repair, make surethe passenger air bag deactivation switch is in the same position (ON or OFF) as when the vehiclearrived for service.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPRECAUTIONS AND PREPARATIONBR-3SBR686CPrecautions for Brake SystemG Use brake fluid DOT 3.G Never reuse drained brake fluid.G Becareful nottosplashbrakefluidonpaintedareas;itmaycausepaint damage. If brakefluidissplashedonpainted areas, wash it away with water immediately.G To clean master cylinder parts, disc brake caliper parts orwheel cylinder parts, use clean brake fluid.G Never use mineral oils such as gasoline or kerosene. Theywill ruin rubber parts of the hydraulic system.G Use flare nut wrench when removing and installing braketubes.G Always torque brake lines when installing.G Burnishthebrakecontact surfacesafter refinishingorreplacing drums or rotors, after replacing pads or linings,or if asoft pedal occursat verylowmileage. Refer toBrake Burnishing Procedure, ON-VEHICLE SERVICE,BR-6.WARNING:G Clean brakes with a vacuum dust collector to minimize thehazard of airborne materials.Commercial Service ToolsTool name Description1 Flare nut crowfoot2 Torque wrenchNT360Removing and installing each brake pipinga: 10 mm (0.39 in)Brake fluid pressure gaugeNT151Measuring brake fluid pressurePRECAUTIONS AND PREPARATIONBR-4NVH Troubleshooting ChartUse the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.Reference pageBR-21,27BR-21,27BR-25BR-22BR-23,27BR-24BR-27NVHinPDsectionNVHinPDsectionNVHinFA,RAsectionNVHinFAsectionNVHinFAsectionNVHinRAsectionNVHinSTsectionPossible cause andSUSPECTED PARTSLiningsorpads-damagedLiningsorpads-unevenwearReturnspringdamagedShimsdamagedRotorordrumimbalanceRotorordrumdamageRotorordrumrunoutRotorordrumdeformationRotorordrumdeflectionRotorordrumrustRotorthicknessvariationDrumoutofroundPROPELLERSHAFTDIFFERENTIALAXLEANDSUSPENSIONTIRESROADWHEELDRIVESHAFTSTEERINGSymptom BRAKENoise X X X X X X X X X X XShake X X X X X X XShimmy, Judder X X X X X X X X X X X XX: ApplicableGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXNOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGBR-5SBR451DChecking Brake Fluid LevelG Check fluid level in reservoir tank. It should be between Maxand Min lines on reservoir tank.G If fluid level is extremely low, check brake system for leaks.G Ifthebrakewarninglampcomeson,checkbrakefluidlevelswitch and parking brake switch.SBR389CChecking Brake LineCAUTION:If leakageoccursaroundjoints, retightenor, if necessary,replace damaged parts.1. Check brake lines (tubes and hoses) for cracks, deteriorationor other damage. Replace any damaged parts.2. Checkfor oil leakagebyfullydepressingbrakepedal whileengine is running.SBR992Changing Brake FluidCAUTION:G Refill with new brake fluid DOT 3.G Always keep fluid level higher than minimum line on res-ervoir tank.G Never reuse drained brake fluid.G Becareful nottosplashbrakefluidonpaintedareas;itmaycausepaint damage. If brakefluidissplashedonpainted areas, wash it away with water immediately.1. Clean inside of reservoir tank, and refill with new brake fluid.2. Connect a vinyl tube to each air bleeder valve.3. Drainbrakefluidfromeachairbleedervalvebydepressingbrake pedal.4. Refill until brake fluid comes out of each air bleeder valve.Use same procedure as in bleeding hydraulic system to refillbrake fluid. Refer to Bleeding Brake System, BR-7.Brake Burnishing ProcedureBurnish the brake contact surfaces according to the following pro-cedure after refinishing or replacing drums or rotors, after replac-ing pads or linings, or if a soft pedal occurs at very low mileage.CAUTION:Only perform this procedure under safe road and traffic con-ditions. Use extreme caution.1. Drive the vehicle on a straight smooth road at 50 km/h(31 MPH).2. Usemediumbrakepedal/foot effort tobringthevehicletoacomplete stop from 50 km/h (31 MPH). Adjust brake pedal/footpressuresuchthat vehiclestoppingtimeequals3to5sec-onds.3. To cool the brake system, drive the vehicle at 50 km/h(31 MPH) for 1 minute without stopping.4. Repeat steps 1 to 3, 10 times or more to complete the burnish-ing procedure.ON-VEHICLE SERVICEBR-6SBR995Bleeding Brake SystemCAUTION:G Carefully monitor brake fluid level at master cylinder dur-ing bleeding operation.G If master cylinder is suspected to have air inside, bleed airfrommastercylinderfirst.RefertoInstallation,MAS-TER CYLINDER, BR-17.G Fill reservoir with new brake fluid DOT 3. Make sure it isfull at all times while bleeding air out of system.G Place a container under master cylinder to avoid spillageof brake fluid.G TurnignitionswitchOFFanddisconnect ABSactuator(2WD)/ABS actuator and electric unit (4WD) connector orbattery cable.G Bleed air in the following order.a. LSV air bleeder (Models equipped with LSV)b. Left rear brakec. Right rear braked. Left front brakee. Right front brakef . ABSactuator (2WD) or ABSactuator and electric unit(4WD)SBR419C1. Connect a transparent vinyl tube to air bleeder valve.2. Fully depress brake pedal several times.3. With brake pedal depressed, open air bleeder valve to releaseair.4. Close air bleeder valve.5. Release brake pedal slowly.6. Repeat steps 2 through 5 until clear brake fluid comes out ofair bleeder valve.7. Tighten air bleeder to the specified torque.: 7 - 9 Nm (0.7 - 0.9 kg-m, 61 - 78 in-lb)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXON-VEHICLE SERVICEBR-7ABR675ABR676BRAKE HYDRAULIC LINEBR-8SBR992REMOVALCAUTION:G Becareful nottosplashbrakefluidonpaintedareas;itmaycausepaint damage. If brakefluidissplashedonpainted areas, wash it away with water immediately.G All hoses must be free from excessive bending, twistingand pulling.1. Connect vinyl tube to air bleeder valve.2. Drainbrakefluidfromeachairbleedervalvebydepressingbrake pedal.3. Remove flare nut connecting brake tube and hose, then with-draw lock spring.4. Cover openings to prevent entrance of dirt whenever discon-necting brake line.INSPECTIONCheckbrakelines(tubesandhoses)forcracks, deteriorationorother damage. Replace any damaged parts.SBR686CINSTALLATIONCAUTION:G Refill with new brake fluid DOT 3.G Never reuse drained brake fluid.1. Tighten all flare nuts and connecting bolts.Flare nut:: 15 - 18 Nm (1.5 - 1.8 kg-m, 11 - 13 ft-lb)Connecting bolt:: 17 - 19 Nm (1.7 - 2.0 kg-m, 12 - 14 ft-lb)2. Refill until new brake fluid comes out of each air bleeder valve.3. Bleed air. Refer to Bleeding Brake System, BR-7.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXBRAKE HYDRAULIC LINEBR-9Load Sensing Valve (2WD)ABR700REMOVAL AND INSTALLATIONCAUTION:G Refill with new brake fluid DOT 3.G Becareful nottosplashbrakefluidonpaintedareas;itmaycausepaint damage. If brakefluidissplashedonpainted areas, wash it away with water immediately.1. Replace damaged load sensing valve linkage as an assembly.2. When disassembling, apply multi-purpose grease to linkage.3. Tighten all flare nuts and bolts.: 15 - 18 Nm (1.5 - 1.8 kg-m, 11 - 13 ft-lb)4. Bleed air. Refer to Bleeding Brake System, BR-7.CONTROL VALVEBR-10ABR782INSPECTION1. Ensure vehicle is unladen condition*.* Fuel,radiatorcoolantandengineoil full.Sparetire,jack,hand tools and mats in designated positions.2. Have a driver sit in the drivers seat and one person sit on therearofthevehicle. Thenhavethepersonontherearofthevehicle slowly get off. This is necessary to stabilize suspensiondeflection.3. Adjust length L as follows:a. Press lever to the stopper bolt, then check length L.Length L:Approx. 203 mm (7.99 in)b. If length L is not within specification, adjust spring length.SBR013B4. Install pressure gauge to front and rear brake air bleeder.5. Bleed air from the Tool.6. Raise front brake pressure to 4,904 kPa (49.0 bar, 50 kg/cm2,711 psi) and 9,807 kPa (98.1 bar, 100 kg/cm2, 1,422 psi) andcheck rear brake pressure.Rear brake pressure:Refer to table below.SBR014B7. Set down weight slowly over axle center so that sensor springlength becomes the same as when in loaded condition (refertotablebelow).Checkrearbrakepressureinthesamewaydescribed in step 6.Unit: kPa (bar, kg/cm2, psi)Front brakepressureRear brake pressureUnladenconditionL = 203 mm (7.99 in)LoadedconditionL = 208.0 mm (8.19 in)4,904(49.0, 50, 711)1,667 - 2,648(16.7 - 26.5, 17 - 27, 242 - 384)3,334 - 4,315(33.3 - 43.2, 34 - 44, 483 - 626)9,807(98.1, 100,1,422)2,844 - 3,825(28.4 - 38.2, 29 - 39, 412 - 555)3,629 - 5,590(36.3 - 55.9, 37 - 57, 526 - 811)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXCONTROL VALVELoad Sensing Valve (2WD) (Contd)BR-11ABR355Proportioning Valve (4WD)ABR184SBR705AAINSPECTIONCAUTION:G Carefully monitor brake fluid level at master cylinder.G Use new brake fluid DOT 3.G Becareful nottosplashbrakefluidonpaintedareas;itmaycausepaint damage. If brakefluidissplashedonpainted areas, wash it away with water immediately.G Depress pedal slowly when raising front brake pressure.G Checkrear brakepressure2secondsafter front brakepressure reaches specified value.G Disconnect harnessconnector fromABSactuator andelectric unit before checking.1. Remove front LH tire.2. Connect tool to air bleeders on front LH brake caliper and rearLH or RH brake wheel cylinder.3. Install front LH tire.Before installing front LH tire, confirm the tool is not touchingthe front LH wheel.4. Bleed air from the tool.5. Check fluid pressure by depressing brake pedal.Unit: kPa (kg/cm2, psi)Applied pressure (Front brake) D16,375 (65, 924)Output pressure (Rear brake) D23,334 - 3,825(34 - 39, 484 - 555)If output pressureisout of specification, replacemastercylinderassembly.6. Bleed air after disconnecting the tool. Refer to Bleeding BrakeSystem, BR-7.7. Install front LH tire.REMOVAL AND INSTALLATIONAlways replace together with master cylinder as an assembly.G Refer to MASTER CYLINDER, BR-15.BRAKE HYDRAULIC LINE/CONTROL VALVEBR-12Removal and InstallationABR815GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXBRAKE PEDAL AND BRACKETBR-13SBR997InspectionCheck brake pedal for following items:G Brake pedal bendG Clevis pin deformationG Crack of any welded portionG Crack or deformation of clevis pin stopperSBR278ABAdjustmentCheck brake pedal free height from metal floor.H: Free heightRefer to SDS, BR-96.D: Depressed heightRefer to SDS, BR-96.Under force of 490 N (50 kg, 110 lb)with engine runningC: Clearance between pedal stopper andthreaded end of stop lamp switch0.3 - 1.0 mm (0.012 - 0.039 in)A: Pedal free play at pedal pad1 - 3 mm (0.04 - 0.12 in)SBR930If necessary, adjust brake pedal free height.1. Loosen lock nut and adjust pedal free height by turning brakebooster input rod. Then tighten lock nut.G Make sure that the tip of input rod stays inside.2. Loosenlock nut andadjust clearanceC withstoplampswitch respectively, then tighten lock nut.3. Check pedal free play.G Make sure that stop lamp is off when pedal is released.4. Check brake pedals depressed height while engine is running.If lowerthanspecification, checkforleaks, airinsystem, ordamage to components (master cylinder, wheel cylinder, etc.).Make necessary repairs.BRAKE PEDAL AND BRACKETBR-14ABR679RemovalCAUTION:G Becareful nottosplashbrakefluidonpaintedareas;itmaycausepaint damage. If brakefluidissplashedonpainted areas, wash it away with water immediately.G In the case of brake fluid leakage from the master cylinder,disassemble the cylinder. Thencheck pistoncups fordeformation or scratches and replace necessary parts.1. Connect a vinyl tube to air bleeder valve.2. Drain brake fluid from each air bleeder valve, depressing brakepedal to empty fluid from master cylinder.3. Remove brake pipe flare nuts.4. Remove master cylinder mounting nuts.SBR938ADisassembly1. Bend claws of stopper cap outward.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXMASTER CYLINDERBR-15SBR939A2. Remove piston assemblies.G If it isdifficult toremovesecondarypistonassembly,gradually apply compressed air through fluid outlet.3. Draw out reservoir tank.InspectionCheck master cylinder inner wall for pin holes or scratches.Replace if damaged.ABR680Assembly1. Insert secondary piston assembly. Then insert primary pistonassembly.G Pay attention to direction of piston cups in figure at left.Also, insert pistons squarely to avoid scratches on cylin-der bore.ABR681SBR940A2. Install stopper cap.G Before installing stopper cap, ensure that claws are bentinward.3. Push reservoir tank seals into cylinder body.4. Push reservoir tank into cylinder body.MASTER CYLINDERDisassembly (Contd)BR-16ABR190InstallationCAUTION:G Refill with new brake fluid DOT 3.G Never reuse drained brake fluid.1. Place master cylinder onto brake booster and secure mount-ing nuts lightly.2. Tighten mounting nuts.: 12 - 15 Nm (1.2 - 1.5 kg-m, 9 - 11 ft-lb)3. Fill up reservoir tank with new brake fluid.4. Plugall portsonmaster cylinder withfingerstoprevent airsuction while releasing brake pedal.5. Have driver depress brake pedal slowly several times until noair comes out of master cylinder.6. Fit brake lines to master cylinder.7. Tighten flare nuts.: 15 - 18 Nm (1.5 - 1.8 kg-m, 11 - 13 ft-lb)8. Bleed air frombrake system. Refer to Bleeding BrakeSystem, BR-7.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXMASTER CYLINDERBR-17SBR002AOn-vehicle ServiceOPERATING CHECKG Depress brake pedal several times with engine off. Afterexhaustingvacuum, makesurethereisnochangeinpedalstroke.G Depressbrakepedal, thenstart engine. If pedal goesdownslightly, operation is normal.SBR365AAAIRTIGHT CHECKG Start engine, andstopit after oneor twominutes. Depressbrakepedal several timesslowly. Boosterisairtight if pedalstroke is less each time.G Depress brake pedal while engine is running, and stop enginewithpedal depressed. Thepedal strokeshouldnot changeafter holding pedal down for 30 seconds.ABR373RemovalCAUTION:G Becareful nottosplashbrakefluidonpaintedareas;itmaycausepaint damage. If brakefluidissplashedonpainted areas, wash it away with water immediately.G Be careful not todeformor bendbrake pipes duringremoval of booster.ABR749InspectionOUTPUT ROD LENGTH CHECK1. Applyvacuumof 66.7kPa(500mmHg, 19.69inHg) tobrake booster with a handy vacuum pump.2. Add preload of 19.6 N (2 kg, 4.4 lb) to output rod.3. Check output rod length.Specified length:10.275 - 10.525 mm (0.4045 - 0.4144 in)BRAKE BOOSTERBR-18SBR116BEInstallationCAUTION:G Be careful not to deform or bend brake pipes during instal-lation of booster.G Replace clevis pin if damaged.G Refill with new brake fluid DOT 3.G Never reuse drained brake fluid.G Takecarenot todamagebrakebooster mountingboltthreads when installing. Due to the narrowangle ofinstallation, thethreadscanbedamagedbythedashpanel.A: 2WD160 mm (6.30 in)4WD165 mm (6.50 in)1. Beforefittingbooster, temporarilyadjust clevistodimensionshown.2. Fit booster, then secure mounting nuts (brake pedal bracket tobrake booster) lightly.3. Connect brake pedal and booster input rod with clevis pin.4. Secure mounting nuts.: 13 - 16 Nm (1.3 - 1.6 kg-m, 9 - 12 ft-lb)5. Install master cylinder. Refer to Installation, MASTERCYLINDER, BR-17.6. Adjust brake pedal height and free play. Refer to BR-14.7. Secure lock nut for clevis.: 16 - 22 Nm (1.6 - 2.2 kg-m, 12 - 16 ft-lb)8. Bleed air. Refer to Bleeding Brake System, BR-7.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXBRAKE BOOSTERBR-19SBR225BRemoval and InstallationCAUTION:When installing vacuum hoses, pay attention to the followingpoints.G Donot applyanyoil orlubricantstovacuumhoseandcheck valve.G Insert vacuum tube into vacuum hose as shown.SBR498AGInstall check valve, paying attention to its direction.InspectionHOSES AND CONNECTORSCheck vacuum lines and connections and check valve forairtightness, improper attachment, chafing and deterioration.SBR943ACHECK VALVECheck vacuum with a vacuum pump.Connect to boostersideVacuum should exist.Connect to enginesideVacuum should not exist.VACUUM HOSEBR-20Pad ReplacementWARNING:Clean brake pads with a vacuum dust collector to minimize thehazard of airborne materials.CAUTION:G When cylinder body is open, do not depress brake pedalor caliper piston will pop out.G Be careful not to damage piston boot or get oil on rotor.Always replace shims when replacing pads.G If shimsarerustedorshowpeelingof therubbercoat,replace them with new shims.G It is not necessary to remove connecting bolt except fordisassemblyorreplacementofcaliperassembly. Inthiscase, suspend cylinder body with wire so as not to stretchbrake hose.G Burnishthebrakecontact surfacesafter refinishingorreplacing drums or rotors, after replacing pads or linings,or if asoft pedal occursat verylowmileage. Refer toBrake Burnishing Procedure, ON-VEHICLE SERVICE,BR-6.SBR081A1. Remove master cylinder reservoir cap.2. Remove lower pin bolt.SBR010B3. Open cylinder body upward. Then remove pad retainers, returnspring and inner and outer shims.Standard pad thickness:10 mm (0.39 in)Pad wear limit:2.0 mm (0.079 in)G Carefully monitor brake fluid level because brake fluid willreturn to reservoir when pushing back piston.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXFRONT DISC BRAKEBR-21SBR983DSBR083ARemovalWARNING:Clean brake pads with a vacuum dust collector to minimize thehazard of airborne materials.CAUTION:Suspend caliper assembly with wire so as not to stretch brakehose.Remove torque member fixing bolts and connecting bolt.G It is not necessary to remove connecting bolt except fordisassemblyorreplacementofcaliperassembly. Inthiscase, suspendcaliper assemblywithwiresoasnot tostretch brake hose.FRONT DISC BRAKEBR-22SBR085ADisassemblyWARNING:Do not place your fingers in front of piston.CAUTION:G Do not scratch or score cylinder wall.G CL28VD type front disc brake uses plastic pistons. Handlethem carefully.1. Push out pistons and dust covers with compressed air.Use a wooden block so that both pistons come out evenly.2. Remove piston seals with a suitable tool.Inspection CaliperCYLINDER BODYG Check inside surface of cylinders for scores, rust, wear, dam-age or presence of foreign objects. If any of the above condi-tions are observed, replace cylinder body.G Minor damage from rust or foreign objects may be eliminatedby polishing the surface with a fine emery sandpaper. Replacecylinder body if necessary.CAUTION:Use brake fluid to clean. Never use mineral oil.SBR177CPISTONCAUTION:Piston sliding surface is plated. Do not polish with emery sand-paper even if rust or foreign objects are stuck to sliding surface.Check pistons for uneven surface, chips or cracks. Replace if anyof these conditions are observed.SLIDE PIN, PIN BOLT AND PIN BOOTCheck for wear, cracks or other damage. Replace if any of theseconditions are observed.SBR089AInspection RotorRUNOUT1. Check runout using a dial indicator.G Makesurethat wheel bearingaxial endplayiswithinspecification before measuring. Refer to FA section(Front Wheel Bearing, ON-VEHICLE SERVICE).Maximum runout:0.07 mm (0.0028 in)2. If the runout is out of specification, machine rotor with on-carbrakelathe(MAD, DL-8700, AMMCO700and705 orequivalent).GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXFRONT DISC BRAKEBR-23SBR090ATHICKNESSThickness variation (At least 8 positions):Maximum 0.02 mm (0.0008 in)If thickness variation exceeds specification, machine rotor with on-car brake lathe.Rotor repair limit:24.0 mm (0.945 in)SBR178CAssembly1. Insert piston seal into groove on cylinder body.2. With piston boot fitted to piston, insert piston boot into grooveon cylinder body and install piston.3. Properly secure piston boot.CAUTION:G Secure dust seal properly.G Lubricate with new brake fluid before installing plastic pis-tons into cylinder body.SBR179CASBR084AInstallationCAUTION:G Refill with new brake fluid DOT 3.G Never reuse drained brake fluid.1. Install caliper assembly.2. Install brake hose to caliper securely.3. Install all parts and secure all bolts.4. Bleed air. Refer to Bleeding Brake System, BR-7.FRONT DISC BRAKEInspection Rotor (Contd)BR-24SBR979DSBR978DGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXREAR DRUM BRAKEBR-25RemovalWARNING:Cleanbrakeliningwithavacuumdustcollectortominimizethe hazard of airborne materials.CAUTION:Make sure parking brake lever is completely released.SBR280B1. Release parking brake lever fully, then remove drum.G If drum is hard to remove, the following procedure shouldbe carried out.a. Removeplug, thenshortenadjuster tomakeclearancebetween brake shoe and drum.SBR093Ab. Install two bolts as shown. Tighten the two bolts gradually.ABR3692. After removing retainer, remove spring by rotating shoes.G Be careful not to damage wheel cylinder piston boots.G Be careful not to damage parking brake cable when sepa-rating it.3. Remove adjuster.4. Disconnect parking brake cable from toggle lever.ABR4085. Remove retainer clip with a suitable tool. Then separate togglelever and brake shoe.REAR DRUM BRAKEBR-26ABR370Inspection Wheel CylinderG Check wheel cylinder for leakage.G Check for wear, damage and loose conditions.Replace if any such condition exists.SBR215BWheel Cylinder OverhaulG Check all internal parts for wear, rust and damage. Replace ifnecessary.G Pay attention not to scratch cylinder when installing pistons.SBR095AInspection DrumMaximum inner diameter (Repair limit):LT26B 261.5 mm (10.30 in)LT30A 296.5 mm (11.67 in)G Contact surface should be finished with No. 120 to 150 emerysandpaper.G Usingabrakelathe, machinebrakedrumif it showsscoremarks, partial wear or stepped wear.G After brake drumhas been completely reconditioned orreplaced, check drum and shoes for proper contact pattern.SBR021AInspection LiningCheck lining thickness.Standard lining thickness:LT26B 5.5 mm (0.217 in)LT30A 6.1 mm (0.240 in)Lining wear limit (A):LT26B 1.5 mm (0.059 in)LT30A 1.5 mm (0.059 in)ABR371InstallationG Always performshoe clearance adjustment. Refer toBR-30.G Burnishthebrakecontact surfacesafter refinishingorreplacing drums or rotors, after replacing pads or linings,or if asoft pedal occursat verylowmileage. Refer toBrake Burnishing Procedure, ON-VEHICLE SERVICE,BR-6.1. Fit toggle lever to brake shoe with retainer clip.2. Apply brake grease to the contact areas shown at left.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXREAR DRUM BRAKEBR-27ABR3963. Shorten adjuster by rotating it.G Pay attention to direction of adjuster.Wheel ScrewLeft Left-hand threadRight Right-hand thread4. Connect parking brake cable to toggle lever.5. Install all parts.G Be careful not to damage wheel cylinder piston boots.ABR3726. Check all parts are installed properly.G After installation is completed, adjust shoe-to-drum clear-ance.7. Install brake drum.8. When installing newwheel cylinder or overhauling wheelcylinder, bleed air. Refer to Bleeding Brake System, BR-7.9. Adjust parking brake. Refer to BR-30.G Install all the parts by referring to the figure below.SBR099ALT30A modelG After installing crank lever on back plate, make sure that thereis no play between crank lever and back plate. If play exists,adjust boltA and lock nutB .SBR100CAREAR DRUM BRAKEInstallation (Contd)BR-28ABR814GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPARKING BRAKE CONTROLBR-29Removal and InstallationG Be careful not to damage cable.G Make sure there is no free play after installation.Inspection1. Check control lever for wear or other damage. Replace if nec-essary.2. Check wires for discontinuity or deterioration. Replace if nec-essary.3. Check warning lamp and switch. Correct if necessary.4. Check part at each connecting portion and, if found deformedor damaged, replace.SBR980DAdjustmentAdjust parking brake as follows:1. Fully release parking brake lever.2. LoosenA and rotateB until parking brake cable loosens.3. Depressbrakepedal several timesuntil clickingsounddoesnot occur from rear brakes.4. Adjust clearance between rear brake shoe and drum.5. Adjust parking brake lever stroke by rotatingB .6. Pull parking brake lever with specified force. Check leverstroke and ensure smooth operation.7. Readjust clearance between rear brake shoe and drum.ABR701ABR405PARKING BRAKE CONTROLBR-30PurposeThe Rear Wheel Anti-Lock Brake System (ABS) consists of electronic and hydraulic components. It controlsrear braking force so locking of the rear wheels can be avoided.The ABS:1) Improves proper tracking performance during severe braking.2) Eases obstacle avoidance during severe braking.3) Improves vehicle stability.OperationG When the vehicle speed is less than 10 km/h (6 MPH) this system does not work.G The Rear Wheel Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABSwarning lamp for a few seconds each time the ignition switch is turned ON. After the engine is started, theABS warning lamp turns off. The system performs a circuit check when the ignition switch is first turnedON. If a malfunction is found during this check, the ABS warning lamp will stay on.G While driving, a mechanical noise may be heard and slight pedal pulsation may be felt during ABS opera-tion. This is a normal condition.ABS Hydraulic CircuitABR406GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXREAR WHEEL ANTI-LOCK BRAKE SYSTEM2WDBR-31System ComponentsABR783ABR665System DescriptionREAR SENSORThe rear sensor unit consists of a gear-shaped sensor rotor and asensor unit. The sensor unit consists of a bar magnet around whichacoil iswound. Thesensor rotor isinstalledonthecompanionflange and the sensor unit is installed on the rear axle housing. Asine-wave current is generated by the rear sensor unit as the rearaxlepinionrotates. Thefrequencyandvoltageincreaseastherotating speed increases.ABR403ABS CONTROL UNITThe ABS control unit computes the rear axle pinion rotating speedby reading the signal from the rear sensor unit. Then it supplies aDCcurrent totheABSactuator. If anyelectrical malfunctionisdetected in the system, the ABS control unit causes the ABS warn-ing lamp to turn on. In this condition, the ABS system will be deac-tivatedbytheABScontrol unit, andthevehiclesbrakesystemreverts to normal operation.REAR WHEEL ANTI-LOCK BRAKE SYSTEM2WDBR-32Removal and InstallationCAUTION:Be careful not to damage sensor edge and sensor rotor teeth.In case the final drive assembly needs to be removed, discon-nect theABSsensorfromtheassemblyandmoveit away.Failuretodosomayresult indamagetothesensorwiresmaking the sensor inoperative.For final drive models using collapsible spacer (H190A, C200),bearing preload must be adjusted whenever companion flangeis removed. Therefore, final drive overhaul is required.REAR SENSOR AND CONTROL UNITABR695GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXREAR WHEEL ANTI-LOCK BRAKE SYSTEM2WDBR-33ABR784ACTUATORRemoval1. Disconnect battery cable.2. Drain brake fluid.Refer to Changing Brake Fluid, BR-6.3. Disconnect connectors, brakepipesandremovefixingboltsand flare nuts.ABR788InstallationCAUTION:After installation, refill brakefluid. Thenbleedair. Refer toBleeding Procedure, BR-7.1. Connect brake pipes temporarily.2. Secure fixing bolts.3. Torque brake pipe flare nuts.4. Connect connectors and battery cable.REAR WHEEL ANTI-LOCK BRAKE SYSTEM2WDRemoval and Installation (Contd)BR-34SEF233GSEF234GHow to Perform Trouble Diagnoses for Quickand Accurate RepairINTRODUCTIONTheABSsystemhasanelectroniccontrol unit tocontrol majorfunctions. The control unit accepts input signals from sensors andinstantly drives the actuators. It is essential that both kinds of sig-nals are proper and stable. It is also important to check for conven-tional problemssuchasairleaksinboosterlines, lackof brakefluid, or other problems with the brake system.It is much more difficult to diagnose a problem that occurs intermit-tently rather than continuously. Most intermittent problems arecaused by poor electric connections or faulty wiring. In this case,careful checking of suspicious circuits may help prevent thereplacement of good parts.A visual check only may not find the cause of the problems, so aroad test should be performed.Before undertaking actual checks, take a few minutes to talk witha customer who approaches with an ABS complaint. The customeris a very good source of information on such problems; especiallyintermittent ones. Throughthetalkswiththecustomer, findoutwhat symptoms are present and under what conditions they occur.Start yourdiagnosisbylookingforconventional problemsfirst.This is one of the best ways to troubleshoot brake problems on anABS controlled vehicle.Also check related service bulletins for information.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES2WDBR-35WORK FLOWCHECK IN Reference itemLISTEN TO CUSTOMER COMPLAINTSINVESTIGATE ITEMS YOU SHOULD CARRY OUTRELATED TO EACH SYMPTOM AND NOTEGo to MALFUNCTIONCODE/SYMPTOMCHART, BR-44.CHECK FOR ANY SERVICE BULLETINS.ELIMINATE GOOD SYSTEMS AND GOOD PARTSGo to PreliminaryCheck, BR-37.Not self-diagnostic item Self-diagnostic itemDETERMINE MALFUNC-TIONING CIRCUIT(S) ORPART(S).Go to Self-diagnosis,BR-42.Self-diagnosisELIMINATE GOOD PART(S), HARNESS(ES) OR CON-NECTOR(S) THROUGH ELECTRICAL TESTINGGGo to DiagnosticProcedure(s) 8 - 12,BR-50 - 52.GGo to ComponentParts and HarnessConnector Location,BR-38.Malfunctioningharness(es) andconnector(s)Malfunctioning partsINSPECTION OF EACHCOMPONENT Go to Diagnostic Pro-cedure(s) 1 - 7, BR-46 -49.REPAIRREPAIR OR REPLACENGFINAL CHECKOKCHECK OUTTROUBLE DIAGNOSES2WDHow to Perform Trouble Diagnoses for Quickand Accurate Repair (Contd)BR-36SBR451DPreliminary CheckSBR389CSBR058CSBR059CABR665Check brake fluid level in reservoirtank.Low fluid level may indicate brake padwear or leakage from brake line.Check brake line for leakage.OKNGRepair.Check brake booster for operation and airtightness. Refer to BR-19.OKNGReplace.Check brake pads, rotors, linings anddrums. Refer to BR-27.OKNGReplace.Check brake fluid level in reservoir tankagain.OKNGFill up brake fluid.Check warning lamp activation.When ignition switch is turned ON, warn-ing lamp turns on.OKNGCheck fuse, warning lampbulb and warning lamp cir-cuit.Check warning lamp for deactivation afterengine is started.OKNGGo to Self-diagnosis,BR-42.Drive vehicle at speeds over 40 km/h (25MPH) for at least one minute.Ensure warning lamp remains off whiledriving.OKNGGo to Self-diagnosis,BR-42.ENDGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES2WDBR-37Component Parts and Harness ConnectorLocationABR785TROUBLE DIAGNOSES2WDBR-38SchematicABR567GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES2WDBR-39Wiring Diagram ABSABR571TROUBLE DIAGNOSES2WDBR-40ABR808GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES2WDWiring Diagram ABS (Contd)BR-41Self-diagnosisCHECKING THE NUMBER OF WARNING LAMP FLASHESWhen a problem occurs in the ABS, the ABS warning lamp on the instrument panel turns on. As shown in thetable, the control unit performs self-diagnosis.To obtain satisfactory self-diagnosing results, the vehicle must be driven above 40 km/h (25 MPH) for at leastone minute before the self-diagnosis is performed. After the vehicle has been stopped, the number of ABSwarning lamp flashes is counted by grounding the check terminal, with the engine running, thereby identify-ing a malfunctioning part or unit by the number of flashes.If more than two parts or units malfunction at the same time, the ABS warning lamp will flash to indicate oneof the malfunctioning parts or units. After the part or unit has been repaired, the ABS warning lamp will thenflash to indicate that the other part or unit is malfunctioning.TROUBLE DIAGNOSES2WDBR-42ABR665SELF-DIAGNOSIS PROCEDURE 1ABR664ABR665ABR7861. Turn ignition switch ON.2. Check warning lamp activation.When ignition switch is turned on, warn-ing lamp should turn on.OKNGGo to Main Power Supplyand Ground CircuitCheck, BR-45.If OK, replace ABS controlunit.Check warning lamp deactivates within afew seconds.OKNGGo to Self-Diagnosis Pro-cedure 2, BR-44.Check warning lamp reactivation.OKNGGo to Self-Diagnosis Pro-cedure 2, BR-44.Drive vehicle for 1 minute or more at 40km/h (25 MPH) or more.Does warning lamp activate again?NoYesGo to Self-Diagnosis Pro-cedure 2, BR-44.1. Stop engine.2. Turn ignition switch ON.Check actuator clicking noise, whenwarning lamp turns off.NGOKSelf-operating function isOK.Check actuator.Go to Electrical Component Inspection,BR-53.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES2WDSelf-diagnosis (Contd)BR-43ABR696SELF-DIAGNOSIS PROCEDURE 21. Start engine.2. Ground the check terminal of check con-nector.3. Check the warning lamp flashing.YesNo Check brake fluid level.Go to Main Power Supplyand Ground Circuit Check,BR-45.OKReplace ABS control unit.Count the number of flashes.Go to MALFUNCTION CODE/SYMPTOMCHART below.MALFUNCTION CODE/SYMPTOM CHARTCode No./Symptom(No. of warning lamp flashes)Malfunctioning part Diagnostic Procedure2 Actuator ISO solenoid (open-circuit) 17 Actuator ISO solenoid (short-circuit) 14 Actuator ISO solenoid (blocked) 23 Actuator DUMP solenoid (open-circuit) 38 Actuator DUMP solenoid (short-circuit) 39 Rear sensor (open-circuit) 410 Rear sensor (short-circuit) 46 Rear sensor (erratic) 513Control unit 6 141516 None (system OK) None5 Other 7Pedal vibration or noise 12Long stopping distance 10Brake pedal stroke is large 9ABS does not work 11ABS works frequently 8TROUBLE DIAGNOSES2WDSelf-diagnosis (Contd)BR-44ABR624Main Power Supply and Ground Circuit CheckABR625ABR626ABR627ABR628CHECK WARNING LAMP POWER SUP-PLY.1. Connect battery cable and confirm bat-tery voltage is 12V.2. Disconnect ABS control unit connector.3. Turn ignition switch ON.4. Do approx. 12 volts exist between ABScontrol unit connector terminals2 and11 ?YesNoCHECK GROUND CIR-CUIT.Check harness continuitybetween ABS control unitterminal11 and suitablebody ground.Continuity should exist.OK NGRepair har-ness orconnectors.Check and replace fuse orwarning lamp if necessary.Repair ignition harness,relay and warning lampconnectors.CHECK ABS CONTROL UNIT POWERSUPPLY.1. Turn ignition switch ON.2. Do approx. 12 volts exist between ABScontrol unit connector terminals12 ,3and11 ?YesNoCheck and replace fuse orrepair harness and connec-tors.CHECK STOP LAMP SWITCH POWERSUPPLY.1. Depress brake pedal.2. Do approx. 12 volts exist between ABScontrol unit connector terminals8and11 ?YesNoAdjust stop lamp switch ifnecessary. Replace stoplamp switch, if necessary,or repair harness or con-nectors.CHECK PARKING BRAKE SWITCHPOWER SUPPLY.1. Confirm that brake fluid level isadequate.If necessary, refill it.2. Start engine.3. Do approx. 12 volts exist between ABScontrol unit connector terminals5 and11 without parking brake applied?Do approx. 0 volts exist with parkingbrake applied?NoAdjust parking brakeswitch, if necessary.Replace parking brakeswitch, if necessary, orrepair harness or connec-tors.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES2WDBR-45ABR629Diagnostic Procedure 1ABS ACTUATOR ISO SOLENOID SHORT CIRCUIT OROPEN (Warning lamp flashing number 2 or 7)ABR630ABR631Remove battery negative terminal connec-tor.CHECK ISO SOLENOID.Check resistance between ABS controlunit connector terminals1 and11 .Resistance: Approximately 4NGOKReplace ABS control unit.CHECK ABS CONTROL UNIT GROUNDCIRCUIT.Go to Main Power Supply and GroundCircuit Check, BR-45.OKNGRepair harness or connec-tors.CHECK ABS ACTUATOR GROUND CIR-CUIT.Check harness continuity between ABSactuator terminal2 and suitable bodyground.OKNGRepair harness or connec-tors.CHECK ISO SOLENOID.Check resistance between ABS actuatorconnector terminals2 and3.Resistance: Approximately 4NGOKRepair harness and con-nectors between ISO sole-noid and ABS control unit.Replace ABS actuator.ABR632ABR787Diagnostic Procedure 2ABS ACTUATOR ISO SOLENOID BLOCKED (Warninglamp flashing number 4)Remove battery negative terminal connector.CHECK ABS ACTUATOR SWITCH.Does continuity exist between ABS controlunit terminal4 and suitable bodyground?Continuity should not exist.NGOKReplace ABS control unit.Does continuity exist between ABS actua-tor terminal4 and suitable body ground?Continuity should not exist.OKNGReplace ABS actuator.Repair harness and connectors betweenABS actuator and ABS control unit.TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS2WDBR-46ABR634ABR635ABR636Diagnostic Procedure 3ABS ACTUATOR DUMP SOLENOID SHORT CIRCUIT OROPEN (Warning lamp flashing number 3 or 8)Remove battery negative terminalconnector.CHECK DUMP SOLENOID.Check resistance between ABS controlunit connector terminals17 and11 .Resistance:Approximately 1.5NGOKReplace ABS control unit.CHECK ABS CONTROL UNIT GROUNDCIRCUIT.Go to Main Power Supply and GroundCheck, BR-45.OKNGRepair harness orconnectors.CHECK ABS ACTUATOR GROUNDCIRCUIT.Check harness continuity between ABSactuator terminal2 and suitable bodyground.OKNGRepair harness orconnectors.CHECK DUMP SOLENOID.Check resistance between ABS actuatorconnector terminals1 and2.Resistance:Approximately 1.5NGOKRepair harness orconnectors between dumpsolenoid and ABS controlunit.Replace ABS actuator.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS2WDBR-47ABR637Diagnostic Procedure 4ABR638REAR SENSOR OPEN OR SHORT CIRCUIT (Warninglamp flashing number 9 or 10)Remove battery negative terminal connec-tor.CHECK REAR SENSOR.Check resistance between ABS controlunit connector terminals10 and9.Resistance:1.05 - 1.35 kNGOKReplace ABS control unit.Check resistance between rear sensorunit connector terminals8 and9.Resistance:1.05 - 1.35 kNGOKRepair harness or connec-tors between ABS controlunit and rear sensor.Replace rear sensor unit.Diagnostic Procedure 5SENSOR SIGNAL ERRATIC (Warning lamp flashingnumber 6)CHECK REAR SENSOR ROTOR TOOTHCONDITION.1. Remove propeller shaft.2. Remove companion flange, refer toDISASSEMBLY in PD section.3. Check rotor on companion flange.OKNGReplace rear sensor rotorwith companion flange.Replace ABS control unit.Diagnostic Procedure 6ABS CONTROL UNIT (Warning lamp flashing 13, 14 or15)ABS control unit malfunction.Replace ABS control unit.TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS2WDBR-48Diagnostic Procedure 7 (Warning lamp flashing5)Overhaul both rear brakes.Go to SELF-DIAGNOSIS PROCEDURE1, BR-43.Check whether system is OK.NGOKInspection ENDCheck whether warning lamp flashing isstill 5.NoYesReplace ABS actuator.Inspect system again referring to numberof warning lamp flashes.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS2WDBR-49SBR013BDiagnostic Procedure 8 (ABS works frequently)CHECK BRAKE FLUID PRESSURE.Check whether brake fluid pressure distri-bution is normal.Refer to BR-12.OKNGReplace master cylinder.Perform usual brake inspection.OKNGRepair.When wheel lock occurs frequently due tohard braking operation, the ABS operatesat each occurrence of wheel lock.Accordingly, frequent ABS operation isnormal under severe braking conditionswhere wheel lock would occur frequentlydue to braking.TROUBLE DIAGNOSES FOR SYMPTOMS2WDBR-50SAT797ADiagnostic Procedure 9 (Brake pedal stroke islarge)Check whether the symptom usuallyappears.YesNoVehicles equipped withABS may have a tendencyto increase pedal strokeduring operation.Check for accumulation of air by trying tobleed air.NoPerform brake inspection.Refer to BR-21.SBR530ADiagnostic Procedure 10 (Long stoppingdistance)Check if road condition is slippery withsnow or gravel.NoYesStopping distance may belonger than vehicles whichare not equipped with ABS.Disconnect ABS actuator connector andcheck whether stopping distance is stilllong.YesNoConnect ABS actuator con-nector.Go to Self-Diagnosis Pro-cedure 1, BR-43.Perform usual brake inspection and airbleeding.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR SYMPTOMS2WDBR-51Diagnostic Procedure 11 (ABS does not work.)Check whether warning lamp activates.Go to Self-Diagnosis Procedure 1,BR-43.NoYesGo to Self-Diagnosis Pro-cedure 2, BR-44.Check whether vehicle speed is under 10km/h (6 MPH).NoYesABS does not work in thiscondition.Check ABS actuator and rear sensor.Go to Electrical Component Inspection,BR-53.OKNGReplace damaged parts.Check main power supply and ground cir-cuit.Go to Main Power Supply and GroundCircuit Check, BR-45.OKNGRepair faulty part.Check operation of ABS.Refer to in Electrical ComponentInspection, BR-53.NGReplace ABS control unit.SAT797ADiagnostic Procedure 12 (Pedal vibration ornoise)Check whether the symptom appears onlywhen brake is applied suddenly.NoYesWhen brake is suddenlyapplied, ABS works andproduces pedal vibration ornoise.Check whether the noise only appearsand warning lamp only activates anddeactivates when the ignition switch isturned on.YesSelf-operation of ABS func-tions properly.TROUBLE DIAGNOSES FOR SYMPTOMS2WDBR-52SBR373DElectrical Components InspectionREAR SENSOR UNIT AND ACTUATORABR639ABR786SBR545BABR640CHECK REAR SENSOR SIGNAL.1. Raise vehicle. Confirm it is safe torotate rear wheels.2. Start engine and rotate rear wheelswith transmission in D position or firstgear position.3. Check rear sensor signal voltagebetween control unit terminals10 and9 with AC voltmeter.Voltage: 0.4V or moreM/T at 700 rpmA/T at 850 rpmOKNGCHECK REAR SENSORROTOR for followingpoints:G Tooth conditionG Installation on compan-ion flangeG DeformationG WearG LoosenessNG OKReplacerear sensorrotor withcompanionflange.Replacerear sensorunit.CHECK ABS ACTUATOR OPERATION.Go to Self-diagnosis Procedure 2,BR-44. Clicking noise sounds fromactuator, when the ignition switch isturned on with battery cable connected.OKNGCHECK PULSING VOLT-AGE FROM ABS CON-TROL UNIT.Check pulsing voltage forISO and DUMP solenoidbetween ABS control unitterminals17 and11 , andterminals1 and11 .Voltage: 0.3 - 3.5V forapprox. 13 msec.Use suitable digital voltme-ter. Pulsing voltageappears when ABS warn-ing lamp goes off after igni-tion is turned on.NG OKCHECK ABS OPERATION as follows:1. Perform ABS check in a safe placewithout obstacles in the vicinity.2. Drive the vehicle for more than oneminute at speeds over 40 km/h (25MPH), then check that the warninglamp does not light on the instrumentpanel. After this, check for operation.3. Check if ordinary braking effect occurs,and also check that the rear wheels donot lock when abrupt braking causesthe front wheels to lock.OK NGReplaceABS con-trol unit.ReplaceABS actua-tor.ABS is in goodcondition.Replace ABSactuator.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR SYMPTOMS2WD BR-53PurposeThe Anti-Lock Brake System (ABS) consists of electronic and hydraulic components. It allows for control ofbraking force so locking of the wheels can be avoided.The ABS:1) Improves proper tracking performance through steering wheel operation.2) Eases obstacle avoidance through steering wheel operation.3) Improves vehicle stability.OperationG When the vehicle speed is less than 10 km/h (6 MPH) this system does not work.G The Anti-Lock Brake System (ABS) has a self-test function. The system turns on the ABS warning lampfor 1 second each time the ignition switch is turned ON. After the engine is started, the ABS warninglamp turns off. The system performs a test the first time the vehicle reaches 6 km/h (4 MPH). A mechani-cal noise may be heard as the ABS performs this self-test. This is a normal part of the self-test feature. Ifa malfunction is found during this check, the ABS warning lamp will stay on.G While driving, a mechanical noise may be heard during ABS operation. This is a normal condition.ABS Hydraulic CircuitSBR859D1 Inlet solenoid valve2 Outlet solenoid valve3 Reservoir4 Pump5 Motor6 Inlet valve7 Outlet valve8 Bypass check valve9 DamperANTI-LOCK BRAKE SYSTEM4WDBR-54System ComponentsABR809System DescriptionWHEEL SENSORThe sensor unit consists of a gear-shaped sensor rotor and a sen-sor element. The element contains a bar magnet around which acoil is wound. The sensor is installed on the back of the brake rotorandthebackof therear brakedrum.Asthewheel rotates, thesensor generates a sine-wave pattern. The frequency and voltageincrease(s) as the rotating speed increases.ABR665CONTROL UNIT (built-in ABS actuator and electric unit)The control unit computes the wheel rotating speed by the signalcurrent sent from the sensor. Then it supplies a DC current to theactuator solenoid valve. It also controls ON-OFF operation of thevalve relay and motor relay. If any electrical malfunction should bedetected in the system, the controlunit causes the warning lamptolight up. Inthiscondition, theABSwill bedeactivatedbythecontrol unit, andthevehicles brakesystemreverts tonormaloperation. (For control unit layout, refer to ABS ACTUATOR ANDELECTRIC UNIT, BR-56.)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXANTI-LOCK BRAKE SYSTEM4WDBR-55G SENSORThe G sensor senses deceleration during braking to determine whether the vehicle is being driven on a high road (asphalt road, etc.) or a low road (snow-covered road, etc.). It then sends a signal to the ABS con-trol unit.ABR717The reed switch turns on when it is affected by a magnetic field. During sudden deceleration (braking on ahigh road), the weight moves and the magnet in the weight moves away from the reed switch. The mag-netic field then diminishes and the reed switch turns off.SBR071EABS ACTUATOR AND ELECTRIC UNITThe ABS actuator and electric unit contains:G An electric motor and pumpG Two relaysG Six solenoid valves, each inlet and outlet for LH front RH front RearG ABS control unitThis component controls the hydraulic circuit and increases, holdsor decreaseshydraulicpressuretoall or individual wheels. TheABS actuator and electric unit is serviced as an assembly.ABS actuator operationInlet solenoidvalveOutlet solenoidvalveNormal brake operation OFF (Open) OFF (Closed)Master cylinder brake fluid pressure is directly trans-mitted to wheel cylinder via the inlet solenoid valve.ABS operationPressure hold ON (Closed) OFF (Closed)Hydraulic circuit is shut off to hold the wheel cylinderbrake fluid pressure.PressuredecreaseON (Closed) ON (Open)Wheel cylinder brake fluid is sent to reservoir via theoutlet solenoid valve. Then it is pushed up to themaster cylinder by pump.PressureincreaseOFF (Open) OFF (Closed)Master cylinder brake fluid pressure is transmitted towheel cylinder.ANTI-LOCK BRAKE SYSTEM4WDSystem Description (Contd)BR-56Removal and InstallationCAUTION:Be careful not to damage sensor edge and sensor rotor teeth.When removing the front wheel hub or rear axle shaftassembly, disconnect the ABS wheel sensor from the assem-bly and move it away.FRONT WHEEL SENSORABR686GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXANTI-LOCK BRAKE SYSTEM4WDBR-57REAR WHEEL SENSORABR687ANTI-LOCK BRAKE SYSTEM4WDRemoval and Installation (Contd)BR-58ABR718G SENSORAlwaysreplaceGsensorifbumpedordropped. Otherwise,performance characteristics of Gsensor will be changed,which in turn changes ABS control performance characteris-tics.ABS ACTUATOR AND ELECTRIC UNITABR704Removal1. Disconnect battery cable.2. Drain brake fluid. Refer to Changing Brake Fluid, BR-6.3. Remove mounting bracket fixing bolts and nuts.4. Disconnect connector, brake pipes and remove fixing nuts.InstallationCAUTION:After installation, refill brakefluid. Thenbleedair. Refer toBleeding Brake System, BR-7.1. Connect brake pipes temporarily.2. Tighten fixing bolts and nuts.3. Tighten brake pipes.4. Connect connector and battery cable.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXANTI-LOCK BRAKE SYSTEM4WDRemoval and Installation (Contd)BR-59SEF233GSEF234GHow to Perform Trouble Diagnoses for Quickand Accurate RepairINTRODUCTIONTheABSsystemhasanelectroniccontrol unit tocontrol majorfunctions. The control unit accepts input signals from sensors andinstantly drives the actuators. It is essential that both kinds of sig-nals are proper and stable. It is also important to check for conven-tional problemssuchasairleaksinboosterlines, lackof brakefluid, or other problems with the brake system.It is much more difficult to diagnose a problem that occurs intermit-tently rather than continuously. Most intermittent problems arecaused by poor electric connections or faulty wiring. In this case,careful checking of suspicious circuits may help prevent thereplacement of good parts.A visual check only may not find the cause of the problems, so aroad test should be performed.Before undertaking actual checks, take a few minutes to talk witha customer who approaches with an ABS complaint. The customeris a very good source of information on such problems; especiallyintermittent ones. Throughthetalkswiththecustomer, findoutwhat symptoms are present and under what conditions they occur.Start yourdiagnosisbylookingforconventional problemsfirst.This is one of the best ways to troubleshoot brake problems on anABS controlled vehicle.Also check related service bulletins for information.TROUBLE DIAGNOSES4WDBR-60WORK FLOWCHECK IN Reference itemLISTEN TO CUSTOMER COMPLAINTSINVESTIGATE ITEMS YOU SHOULD CARRY OUTRELATED TO EACH SYMPTOM AND NOTEGo to MALFUNCTIONCODE/SYMPTOMCHART, BR-70.CHECK FOR ANY SERVICE BULLETINS.ELIMINATE GOOD SYSTEMS AND GOOD PARTSGo to PreliminaryCheck, BR-62.Not self-diagnostic item Self-diagnostic itemDETERMINE MALFUNC-TIONING CIRCUIT(S) ORPART(S).Go to Self-diagnosis,BR-68.Self-diagnosisELIMINATE GOOD PART(S), HARNESS(ES) OR CON-NECTOR(S) THROUGH ELECTRICAL TESTINGGGo to DiagnosticProcedure(s) 7 - 13,BR-87 - 92.GGo to ComponentParts and HarnessConnector Location,BR-63.Malfunctioningharness(es) andconnector(s)Malfunctioning partsINSPECTION OF EACHCOMPONENT Go to Diagnostic Pro-cedure(s) 1 - 6, BR-78 -86REPAIRREPAIR OR REPLACENGFINAL CHECKOKCHECK OUTGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES4WDHow to Perform Trouble Diagnoses for Quickand Accurate Repair (Contd)BR-61SBR451DPreliminary CheckSBR389CSBR058CSBR059CABR665Check brake fluid level in reservoirtank.Low fluid level may indicate brake padwear or leakage from brake line.Check brake line for leakage.OKNGRepair.Check brake booster for operation and airtightness. Refer to BR-19.OKNGReplace.Check brake pads, rotors, linings anddrums. Refer to BR-27.OKNGReplace.Check brake fluid level in reservoir tankagain.OKNGFill up brake fluid.Check warning lamp activation.When ignition switch is turned ON, warn-ing lamp turns on.OKNGCheck fuse, warning lampbulb and warning lamp cir-cuit.Check warning lamp for deactivation afterengine is started.OKNGGo to Self-diagnosis,BR-68, 72.Drive vehicle at speeds over 30 km/h (19MPH) for at least one minute.Ensure warning lamp remains off whiledriving.OKNGGo to Self-diagnosis,BR-68, 72.ENDTROUBLE DIAGNOSES4WDBR-62Component Parts and Harness ConnectorLocationABR813GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES4WDBR-63SchematicABR566TROUBLE DIAGNOSES4WDBR-64Wiring Diagram ABS ABR568GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES4WDBR-65ABR781TROUBLE DIAGNOSES4WDWiring Diagram ABS (Contd)BR-66ABR719GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES4WDWiring Diagram ABS (Contd)BR-67Self-diagnosisFUNCTIONG When a problem occurs in the ABS, the warning lamp on theinstrument panel comes on. To start the self-diagnostic resultsmode, ground the self-diagnostic (check) terminallocated onData Link Connector for CONSULT. The location of the mal-function is indicated by the warning lamp flashing.ABR697SELF-DIAGNOSIS PROCEDUREABR665ABR698Drive vehicle over 30 km/h (19 MPH) forat least one minute.Turn ignition switch OFF.Ground terminal 4 of Data link con-nector for CONSULT with a suitable har-ness.Turn ignition switch ON while ground-ing terminal 4.Do not depress brake pedal.After 3.0 seconds, the warning lampstarts flashing to indicate the malfunctioncode No. (See NOTE.)Verify the location of the malfunction withthe malfunction code chart. Refer toBR-70. Then make the necessary repairsfollowing the diagnostic procedures.After the malfunctions are repaired, erasethe malfunction codes stored in the con-trol unit. Refer to BR-69.Rerun the self-diagnostic results mode toverify that the malfunction codes havebeen erased.Disconnect the check terminal from theground. The self-diagnostic results modeis now complete.NOTE: The indication terminatesafter five minutes.However, when the ignitionswitch is turned fromOFF to ON, the indica-tion starts flashing again.A(Go to next page.)TROUBLE DIAGNOSES4WDBR-68ACheck warning lamp for deactivation afterdriving vehicle over 30 km/h (19 MPH)for at least one minute.After making certain that warning lampdoes not come on, test the ABS in a safearea to verify that it functions properly.HOW TO READ SELF-DIAGNOSTIC RESULTS (Malfunction codes)G Determine the code No. by counting the number of times the warning lamp flashes on and off.G When severalmalfunctions occur at one time, up to three code numbers can be stored; the latest mal-function will be indicated first.G The indication begins with the start code 12. After that a maximum of three code numbers appear in theorder of the latest one first. The indication then returns to the start code 12 to repeat (the indication willstay on for five minutes at the most).G The malfunction code chart is on the next page.SBR457DABR256HOW TO ERASE SELF-DIAGNOSTIC RESULTS(Malfunction codes)1. Disconnect the check terminal from ground (ABS warning lampwill stay lit).2. Within 12.5 seconds, ground the check terminal 3 times. Eachterminal ground must last more than 1 second. The ABS warn-inglampgoesout aftertheeraseoperationhasbeencom-pleted.3. Perform self-diagnosis again. Refer to BR-68. Only the start-code should appear, with no malfunction codes.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES4WDSelf-diagnosis (Contd)BR-69MALFUNCTION CODE/SYMPTOM CHARTCode No./Symptom(No. of warning lamp flashes)Malfunctioning part Diagnostic procedure45 Actuator front left outlet solenoid valve 246 Actuator front left inlet solenoid valve 241 Actuator front right outlet solenoid valve 242 Actuator front right inlet solenoid valve 255 Actuator rear outlet solenoid valve 256 Actuator rear inlet solenoid valve 225 1 Front left sensor (open-circuit) 126 1 Front left sensor (short-circuit) 121 1 Front right sensor (open-circuit) 122 1 Front right sensor (short-circuit) 131 1 Rear right sensor (open-circuit) 132 1 Rear right sensor (short-circuit) 135 1 Rear left sensor (open-circuit) 136 1 Rear left sensor (short-circuit) 118 1 Sensor rotor 117 G sensor and circuit 561 3 Actuator motor or motor relay 363 Solenoid valve relay 257 2 Power supply (Low voltage) 471 Control unit 6Warning lamp stays on when ignitionswitch is turned ONControl unit power supply circuitWarning lamp bulb circuitControl unit or control unit connectorSolenoid valve relay stuckPower supply for solenoid valve relay coil13Warning lamp does not come onwhen ignition switch is turned ONFuse, warning lamp bulb or warning lamp circuitControl unit12Pedal vibration and noise 11Long stopping distance 9Unexpected pedal action 8ABS does not work 10ABS works frequently 71: If one or more wheels spin on a rough or slippery road for 40 seconds or more, the ABS warning lamp will illuminate. This doesnot indicate a malfunction. Only in the case of the short-circuit (Code Nos. 26, 22, 32 and 36), after repair the ABS warning lampalso illuminates when the ignition switch is turned ON. In this case, drive the vehicle at speeds greater than 30 km/h (19 MPH)for approximately 1 minute as specified in SELF-DIAGNOSIS PROCEDURE, BR-68. Check to ensure that the ABS warninglamp goes out while the vehicle is being driven.2: The trouble code 57, which refers to a low power supply voltage, does not indicate that the ABS control unit is malfunctioning.Do not replace the ABS control unit with a new one.3: The trouble code 61 can sometimes appear when the ABS motor is not properly grounded. If it appears, be sure to check thecondition of the ABS motor ground circuit connection.TROUBLE DIAGNOSES4WDSelf-diagnosis (Contd)BR-70CONSULTCONSULT APPLICATION TO ABSITEMSELF-DIAGNOSTICRESULTSDATA MONITOR ACTIVE TESTFront right wheel sensor X X Front left wheel sensor X X Rear right wheel sensor X X Rear left wheel sensor X X G switch (G sensor) X X XStop lamp switch X Front right inlet solenoid valve X X XFront right outlet solenoid valve X X XFront left inlet solenoid valve X X XFront left outlet solenoid valve X X XRear inlet solenoid valve X X XRear outlet solenoid valve X X XActuator solenoid valve relay X X Actuator motor relay(ABS MOTOR is shown on the Data Monitorscreen.)X X XABS warning lamp X Battery voltage X X X: Applicable: Not applicableECU (ABS control unit) part number modeIgnore the ECU part number displayed in the ECU PART NUMBER MODE. ECU (ABS control unit) is part ofthe ABS actuator and electric unit, serviced as an assembly.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES4WDBR-71SEF321VCONSULT Inspection ProcedureSELF-DIAGNOSIS PROCEDURESBR455DSBR080ESST412BSBR950C1) Turn ignition switch OFF.2) Connect CONSULT to Data Link Con-nector for CONSULT.1) Start engine.2) Drive vehicle over 30 km/h (19 MPH)for at least one minute.1) Stop vehicle with engine runningand touch START on CONSULTscreen.2) Touch ABS.3) Touch SELF-DIAG RESULTS.G The screen shows the detected mal-function and how many times the igni-tion switch has been turned since themalfunction.Make the necessary repairs following thediagnostic procedures.After the malfunctions are repaired, erasethe self-diagnostic results stored in thecontrol unit by touching ERASE.Check warning lamp for deactivation afterdriving vehicle over 30 km/h (19 MPH) forat least one minute.Test the ABS in a safe area to verify that itfunctions properly.Note: SELF-DIAG RESULTS screen shows the detected malfunction andhow many times the ignition switch has been turned since the mal-function.TROUBLE DIAGNOSES4WDBR-72SELF-DIAGNOSTIC RESULTS MODEDiagnostic item Diagnostic item is detected when ...DiagnosticprocedureFR RH SENSOR[OPEN]G Circuit for front right wheel sensor is open.(An abnormally high input voltage is entered.)1FR LH SENSOR[OPEN]G Circuit for front left wheel sensor is open.(An abnormally high input voltage is entered.)1RR RH SENSOR[OPEN]G Circuit for rear right sensor is open.(An abnormally high input voltage is entered.)1RR LH SENSOR[OPEN]G Circuit for rear left sensor is open.(An abnormally high input voltage is entered.)1FR RH SENSOR[SHORT]G Circuit for front right wheel sensor is shorted.(An abnormally low input voltage is entered.)1FR LH SENSOR[SHORT]G Circuit for front left wheel sensor is shorted.(An abnormally low input voltage is entered.)1RR RH SENSOR[SHORT]G Circuit for rear right sensor is shorted.(An abnormally low input voltage is entered.)1RR LH SENSOR[SHORT]G Circuit for rear left sensor is shorted.(An abnormally low input voltage is entered.)1ABS SENSOR[ABNORMAL SIGNAL]G Teeth damage on sensor rotor or improper installation of wheel sensor.(Abnormal wheel sensor signal is entered.)1FR RH IN ABS SOL[OPEN]G Circuit for front right inlet solenoid valve is open.(An abnormally low output voltage is entered.)2FR LH IN ABS SOL[OPEN]G Circuit for front left inlet solenoid valve is open.(An abnormally low output voltage is entered.)2RR IN ABS SOL[OPEN]G Circuit for rear inlet solenoid valve is open.(An abnormally low output voltage is entered.)2FR RH IN ABS SOL[SHORT]G Circuit for front right inlet solenoid valve is shorted.(An abnormally high output voltage is entered.)2FR LH IN ABS SOL[SHORT]G Circuit for front left inlet solenoid valve is shorted.(An abnormally high output voltage is entered.)2RR IN ABS SOL[SHORT]G Circuit for rear inlet solenoid valve is shorted.(An abnormally high output voltage is entered.)2FR RH OUT ABS SOL[OPEN]G Circuit for front right outlet solenoid valve is open.(An abnormally low output voltage is entered.)2FR LH OUT ABS SOL[OPEN]G Circuit for front left outlet solenoid valve is open.(An abnormally low output voltage is entered.)2RR OUT ABS SOL[OPEN]G Circuit for rear outlet solenoid valve is open.(An abnormally low output voltage is entered.)2FR RH OUT ABS SOL[SHORT]G Circuit for front right outlet solenoid valve is shorted.(An abnormally high output voltage is entered.)2FR LH OUT ABS SOL[SHORT]G Circuit for front left outlet solenoid valve is shorted.(An abnormally high output voltage is entered.)2RR OUT ABS SOL[SHORT]G Circuit for rear outlet solenoid valve is shorted.(An abnormally high output voltage is entered.)2ABS ACTUATOR RELAY[ABNORMAL]G Actuator solenoid valve relay is ON, even if control unit sends off signal.G Actuator solenoid valve relay is OFF, even if control unit sends on signal.2ABS MOTOR RELAY[ABNORMAL]G Circuit for ABS motor relay is open or shorted.G Circuit for actuator motor is open or shorted.G Actuator motor relay is stuck.3BATTERY VOLT[VB-LOW]G Power source voltage supplied to ABS control unit is abnormally low. 4CONTROL UNIT G Function of calculation in ABS control unit has failed. 6G-SENSOR[ABNORMAL]G G sensor circuit is open or shorted. 5: If one or more wheels spin on a rough or slippery road for 40 seconds or more, the ABS warning lamp will illuminate. This doesnot indicate a malfunction. Only in the case of the short-circuit, after repair the ABS warning lamp also illuminates when the igni-tion switch is turned ON. In this case, drive the vehicle at speeds greater than 30 km/h (19 MPH) for approximately 1 minute asspecified in SELF-DIAGNOSIS PROCEDURE, BR-68. Check to ensure that the ABS warning lamp goes out while the vehicleis being driven.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES4WDCONSULT Inspection Procedure (Contd)BR-73SBR455DDATA MONITOR PROCEDURESBR080ESST412BSBR936CSBR937C1) Turn ignition switch OFF.2) Connect CONSULT to Data Link Connector for CONSULT.3) Turn ignition switch ON.1) Touch START on CONSULT screen.2) Touch ABS.3) Touch DATA MONITOR.1) Touch SETTING on SELECT MONITOR ITEM screen.2) Touch LONG TIME on SET RECORDING COND screen.3) Touch START on SELECT MONITOR ITEM.TROUBLE DIAGNOSES4WDCONSULT Inspection Procedure (Contd)BR-74SBR455DACTIVE TEST PROCEDUREG When conducting Active test, vehicle must be stationary.G When ABS warning lamp stays on, never conduct Active test.SBR080ESST412BSBR857DSBR934C1) Turn ignition switch OFF.2) Connect CONSULT to Data Link Connector for CONSULT.3) Start engine.1) Touch START on CONSULT screen.2) Touch ABS.3) Touch ACTIVE TEST.1) Select active test item by touching screen.2) Touch START.Carry out the active test by touching screen key.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES4WDCONSULT Inspection Procedure (Contd)BR-75DATA MONITOR MODEMONITOR ITEM CONDITION SPECIFICATIONFR RH SENSORFR LH SENSORRR RH SENSORRR LH SENSORDrive vehicle.(Each wheel is rotating.)Wheel speed signal(Almost the same speed as speedometer.)STOP LAMP SW Brake is depressed.Depress the pedal: ONRelease the pedal: OFFG-SWITCHVehicle is driven.Vehicle is stopped.Brake is applied.During sudden braking while driving on high roads (asphaltroads, etc.): ONWhile vehicle is stopped or during constant-speed driving: OFFFR RH IN SOLFR RH OUT SOLFR LH IN SOLFR LH OUT SOLRR IN SOLRR OUT SOL1. Drive vehicle at speeds over30 km/h (19 MPH) for atleast one minute.2. Engine is running.Operating conditions for each solenoid valve are indicated.ABS is not operating: OFFMOTOR RELAYABS is not operating: OFFABS is operating: ONACTUATOR RELAYIgnition switch is ON orengine is running.Ignition switch ON (Engine stops): OFFEngine running: ONWARNING LAMPABS warning lamp is turned on: ONABS warning lamp is turned off: OFFBATTERY VOLT Power supply voltage for control unitACTIVE TEST MODETEST ITEM CONDITION JUDGEMENTFR RH SOLENOIDFR LH SOLENOIDREAR SOLENOIDEngine is running.Brake fluid pressure control operationIN SOL OUT SOLUP (Increase):KEEP (Hold):DOWN (Decrease):OFFONONOFFOFFONABS MOTORABS actuator motorON: Motor runs (ABS motor relay ON)OFF: Motor stops (ABS motor relay OFF)G SWITCH Ignition switch is ON.G SWITCH (G SENSOR),ON: Set G SWITCH MONITOR ON(G switch circuit is closed.)OFF: Set G SWITCH MONITOR OFF(G switch circuit is open.)Note: Active test will automatically stop ten seconds after the test starts. (LIMIT SIGNAL monitor showsON.)TROUBLE DIAGNOSES4WDCONSULT Inspection Procedure (Contd)BR-76ABR663Ground Circuit CheckABS ACTUATOR AND ELECTRIC UNIT GROUNDG Check resistance between ABS actuator and electric unit con-nector terminals and ground.Resistance: approximately 0GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES4WDBR-77ABR641Diagnostic Procedure 1 (Wheel sensor or rotor)Malfunction code No. 21, 22, 25, 26, 31, 32, 35, 36 or 18ABR642ABR643INSPECTION START1. Disconnect connectors from ABS actua-tor and electric unit and wheel sensorof malfunction code No. Check termi-nals for damage or loose connections.Then reconnect connectors.2. Carry out self-diagnosis again.Does warning lamp activate again?YesNoInspection endCHECK WHEEL SENSOR ELECTRICAL.1. Disconnect ABS actuator and electricunit connector.2. Check resistance between ABS actua-tor and electric unit connectorE39(body side) terminals.Code No. 21 or 22 (Front RH wheel)Terminals4 and5Code No. 25 or 26 (Front LH wheel)Terminals6 and7Code No. 31 or 32 (Rear RH wheel)Terminals8 and9Code No. 35 or 36 (Rear LH wheel)Terminals1 and2Resistance: Front 1.28 - 1.92 kRear 1.28 - 1.92 kNGOKA (Go to next page.)CHECK WHEEL SENSOR.Check each sensor for resistance.Resistance: Front 1.28 - 1.92 kRear 1.28 - 1.92 kNGOKCheck the following.G Harness connectorsE2 ,E16,E39,E53,C11,C12,C102G Harness for open orshort between wheelsensor connectors andABS actuator and elec-tric unitIf NG, repair harness orconnectors.REPLACE.Replace wheel sensor.TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS4WDBR-78ANoteCHECK TIRE.Check for inflation pressure, wear andsize of each tire.OKNGNoteAdjust tire pressure orreplace tire(s).NoteCHECK WHEEL BEARING.Check wheel bearing axial end play.OKNoteCHECK SENSOR ROTOR.Check sensor rotor for damaged teeth.OKNGNoteReplace sensor rotor.CHECK HARNESS CONNECTOR.Check ABS actuator and electric unit pinterminals for damage or the connection ofABS actuator and electric unit harnessconnector. Reconnect ABS actuator andelectric unit harness connector. Thenretest.Note:Wheelpositionshouldbedistinguishedbycodenum-bers except code No. 18 (sensor rotor).GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS4WDDiagnostic Procedure 1 (Wheel sensor or rotor)(Contd)BR-79ABR774Diagnostic Procedure 2 (ABS actuator solenoidvalve and solenoid valve relay)ABR646Malfunction code Nos. 41, 42, 45, 46, 55, 56, 63CHECK FUSIBLE LINK.Check 40A fusible link . For fusible linklayout, refer to POWER SUPPLY ROUT-ING in EL section.OKNGA (Go to next page.)CHECK CONNECTOR.1. Disconnect ABS actuator and electricunit connector. Check terminals fordamage or loose connection. Thenreconnect connector.2. Carry out self-diagnosis again.Does warning lamp activate again?YesNoInspection endCHECK ABS ACTUATOR AND ELECTRICUNIT GROUND CIRCUIT.Refer to ABS ACTUATOR AND ELEC-TRIC UNIT GROUND in Ground CircuitCheck, BR-77.OKNGRepair harness and con-nector.CHECK SOLENOID VALVE RELAYPOWER SUPPLY CIRCUIT.1. Disconnect ABS actuator and electricunit connector.2. Check voltage between ABS actuatorand electric unit connectorE39 (bodyside) terminal18 and ground.Battery voltage should exist.OKNGCheck the following.G Harness connectorE39G Harness for open orshort between ABSactuator and electric unitand fusible linkIf NG, repair harness orconnector.REPLACE.Replace ABS actuator and electric unit.TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS4WDBR-80ABR647AREPLACE.Replace fusible link.Does the fusible link blow out whenignition switch is turned ON?YesNoInspection endCHECK SOLENOID VALVE RELAYPOWER SUPPLY CIRCUIT FOR SHORT.1. Disconnect battery cable and ABSactuator and electric unit connector.2. Check continuity between ABS actuatorand electric unit connectorE39 (bodyside) terminal18 and ground.Continuity should not exit.OKNGCheck the following.G Harness connectorE39G Harness for open orshort between ABSactuator and electric unitand fusible linkIf NG, repair harness orconnector.REPLACE.Replace ABS actuator and electric unit.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS4WDDiagnostic Procedure 2 (ABS actuator solenoidvalve and solenoid valve relay) (Contd)BR-81ABR648Diagnostic Procedure 3 (Motor relay or motor)Malfunction code No. 61ABR649CHECK FUSIBLE LINK.Check 40A fusible link . For fusible linklayout, refer to POWER SUPPLY ROUT-ING in EL section.OKNGA (Go to next page.)CHECK CONNECTOR.1. Disconnect ABS actuator and electricunit connector. Check terminals fordamage or loose connection. Thenreconnect connector.2. Carry out self-diagnosis again.Does warning lamp activate again?YesNoInspection endCHECK ABS ACTUATOR AND ELECTRICUNIT GROUND CIRCUIT.Refer to ABS ACTUATOR AND ELEC-TRIC UNIT GROUND in Ground CircuitCheck, BR-77.OKNGRepair harness and termi-nals.CHECK MOTOR RELAY POWER SUP-PLY CIRCUIT.1. Disconnect ABS actuator and electricunit connector.2. Check voltage between ABS actuatorand electric unit connectorE39 (bodyside) terminal17 and ground.Battery voltage should exist.OKNGCheck the following.G Harness connectorE39G Harness for open orshort between ABSactuator and electric unitand fusible linkIf NG, repair harness orconnector.REPLACE.Replace ABS actuator and electric unit.TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS4WDBR-82ABR650AREPLACE.Replace fusible link.Does the fusible link blow out whenignition switch is turned ON?YesNoInspection endCHECK MOTOR RELAY POWER SUP-PLY CIRCUIT FOR SHORT.1. Disconnect battery cable and ABSactuator and electric unit connectorE39.2. Check continuity between ABS actuatorand electric unit connectorE39 (bodyside) terminal17 and ground.Continuity should not exist.OKNGCheck the followingG Harness connectorE39G Harness for open orshort between ABSactuator and electric unitand fusible linkIf NG, repair harness orconnector.REPLACE.Replace ABS actuator and electric unit.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS4WDDiagnostic Procedure 3 (Motor relay or motor)(Contd)BR-83ABR651Diagnostic Procedure 4 (Low voltage)ABR652ABR775Malfunction code No. 57CHECK FUSE.Check 10A fuse . For fuse layout, referto POWER SUPPLY ROUTING in ELsection.OKNGA (See below.)CHECK CONNECTOR.1. Disconnect ABS actuator and electricunit connector. Check terminals fordamage or loose connection. Thenreconnect connector.2. Carry out self-diagnosis again.Does warning lamp activate again?YesNoInspection end.CHECK ABS ACTUATOR AND ELECTRICUNIT GROUND CIRCUIT.Refer to ABS ACTUATOR AND ELEC-TRIC UNIT GROUND in Ground CircuitCheck, BR-77.OKNGRepair harness and con-nector.CHECK ABS ACTUATOR AND ELEC-TRIC UNIT POWER SUPPLY CIRCUIT.1. Disconnect ABS actuator and electricunit connector.2. Check voltage between ABS actuatorand electric unit connectorE39 (bodyside) terminal15 and ground.Battery voltage should exist whenignition switch is turned ON.OKNGCheck the following.G Harness connectorE39G Harness for open or shortbetween ABS actuatorand electric unit and fuseREPLACE.Replace ABS actuator and electric unit.AREPLACE.Replace fuse.Does the fuse blow out when ignitionswitch is turned ON?YESNoInspection endCHECK ABS ACTUATOR AND ELEC-TRIC UNIT POWER SUPPLY CIRCUITFOR SHORT.1. Disconnect battery cable and ABSactuator and electric unit connectorE39.2. Check continuity between ABS actuatorand electric unit connectorE39 (bodyside) terminal15 and ground.Continuity should not exist.OKNGCheck the following.G Harness connectorE39G Harness for open or shortbetween ABS actuatorand electric unit and fuseIf NG, repair harness orconnector.REPLACE.Replace ABS actuator and electric unit.TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS4WDBR-84ABR653Diagnostic Procedure 5 (G sensor)Malfunction code No. 17ABR654ABR655CHECK CONNECTOR.1. Disconnect ABS actuator and electricunit connector. Check terminals fordamage or loose connection. Thenreconnect connector.2. Carry out self-diagnosis again.Does warning lamp activate again?YesNoInspection endCHECK G SENSOR.Refer to G SENSOR in Electrical Compo-nents Inspection, BR-94.OKNGReplace G sensor.CHECK G SENSOR POWER SUPPLYCIRCUIT.1. Disconnect G sensor connectors.2. Check voltage between G sensor con-nectorM69 ,M70 (body side) termi-nals2,15 and ground.Battery voltage should exist.OKNGCheck the following.G Harness connectorsM69 ,M70 ,E39G Harness for open orshort between G sensorand ABS actuator andelectric unitIf NG, repair harness orconnectors.CHECK G SENSOR CIRCUITS.1. Disconnect ABS actuator and electricunit connector and G sensor connec-tors.2. Check continuity between ABS actuatorand electric unit connectorE39 (bodyside) terminals10 ,20 and G sensorconnectorsM69 ,M70 (body side) ter-minals10 ,20 .Continuity should exist.OKNGCheck the following.G Harness connectorsM69 ,M70 ,E39,E53G Harness for open orshort between G sensorand ABS actuator andelectric unitIf NG, repair harness orconnectors.REPLACE.Replace ABS actuator and electric unit.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS4WDBR-85ABR657Diagnostic Procedure 6 (Control unit)Malfunction code No. 71CHECK CONNECTOR.1. Disconnect ABS actuator and electricunit connector.Check terminals for damage or looseconnections. Then reconnect connector.2. Carry out self-diagnosis again.Does warning lamp activate again?YesNoInspection endCHECK ABS ACTUATOR AND ELECTRICUNIT POWER SUPPLY CIRCUIT.Check voltage. Refer to in DiagnosticProcedure 4, BR-84.CHECK SELF-DIAGNOSTIC RESULTS.Does warning lamp indicate code No. 71again?NoYesReplace ABS actuator andelectric unit.INSPECTION.Inspect the system according to the codeNo.TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS4WDBR-86Diagnostic Procedure 7 (ABS worksfrequently.)CHECK BRAKE FLUID PRESSURE.Check brake fluid pressure distribution.Refer to Proportioning Valve, Inspection,BR-12.OKNGRepair. Then perform Pre-liminary Check, refer toBR-62.CHECK WHEEL SENSOR.1. Check wheel sensor connector for ter-minal damage or loose connections.2. Perform wheel sensor mechanicalcheck.Refer to CHECK SENSOR ROTOR inDiagnostic Procedure 1, BR-78.OKNGRepair.CHECK FRONT AXLES.Check front axles for excessive loose-ness. Refer to FA section (Front WheelBearing, ON-VEHICLE SERVICE).OKNGRepair.Go to in Diagnostic Procedure 8,BR-88.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR SYMPTOMS4WDBR-87SBR540ADiagnostic Procedure 8 (Unexpected pedalaction)ABR665CHECK BRAKE PEDAL STROKE.Check brake pedal stroke. Is strokeexcessively large?NoYesPerform PreliminaryCheck, refer to BR-62.CHECK MECHANICAL BRAKE SYSTEMPERFORMANCE.Disconnect ABS actuator and electric unitconnector and check whether brake iseffective.YesNoPerform PreliminaryCheck, refer to BR-62.CHECK WARNING LAMP ACTIVATE.Ensure warning lamp remains off whiledriving.OKNGCarry out self-diagnosis.Refer to BR-68, 72.CHECK WHEEL SENSOR.1. Check wheel sensor connector for ter-minal damage or loose connection.2. Perform wheel sensor mechanicalcheck.Refer to CHECK SENSOR ROTOR inDiagnostic Procedure 1, BR-78.OKNGRepair.CHECK HARNESS CONNECTOR.Check ABS actuator and electric unit pinterminals for damage or the connection ofABS actuator and electric unit harnessconnector.Reconnect ABS actuator and electric unitharness connector. Then retest.Diagnostic Procedure 9 (Long stoppingdistance)CHECK ABS PERFORMANCE.Disconnect ABS actuator and electric unitconnector and check whether stoppingdistance is still long.YesNoGo to in DiagnosticProcedure 8, BR-88.Perform Preliminary Check and air bleed-ing (if necessary).Note:StoppingdistancemaybelongerforvehicleswithoutABS when road condition is slippery.TROUBLE DIAGNOSES FOR SYMPTOMS4WDBR-88Diagnostic Procedure 10 (ABS does not work.)CHECK WARNING LAMP ACTIVATE.Does the ABS warning lamp activate?NoYesCarry out self-diagnosis.Refer to BR-68, 72.Go to in Diagnostic Procedure 8,BR-88.Note: ABS does not work when vehicle speed is under 10 km/h(6 MPH).SAT797ADiagnostic Procedure 11 (Pedal vibration andnoise)INSPECTION START1. Apply brake.2. Start engine.3. Does the symptom appear only whenengine is started?NoYesCarry out self-diagnosis.Refer to BR-68, 72.CHECK IF SYMPTOM APPEARS.Does the symptom appear when electricalequipment switches (such as headlamp)are operated?YesNoGo to in DiagnosticProcedure 8, BR-88.CHECK WHEEL SENSOR.Check wheel sensor shield ground. Forlocation of shield ground, refer to wiringdiagram and HARNESS LAYOUT in ELsection.OKNGRepair wheel sensor.CHECK HARNESS CONNECTOR.Check ABS actuator and electric unit pinterminals for damage or the connection ofABS actuator and electric unit harnessconnector.Reconnect ABS actuator and electric unitharness connector, then retest.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR SYMPTOMS4WDBR-89Note: ABS may operate and cause vibration under any of thefollowing conditions.G Applying brake gradually when shifting or operatingclutch.G Low friction (slippery) road.G High speed cornering.G Driving over bumps and pot holes.G Engine speed is over 5,000 rpm with vehicle stopped.ABR776ABR665ABR777ABR778Diagnostic Procedure 12 (Warning lamp doesnot come on when ignition switch is turnedON.)CHECK FUSE.Check 10A fuse . For fuse layout, referto POWER SUPPLY ROUTING in EL sec-tion.OKNGReplace fuse.CHECK WARNING LAMP ACTIVATE.Disconnect ABS actuator and electric unitconnector.Does the warning lamp activate?NoYesA (Go to next page.)CHECK HARNESS FOR SHORT.1. Disconnect ABS actuator and electricunit connector and combination meterconnectorM39 .2. Check continuity between ABS actuatorand electric unit connectorE39 (bodyside) terminal21 and ground.Continuity should not exist.OKNGRepair harness or connec-tor.CHECK COMBINATION METER (ABSWARNING LAMP) GROUND CIRCUIT.Check continuity between combinationmeter connectorM39 harness terminal33 and ground.Continuity should exist.OKNGRepair harness or connec-tor.CHECK COMBINATION METER.Check combination meter. Refer toWARNING LAMPS in EL section.TROUBLE DIAGNOSES FOR SYMPTOMS4WDDiagnostic Procedure 11 (Pedal vibration andnoise) (Contd)BR-90ACHECK HARNESS CONNECTOR.Check ABS actuator and electric unit pinterminals for damage or connection ofABS actuator and electric unit harnessconnector. Reconnect ABS actuator andelectric unit harness connector. Thenretest.NGOKInspection endREPLACE.Replace ABS actuator and electric unit.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES FOR SYMPTOMS4WDDiagnostic Procedure 12 (Warning lamp doesnot co