brake system - 123seminarsonly.com€¦ · brake system. brake booster operational test 1....

BRAKE SYSTEM

BR-1

DESCRIPTIONThe service brakes consist of a foot brake which changes rotational energy to thermal energy tostop the vehicle while it is being driven and a parking brake to keep the vehicle from moving whileit is parked.

OPERATIONFOOT BRAKEWhen the brake pedal is depressed, a vacuum builds up in the booster which amplifies the pedalforce, pressing on the piston in the master cylinder. The piston movement raises the hydraulicpressure in the cylinder. This hydraulic pressure then acts to press the brake pads and shoesagainst the rotating discs and brake drums. The resulting friction converts the rotational energyto thermal energy, stopping the vehicle.

GENERAL DESCRIPTION1. Care must be taken to replace each part properly as it could affect the performance of the brakesystem and result in a driving hazard. Replace the parts with parts of the same part number orequivalent.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 INsection.

-BRAKE SYSTEM GENERAL DESCRIPTIONBR-2

DESCRIPTIONThe service brakes consist of a foot brake which changes rotational energy to thermal energy tostop the vehicle while it is being driven and a parking brake to keep the vehicle from moving whileit is parked.

OPERATIONFOOT BRAKEWhen the brake pedal is depressed, a vacuum builds up in the booster which amplifies the pedalforce, pressing on the piston in the master cylinder. The piston movement raises the hydraulicpressure in the cylinder. This hydraulic pressure then acts to press the brake pads and shoesagainst the rotating discs and brake drums. The resulting friction converts the rotational energyto thermal energy, stopping the vehicle.

GENERAL DESCRIPTION1. Care must be taken to replace each part properly as it could affect the performance of the brakesystem and result in a driving hazard. Replace the parts with parts of the same part number orequivalent.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 INsection.

-BRAKE SYSTEM DESCRIPTIONBR-2

PREPARATIONSST (SPECIAL SERVICE TOOLS)

09990-00300 ABS Actuator Checker Sub-harness “I”

09990-00200 ABS Actuator Checker Sub-harness “C”

09751-3601 1 Brake Tube Union Nut 10 x 12 mm Wrench

09990-00150 ABS Actuator Checker and Sub-harness

09737-00010 Brake Booster Push Rod Gauge

09718-00010 Shoe Hold Down Spring Driver

09990-00163 ABS Actuator Checker Sheet ’A’

09843-18020 Diagnosis Check Wire

09709-29017 LSPV Gauge Set

-BRAKE SYSTEM PREPARATIONBR-4

RECOMMENDED TOOLS09082-00050 TOYOTA Electrical Tester Set

SAEJ1703 or FMVSS No. 116 DOT 3

09905-00013 Snap Ring Pliers

LUBRICANT

EQUIPMENT

Vernier calipers

Torque wrench

Dial indicator

Micrometer

Classification

Brake fluid

Brake drum

Brake disc

Brake disc

CapacityItem

-BRAKE SYSTEM PREPARATIONBR-5

TR

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BLE

SH

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se the table below to help you find the cause of the problem

. The num

bers indicate the priorityof the likely cause of the problem

. Check each part in order. If necessary, replace these parts.

Parking brake (Lever travel out of adjustment)

Rear brake (Shoe clearance out of adjustment)

Booster push rod (Out of adjustment)

Pad or lining (Cracked or distorted)

Anchor or return spring (Faulty)

Hard pedal but brake inefficient

Piston seal (Worn or damaged)

Booster system (Vacuum leaks)

Brake pedal (Freeplay minimal)

Hold-down spring (Damaged)

Parking brake wire (Sticking)

Anti-squeal shim (Damaged)

Low pedal or spongy pedal

Brake pad or lining (Worn)

Brake system (Fluid leaks)

Pad support plate (Loose)

Pad or lining (Hardened)

Installation bolt (Loose)

Master cylinder (Faulty)

Brake system (Air in)

Pad or lining (Dirty)

Pad or lining (oily)

Sliding pin (Worn)

Noise from

brakes

Piston (Frozen)

Piston (Stuck)

Disc (Scored)

BR-1 1, BR-16

Brake drag

BR-24 , BR-31

Brake pull

BR-24 ,BR-31

Part N

ame

See page

Trouble

BR-31

BR-31

BR-24

BR-22

BR-31

BR-24

BR-9

BR-8

BR-7

BR-24 , BR-31BR-24 , BR-31BR-24 , BR-31

BR-24 , BR-31BR-24 , BR-31BR-24 , BR-31

BR-24 , BR-31

BR-24 , BR-31BR-24 , BR-31

-B

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SY

ST

EM

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R-6

CHECK AND ADJUSTMENTBRAKE PEDAL CHECK AND ADJUSTMENT1. CHECK THAT PEDAL HEIGHT IS CORRECT, ASSHOWN

Pedal height from asphalt sheet:4M/T143.0-153.0 mm (5.63-6.02 in.)Others138.5-148.5 mm (5.45-5.85 in.)

If the pedal height is incorrect, adjust it.2. IF NECESSARY, ADJUST PEDAL HEIGHT(a) Disconnect the connector from the stop light switch.(b) Loosen the stop light switch lock nut and remove thestop light switch.(c) Loosen the push rod lock nut.(d) Adjust the pedal height by turning the pedal push rod.(e) Tighten the push rod lock nut.

Torque: 25 N-m (260 kgf-cm, 19 ft-lbf)

(f) Install the stop light switch and turn it until it lightlycontacts the pedal stopper.(g) Turn the stop light switch back one turn.(h) Check the clearance (A) between stop light switch andpedal:

Clearance:0.5-2.4 mm (0.02-0.09 in.)

(i) Tighten the stop light switch lock nut.(j) Connect the connector to the stop light switch.(k) Check that the stop lights come on when the brakepedal is depressed, and go off when the brake pedal isreleased:(l) After adjusting the pedal height, check the pedal free-play.HINT: If clearance (A) between the stop light switchand the brake pedal stopper has been adjusted cor-rectly, the pedal freeplay will meet the specifications.3. CHECK THAT PEDAL FREEPLAY IS CORRECT, ASSHOWN(a) Stop the engine and depress the brake pedal severaltimes until there is no more vacuum left in the boost-er.(b) Push in the pedal by hand until the beginning of theresistance is felt, then measure the distance, asshown.

Pedal freeplay:1-6 mm (0.04-0.24 in.)

If incorrect, check the stop light switch clearance.And if the clearance is OK, then troubleshoot thebrake system.

-BRAKE SYSTEM CHECK AND ADJUSTMENTBR-7

4. CHECK THAT PEDAL RESERVE DISTANCE IS COR-RECT, AS SHOWNRelease the parking brake.With the engine running, depress the pedal and meas-ure the pedal reserve distance, as shown.Pedal reserve distance from asphalt sheet at 490 N(50 kgf, 110.2 lbf):

More than 50 mm (1.97 in.)

If the reserve distance is incorrect, troubleshoot thebrake system.

BRAKE BOOSTER OPERATIONAL TEST1. OPERATING CHECK(a) Depress the brake pedal several times with the engineoff and check that there is no change in the pedalreserve distance.(b) Depress the brake pedal and start the engine. If thepedal 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 thepedal goes down the furthest the 1st time, but gradu-ally rises after the 2nd or 3rd time, the booster is airtight.(b) Depress the brake pedal while the engine is running,and stop the engine with the pedal depressed. (f thereis no change in the pedal reserve travel after holdingthe pedal for 30 seconds, the booster is air tight.

BRAKE SYSTEM BLEEDINGHINT: If any work is done on the brake system or if airin the brake lines is suspected, bleed the system of air.

NOTICE: Do not let brake fluid remain on a painted sur-face. Wash it off immediately.

1. FILL BRAKE RESERVOIR WITH BRAKE FLUIDFluid: SAEJ1703 or FMVSS No. 116 DOT3

2. BLEED MASTER CYLINDERHINT: If the master cylinder has been disassembled orif the reservoir becomes empty, bleed the air from themaster cylinder.(a) Disconnect the brake lines from the master cylinder.(b) Slowly depress the brake pedal and hold it.


PARKING BRAKE CHECK ANDADJUSTMENT1. CHECK THAT PARKING BRAKE LEVER TRAVEL ISCORRECTPull the parking brake lever all the way up, and countthe number of clicks.Parking brake lever travel at 196 N (20 kgf, 44.1 lbf):4-7 clicksIf incorrect, adjust the parking brake.2. IF NECESSARY, ADJUST PARKING BRAKEHINT: Before adjusting the parking brake, make surethat the rear brake shoe clearance has been adjusted.For shoe clearance adjustment, see step 9 to 10 onpages BR-37 and BR-38 .(a) Remove the console box.(b) Loosen the lock nut and turn the adjusting nut untilthe lever travel is correct.(c) Tighten the lock nut.

3. BLEED BRAKE LINE(a) Connect the vinyl tube to the brake caliper.(b) Depress the brake pedal several times, then loosenthe bleeder plug with the pedal held down.(c) At the point when fluid stops coming out, tighten thebleeder plug, then release the brake pedal.(d) Repeat (b) and (c) until all the air in the fluid has beenbled out.(e) Repeat the above procedure to bleed the air out of thebrake line for each wheel.4. CHECK FLUID LEVEL IN RESERVOIRCheck the fluid level and add fluid if necessary.Fluid: SAEJ1703 or FMVSS No. 116 DOT3

(c) Block off the outer holes with your finger and releasethe brake pedal.(d) Repeat (b) and (c) 3 or 4 times.


Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)

(d) Install the console box.


1. REMOVE AIR CLEANER ASSEMBLY2. DISCONNECT LEVEL WARNING SWITCH CONNEC-TOR3. DRAW OUT FLUID WITH SYRINGE


4. DISCONNECT BRAKE LINESUsing SST, disconnect the brake lines from the mastercylinder.SST 09751 - 360115. REMOVE MASTER CYLINDERRemove the mounting nuts and pull out the mastercylinder and gasket.

MASTER CYLINDER (w o ABS)MASTER CYLINDER REMOVAL

-BRAKE SYSTEM MASTER CYLINDER(w o ABS)BR-1 1

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 GROMMETS4. PLACE CYLINDER IN VISE

MASTER CYLINDER DISASSEMBLY1. REMOVE MASTER CYLINDER BOOTUsing a screwdriver, remove the master cylinder boot.

COMPONENTS

-BRAKE SYSTEM MASTER CYLINDER(w/o ABS)BR-12

MASTER CYLINDER COMPONENTSINSPECTIONHINT: Clean the disassembled parts with compressedair.1. INSPECT CYLINDER BORE FOR RUST OR SCORING2. INSPECT CYLINDER FOR WEAR OR DAMAGEIf necessary, clean or replace the cylinder.

6. REMOVE PISTONS(a) Push in the piston with a screwdriver and remove thesnap ring with snap ring pliers.(b) Remove the No.1 piston and spring by hand, pullingstraight out, not at an angle.

NOTICE: If pulled out at an angle, there is a possibilitythat the cylinder bore could be damaged.

MASTER CYLINDER ASSEMBLY1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TORUBBER PARTS INDICATED BY ARROWS

(c) Place a rag and 2 wooden blocks on the work tableand lightly tap the cylinder flange against the blockedges until the No.2 piston drops out of the cylinder.HINT: Make sure the distance (A) from the rag to thetop of the blocks is at least 100mm (3.94in.).

5. REMOVE PISTON STOPPER BOLTUsing a screwdriver, push the pistons in all the wayand remove the piston stopper bolt and gasket.HINT: Tape the screwdriver tip before use.


2. INSTALL PISTONSNOTICE: Be careful not to damage the rubber lips an thepistons.

(a) Insert the 2 pistons straight in, not at an angle.NOTICE: If inserted at an angle, there is a possibility thatthe cylinder bore could be damaged.

(b) Push in the piston with a screwdriver and install thesnap ring with snap ring pliers.HINT: Tape the screwdriver tip before use.

3. INSTALL PISTON STOPPER BOLTUsing a screwdriver, push the piston in all the way andinstall the piston stopper bolt over a new gasket.Torque the bolt.Torque: 10 N-m (100 kgf-cm, 7 ft-lbf)

4. INSTALL 2 GROMMETS

MASTER CYLINDER INSTALLATION1. ADJUST LENGTH OF BRAKE BOOSTER PUSH RODBEFORE INSTALLING MASTER CYLINDER(See BRAKE BOOSTER INSTALLATION)

5. INSTALL RESERVOIR(a) Install the cap and strainer to the reservoir.(b) Push the reservoir onto the cylinder.(c) Install the set screw while pushing on the reservoir.

Torque: 1.7 N-m (17.5 kgf-cm, 15.2 in.-lbf)

6. INSTALL MASTER CYLINDER BOOTAlign the grooves on the master cylinder boot andmaster cylinder flange as shown, install the cylinderboot on the master cylinder.


3. CONNECT BRAKE LINESUsing SST, connect the 2 brake lines to the mastercylinder. Torque the union nuts.SST 09751-36011

Torque: 15 N-m (155 kgf-cm, 11 ft-Ibf)

4. CONNECT LEVEL WARNING SWITCH CONNECTOR5. INSTALL AIR CLEANER ASSEMBLY6. FILL BRAKE RESERVOIR WITH BRAKE FLUID ANDBLEED BRAKE SYSTEM(See BRAKE SYSTEM BLEEDING)7. CHECK FOR LEAKS8. CHECK AND ADJUST BRAKE PEDAL(See BRAKE PEDAL CHECK AND ADJUSTMENT)

2. INSTALL MASTER CYLINDERInstall the master cylinder and a new gasket on thebrake booster with the 2 nuts.



1. REMOVE AIR CLEANER ASSEMBLY2. DISCONNECT LEVEL WARNING SWITCH CONNEC-TOR3. DRAW OUT FLUID WITH SYRINGE


4. DISCONNECT BRAKE LINESUsing SST, disconnect the brake lines from the mastercylinder and 2-way.SST 09751- 360115. REMOVE MASTER CYLINDERRemove the mounting nuts and pull out the mastercylinder and gasket.

MASTER CYLINDER (w ABS)MASTER CYLINDER REMOVAL

-BRAKE SYSTEM MASTER CYLINDER(w ABS)BR-16

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 GROMMETS4. PLACE CYLINDER IN VISE

MASTER CYLINDER DISASSEMBLY1. REMOVE MASTER CYLINDER BOOTUsing a screwdriver, remove the master cylinder boot.

COMPONENTS-BRAKE SYSTEM MASTER CYLINDER(w/ ABS)

BR-17

MASTER CYLINDER COMPONENTSINSPECTIONHINT: Clean the disassembled parts with compressedair.1. INSPECT CYLINDER BORE FOR RUST OR SCORING2. INSPECT CYLINDER FOR WEAR OR DAMAGEIf necessary, clean or replace the cylinder.

6. REMOVE PISTONS(a) Push in the piston with a screwdriver and remove thesnap ring with snap ring pliers.(b) Remove the No.1 piston and spring by hand, pullingstraight out, not at an angle.

NOTICE: If pulled out at an angle, there is a possibilitythat the cylinder bore could be damaged.

(c) Place a rag and 2 wooden blocks on the work tableand lightly tap the cylinder flange against the blockedges until the No.2 piston drops out of the cylinder.HINT: Make sure the distance (A) from the rag to thetop of the blocks is at least 100mm (3.94in.).

5. REMOVE PISTON STOPPER BOLTUsing a screwdriver, push the pistons in all the wayand remove the piston stopper bolt and gasket.HINT: Tape the screwdriver tip before use.

MASTER CYLINDER ASSEMBLY1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TORUBBER PARTS INDICATED BY ARROWS

-BRAKE SYSTEM MASTER CYLINDER(w/ ABS)BR-18

2. INSTALL PISTONSNOTICE: Be careful not to damage the rubber lips on thepistons.

(a) Insert the 2 pistons straight in, not at an angle.NOTICE: If inserted at an angle, there is a possibility thatthe cylinder bore could be damaged.

(b) Push in the piston with a screwdriver and install thesnap ring with snap ring pliers.HINT: Tape the screwdriver tip before use.

3. INSTALL PISTON STOPPER BOLTUsing a screwdriver, push the piston in all the way andinstall the piston stopper bolt over a new gasket.Torque the bolt.


4. INSTALL 2 GROMMETS

MASTER CYLINDER INSTALLATION1. ADJUST LENGTH OF BRAKE BOOSTER PUSH RODBEFORE INSTALLING MASTER CYLINDER(See BRAKE BOOSTER INSTALLATION)

5. INSTALL RESERVOIR(a) Install the cap and strainer to the reservoir.(b) Push the reservoir onto the cylinder.(c) Install the set screw while pushing on the reservoir.

Torque: 1.7 N-m (17.5 kgf-cm, 15.2 in.-lbf)

6. INSTALL MASTER CYLINDER BOOTWith the UP mark on the master cylinder boot facingupwards, install the cylinder boot on the master cylin-der.


3. CONNECT BRAKE LINESUsing SST, connect the brake lines to the mastercylinder and 2-way. Torque the union nuts.SST 09751-36011


4. CONNECT LEVEL WARNING SWITCH CONNECTOR5. INSTALL AIR CLEANER ASSEMBLY6. FILL BRAKE RESERVOIR WITH BRAKE FLUID ANDBLEED BRAKE SYSTEM(See BRAKE SYSTEM BLEEDING)7. CHECK FOR LEAKS8. CHECK AND ADJUST BRAKE PEDAL(See BRAKE PEDAL CHECK AND ADJUSTMENT)

2. INSTALL MASTER CYLINDERInstall the master cylinder and a new gasket on thebrake booster with the 3 nuts.



1. REMOVE MASTER CYLINDER(See MASTER CYLINDER REMOVAL)2. DISCONNECT VACUUM HOSE FROM BRAKE BOO-STER3. REMOVE PEDAL RETURN SPRING4. REMOVE CLIP AND CLEVIS PIN

5. REMOVE BRAKE BOOSTER(a) Remove the No.1 brake tube clamp, as shown in theillustration.

BRAKE BOOSTERBRAKE BOOSTER REMOVAL

-BRAKE SYSTEM BRAKE BOOSTERBR-21

BRAKE BOOSTER INSTALLATION1. INSTALL BRAKE BOOSTER(a) Install the booster and a new gasket.(b) Install the clevis to the operating rod.(c) Install and torque the booster installation nuts.

Torque: 13 N-m (130 kgf-cm. 8 ft-lbf)

(d) Insert the clevis pin into the clevis and brake pedal,and install the clip to the clevis pin.(e) Install the pedal return spring.(f) Install the No.1 brake tube clamp to the body.

(b) Remove the No.2 brake tube clamp, as shown in theillustration.

(c) Remove the 4 nuts.(d) Pull out the brake booster and gasket.

(g) Install the No.2 brake tube clamp to the body.


(c) Turn SST upside down, and set it on the booster.SST 09737-00010(d) Measure the clearance between the booster push rodand pin head (SST).

Clearance:0 mm (0 in.)

(e) Adjust the booster push rod length until the push rodslightly touches the pin head.HINT: When loosening the push rod nut, depress thebrake pedal enough so that the push rod sticks out.3. INSTALL MASTER CYLINDER4. CONNECT VACUUM HOSE TO BRAKE BOOSTER5. FILL BRAKE RESERVOIR WITH BRAKE FLUID ANDBLEED BRAKE SYSTEM(See BRAKE SYSTEM BLEEDING)6. CHECK FOR LEAKS7. CHECK AND ADJUST BRAKE PEDAL(See BRAKE PEDAL CHECK AND ADJUSTMENT)Check and adjust the brake pedal, then tighten theclevis lock nut.

Torque: 25 N-m (260 kgf-cm. 19 ft-lbf)

8. PERFORM OPERATIONAL CHECK(See BRAKE BOOSTER OPERATIONAL TEST)

2. ADJUST LENGTH OF BOOSTER PUSH ROD(a) Install the gasket on the master cylinder.(b) Set SST on the gasket, and lower the pin until its tipslightly touches the piston.SST 09737-00010


BRAKE PADS REPLACEMENTHINT: If a squealing noise is made by the front brakeswhile driving, check the pad wear indicator. If there isevidence of the indicator contacting the disc, thebrake pad should be replaced as a set.

1. REMOVE FRONT WHEELRemove the wheel and temporarily fasten the discwith the hub nuts.

FRONT BRAKECOMPONENTS

-BRAKE SYSTEM FRONT BRAKEBR-24

4. REMOVE FOLLOWING PARTS:(a) 2 brake pads(b) 3 anti-squeal shims(c) Pad wear indicator plate(d) 4 pad support plates5. CHECK DISC THICKNESS AND RUNOUT(See FRONT BRAKE COMPONENTS INSPECTION ANDREPAIR)

2. INSPECT PAD LINING THICKNESSCheck the pad thickness through the caliper inspec-tion hole and replace the pads if it is not withinspecification.

Minimum thickness:1.0 mm (0.039 in.)

(b) Remove the brake caliper and suspend it so the hoseis not stretched.HINT: Do not disconnect the brake hose.

3. REMOVE CALIPER FROM TORQUE PLATE(a) Remove the 2 installation bolts from the torque plate.

6. INSTALL PAD SUPPORT PLATESInstall the 4 pad support plates.


8. INSTALL CALIPER(a) Draw out a small amount of brake fluid from thereservoir.(b) Press in the piston with a hammer handle or an equiv-alent.HINT: If the piston is difficult to push in, loosen thebleeder plug and push in the piston while letting somebrake fluid escape.

CALIPER REMOVAL1. DISCONNECT FLEXIBLE HOSE(a) Remove the union bolt and 2 gaskets from the brakecaliper, then disconnect the flexible hose from thebrake caliper.(b) Use a container to catch the brake fluid as it drainsout.

7. INSTALL NEW PADS(a) Install a pad wear indicator plate on the inside pad.(b) Apply disc brake grease to both sides of the inner anti-squeal shim.(c) Install the 2 anti-squeal shims to the outside pad.(d) Install the anti-squeal shim to the inside pad.

(e) Install the inside pad with the pad wear indicator platefacing upward.(f) Install the outside pad.

NOTICE: There should be no oil or grease adhering to thefriction surfaces of the pads or disc.

(c) Install the brake caliper.(d) Install and torque the 2 installation bolts.

Torque: 25 N-m (255 kgf-cm. 18 ft-lbf )9. INSTALL FRONT WHEEL10. CHECK THAT FLUID LEVEL IS MAX LINE


3. REMOVE PISTON FROM CYLINDER(a) Put a piece of cloth or equivalent between the pistonand the caliper.(b) Use compressed air to remove the piston from thecylinder.

CAUTION: Do not place your fingers in front of the pistonwhen using compressed air.

2. REMOVE CYLINDER BOOT SET RING AND CYLIN-DER BOOTUsing a screwdriver, remove the cylinder boot set ringand cylinder boot.

CALIPER DISASSEMBLY1. REMOVE FOLLOWING PARTS:(a) 2 sliding bushings(b) 4 dust boots

2. REMOVE CALIPER FROM TORQUE PLATERemove the 2 installation bolts and caliper.3. REMOVE 2 BRAKE PADS

4. REMOVE PISTON SEAL FROM BRAKE CYLINDERUsing a screwdriver, remove the piston seal.


3. MEASURE DISC RUNOUTMeasure disc runout 10 mm (0.39 in.) from the outeredge of the disc.

Maximum disc runout:0.09 mm (0.0035 in.)

If runout greater than maximum, attempt to adjust tobelow this maximum figure.HINT: Before measuring the runout, confirm that thefront bearing play is within specification (See SA sec-tion).4. IF NECESSARY, ADJUST DISC RUNOUT(a) Remove the torque plate from the knuckle.(b) Remove the 4 hub nuts and the disc. Reinstall the disc1/4 of a turn round from its original position on thehub. lnstall and torque the 4 hub nuts.

Torque: 103 N-m (1,050 kgf-cm, 76 ft-lbf)

Remeasure the disc runout. Make a note of the runoutand the disc’s position on the hub.

FRONT BRAKE COMPONENTSINSPECTION AND REPAIR1. MEASURE PAD LINING THICKNESSUsing a ruler, measure the pad lining thickness.

Standard thickness:10.0 mm (0.39 in.)Minimum thickness:1.0 mm (0.039 in.)

Replace the pad if the pad’s thickness is at the mini-mum thickness or less, or if the pad has excessivelyuneven wear.

2. MEASURE DISC THICKNESSStandard 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 theminimum thickness or less. Replace the disc or grind iton a lathe if it is scored or is worn unevenly.


(c) Repeat (b) until the disc has been installed on the 2remaining hub positions.(d) If the minimum runout recorded in (b) and (c) is lessthan 0.09 mm (0.0035 in.), install the disc in thatposition and install and torque the torque plate.


(e) If the minimum runout recorded in (b) and (c) is greaterthan 0.09 mm (0.0035 in.), replace the disc and repeat3.

2. INSTALL PISTON SEAL AND PISTON IN CYLINDER

CALIPER ASSEMBLY1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TOPARTS INDICATED WITH ARROWS

3. INSTALL CYLINDER BOOT AND SET RING

(f) Install the torque plate and tighten the 2 bolts.Torque: 88 N-m (900 kgf-cm, 65 ft-lbf


3. INSTALL FLEXIBLE HOSEInstall the flexible hose on the brake caliper with the 2new gaskets.

Torque: 30 N-m (310 kgf. cm, 22 ft-lbf)

HINT: Insert the flexible hose lock pin securely in thelock hole on the brake caliper.4. FILL BRAKE RESERVOIR WITH BRAKE FLUID ANDBLEED BRAKE SYSTEM(See BRAKE SYSTEM BLEEDING)5. CHECK FOR LEAKS

CALIPER INSTALLATION1. INSTALL BRAKE PADSInstall the inside and outside 2 pads.2. INSTALL CALIPER(a) Install the brake caliper.(b) Install and torque the 2 installation bolts.


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 brakecaliper grooves.

(c) Install the bushing into the boots.(d) Insure that the boots is secured firmly to the bushinggrooves.


REAR BRAKE REMOVAL1. INSPECT SHOE LINING THICKNESSRemove the inspection hole plug, and check the shoelining 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 DRUMHINT: If the brake drum cannot be removed easily,perform the following steps.(a) Insert a screwdriver through the hole in the backingplate, and hold the automatic adjusting lever awayfrom the adjuster.(b) Using another screwdriver, reduce the brake shoeadjuster by turning the adjusting wheel.

REAR BRAKECOMPONENTS

-BRAKE SYSTEM REAR BRAKEBR-31

(b) Using SST, remove the shoe hold-down spring, cupsand pin.SST 09718-00010(c) Disconnect the anchor spring from the front shoe andremove the front shoe.(d) Remove the anchor spring from the rear shoe.

5. REMOVE REAR SHOE(a) Using SST, remove the shoe hold-down spring, cupsand pin.SST 09718-00010

4. REMOVE FRONT SHOE(a) Using a screwdriver, remove the return spring andclamp.

(b) Using pliers, remove the adjusting lever spring.

(c) Remove the adjuster.


6. REMOVE AUTOMATIC ADJUSTING LEVER ANDPARKING BRAKE LEVER(a) Remove the E-ring.(b) Remove the automatic adjusting lever.(c) Remove the C-washer.(d) Remove the parking brake lever.

8. DISASSEMBLE WHEEL CYLINDERRemove the following parts from the wheel cylinder:• 2 boots• 2 pistons• 2 piston cups• Spring

7. REMOVE WHEEL CYLINDER(a) Using SST, disconnect the brake line. Use a containerto catch the brake fluid.SST 09751-36011(b) Remove the 2 bolts and the wheel cylinder.

(d) Using pliers, disconnect the parking brake cable fromthe lever and remove the rear shoe.


2. MEASURE BRAKE SHOE LINING THICKNESSStandard 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 signsof 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 evenbraking.3. MEASURE BRAKE DRUM INSIDE DIAMETER

Standard inside diameter:180.0 mm (7.087 in.)Maximum inside diameter:181.0 mm (7.126 in.)

If the drum is scored or worn, the brake drum may belathed to the maximum inside diameter.

REAR BRAKE COMPONENTSINSPECTION AND REPAIR1. INSPECT DISASSEMBLED PARTSInspect the disassembled parts for wear, rust ordamage.

4. INSPECT REAR BRAKE LINING AND DRUM FORPROPER CONTACTIf the contact between the brake lining and drum isimproper, repair the lining with a brake shoe grinder,or replace the brake shoe assembly.


3. INSTALL WHEEL CYLINDERInstall the wheel cylinder on the backing plate with the2 bolts.


4. CONNECT BRAKE LINE TO WHEEL CYLINDERUsing SST, connect the brake line.SST 09751- 36011


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 pointedinward.(c) Install the 2 boots.

1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TOFOLLOWING PARTS:(a) 2 piston cups(b) 2 pistons(c) 2 boots

REAR BRAKE INSTALLATIONHINT: Assemble the parts in the correct direction, asshown.


5. APPLY HIGH TEMPERATURE GREASE TO FOL-LOWING PARTS:(a) Backing plate and brake shoe contact points(b) Anchor plate and brake shoe contact points

6. INSTALL PARKING BRAKE LEVER AND AUTOMAT-IC ADJUSTING LEVER(a) Install the parking brake lever with a new C-washer.(b) Install the automatic adjusting lever with the E-ring.

7. INSTALL ADJUSTER AND REAR SHOE(a) Using pliers, connect the parking brake cable to thelever.

(c) Adjusting bolt(d) Adjuster and brake shoe contact points

(b) Set the adjuster.(c) Install the adjusting lever spring.


(d) Set the rear shoe in place with the end of the shoeinstalled in the wheel cylinder and the other end in theanchor plate.(e) Using SST, install the shoe hold-down spring, cupsand pin.SST 09718-00010

NOTICE: Do not allow oil or grease to get on the rubbingface.

8. INSTALL FRONT SHOE(a) Install the anchor spring between the front and rearshoes.(b) Set the front shoe in place with the end of the shoeinstalled in the wheel cylinder and the adjuster inplace.

NOTICE: Do not allow oil or grease to get on the rubbingface.

9. CHECK OPERATION OF AUTOMATIC ADJUSTINGMECHANISM(a) Move the parking brake lever of the rear shoe backand forth, as shown. Check that the adjuster turns.If the adjuster does not turn, check for incorrectinstallation of the rear brake.

(c) Using SST, install the shoe hold-down spring, cupsand pin.SST 09718 - 00010

(d) Install the clamp.(e) Using a screwdriver, install the return spring.


10. CHECK CLEARANCE BETWEEN BRAKE SHOESAND DRUM(a) Remove the brake drum.(b) Measure the brake drum inside diameter and diameterof the brake shoes. Check that the difference betweenthe diameters is the correct shoe clearance.

Shoe clearance:0.6 mm (0.024 in.)

If incorrect, check the parking brake system.11. INSTALL BRAKE DRUM12. INSTALL REAR WHEEL13. FILL BRAKE RESERVOIR WITH BRAKE FLUID ANDBLEED BRAKE SYSTEM(See BRAKE SYSTEM BLEEDING)14. CHECK FOR LEAKS

(b) Adjust the adjuster length to the shortest possibleamount.(c) Install the brake drum.(d) Pull the parking brake lever all the way up until aclicking sound can no longer be heard.


PROPORTIONING VALVE (P VALVE)FLUID PRESSURE CHECK7. INSTALL LSPV GAUGE (SST)SST 09709-29017

2. BLEED AIR FROM FLUID PRESSURE GAUGE3. RAISE FRONT BRAKE PRESSURE AND CHECKREAR WHEEL CYLINDER PRESSURE

When inspecting the fluid pressure, inspect the leftfront and right rear together, and the right front andleft rear together.

Rear wheel cylinder pressure kPa (kgf/cm2, psi)Front brake pressure kPa (kgf/cm2, psi)

2,942 (30.0, 427)7,845 (80.0, 1,138)

2,452 (25.0, 356)7,845 (80.0, 1,138)

2,452 (25.0, 356)7,845 (80.0, 1,138)

2,452 (25.0, 356)4,452 (45.4, 646)

2,942 (30.0, 427)4,168 (42.5, 604)

2,452 (25.0, 356)3,805 (38.8, 552)

4 M/T(w/o ABS)

Others(w/o ABS)

w/ ABS

-BRAKE SYSTEM PROPORTIONING VALVE (P VALVE)BR-39

If the rear wheel cylinder pressure is incorrect, replacethe P valve assembly.4. BLEED BRAKE SYSTEM5. CHECK FOR LEAKS

-BRAKE SYSTEM PROPORTIONING VALVE (P VALVE)BR-40

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 aminimum, even on curves.• In case a malfunction occurs, a diagnosis function and fail-safe system have been adopted for

the ABS.

ANTI-LOCK BRAKE SYSTEM (ABS)-BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS)

BR-41

From the wheel speed signals from each sensor, it calculates acceleration,deceleration and slip values and sends signals to the actuator to controlbrake fluid pressure.

Lights up to alert the driver when trouble has occurred in the Anti-LockBrake System.

Controls the brake fluid pressure to each brake cylinder through signals from the ECU.

Detect the wheel speed of each of the left and right front wheels.

Detect the wheel speed of each of the left and right rear wheels.

COMPONENTS FUNCTION

SYSTEM PARTS LOCATION

ABS Warning Light

Front Speed Sensor

Rear Speed Sensor

Component

A6S ECU

Function

Actuator

-BRAKE SYSTEM ANTI-LOCK BRAKE SYSTEM (ABS)BR-42

WIRING DIAGRAM


CONNECTORS


DIAGNOSIS SYSTEMDESCRIPTIONIf a malfunction occurs, the system will identify theproblem and the ECU will store the diagnostic troublecodes for the trouble items.At the same time, the system informs the driver of amalfunction via the ”ABS” warning light in the combi-nation meter.By turning on the ignition switch, disconnecting theservice connector and use SST to connect Tc and E1of the data link connector 1, the trouble can be ident-ified by the number of blinks (diagnostic trouble code)of the warning light.In the event of 2 codes, that having the smallestnumbered code will be identified 1st.HINT: The warning light does not show the diagnostictrouble codes while the vehicle is running.

DIAGNOSIS SYSTEM INSPECTION1. INSPECT BATTERY POSITIVE VOLTAGEInspect 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 3seconds.If not, inspect and repair or replace the fuse, bulb andwire harness.


(d) In event of a malfunction, 4 seconds later the warninglight will begin to blink. Read the number of blinks.(See DIAGNOSTIC TROUBLE CODE)HINT: The 1st number of blinks will equal the 1st digitof a 2 digit diagnostic trouble code. After a 1.5 secondpause, the 2nd number of blinks will equal the 2ndnumber of a 2 digit code. If there are 2 or more codes,there will be a 2.5 second pause between each, andindication will begin after 4.0 second pause from thesmaller value and continue in order to larger.(e) If the system is operating normally (no malfunction),the warning light will blink once every 0.5 seconds.(f) Repair the system.(g) After the malfunctioning components has been repai-red, clear the diagnostic trouble codes stored in theECU.HINT: If you disconnect the battery cable while repair-ing, all diagnostic trouble codes in the ECU will erased.(h) Remove the SST from terminals Tc and E1 of the datalink 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 onfor 3 seconds.

(c) Using SST, connect terminals Tc and E1 of the datalink connector 1.SST 09843-18020

3. READ DIAGNOSTIC TROUBLE CODE(a) Turn the ignition switch on.(b) Disconnect the service connector.


DIA

GN

OS

TIC

TR

OU

BLE

CO

DE

HIN

T: Using S

ST, connect the term

inals Tc and E

1, and disconnect the service connector.S

ST

09843-18020

� Pump motor, relay and battery� Wire harness, connector and ground bolt or actuator pump motor circuit

� Actuator inside wire harness� Control relay� Wire harness and connector of pump motor relay circuit

� Actuator inside wire harness� Control relay� Wire harness and connector of solenoid relay circuit

� Speed sensor� Sensor rotor� Wire harness and connector of speed sensor

Abnormal battery voltage (less than 9.5 V/more than16.2 V)

Open or short circuit in solenoid of front left wheel

Open or short circuit in solenoid of rear left wheel

Open circuit in front left or rear right wheel speed sensor

Open circuit in front right or rear left wheel speed sensor

� Actuator solenoid� Wire harness and connector of actuator solenoid circuit

Rear left wheel speed sensor signal malfunction

Actuator pump motor locked or open circuit in pumpmotor

Open or short circuit in solenoid of rear right wheel

. Front right wheel speed sensor signal malfunction

Rear right wheel speed sensor signal malfunction

Open or short circuit in solenoid of front right wheel

Front left wheel speed sensor signal malfunction

Short circuit in pump motor relay circuit

Short circuit in solenoid relay circuit

Open circuit in pump motor relay circuit

Open circuit in solenoid relay circuit

Wrong both rear axle hubs

� Battery� Voltage regulator

Light PatternDiagnosis

� Rear sensor rotors

Malfunction in ECU

Trouble PartCode No.

Always on

24

� ECU

33

32

37

34

36

35

23

22

-B

RA

KE

SY

ST

EM

AN

TI-LO

CK

BR

AK

E S

YS

TE

M (A

BS

)B

R-47

ECU TERMINAL VALUESMEASUREMENT USING TOYOTABREAK-OUT-BOX AND TOYOTAHAND-HELD TESTER1. Hook up the TOYOTA hand-held tester and TOYOTAbreak-out-box to the vehicle.2. Read the ECU input/output values by following theprompts on the tester screen.HINT: TOYOTA hand-held tester has a ”Snapshot”function. This records the measured values and iseffective in the diagnosis of intermittent problems.Please refer to the TOYOTA hand - held tester /TOYOTA break-out-box operator’s manual for fur-ther details.

DIAGNOSTIC TROUBLE CODES CLEARINGCLEAR DIAGNOSTIC TROUBLE CODES(a) Turn the ignition switch on.(b) Using SST, connect terminals Tc and E1 of the datalink connector 1.SST 09843-18020HINT: Keep the vehicle stationary.

(d) Check that the warning light shows the normal code.(e) Remove the SST from terminals Tc and E1 of the datalink connector 1.(f) Check that the warning light goes off.

(c) Clear the diagnostic trouble codes stored in the ECUby depressing the brake pedal 8 or more times within3 seconds.


� Also check the parts of the brake system (brake cylinder, pads, hydraulic line, etc.) not specifically part of the ABS.

Skidding noise occurs while ABS operating.(ABS operates inefficiently)

Does not come on for 3 seconds after ignition switched ON.

ABS operates just before stopping during normal braking.Brake pedal pulsates abnormally while ABS is operating.

Always comes on after ignition switch is turned ON.

ABS operates during normal braking.

TROUBLESHOOTING

Comes on while running.

Braking inefficient. �

”ABS” warning lightGoes on and off.

Brakes pull. �

Brake condition

Problem No.


Is there 10 - 14 V between terminal IG1 on ECU wireharness side connector and body ground? (ignitionswitch on)

Does warning light go off when both the ECUconnectors and service connector are disconnected?(Ignition switch on)

� Inspect control relay, and replace if necessary.� Short circuit in wire harness between service connector and control relay terminal W.

Does warning light show the diagnostic trouble code?(Ignition switch on)

Does warning light show the diagnostic normal code?(Ignition switch on)

Short circuit in wire harness between ECUterminal W and service connector or warning light.

Disconnect the service connector and connectterminals Tc and E1 of data link connector 1.

Are connector of ECU properly connected?And are all terminals in the connector?

”ABS” warning light comes on.

See diagnostic trouble code.

Faulty ECU connector.

Faulty power circuit.

YES(Goes off)

NO(Stays on)

Faulty ECU

YES

YES

YES

YES


HINT: If the diode is short-circuited, a malfunction atECU terminal W will occur. When inspecting the termi-nal, connect the ECU connector, and disconnect theservice connector. Then turn the ignition switched ON,and check that the warning light goes on. If it does, theECU terminal is OK.

Disconnect connectors from ECU and ground terminalW of ECU wire harness side connector. (Ignitionswitched ON)

With ignition switched off, disconnect control relayconnectors, and check continuity between terminalsW and GND on control relay.

Disconnect the service connector and ground the femaleside connector. (Ignition switched ON)

”ABS” warning light does not come on for 3 seconds after ignition switched ON.

Bulb burned out or open circuit in wire harnessbetween warning light and GAUGE fuse.

Reverse tester leads and check again.Is there one way continuity between terminals?

Open circuit in wire harness between ECUterminal W and warning light.

Short circuit in control relay inside diode.

Does warning light come on?

Does warning light come on?

Faulty ECU

YES

YES

YES


� 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.

Does any abnormal change occur in continuity whenthe connectors or wire harness of the speed sensor andintermediate connectors are twisted or bent?

Disconnect connectors from ECU, inspect continuitybetween each speed sensor terminals on wire harnessside.

� Check for short circuit in wire harness between terminal Tc or Ts and E1 of data link connector 1.

Disconnect the service connector and connect terminalsTc and E1 of data link connector 1.

Does warning light show the diagnostic normal code?(Ignition switched ON)

Try speed sensor diagnosis system: Is sensor signalchange OK?

Try speed sensor diagnosis system. Is sensor signallevel OK?

Is each speed sensor installed in place?And is each installation bolt tightened securely?

NO(No change)

Continued on next page

Inspect speed sensor, and replace if necessary.

Inspect sensor rotor, and replace if necessary.

”ABS” warning light goes on and off.

Speed sensor installation faulty.

YES

(Abnormal change)


Faulty wire harness.

YES

YES

YES

YES


Is there battery voltage between ECU terminal STP andbody ground when depressing brake pedal?

Disconnect the service connector and connect terminalsTc and E1 of data link connector 1.

Does warning light show the diagnostic normal code?(Ignition switched ON)

Open circuit in stop light switch and/ or wireharness.

Is there foreign material or ferric chips on the sensor tip?

Anti-lock brake system operations inefficiently.

Clean chips from the speed sensor.

Inspect the actuator operation.

Continued from previous page


Is actuator operation OK?

Inspect actuator.

Faulty actuator.

Replace ECU.

NO

YES

YES

YES

YES


SPEED SENSOR DIAGNOSIS SYSTEMDIAGNOSIS SYSTEM INSPECTIONPRECAUTIONWhile checking the speed sensor diagnosis system. ABSdoes not operate and brake system operates as a normalbrake system.1. INSPECT BATTERY POSITIVE VOLTAGEInspect 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 3seconds.If not inspect and repair or replace the fuse, bulb andwire 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 datalink connector 1 in the engine room.SST 09843-18020(b) Pull the parking brake lever up, and start the engine.

(c) Check that the warning light blinks about 4 timesevery 1 second, as shown.


(c) Read the number of blinks of the ”ABS” warning light.(See DIAGNOSTIC TROUBLE CODE)HINT: If normal, the warning light blinks 2 times every1 second.If 2 or more malfunctions are indicated at the sametime, the smallest numbered code will be displayed 1st.

6. REPAIR MALFUNCTIONING PARTSRepair or replace the malfunctioning parts.HINT: When repairing or replacing parts, turn theignition switch to OFF.7. REMOVE SSTRemove the SST from terminals Ts, Tc and E1 of thedata link connector 1.

5. READ DIAGNOSTIC TROUBLE CODE(a) Stop the vehicle, and warning light will begin to blink.(b) Using SST, connect the terminals Tc and E1 of thedata link connector 1.HINT: Do not disconnect Ts and E1.

4. DRIVE VEHICLE(a) Release the parking brake.(b) Drive the vehicle faster than 45 km/h (28 mph) forseveral seconds.


DIA

GN

OS

TIC

TR

OU

BLE

CO

DE

Low voltage of front right speed sensor signal

Abnormal change of rear right speed sensorsignal

Abnormal change of front right speed sensorsignal

Abnormal change of front left speed sensorsignal

Abnormal change of rear left speed sensorsignal

All speed sensors and sensor rotors are normal

Low voltage of rear right speed sensor signal

Low voltage of front left speed sensor signal

Low voltage of rear left speed sensor signal

� Rear right speed sensor� Sensor installation

� Rear left speed sensor� Sensor installation

� Front left speed sensor� Sensor installation

� Front right speed sensor� Sensor installation

� Front right sensor rotor

� Rear right sensor rotor

� Front left sensor rotor

� Rear left sensor rotor

Malfunctioning PartLight Pattern DiagnosisCode No.

72

74

78

77

73

75

76

-B

RA

KE

SY

ST

EM

AN

TI-LO

CK

BR

AK

E S

YS

TE

M (A

BS

)B

R-56

ABS ACTUATORABS ACTUATOR REMOVAL ANDINSTALLATIONRemove and install the parts, as shown.


MAIN POINTS OF REMOVAL ANDINSTALLATION1. DISCONNECT BRAKE LINESUsing SST, disconnect the brake lines from the ABSactuator.SST 09751 -36011

ABS ACTUATOR INSPECTION1. INSPECT BATTERY POSITIVE VOLTAGE

Battery positive voltage:10-14.5 V

2. DISCONNECT CONNECTORS(a) Disconnect the 2 connectors from the control relay.

3. REMOVE POWER STEERING HOSE CLAMP4. BLEED BRAKE SYSTEM

(See BRAKE SYSTEM BLEEDING)

2. REMOVE NO. 1 BRAKE TUBE W / GROMMETCLAMP

(b) Disconnect the connector from the actuator.


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 thesub-wire harness C and I (SST), as shown.SST 09990-00150, 09990-00200, 09990-00300(b) Connect the red cable of the checker to the batterypositive (+) terminal and black cable to the negative(-) terminal. Connect the black cable of the sub-wireharness to the battery negative (-) terminal or bodyground.

(c) Place the ”SHEET A” (SST) on the actuator checker.SST 09990-00163


4. INSPECT BRAKE ACTUATOR OPERATION(a) Start the engine, and run it at idle.(b) Turn the selector switch of the actuator checker to”FRONT RH” position.(c) Push and hold in the MOTOR switch for a few sec-onds. Make sure that you can hear the motor run.(d) Depress the brake pedal and hold it for about 15seconds, and check that the pedal does not go down.

5. (FOR OTHER WHEELS)(a) Turn the selector switch to ”FRONT LH” position.(b) Repeat (c) - (i) of step 4, check the actuator opera-tion as before.(c) Similarly, inspect ”REAR RH” and ”REAR LH” positionHINT: When inspecting ”REAR LH” position, push theREAR LH switch instead of the POWER SWITCH, andyou can inspect in any selector switch position.

(f) Depress the brake pedal and hold it. As you hold thepedal down, push and hold in the POWER SWITCH fora few seconds. Check that the pedal does not godown.(g) With your foot still applied onto the brake pedal,release the POWER SWITCH and check that the pedalgoes down.

(h) With your foot still applied on the brake pedal, pushthe MOTOR switch and check that the brake pedalpulsates.(i) Release the brake pedal.

(e) With your foot still applied onto the brake pedal, pushthe MOTOR switch and check that the brake pedaldoes not pulsate.


6. PUSH MOTOR SWITCH(a) Push and hold in the MOTOR switch for a few sec-onds.(b) Stop the engine.7. DISCONNECT ACTUATOR CHECKER (SST) FROMACTUATORRemove the ”SHEET A” (SST) and disconnect theactuator checker (SST) and sub-wire harness (SST)from the actuator, control relay and body side wireharness.8. CONNECT CONNECTORS(a) Connect the connector to the actuator.

9. CLEAR DIAGNOSTIC TROUBLE CODES(See DIAGNOSTIC TROUBLE CODES CLEARING)

(b) Connect the 2 connectors to the control relay.


(c) Connect the positive lead from the ohmmeter to ter-minal 4 and connect negative lead to terminal 5.(d) Check that there is continuity between terminals.(e) Connect the 2 leads in reverse, and check that there isno continuity between terminals.If continuity is not as specified, replace the relay.HINT: For the different type ohmmeter, there is nocontinuity 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 toterminal 1 and negative (-) lead to terminal 9.(b) Check that there is continuity between terminals 2and 5.(c) Check that there is no continuity between terminals 2and 6.If operation is not as specified, replace the relay.

CONTROL RELAYCONTROL RELAY INSPECTION1. INSPECT CONTINUITY OF MOTOR RELAY CIRCUIT(a) Check that there is continuity between terminals 9and 10.(b) Check that there is no continuity between terminals 7and 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 toterminal 10 and negative (-) lead to terminal 9.(b) Check that there is continuity between terminals 7and 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 1and 9.(b) Check that there is no continuity between terminals 2and 5.


(c) Measure the resistance between terminals.Resistance:0.92-1.22 k�

If resistance value is not as specified, replace thesensor.

(d) Check that there is no continuity between each termi-nal and sensor body.If there is continuity, replace the sensor.(e) Connect the speed sensor connector.(f) Install the fendershield.

FRONT SPEED SENSOR INSPECTION1. INSPECT SPEED SENSOR(a) Remove the fendershield.(b) Disconnect the speed sensor connector.

FRONT SPEED SENSORCOMPONENTS


FRONT SPEED SENSOR AND SENSORROTOR SERRATIONS INSPECTIONINSPECT FRONT SPEED SENSOR AND SENSORROTOR SERRATIONS BY USING OSCILLOSCOPE(a) Connect an oscilloscope to the speed sensor connec-tor.(b) Run the vehicle at 20 km/h (12.4 mph), and inspectspeed sensor output wave.(c) Check that C is 0.5 V or more.If not as specified, replace the speed sensor.(d) Check that B is 30% or more of A.If not as specified, replace the sensor rotor.

3. VISUALLY INSPECT SENSOR ROTOR SERRATIONS(a) Remove the drive shaft.(See SA section)(b) Inspect the sensor rotor serrations for scratches,cracks, warping or missing teeth.(c) Install the drive shaft.(See SA section)

NOTICE: To prevent damage to the serrations, do notstrike the drive shaft.

FRONT SPEED SENSOR REMOVAL1. DISCONNECT SPEED SENSOR CONNECTOR(a) Remove the fendershield.(b) Disconnect the speed sensor connector.

2. INSPECT SENSOR INSTALLATIONCheck that the sensor installation bolt is tightenedproperly. If not, tighten the bolt.

Torque: 7.8 N-m (80 kgf-cm, 69 in.-Ibf)


FRONT SPEED SENSOR INSTALLATION1. INSTALL SPEED SENSORInstall the speed sensor to the steering knuckle.


2. REMOVE SPEED SENSOR(a) Remove the 2 clamp bolts and a clip holding thesensor harness to the body and shock absorber.

2. CONNECT SPEED SENSOR CONNECTOR(a) Install the sensor harness.


(b) Connect the speed sensor connector.(c) Install the fendershield.

(b) Remove the speed sensor from the steering knuckle.


(d) Check that there is no continuity between each termi-nal and sensor body.If there is continuity, replace the sensor.(e) Connect the speed sensor connector.(f) Install the seat cushion.

(c) Measure the resistance between terminals.Resistance:0.9 -1.3 k�

If resistance value is not as specified, replace thesensor.

REAR SPEED SENSORINSPECTION1. INSPECT SPEED SENSOR(a) Remove the seat cushion.(b) Disconnect the speed sensor connector.

REAR SPEED SENSORCOMPONENTS


REAR SPEED SENSOR AND SENSOR ROTOR SERRATIONS INSPECTIONINSPECT REAR SPEED SENSOR AND SENSORROTOR SERRATIONS BY USING OSCILLOSCOPE(a) Connect an oscilloscope to the speed sensor connec-tor.(b) Run the vehicle at 20 km/h (12.4 mph), and inspectspeed sensor output wave.(c) Check that C is 0.5 V or more.If not as specified, replace the speed sensor.(d) Check that B is 30% or more of A.If not as specified, replace the brake drum.

3. VISUALLY INSPECT SENSOR ROTOR SERRATIONS(a) Remove the brake drum.(See SA section)(b) Inspect the sensor rotor serrations for scratches,cracks, warping or missing teeth.(c) Install the brake drum.(See SA section)

REAR SPEED SENSOR REMOVAL1. DISCONNECT SPEED SENSOR CONNECTOR(a) Remove the seat cushion.(b) Disconnect the speed sensor connector, and pull outthe sensor wire harness with the grommet.

2. INSPECT SENSOR INSTALLATIONCheck that the sensor installation bolt is tightenedproperly. If not, tighten the bolt.

Torque: 7.8 N-m (80 kgf-cm, 69 in.-Ibf)


REAR SPEED SENSOR INSTALLATION1. INSTALL SPEED SENSORInstall the speed sensor to the axle beam.


2. CONNECT SPEED SENSOR CONNECTOR(a) Pass the sensor harness through the body panel, andconnect the connector.

(c) Remove the 3 clamp bolts holding the sensor wireharness to the suspension arm.

2. REMOVE SPEED SENSORRemove the speed sensor from the axle beam.

(b) Install the grommet securely.


(c) Install the sensor harness.Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)


ANTI-LOCK BRAKE SYSTEM CIRCUITSYSTEM CIRCUIT INSPECTION1. INSPECT SYSTEM CIRCUIT WITH CONNECTORCONNECTED(a) Remove the ABS ECU.(b) Using a voltmeter with high impedance (10 k�/Vminimum), measure the voltage at each terminal andbody ground.

IG switch on and ”ABS” warning light goes off






IG switch on and ”ABS” warning light goes on

IG switch on and ”ABS” warning light goes on

IG switch on and DLC1 Ts-E 1 not connected

IG switch on and DLC1 Tc-E 1 not connected

lG switch on and DLC1 Ts-E 1 connected

IG switch off and brake pedal depressed

Engine running and PKB lever returned

IG switch on and DLC1 Tc-E 1 connected

IG switch off and brake pedal returned

Engine running and PKB lever pulled Parking lever switchLevel warning switch

Stop light switchStop light

TesterConnection

Specified Value Trouble Part

IG switch off

IG switch off

I G switch off

lG switch off

!G switch off

ECU-IG FuseIG switch on

Check Item

10 - 14.5 V

10 - 14.5 V

10-14.5 V

10 - 14.5 V

10 - 14.5 V

10 - 14.5 V

10 - 14.5 V

10-14.5 V

10 - 14.5 V

10 - 14.5 V

10 - 14.5 V DOME Fuse

10 - 14.5 V

Continuity

Continuity

Continuity

Continuity

Condition

Continuity

Continuity

Continuity

Continuity

Continuity Continuity

About 0 V

About 0 V

About 0 V

About 0 V

About 0 V

ABS ECU

ABS ECU

Voltage

Voltage

Voltage

Voltage

Voltage Actuator

Actuator

Voltage

Voltage

Voltage

Voltage

Voltage

Voltage

Voltage

SRRHSRRR

SFLRSFLH

PKB

BAT

STP

FSS

FR-

IG1

FL-

??

TC

TS

SR

W

R-


If the circuit is not as specified, check and repair orreplace the trouble part in the table above.





TesterConnection

Specified Value Trouble Part

IG switch off

IG switch off

Check Item

10-14.5 V

10 - 14.5 V

10 - 14.5 V

10 - 14.5 V

Continuity

Continuity

Condition

Continuity

Continuity

ABS ECU

Actuator

ABS ECU

Actuator

Voltage

Voltage

Voltage

Voltage

RR-

RL-

SRLH

SRLR

SFRH

SFRR


2. INSPECT SYSTEM CIRCUIT WITH CONNECTORDISCONNECTED(a) Disconnect the connectors from the ECU, inspect atthe wire harness side connector.

If the circuit is not as specified, check and repair or replacethe trouble part in the table above.(b) Connect the connectors, and install the ECU in place.

SRLR↔Body Ground

SRRH↔Body Ground

SRLH↔Body Ground

SFRH↔Body Ground

SRRR↔Body Ground

SFRR↔Body Ground

SFLH↔Body Ground

SFLR↔Body Ground

Front LHspeed sensor

Rear LHspeed sensor

Rear RHspeed sensor

Front RHspeed sensor

TesterConnection

TesterConnection

Specified Value

Specified Value

0.92-1.22 k�

0.92-1.22 k�Control relay

Control relay 0.9 - 1.3 k�

About 5.0�

0.9 - 1.3 k�

About 5.0�

Check Item

About 5.0 �

About 2.2�

About 5.0 �

Trouble Part

About 2.2 �

About 2.2 �

Trouble Part

About 2.2 �

FL + ↔ FL-Resistance

RL + ↔ RL- Resistance

Check Item

56 -68 �

Resistance

Resistance

72 - 88 � RR + ↔ RR-

Resistance

Resistance

Resistance

FR + ↔ FR- Continuity

Resistance

Resistance

Resistance

Resistance

Continuity

Resistance

Resistance

Resistance

Actuator

Actuator

Actuator

Actuator

Actuator

MR↔ R-

Actuator

Actuator

Actuator Actuator

R- ↔ SR

MT↔ Body Ground


SERVICE SPECIFICATIONSSERVICE DATA

Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf)

Brake booster push rod to piston clearance (W/SST)

Parking brake lever travel at 196 N (20 kgf, 44.1 lbf)

TORQUE SPECIFICATIONS

Front disc brake torque plate x Steering knuckle

Rear drum brake wheel cylinder x Backing plate

ABS actuator x ABS actuator No. 1 bracket

Brake pedal height (from asphalt sheet)

Front disc brake caliper installation bolt

Brake pedal height (from asphalt sheet)

Front disc brake caliper x Flexible hose

Master cylinder x Piston stopper bolt

ABS actuator installation bolt and nut

Front speed sensor installation bolt

Rear speed sensor installation bolt

143.0-153.0 mm (5.63-6.02 in.)

138.5-148.5 mm (5.45-5.85 in.)

Rear brake drum to shoe clearance

Master cylinder x Brake booster

Rear brake drum inside diameter

Rear brake drum inside diameter

Brake booster x pedal bracket

More than 50 mm (1.97 in.)

Brake booster clevis lock nut

Master cylinder x Reservoir

Rear brake lining thickness

Rear brake lining thickness

Front brake pad thickness

1-6 mm (0.04-0.24 in.)

Front brake pad thickness

Front brake disc thickness

Front brake disc thickness

Front brake disc runout 0.09 mm (0.0035 in.)

Brake pedal freeplay

10.0 mm (0.394 in.)

18.0 mm (0.709 in.)

17.0 mm (0.669 in.)

Brake tube union nut

181 mm (7.126 in.)

180 mm (7.087 in.)

4.0 mm (0.157 in.)

1.0 mm (0.039 in.)

0.6 mm (0.024 in.)

1.0 mm (0.039 in.)

Part tightened

0 mm (0 in.)

Bleeder plug

4 - 7 clicks

15.2 in.-lbf

48 in.-lbf

74 in.-lbf

69 in.-lbf

69 in.-lbf

kgf-cm

Others

4M/T

Limit

Limit

Limit

Limit

ft-lbf

Limit

17.5

STD

STD

310

900

260

100

130

100

130

155

195

STD

STD

255

5.4

7.8

N-m

7.8

8.3

-BRAKE SYSTEM SERVICE SPECIFICATIONSBR-73

BR-01BR-02BR-04BR-06BR-07BR-11BR-16BR-21BR-24BR-31BR-39BR-41BR-45BR-54BR-57BR-62BR-63BR-66BR-70BR-73

brake system - 123seminarsonly.com€¦ · brake system. brake booster operational test 1....

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