Brake System: Operating Check Airtight Check

BRAKE SYSTEM GI
SECTION BR MA
EM
LC
EC
CONTENTS FE
PRECAUTIONS ...............................................................3 OPERATING CHECK ...............................................19

CL
Supplemental Restraint System (SRS) ″AIR AIRTIGHT CHECK ...................................................19
BAG″ and ″SEAT BELT PRE-TENSIONER″...............3 Removal.....................................................................19 MT
Precautions for Brake System.....................................3 Inspection...................................................................19
Wiring Diagrams and Trouble Diagnosis.....................4 OUTPUT ROD LENGTH CHECK ..............................19
PREPARATION ...............................................................5 Installation..................................................................20 AT
Commercial Service Tools ...........................................5 VACUUM HOSE.............................................................21
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ...........................................21
TROUBLESHOOTING .....................................................6 Inspection...................................................................21 AX
NVH Troubleshooting Chart.........................................6 HOSES AND CONNECTORS ...................................21
CHECK VALVE ........................................................21
ON-VEHICLE SERVICE ..................................................7 SU
VACUUM PUMP ............................................................22
Checking Brake Fluid Level.........................................7
Removal.....................................................................22
Checking Brake Line ...................................................7
Installation..................................................................23
Changing Brake Fluid ..................................................7
Inspection...................................................................23
Brake Burnishing Procedure........................................7
Component ................................................................24
Bleeding Brake System ...............................................8
BRAKE HYDRAULIC LINE .............................................9
Disassembly...............................................................24 ST
Assembly ...................................................................24
Hydraulic Circuit...........................................................9
FRONT DISC BRAKE ...................................................26
Removal.......................................................................9
Component ................................................................26 RS
Inspection...................................................................10
Pad Replacement ......................................................27
Installation..................................................................10
Removal.....................................................................27
BRAKE PEDAL AND BRACKET..................................11
Disassembly...............................................................28
BT
Removal and Installation ...........................................11
Inspection...................................................................28
Inspection...................................................................11
CALIPER .................................................................28 HA
Adjustment .................................................................11
ROTOR ...................................................................28
MASTER CYLINDER (TOKICO) ...................................13
Assembly ...................................................................29
Removal.....................................................................13
Disassembly...............................................................14
Installation..................................................................29 SC
REAR DRUM BRAKE ...................................................30
Inspection...................................................................14
Components...............................................................30
Assembly ...................................................................14 EL
Removal.....................................................................30
Installation..................................................................15
Inspection - Wheel Cylinder ......................................31
MASTER CYLINDER [BOSCH (NABCO)] ...................16
Wheel Cylinder Overhaul...........................................32
Removal.....................................................................16
Inspection - Drum ......................................................32
IDX
Disassembly...............................................................16
Inspection - Lining .....................................................32
Inspection...................................................................17
Installation..................................................................32
Assembly ...................................................................17
REAR DISC BRAKE......................................................34
Installation..................................................................18
Component ................................................................34
BRAKE BOOSTER........................................................19
Pad Replacement ......................................................34
On-vehicle Service.....................................................19
CONTENTS (Cont’d)
Removal.....................................................................36 How to Perform Trouble Diagnoses for Quick
Disassembly...............................................................36 and Accurate Repair ..................................................65
Inspection...................................................................37 INTRODUCTION ......................................................65
CALIPER .................................................................37 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........66
ROTOR ...................................................................38 Preliminary Check......................................................66
Assembly ...................................................................38 Ground Circuit Check ................................................69
Installation..................................................................41 ABS ACTUATOR AND ELECTRIC UNIT GROUND.....69
PARKING BRAKE CONTROL ......................................42 TROUBLE DIAGNOSIS - GENERAL
Components...............................................................42 DESCRIPTION ...............................................................70
Removal and Installation ...........................................42 Malfunction Code/Symptom Chart.............................70
Inspection...................................................................42 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
Adjustment .................................................................43 ITEMS.............................................................................71
Wheel Sensor or Rotor..............................................71
ABS DIAGNOSTIC PROCEDURE .....................................71
ABS Actuator Solenoid Valve or Solenoid Valve
DESCRIPTION ...............................................................44 Relay..........................................................................74
Purpose......................................................................44 DIAGNOSTIC PROCEDURE .....................................74
ABS (Anti-Lock Brake System) Operation ................44 Motor Relay or Motor.................................................77
ABS Hydraulic Circuit ................................................44 DIAGNOSTIC PROCEDURE .....................................77
System Components .................................................45 Low Voltage ...............................................................79
System Description....................................................45 DIAGNOSTIC PROCEDURE .....................................79
SENSOR .................................................................45 Control Unit................................................................81
CONTROL UNIT ......................................................45 DIAGNOSTIC PROCEDURE .....................................81
ABS ACTUATOR AND ELECTRIC UNIT ....................45 TROUBLE DIAGNOSES FOR SYMPTOMS .................82
Component Parts and Harness Connector 1. ABS Works Frequently ..........................................82
Location .....................................................................47 2. Unexpected Pedal Action ......................................82
Schematic/Sedan.......................................................48 3. Long Stopping Distance ........................................83
Wiring Diagram - ABS -/Sedan..................................49 4. ABS Does Not Work..............................................84
Schematic/Hatchback ................................................53 5. Pedal Vibration and Noise.....................................85
Wiring Diagram - ABS -/Hatchback ...........................54 6. ABS Warning Lamp Does Not Come On
ON BOARD DIAGNOSTIC SYSTEM When Ignition Switch Is Turned On...........................86
DESCRIPTION ...............................................................57 7. ABS Warning Lamp Stays On When Ignition
Self-diagnosis ............................................................57 Switch Is Turned On ..................................................88
FUNCTION ..............................................................57 REMOVAL AND INSTALLATION .................................90
SELF-DIAGNOSIS PROCEDURE ..............................57 Wheel Sensors ..........................................................90
HOW TO READ SELF-DIAGNOSTIC RESULTS
ABS Actuator and Electric Unit..................................91
(MALFUNCTION CODES) ........................................57
REMOVAL ...............................................................91
HOW TO ERASE SELF-DIAGNOSTIC RESULTS
INSTALLATION........................................................91
(MALFUNCTION CODES) ........................................58
Sensor Rotor..............................................................92
CONSULT-II ...............................................................59
REMOVAL ...............................................................92
CONSULT-II APPLICATION TO ABS..........................59
INSTALLATION........................................................92
ECU (ABS CONTROL UNIT) PART NUMBER
MODE .....................................................................59
SERVICE DATA AND SPECIFICATIONS (SDS) .........93
CONSULT-II Inspection Procedure............................59
SELF-DIAGNOSIS PROCEDURE ..............................59
General Specifications...............................................93
SELF-DIAGNOSTIC RESULTS MODE.......................61 Disc Brake .................................................................94
DATA MONITOR PROCEDURE ................................62 Drum Brake................................................................94
ACTIVE TEST PROCEDURE ....................................63 Brake Pedal ...............................................................94
DATA MONITOR MODE ...........................................64 Parking Brake ............................................................94
ACTIVE TEST MODE ...............................................64
TROUBLE DIAGNOSIS - INTRODUCTION..................65
BR-2
PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
Supplemental Restraint System (SRS) “AIR

BAG” and “SEAT BELT PRE-TENSIONER”
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with
NJBR0081
GI
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo- MA
sition varies according to the destination and optional equipment.):
I For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer- EM
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
I For a side collision LC
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). EC
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING: FE
I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be per-
formed by an authorized NISSAN dealer. CL
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section. MT
I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just
before the harness connectors or for the complete harness are related to the SRS. AT
AX
SU
Precautions for Brake System NJBR0002 ST

I Recommended fluid is brake fluid “DOT 3 or DOT 4”.
I Never reuse drained brake fluid.
I Be careful not to splash brake fluid on painted areas. RS
I To clean or wash all parts of master cylinder, disc brake
caliper and wheel cylinder, use clean brake fluid.
I Never use mineral oils such as gasoline or kerosene. They
BT
will ruin rubber parts of the hydraulic system.
I Use flare nut wrench when removing and installing brake HA
tube.
SBR686C
I Always torque brake lines when installing.
I Burnish the brake contact surfaces after refinishing or SC
replacing drums or rotors, after replacing pads or linings,
or if a soft pedal occurs at very low mileage.
Refer to “Brake Burnishing Procedure”, “ON-VEHICLE EL
SERVICE”, BR-7.
WARNING: IDX
I Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.
BR-3
PRECAUTIONS
Wiring Diagrams and Trouble Diagnosis
Wiring Diagrams and Trouble Diagnosis NJBR0003

When you read wiring diagrams, refer to the following:
I GI-11, “HOW TO READ WIRING DIAGRAMS”
I EL-11, “POWER SUPPLY ROUTING”
When you perform trouble diagnosis, refer to the following:
I GI-32, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSIS”
I GI-21, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”
BR-4
PREPARATION
Commercial Service Tools
Commercial Service Tools NJBR0004
Tool name Description GI

1 Flare nut crowfoot Removing and installing each brake piping
2 Torque wrench a: 10 mm (0.39 in)
MA
EM
NT360
Brake fluid pressure Measuring brake fluid pressure

gauge
LC
EC
NT151 FE
CL
MT
AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
BR-5
tom
Symp-
X: Applicable
Reference page
(Possible cause)
BRAKE
SUSPECTED PARTS
der
Noise
Shake
NVH Troubleshooting Chart
Shimmy, Jud-
X
Linings or pads - damaged BR-27, 32, 34
X
Linings or pads - uneven wear BR-27, 32, 34
X
Return springs damaged BR-30
X
Shims damaged BR-26, 34
X
X
Rotor or drum imbalance —
X
Rotor or drum damage —
BR-6
X
Rotor runout BR-28, 38
X
X Rotor or drum deformation —
Rotor or drum deflection —

X
Rotor or drum rust —

X
Rotor thickness variation BR-29, 38

NVH Troubleshooting Chart
Drum out of round BR-32

X
X
DRIVE SHAFT NVH in FA section

X
X
X
AXLE AND SUSPENSION NVH in FA section

X
X
X
TIRES NVH in FA, RA section

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
X
X
ROAD WHEEL NVH in FA section

X
X
X
STEERING NVH in ST section

Use the table below to help you find the cause of the symptom. If necessary, repair or replace these parts.
NJBR0005S01
NJBR0005
ON-VEHICLE SERVICE
Checking Brake Fluid Level
Checking Brake Fluid Level NJBR0006

I Check fluid level in reservoir tank. It should be between Max
and Min lines on reservoir tank. GI
I If fluid level is extremely low, check brake system for leaks.
I Release parking brake lever and see if brake warning lamp MA
goes off. If not, check brake system for leaks.
EM
SBR451D LC
Checking Brake Line NJBR0007
CAUTION: EC
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration FE
or other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running. CL
SBR389C
MT
Changing Brake Fluid NJBR0008
CAUTION: AT
I Refill with new brake fluid “DOT 3 or DOT 4”.
I Always keep fluid level higher than minimum line on res-
ervoir tank.
AX
I Be careful not to splash brake fluid on painted areas; it SU
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
1. Clean inside of reservoir tank, and refill with new brake fluid.
SBR419C
2. Connect a vinyl tube to each air bleeder valve.
3. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
ST
4. Refill until brake fluid comes out of each air bleeder valve.
Use same procedure as in bleeding hydraulic system to refill RS
brake fluid. Refer to “Bleeding Brake System”, BR-8.
BT
HA
Brake Burnishing Procedure NJBR0036

SC
Burnish 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. EL
CAUTION:
Only perform this procedure under safe road and traffic con- IDX
ditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31
MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a
complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
BR-7
ON-VEHICLE SERVICE
Brake Burnishing Procedure (Cont’d)
pressure such that vehicle stopping time equals 3 to 5 sec-
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.
Bleeding Brake System NJBR0009

CAUTION:
I Carefully monitor brake fluid level at master cylinder dur-
ing bleeding operation.
I Fill reservoir with new brake fluid “DOT 3 or DOT 4”. Make
sure it is full at all times while bleeding air out of system.
I Place a container under master cylinder to avoid spillage
of brake fluid.
I For models with ABS, turn ignition switch OFF and dis-
connect ABS actuator connectors or battery ground cable.
SBR995
I Bleed air in the following order.

Right rear brake , Left front brake , Left rear brake , Right
front brake
1. 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 release
air.
4. Close air bleeder valve.
5. Release brake pedal slowly.
6. Repeat steps 2. through 5. until clear brake fluid comes out of
SBR419C air bleeder valve.
BR-8
BRAKE HYDRAULIC LINE
Hydraulic Circuit
Hydraulic Circuit NJBR0010
GI
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
ST
RS
BT
SBR751E
HA
Removal NJBR0011
SC
CAUTION:
I Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on EL
painted areas, wash it away with water immediately.
I All hoses must be free from excessive bending, twisting
and pulling.
IDX
1. Connect vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
SBR992
BR-9
BRAKE HYDRAULIC LINE
Removal (Cont’d)
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.
Inspection NJBR0012
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
Installation NJBR0013
CAUTION:
1. Tighten all flare nuts and connecting bolts.
Specification:
Flare nut
15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
Connecting bolt
SBR686C 17 - 20 N·m (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-8.
BR-10
BRAKE PEDAL AND BRACKET
Removal and Installation
Removal and Installation NJBR0015
GI
MA
EM
LC
EC
FE
CL
JBR752E
MT
Inspection NJBR0016
Check brake pedal for following items. AT
I Brake pedal bend
I Clevis pin deformation AX
I Crack of any welded portion
I Crack or deformation of clevis pin stopper
SU
SBR997
Adjustment NJBR0017 ST
Check brake pedal free height from metal panel. Adjust if neces-
sary.
H: Free height RS
Refer to SDS, BR-94.
C1, C2: Clearance between pedal stopper and threaded
end of stop lamp switch and brake switch BT
0.74 - 1.96 mm (0.0291 - 0.0772 in)
D: Depressed height HA
LHD (M/T): More than 90 mm (3.54 in)
LHD (A/T): More than 95 mm (3.74 in)
RHD (M/T): More than 90 mm (3.54 in) SC
RHD (A/T): More than 95 mm (3.74 in)
Under force of 490 N (50 kg, 110 lb) with engine run- EL
ning
A: Pedal free play at pedal pad
1.0 - 3.0 mm (0.039 - 0.118 in) IDX
SBR657EA
BR-11
BRAKE PEDAL AND BRACKET
Adjustment (Cont’d)
1. Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
2. Check pedal free play.
Make sure that stop lamps go off when pedal is released.
3. Check brake pedal’s depressed height while engine is running.
If lower than specification, check brake system for leaks, accu-
mulation of air or any damage to components (master cylinder,
wheel cylinder, etc.); then make necessary repairs.
SBR229E
BR-12
MASTER CYLINDER (TOKICO)
Removal
Removal NJBR0112
GI
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
SBR554EA
1. Reservoir cap 5. Cylinder body 8. Secondary piston assembly

2. Oil filter 6. O-ring 9. Primary piston assembly
3. Reservoir tank 7. Piston stopper 10. Stopper cap ST
4. Seal
RS
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted BT
areas, wash it away with water immediately.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brake HA
pedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts. SC
4. Remove master cylinder mounting nuts.
EL
IDX
BR-13
Disassembly
Disassembly NJBR0113
1. Bend claws of stopper cap outward and remove stopper cap.
SBR938A
2. Remove valve stopper while piston is pushed into cylinder.

3. Remove piston assemblies.
If it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.
4. Draw out reservoir tank.
SBR231C
Inspection NJBR0114
Check for the following items.
Replace any part if damaged.
Master cylinder:
I Pin holes or scratches on inner wall.
Piston:
I Deformation of or scratches on piston cups.
Assembly NJBR0115
1. Insert secondary piston assembly. Then insert primary piston
assembly.
I Pay attention to alignment of secondary piston slit with valve
stopper mounting hole of cylinder body.
SBR354C
2. Install stopper cap.

Before installing stopper cap, ensure that claws are bent
inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.
SBR940A
BR-14
Assembly (Cont’d)
5. Install valve stopper while piston is pushed into cylinder.
GI
MA
EM
SBR222B LC
CAUTION: EC
I Refill with new brake fluid “DOT 3”.
1. Place master cylinder onto brake booster and secure mount- FE
ing nuts lightly.
2. Torque mounting nuts.
: 12 - 15 N·m (1.2 - 1.5 kg-m, 9 - 11 ft-lb)
CL
3. Fill up reservoir tank with new brake fluid.
SBR704C
4. Plug all ports on master cylinder with fingers to prevent air MT
suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no
air comes out of master cylinder. AT
6. Fit brake lines to master cylinder.
7. Tighten flare nuts. AX
: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
8. Bleed air from brake system. Refer to “Bleeding Brake
System”, BR-8. SU
ST
RS
BT
HA
SC
EL
IDX
BR-15
MASTER CYLINDER [BOSCH (NABCO)]
Removal
Removal NJBR0117
SBR766E
1. Reservoir cap 5. Cylinder body 8. Secondary piston assembly

2. Oil filter 6. Elastic pin 9. Primary piston assembly
3. Reservoir tank 7. Piston stopper pin 10. Circlip
4. Seal
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brake
pedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.
1. Remove the circlip.
BR-16
Disassembly (Cont’d)
2. Drive out elastic pin from cylinder body.
3. Remove reservoir tank and seals.
GI
MA
EM
SBR231E LC
4. Remove piston stopper pin while piston is pushed into cylinder.
5. Remove piston assemblies.
If it is difficult to remove secondary piston assembly,
EC
gradually apply compressed air through fluid outlet.
FE
CL
SBR232E
MT
Inspection NJBR0119
Check for the following items. AT
Replace any part if damaged.
Master cylinder:
I Pin holes or scratches on inner wall.
AX
Piston:
I Deformation of or scratches on piston cups. SU
Assembly NJBR0120 ST
1. Insert secondary piston assembly. Then insert primary piston
assembly.
I Pay attention to alignment of secondary piston slit with RS
valve stopper mounting hole of cylinder body.
BT
HA
SBR233E
2. Install piston stopper pin while piston is pushed into cylinder. SC

Then secure the primary and secondary piston assemblies
with circlip.
3. Push reservoir tank seals and reservoir tank into cylinder body. EL
4. Install elastic pin.
IDX
SBR232E
BR-17
Installation
CAUTION:
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Torque mounting nuts.
: 13 - 15 N·m (1.3 - 1.5 kg-m, 9 - 11 ft-lb)
3. Fill up reservoir tank with new brake fluid.
SBR236E
4. Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no
air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts.
: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
8. Bleed air from brake system.
BR-18
BRAKE BOOSTER
On-vehicle Service
On-vehicle Service NJBR0023

OPERATING CHECK
1. Stop engine and depress brake pedal several times. Check
NJBR0023S01
GI
that pedal stroke does not change.
2. Depress brake pedal, then start engine. If pedal goes down MA
slightly, operation is normal.
AIRTIGHT CHECK NJBR0023S02 EM
1. Start engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. The pedal should go further
SBR002A down the first time, and then it should gradually rise thereaf- LC
ter.
2. Depress brake pedal while engine is running, and stop engine
with pedal depressed. The pedal stroke should not change EC
after holding pedal down for 30 seconds.
FE
CL
SBR365AA
MT
Removal NJBR0024
CAUTION: AT
I Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately. AX
I Be careful not to deform or bend brake pipes, during
removal of booster.
SU
SBR232CB
Inspection NJBR0025 ST
OUTPUT ROD LENGTH CHECK NJBR0025S01
1. Apply vacuum of −66.7 kPa (−667 mbar, −500 mmHg, −19.69
inHg) to brake booster with a handy vacuum pump. RS
2. Add preload of 19.6 N (2 kg, 4.4 lb) to output rod.
3. Check output rod length.
BT
Specified length:
10.275 - 10.525 mm (0.4045 - 0.4144 in)
HA
SBR208E
SC
EL
IDX
BR-19
BRAKE BOOSTER
Installation
CAUTION:
I Be careful not to deform or bend brake pipes, during
installation of booster.
I Replace clevis pin if damaged.
I Take care not to damage brake booster mounting bolt
thread when installing. Due to the acute angle of
installation, the threads can be damaged with the dash
panel.
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket to
master cylinder) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
Specification:
13 - 16 N·m (1.3 - 1.6 kg-m, 9 - 12 ft-lb)
5. Install master cylinder. Refer to “Installation” in “MASTER
CYLINDER”, BR-15, 18.
SBR237EA
BR-20
VACUUM HOSE
Removal and Installation

CAUTION:
When installing vacuum hoses, pay attention to the following GI
points.
I Do not apply any oil or lubricants to vacuum hose and
check valve.
MA
I Insert vacuum tube into vacuum hose as shown.
I Install check valve, paying attention to its direction. EM
SBR225B LC
Inspection NJBR0028
HOSES AND CONNECTORS NJBR0028S01
EC
Check vacuum lines, connections and check valve for airtightness,
improper attachment chafing and deterioration.
FE
CL
MT
CHECK VALVE NJBR0028S02
Check vacuum with a vacuum pump. AT
Connect to booster side Vacuum should exist.
Connect to engine side Vacuum should not exist. AX
SU
SBR844B
ST
RS
BT
HA
SC
EL
IDX
BR-21
VACUUM PUMP
Removal
Removal NJBR0123
SBR631E
1. Remove parts shown below.

I Air duct, air cleaner case (upper)
I Engine cover
I Rocker cover
I Exhaust manifold cover
I EGR tube
2. Disconnect vacuum hose from vacuum pump.
3. Remove cylinder head rear cover plate.
I Use a tool such as seal cutter (SST) to remove.
4. Loosen and remove rear cam sprocket installation bolts.
I Camshaft should not be attached. Using engine inner
resistance, loosen installation bolts.
5. Remove vacuum pump and cylinder head rear cover assem-

bly.
I Remove and install vacuum pump, sprocket, drive chain, and
chain guide as an assembly.
I Loosen mounting bolts in the reverse order of the numbers
shown in the figure to the left.
I Remove only bolts that are shown in the figure. (Be especially
careful not to remove M6 bolts on the vacuum pump.)
I Use a tool such as a seal cutter (SST).
SBR632E
BR-22
VACUUM PUMP
Installation
1. Assemble vacuum pump and cylinder head rear cover
assembly, referring to “Component” in the next page. GI
2. Install vacuum pump and cylinder head rear cover assembly to
cylinder head.
MA
a. Apply ThreeBond 1207C (KP510 00150) without breaks to the
location shown in the figure to the left.
EM
SBR633E LC
b. Tighten the mounting bolts in the numerical order shown by the
figure to the left.
3. Install rear cam sprocket installation bolts.
EC
4. Remove sprocket retaining two M6 bolts.
I M6 bolts will be used for installation. FE
5. Tighten rear cam sprocket installation bolts.
I Camshaft should not be fixed. Using engine inner resistance,
tighten installation bolts. CL
SBR632E
MT
6. Install cylinder head rear cover plate.
I Apply ThreeBond 1207C (KP510 00150) without breaks to the AT
location shown by the figure to the left.
7. Install parts in the reverse order of removal.
CAUTION:
AX
If the engine is started with vacuum pump released (vacuum
hose disconnected), it causes increase of blowby gas amount,
and engine damage may result. When starting the engine, be
SU
sure to close vacuum circuit.
SBR634E
I Remove vacuum hose. Then, connect vacuum gauge with
three-way connector.
I Install three-way connector to the area where vacuum pump RS
negative pressure can be directly measured. (The figure
shown an example.)
I Start the engine, then measure negative pressure. BT
Standard: −86.6 to −101.3 kPa (−866 to −1,013 mbar,
−650 to −760 mmHg, −25.59 to −29.92 inHg)
HA
I If it is not within standard, inspect for suction of air in the middle
SBR611E of route and measure it again.
I If it is still not within standard value, replace the vacuum pump. SC
EL
IDX
BR-23
VACUUM PUMP
Component
Component NJBR0126
SBR612E
Disassemble the components, referring to the “Component”, then
remove vacuum pump.
CAUTION:
Do not disassemble vacuum pump. (Do not loosen three M6
bolts.)
SBR613E
Assembly NJBR0127
Install all parts to cylinder head rear cover as follows.
1. Install vacuum pump.
2. Install chain guide temporarily.
I Adjust the chain guide position by the method explained in step
5.
3. Install rear cam sprocket.

I Installation direction of sprocket is not specified.
I Insert 2 thickness gauges [3.0 mm (0.118 in)] between cover
and rear cam sprocket (shown in the figure). Insert 2 bolts [M6,
thread length: 35 - 40 mm (1.38 - 1.57 in)] into sprocket to
retain it to cover.
I Use thickness gauges [3.0 mm (0.118 in)] for chain alignment
between vacuum pump sprocket and cam sprocket.
4. Attach drive chain to rear cam sprocket and vacuum pump
sprocket.
SBR614E 5. Tighten chain guide installation bolt while pressing chain guide
BR-24
VACUUM PUMP
Assembly (Cont’d)
lightly [approximately 9.8 N (1.0 kg, 2.2 lb)].
6. Remove thickness gauges (2).
I Leave sprocket retaining bolts (M6) until installation. GI
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
BR-25
FRONT DISC BRAKE
Component
Component NJBR0030
SBR579EA
1. Main pin 7. Inner pad 13. Main pin bolt

2. Pin boot 8. Pad retainer 14. Bleed valve
3. Torque member fixing bolt 9. Outer pad 15. Cylinder body
4. Torque member 10. Outer shim 16. Piston seal
5. Shim cover 11. Connecting bolt 17. Piston
6. Inner shim 12. Copper washer 18. Piston boot
SBR615E
1. Main pin 7. Inner pad 13. Main pin bolt

2. Pin boot 8. Pad retainer 14. Bleed valve
3. Torque member fixing bolt 9. Outer pad 15. Cylinder body
4. Torque member 10. Outer shim 16. Piston seal
5. Shim cover 11. Connecting bolt 17. Piston
6. Inner shim 12. Copper washer 18. Piston boot
BR-26
FRONT DISC BRAKE
Pad Replacement
Pad Replacement NJBR0029

WARNING:
Clean brake pads with a vacuum dust collector to minimize the GI
hazard of airborne particles or other materials.
CAUTION: MA
I When cylinder body is open, do not depress brake pedal
because piston will pop out.
I Be careful not to damage piston boot or get oil on rotor. EM
Always replace shims when replacing pads.
I If shims are rusted or show peeling of the rubber coat,
replace them with new shims. LC
I It is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly. In this
case, suspend cylinder body with wire so as not to stretch EC
brake hose.
I Burnish the brake contact surfaces after refinishing or
FE
Refer to “Brake Burnishing Procedure”, “ON-VEHICLE CL
SERVICE”, BR-7.
MT
1. Remove master cylinder reservoir cap.
2. Remove pin bolt. AT
3. Open cylinder body upward. Then remove pad with retainers,
inner and outer shims.
Standard pad thickness: AX
11 mm (0.43 in)
Pad wear limit: SU
2.0 mm (0.079 in)
Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.
SBR976B
ST
RS
BT
HA
SBR932C
Removal NJBR0031
SC
WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials. EL
Remove torque member fixing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for dis- IDX
assembly or replacement of caliper assembly. In this case,
suspend caliper assembly with wire so as not to stretch brake
hose.
SBR979B
BR-27
FRONT DISC BRAKE
Disassembly
WARNING:
Do not place your fingers in front of piston.
CAUTION:
Do not scratch or score cylinder wall.
1. Push out piston with piston boot with compressed air.
2. Remove piston seal with a suitable tool.
SBR772
Inspection NJBR0033
CALIPER NJBR0033S01
Cylinder Body NJBR0033S0101
I Check inside surface of cylinder for score, rust, wear, damage
or presence of foreign materials. If any of the above conditions
are observed, replace cylinder body.
I Minor damage from rust or foreign materials may be eliminated
by polishing surface with a fine emery paper. Replace cylinder
body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
Piston NJBR0033S0102
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign materials are stuck to sliding
surface.
Check piston for score, rust, wear, damage or presence of foreign
materials. Replace if any of the above conditions are observed.
Slide Pin, Pin Bolt and Pin Boot NJBR0033S0103
Check for wear, cracks or other damage. Replace if any of the
above conditions are observed.
ROTOR NJBR0033S02
Rubbing Surface NJBR0033S0201
Check rotor for roughness, cracks or chips.
Runout NJBR0033S0202
1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the
specifications before measuring. Refer to AX section
(“Front Wheel Bearing”, “ON-VEHICLE SERVICE”).
Maximum runout:
0.07 mm (0.0028 in)
3. If the runout is out of specification, find minimum runout posi-
tion as follows:
SBR219C a. Remove nuts and rotor from wheel hub.
BR-28
FRONT DISC BRAKE
Inspection (Cont’d)
b. Shift the rotor one hole and secure rotor to wheel hub with
nuts.
c. Measure runout. GI
d. Repeat steps a. to c. so that minimum runout position can be
found.
4. If the runout is still out of specification, turn rotor with on-car MA
brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or
equivalent).
EM
LC
Thickness NJBR0033S0203
Thickness variation (At least 8 positions): EC
Maximum 0.01 mm (0.0004 in)
If thickness variation exceeds the specification, turn rotor with on-
car brake lathe. FE
Rotor repair limit:
20.0 mm (0.787 in)
CL
MT
Assembly NJBR0034
1. Insert piston seal into groove on cylinder body. AT
2. With piston boot fitted to piston, insert piston boot into groove
on cylinder body and install piston.
AX
3. Properly secure piston boot.
SU
SBR574
Installation NJBR0035 ST
CAUTION:
I Never reuse drained brake fluid. RS
1. Install brake hose to caliper securely.
2. Install all parts and secure all bolts.
BT
HA
SBR980B
SC
EL
IDX
BR-29
REAR DRUM BRAKE
Components
Components NJBR0128
SBR616E
1. Boot 6. Shoe hold-down pin 11. Retainer ring

2. Piston 7. Plug 12. Return spring (Upper)
3. Piston cap 8. Brake drum 13. Return spring (Lower)
4. Spring 9. Shoe hold-down spring 14. Spring
5. Wheel cylinder 10. Adjuster 15. Toggle lever
Removal NJBR0129
WARNING:
Clean brake lining with a vacuum dust collector to minimize
the hazard of airborne materials.
CAUTION:
Make sure parking brake lever is completely released.
BR-30
REAR DRUM BRAKE
Removal (Cont’d)
1. Release parking brake lever fully, then remove drum.
If drum is hard to remove, the following procedures
should be carried out. GI
a. Remove plug. To make shoe clearance, push shoe hold-
down spring to free toggle lever.
MA
EM
SBR617E LC
b. Install two bolts as shown. Tighten the two bolts gradually.
EC
FE
CL
SBR020A
MT
2. After removing retainer, remove spring by rotating shoes.
I Be careful not to damage wheel cylinder piston boots. AT
I Be careful not to damage parking brake cable when sepa-
rating it.
3. Remove adjuster. AX
4. Disconnect parking brake cable from toggle lever.
SU
SBR214B
5. Remove retainer ring with a suitable tool. Then separate toggle

lever and brake shoe. ST
RS
BT
HA
SBR329C
Inspection — Wheel Cylinder NJBR0130

SC
I Check wheel cylinder for leakage.
I Check for wear, damage and loose conditions. Replace if any
such condition exists.
EL
IDX
SBR330C
BR-31
REAR DRUM BRAKE
Wheel Cylinder Overhaul
Wheel Cylinder Overhaul NJBR0131

I Check all internal parts for wear, rust and damage. Replace if
necessary.
I Pay attention so as not to scratch cylinder when installing pis-
tons.
SBR215B
Inspection — Drum NJBR0132

Maximum inner diameter:
204.5 mm (8.05 in)
Maximum out-of-round:
0.03 mm (0.0012 in)
I Contact surface should be fine finished with No. 120 to 150
emery paper.
I Using a drum lathe, resurface brake drum if it shows scoring,
partial wear or stepped wear.
SBR022A
I After brake drum has been completely reconditioned or
replaced, check drum and shoes for proper contact pattern.
Inspection — Lining NJBR0133

Check lining thickness.
Standard lining thickness:
4.5 mm (0.177 in)
Lining wear limit:
1.5 mm (0.059 in)
SMA849B
I Always perform shoe clearance adjustment. Refer to
BR-43.
or if a soft pedal occurs at very low mileage. Refer to
“Brake Burnishing Procedure”, “ON-VEHICLE SERVICE”,
BR-7.
1. Fit toggle lever to brake shoe with retainer ring.
2. Apply brake grease to the contact areas shown at left.
SBR618E
BR-32
REAR DRUM BRAKE
Installation (Cont’d)
3. Shorten adjuster by rotating it.
I To tighten loosened brake shoes, first, insert a screw driver in
the direction shown in the left. Then, move the adjuster in the GI
direction shown by the arrow while disengaging the tooth con-
tact. Never tap the area E.
4. Connect parking brake cable to toggle lever. MA
5. Install all parts.
Be careful not to damage wheel cylinder piston boots.
EM
6. Check all parts are installed properly.
Pay attention to direction of adjuster assembly.
SBR619E 7. Install brake drum. LC
8. When installing new wheel cylinder or overhauling wheel
cylinder, bleed air. Refer to “Bleeding Brake System”, BR-8.
9. Adjust parking brake. Refer to BR-43. EC
FE
CL
MT
AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
BR-33
REAR DISC BRAKE
Component
Component NJBR0038
SBR753E
1. Cable guide 11. Outer shim 21. Snap ring A

2. Cylinder 12. Strut 22. Washer
3. Toggle lever 13. O-ring 23. Wave washer
4. Pin 14. Push rod 24. Washer
5. Pin boot 15. Key plate 25. Bearing
6. Torque member 16. Retaining washer 26. Adjuster
7. Inner shim 17. Spring 27. Cup
8. Inner pad 18. Spring cover 28. Piston
9. Pad retainer 19. Snap ring B 29. Piston boot
10. Outer pad 20. Piston seal
Pad Replacement NJBR0037

WARNING:
CAUTION:
I When cylinder body is open, do not depress brake pedal
because piston will pop out.
I Be careful not to damage piston boot or get oil on rotor.
Always replace shims in replacing pads.
I If shims are rusted or show peeling of rubber coat, replace
them with new shims.
BR-34
REAR DISC BRAKE
Pad Replacement (Cont’d)
I It is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly. In this
case, suspend cylinder body with wire so as not to stretch GI
brake hose.
replacing drums or rotors, after replacing pads or linings, MA
Refer to “Brake Burnishing Procedure”, “ON-VEHICLE
SERVICE”, BR-7. EM
LC
1. Remove master cylinder reservoir cap.
2. Remove brake cable mounting bolt and lock spring.
EC
3. Release parking brake control lever, then disconnect cable
from the caliper.
4. Remove upper pin bolt. FE
5. Open cylinder body downward. Then remove pad retainers,
and inner and outer shims.
Standard pad thickness: CL
9.3 mm (0.366 in)
Pad wear limit: MT
SBR764E
2.0 mm (0.079 in)
AT
AX
SU
SBR916C
6. When installing new pads, push piston into cylinder body by

gently turning piston clockwise, as shown. ST
Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.
RS
BT
HA
SBR641
7. Adjust the piston to the right angle as shown in the figure. SC
EL
IDX
SBR306E
BR-35
REAR DISC BRAKE
Pad Replacement (Cont’d)
8. As shown in the figure, align the piston’s concave to the pad’s
convex, then install the cylinder body to the torque member.
9. Install brake cable, brake cable mounting bolt, lock spring and
master cylinder reservoir cap.
SBR307E
Removal NJBR0039
WARNING:
1. Remove brake cable mounting bolt and lock spring.
2. Release parking brake control lever, then disconnect cable
from the caliper.
3. Remove torque member fixing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for dis-
assembly or replacement of caliper assembly. In this case,
NBR167
suspend caliper assembly with wire so as not to stretch brake
hose.
1. Remove piston by turning it counterclockwise with long nose
pliers or suitable tool.
SBR646
2. Pry off ring A from piston with suitable pliers and remove
adjusting nut.
SBR889
BR-36
REAR DISC BRAKE
Disassembly (Cont’d)
3. Disassemble cylinder body.
a. Pry off ring B with suitable pliers, then remove spring cover,
spring and seat. GI
b. Remove washer, key plate, push rod, O-ring and strut.
MA
EM
SBR088B LC
c. Remove piston seal.
Be careful not to damage cylinder body.
EC
FE
CL
SBR656
MT
4. Remove return spring, toggle lever and cable guide.
AT
AX
SU
SBR767E
CALIPER NJBR0041S01
CAUTION:
Use brake fluid to clean cylinder. Never use mineral oil. RS
Cylinder Body NJBR0041S0101
I Check inside surface of cylinder for score, rust, wear, damage BT
or presence of foreign materials. If any of the above conditions
are observed, replace cylinder body.
I Minor damage from rust or foreign materials may be eliminated HA
by polishing surface with a fine emery paper.
Replace cylinder body if necessary.
SC
Torque Member NJBR0041S0102
Check for wear, cracks or other damage. Replace if necessary.
EL
Piston NJBR0041S0103
CAUTION:
Piston sliding surface is plated. Do not polish with emery IDX
paper even if rust or foreign matter is stuck to sliding surface.
Check piston for score, rust, wear, damage or presence of foreign
materials.
Replace if any of the above conditions are observed.
BR-37
REAR DISC BRAKE
Inspection (Cont’d)
Pin and Pin Boot NJBR0041S0104
Check for wear, cracks or other damage.
Replace if any of the above conditions are observed.
ROTOR NJBR0041S02
Rubbing Surface NJBR0041S0201
Check rotor for roughness, cracks or chips.
Runout NJBR0041S0202
1. Secure rotor to wheel hub with two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that axial end play is within the specifications
before measuring. Refer to AX section (“REAR WHEEL
BEARING”, “On-vehicle Service”).
SBR219C 3. Change relative positions of rotor and wheel hub so that runout
is minimized.
Maximum runout:
0.07 mm (0.0028 in)
Thickness NJBR0041S0203
Rotor repair limit:
Standard thickness
10 mm (0.39 in)
Minimum thickness
9 mm (0.35 in)
Thickness variation (At least 8 portions)
Maximum 0.02 mm (0.0008 in)
Assembly NJBR0042
1. Insert cam with depression facing towards open end of cylin-
der.
SBR247B
BR-38
REAR DISC BRAKE
Assembly (Cont’d)
2. Generously apply rubber grease to strut and push rod to make
insertion easy.
GI
MA
EM
SBR248B LC
3. Fit push rod into square hole in key plate. Also match convex
portion of key plate with concave portion of cylinder.
EC
FE
CL
SBR893
MT
4. Install rod, push rod and key plate.
AT
AX
SU
SBR754E
5. Install seat, spring, spring cover and ring B with suitable press
and drift. ST
RS
BT
HA
SBR869CB
SC
EL
IDX
SBR879-B
BR-39
REAR DISC BRAKE
Assembly (Cont’d)
6. Install cup in the specified direction.
SBR892
7. Install adjuster, bearing, washers and ring A with a suitable

tool.
SBR755E
8. Insert piston seal into groove on cylinder body.

9. With piston boot fitted to piston, insert piston boot into groove
on cylinder body and fit piston by turning it clockwise with long
nose pilers, or suitable tool.
SBR646
10. Fit toggle lever, return spring and cable guide.
SBR767E
11. Adjust the piston to the right angle as shown in the figure.
SBR306E
BR-40
REAR DISC BRAKE
Installation
CAUTION:
I Refill with new brake fluid “DOT 3 or DOT 4”. GI
1. Install caliper assembly. MA
I As shown in the figure, align the piston’s concave to the pad’s
convex, then install the cylinder body to the torque member.
2. Install brake hose to caliper securely. EM
3. Install all parts and secure all bolts.
SBR307E LC
EC
FE
CL
MT
AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
BR-41
PARKING BRAKE CONTROL
Components
Components NJBR0044
SBR658EA

1. To remove parking brake cable, first remove center console.
2. Disconnect warning lamp switch connector.
3. Remove adjusting nut.
4. Remove bolts and nuts securing parking brake cable.
5. Remove parking brake device.
SBR897D
6. Remove lock plate and disconnect cable (disc brake only).
SBR025D
Inspection NJBR0046
1. 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. Replace if necessary.
4. Check parts at each connecting portion and, if found deformed
or damaged, replace.
BR-42
PARKING BRAKE CONTROL
Adjustment
Adjustment NJBR0047
Before or after adjustment, pay attention to the following points.
I For rear disc brake be sure that toggle lever returns to stop- GI
per when parking brake lever is released.
I There is no drag when parking brake lever is released. MA
EM
SBR768E LC
1. Adjust clearance between shoe and drum/pad and rotor as
follows:
a. Release parking brake lever and loosen adjusting nut.
EC
b. Depress brake pedal fully at least 10 times with engine run-
ning. FE
CL
MT
2. Pull control lever 10 times or more to make a lever stroke of
195 mm (7.68 in). At 8 - 9 notches (Sedan) or 4 to 6 (Hatch- AT
back) notches, adjust the parking brake cable by turning the
adjusting nut.
AX
SU
SBR756E
3. Pull control lever with specified amount of force. Check lever

stroke and ensure smooth operation. ST
Number of notches
Sedan: 8 - 9 RS
Hatchback: 4 - 6
BT
HA
SBR033A
4. Bend warning lamp switch plate to ensure: SC

I Warning lamp comes on when lever is lifted “A” notches.
I Warning lamp goes out when lever is fully released.
Number of “A” notches: 1 EL
IDX
BR-43
DESCRIPTION ABS
Purpose
Purpose NJBR0082
The ABS consists of electronic and hydraulic components. It allows for control of braking force so that lock-
ing of the wheels can be avoided.
The ABS:
1) Ensures proper tracking performance through steering wheel operation.
2) Enables obstacles to be avoided through steering wheel operation.
3) Ensures vehicle stability by preventing flat spins.
ABS (Anti-Lock Brake System) Operation NJBR0083
I When the vehicle speed is less than 10 km/h (6 MPH) this system does not work.
I The Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS warning lamp
for 1 second after turning the ignition switch ON. The system performs another test the first time the vehicle
reaches 6 km/h (4 MPH). A mechanical noise may be heard as the ABS performs a self-test. This is a
normal part of the self-test feature. If a malfunction is found during this check, the ABS warning lamp will
come on.
I During ABS operation, a mechanical noise may be heard. This is a normal condition.
ABS Hydraulic Circuit NJBR0084
SBR757E
1. Inlet solenoid valve 4. Pump 6. Bypass check valve

2. Outlet solenoid valve 5. Motor 7. Damper
3. Reservoir
BR-44
DESCRIPTION ABS
System Components
System Components NJBR0086
GI
MA
EM
LC
EC
FE
CL
SBR758E
MT
System Description NJBR0087
SENSOR AT
NJBR0087S01
The sensor unit consists of a gear-shaped sensor rotor and a sen-
sor element. The element contains a bar magnet around which a AX
coil is wound. The sensor is installed on the back side of the brake
rotor. Sine-wave current is generated by the sensor as the wheel
rotates. The frequency and voltage increase(s) as the rotating SU
speed increases.
SBR124B
CONTROL UNIT NJBR0087S02

The control unit computes the wheel rotating speed by the signal
ST
current sent from the sensor. Then it supplies a DC current to the
actuator solenoid valve. It also controls ON-OFF operation of the RS
valve relay and motor relay. If any electrical malfunction should be
detected in the system, the control unit causes the warning lamp
to light up. In this condition, the ABS will be deactivated by the BT
control unit, and the vehicle’s brake system reverts to normal
operation.
HA
SBR759E
ABS ACTUATOR AND ELECTRIC UNIT NJBR0087S03

SC
The ABS actuator and electric unit contains:
I An electric motor and pump
I Two relays
EL
I Eight solenoid valves, each inlet and outlet for
— LH front IDX
— RH front
— LH rear
— RH rear
I ABS control unit
SBR176E
BR-45
DESCRIPTION ABS
System Description (Cont’d)
This components controls the hydraulic circuit and increases, holds
or decreases hydraulic pressure to all or individual wheels. The
ABS actuator and electric unit are not disassemble.
ABS Actuator Operation NJBR0087S0301
Inlet solenoid Outlet solenoid

valve valve
Master cylinder brake fluid pressure is directly

Normal brake operation OFF (Open) OFF (Closed)
transmitted to caliper via the inlet solenoid valve.
Hydraulic circuit is shut off to hold the caliper brake

Pressure hold ON (Closed) OFF (Closed)
fluid pressure.
Caliper brake fluid is sent to reservoir via the outlet

Pressure
ABS operation ON (Closed) ON (Open) solenoid valve. Then it is pushed up to the master
decrease
cylinder by pump.
Pressure Master cylinder brake fluid pressure is transmitted

OFF (Open) OFF (Closed)
increase to caliper.
BR-46
DESCRIPTION ABS
Component Parts and Harness Connector Location
Component Parts and Harness Connector

Location NJBR0088
GI
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
SBR765E
BR-47
DESCRIPTION ABS
Schematic/Sedan
Schematic/Sedan NJBR0089
HBR121
BR-48
DESCRIPTION ABS
Wiring Diagram — ABS —/Sedan
Wiring Diagram — ABS —/Sedan NJBR0090
GI
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
HBR122
BR-49
DESCRIPTION ABS
Wiring Diagram — ABS —/Sedan (Cont’d)
HBR102
BR-50
DESCRIPTION ABS
GI
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
HBR103
BR-51
DESCRIPTION ABS
HBR123
BR-52
DESCRIPTION ABS
Schematic/Hatchback
Schematic/Hatchback NJBR0137
GI
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
HBR105
BR-53
DESCRIPTION ABS
Wiring Diagram — ABS —/Hatchback
Wiring Diagram — ABS —/Hatchback NJBR0138
HBR106
BR-54
DESCRIPTION ABS
Wiring Diagram — ABS —/Hatchback (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
HBR107
BR-55
DESCRIPTION ABS
Wiring Diagram — ABS —/Hatchback (Cont’d)
HBR108
BR-56
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ABS
Self-diagnosis
Self-diagnosis NJBR0091
FUNCTION
I When a problem occurs in the ABS, the ABS warning lamp on
NJBR0091S01
GI
the instrument panel comes on. To start the self-diagnostic
results mode, ground the self-diagnostic (check) terminal MA
located on “Data link connector”. The location of the malfunc-
tion is indicated by the ABS warning lamp flashing.
SELF-DIAGNOSIS PROCEDURE EM
NJBR0091S02
1. Drive vehicle over 30 km/h (19 MPH) for at least one minute.
2. Turn ignition switch “OFF”. LC
3. Ground terminal “9” of “Data link connector” with a suitable
harness.
4. Turn ignition switch “ON” while grounding terminal “9”.
EC
Do not depress brake pedal.
Do not start engine.
FE
CL
SEF378Y
MT
5. After 3.0 seconds, the ABS warning lamp starts flashing to
indicate the malfunction code No. (See NOTE.) AT
6. Verify the location of the malfunction with the malfunction code
chart. Refer to BR-70. Then make the necessary repairs fol-
lowing the diagnostic procedures. AX
7. After the malfunctions are repaired, erase the malfunction
codes stored in the control unit. Refer to BR-58.
8. Rerun the self-diagnostic results mode to verify that the mal- SU
function codes have been erased.
SBR759E
9. Disconnect the check terminal from the ground. The self-diag-

nostic results mode is now complete. ST
10. Check ABS warning lamp for deactivation after driving vehicle
over 30 km/h (19 MPH) for at least one minute.
RS
11. After making certain that ABS warning lamp does not come on,
test the ABS SELF-DIAGNOSIS in a safe area to verify that it
functions properly. BT
NOTE:
The indication terminates after five minutes.
However, when the ignition switch is turned from “OFF” to “ON”, the HA
SEF378Y indication starts flashing again.
HOW TO READ SELF-DIAGNOSTIC RESULTS SC
(MALFUNCTION CODES) NJBR0091S03
1. Determine the code No. by counting the number of times the
ABS warning lamp flashes on and off. EL
2. When several malfunctions occur at one time, up to three code
numbers can be stored; the latest malfunction will be indicated
first. IDX
3. The indication begins with the start code 12. After that a maxi-
mum of three code numbers appear in the order of the latest
one first. The indication then returns to the start code 12 to
repeat (the indication will stay on for five minutes at the most).
BR-57
Self-diagnosis (Cont’d)
4. The malfunction code chart is given on the BR-70 page.
SBR457D
HOW TO ERASE SELF-DIAGNOSTIC RESULTS

(MALFUNCTION CODES) NJBR0091S04
1. Disconnect the check terminal from ground (ABS warning lamp
will stay lit).
2. Within 12.5 seconds, ground the check terminal 3 times. Each
terminal ground must last more than 1 second. The ABS warn-
ing lamp goes out after the erase operation has been com-
pleted.
3. Perform self-diagnosis again. Refer to BR-57. Only the start
code should appear, no malfunction codes.
ABR256
BR-58
CONSULT-II
CONSULT-II NJBR0092
CONSULT-II APPLICATION TO ABS NJBR0092S01
GI
SELF-DIAGNOSTIC
ITEM DATA MONITOR ACTIVE TEST
RESULTS
MA
Front right wheel sensor X X —
Front left wheel sensor X X —

EM
Rear right wheel sensor X X —
Rear left wheel sensor X X —

LC
Stop lamp switch — X —
Front right inlet solenoid valve X X X

EC
Front right outlet solenoid valve X X X
Front left inlet solenoid valve X X X FE

Front left outlet solenoid valve X X X
Rear right inlet solenoid valve X X X CL

Rear right outlet solenoid valve X X X
Rear left inlet solenoid valve X X X MT

Rear left outlet solenoid valve X X X
Actuator solenoid valve relay X X — AT

Actuator motor relay
(ABS MOTOR is shown on the ACTIVE TEST X X X AX
screen.)
ABS warning lamp — X —

SU
Battery voltage X X —
Control unit X — —
X: Applicable
—: Not applicable
ECU (ABS CONTROL UNIT) PART NUMBER MODE

ST
NJBR0092S02
Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order
the ABS actuator and electric unit. RS
BT
HA
CONSULT-II Inspection Procedure NJBR0093

SC
SELF-DIAGNOSIS PROCEDURE NJBR0093S01
1. Turn ignition switch OFF. EL
2. Connect CONSULT-II to data link connector.
3. Start engine.
4. Drive vehicle over 30 km/h (19 MPH) for at least one minute. IDX
SEF378Y
BR-59
CONSULT-II Inspection Procedure (Cont’d)
5. Stop vehicle with engine running and touch “START” on CON-
SULT-II screen.
PBR455D
6. Touch “ABS”.
PBR385C
7. Touch “SELF-DIAG RESULTS”.

I The screen shows the detected malfunction and how many
times the ignition switch has been turned since the malfunc-
tion.
8. Make the necessary repairs following the diagnostic proce-
dures.
PST412B
9. After the malfunctions are repaired, erase the self-diagnostic

results stored in the control unit by touching “ERASE”.
10. Check ABS warning lamp for deactivation after driving vehicle
over 30 km/h (19 MPH) for at least one minute.
NOTE:
“SELF-DIAG RESULTS” screen shows the detected malfunction
and how many times the ignition switch has been turned since the
malfunction.
SBR561E
BR-60
SELF-DIAGNOSTIC RESULTS MODE =NJBR0093S02
Reference GI
Diagnostic item Diagnostic item is detected when ...
Page
FR RH SENSOR I Circuit for front right wheel sensor is open.

BR-71 MA
[OPEN]*1 (An abnormally high input voltage is entered.)
FR LH SENSOR I Circuit for front left wheel sensor is open.

BR-71
[OPEN]*1 (An abnormally high input voltage is entered.) EM
RR RH SENSOR I Circuit for rear right sensor is open.
BR-71
LC
RR LH SENSOR I Circuit for rear left sensor is open.
BR-71
FR RH SENSOR I Circuit for front right wheel sensor is shorted. EC

BR-71
[SHORT]*1 (An abnormally low input voltage is entered.)
FR LH SENSOR I Circuit for front left wheel sensor is shorted. FE

BR-71
RR RH SENSOR I Circuit for rear right sensor is shorted.

BR-71 CL
RR LH SENSOR I Circuit for rear left sensor is shorted.
BR-71
[SHORT]*1 (An abnormally low input voltage is entered.) MT
ABS SENSOR I Teeth damage on sensor rotor or improper installation of wheel sensor.
BR-71
[ABNORMAL SIGNAL] (Abnormal wheel sensor signal is entered.)
AT
FR RH IN ABS SOL I Circuit for front right inlet solenoid valve is open.
BR-74
[OPEN] (An abnormally low output voltage is entered.)
FR LH IN ABS SOL I Circuit for front left inlet solenoid valve is open. AX
BR-74
RR RH IN ABS SOL I Circuit for rear right inlet solenoid valve is open. SU
BR-74
RR LH IN ABS SOL I Circuit for rear left inlet solenoid valve is open.
BR-74
FR RH IN ABS SOL I Circuit for front right inlet solenoid valve is shorted.
BR-74
[SHORT] (An abnormally high output voltage is entered.) ST
FR LH IN ABS SOL I Circuit for front left inlet solenoid valve is shorted.
BR-74
[SHORT] (An abnormally high output voltage is entered.)
RS
RR RH IN ABS SOL I Circuit for rear right inlet solenoid valve is shorted.
BR-74
RR LH IN ABS SOL I Circuit for rear left inlet solenoid valve is shorted. BT
BR-74
FR RH OUT ABS SOL I Circuit for front right outlet solenoid valve is open. HA
BR-74
FR LH OUT ABS SOL I Circuit for front left outlet solenoid valve is open.
BR-74 SC
RR RH OUT ABS SOL I Circuit for rear right outlet solenoid valve is open.
BR-74
[OPEN] (An abnormally low output voltage is entered.) EL
RR LH OUT ABS SOL I Circuit for rear left outlet solenoid valve is open.
BR-74
IDX
FR RH OUT ABS SOL I Circuit for front right outlet solenoid valve is shorted.
BR-74
FR LH OUT ABS SOL I Circuit for front left outlet solenoid valve is shorted.
BR-74
BR-61
Reference
Diagnostic item Diagnostic item is detected when ...
Page
RR RH OUT ABS SOL I Circuit for rear right outlet solenoid valve is shorted.
BR-74
RR LH OUT ABS SOL I Circuit for rear left outlet solenoid valve is shorted.
BR-74
ABS ACTUATOR RELAY I Actuator solenoid valve relay is ON, even control unit sends off signal.
BR-74
[ABNORMAL] I Actuator solenoid valve relay is OFF, even control unit sends on signal.
ABS MOTOR RELAY I Circuit for actuator motor is open or shorted.

BR-77
[ABNORMAL] I Actuator motor relay is stuck.
BATTERY VOLT
I Power source voltage supplied to ABS control unit is abnormally low. BR-79
[ABNORMAL]
CONTROL UNIT I Function of calculation in ABS control unit has failed. BR-81
*1: Be sure to confirm the ABS warning lamp illuminates when the ignition switch is turned ON after repairing the shorted sensor circuit,
but the lamp goes out when driving the vehicle over 30 km/h (19 MPH) for one minute in accordance with SELF-DIAGNOSIS
PROCEDURE.
DATA MONITOR PROCEDURE NJBR0093S03

1. Turn ignition switch OFF.
2. Connect CONSULT-II to data link connector.
3. Turn ignition switch ON.
4. Touch “START” on CONSULT-II screen.
PBR455D
5. Touch “ABS”.
PBR385C
6. Touch “DATA MONITOR”.

7. Touch “SETTING” on “SELECT MONITOR ITEM” screen.
8. Touch “LONG TIME” on “SET RECORDING COND” screen.
9. Touch “START” on “SELECT MONITOR ITEM”.
PST412B
BR-62
ACTIVE TEST PROCEDURE NJBR0093S04
I When conducting Active test, vehicle must be stationary.
I When ABS warning lamp stays on, never conduct Active test. GI
1. Turn ignition switch OFF.
2. Connect CONSULT-II to data link connector. MA
3. Start engine.
4. Touch “START” on CONSULT-II screen.
EM
PBR455D LC
5. Touch “ABS”.
EC
FE
CL
PBR385C
MT
6. Touch “ACTIVE TEST”.
AT
AX
SU
PST412B
7. Select active test item by touching screen.

ST
RS
BT
HA
PBR976C
8. Touch “START”. SC
9. Carry out the active test by touching screen key.
EL
IDX
PBR934C
BR-63
DATA MONITOR MODE NJBR0093S05
MONITOR ITEM CONDITION SPECIFICATION
FR RH SENSOR
FR LH SENSOR Drive vehicle. Displays computed vehicle speed from wheel sensor signal.
RR RH SENSOR (Each wheel is rotating.) Almost the same speed as speedometer.
RR LH SENSOR
Turn ignition switch ON and Depress the pedal: ON

STOP LAMP SW
depress brake pedal. Release the pedal: OFF
FR RH IN SOL
FR RH OUT SOL
FR LH IN SOL
FR LH OUT SOL Ignition switch is turned ON or Operating conditions for each solenoid valve are indicated.
RR IN SOL engine is running. ABS is not operating: OFF
RR OUT SOL
RL IN SOL
RL OUT SOL
Displays ON/OFF condition of ABS actuator relay.

ACTUATOR RLY When turning ignition switch ON, ABS actuator relay is oper-
ated.
Ignition switch is turned ON or ABS is not operating: OFF

MOTOR RELAY
engine is running. ABS is operating: ON
Warning lamp is turned on: ON

WARNING LAMP
Warning lamp is turned off: OFF
BATTERY VOLT Power supply voltage for control unit
ACTIVE TEST MODE NJBR0093S06
TEST ITEM CONDITION JUDGEMENT
Brake fluid pressure control operation
FR RH SOLENOID IN SOL OUT SOL

FR LH SOLENOID
UP (Increase): OFF OFF
RR RH SOLENOID
RR LH SOLENOID Ignition switch is turned ON. KEEP (Hold): ON OFF
DOWN (Decrease): ON ON
ABS actuator motor

ABS MOTOR ON: Motor runs
OFF: Motor stops
NOTE:
Active test will automatically stop ten seconds after the test starts. (TEST IS STOPPED monitor shows ON.)
BR-64
TROUBLE DIAGNOSIS — INTRODUCTION ABS
How to Perform Trouble Diagnoses for Quick and Accurate Repair
How to Perform Trouble Diagnoses for Quick

and Accurate Repair
INTRODUCTION
NJBR0094
GI
NJBR0094S01
The ABS system has an electronic control unit to control major
functions. The control unit accepts input signals from sensors and MA
instantly drives actuator. It is essential that both kinds of signals are
proper and stable. It is also important to check for conventional
problems: such as air leaks in the booster or lines, lack of brake EM
fluid, or other problems with the brake system.
It is much more difficult to diagnose a problem that occurs intermit-
SEF233G tently rather than continuously. Most intermittent problems are LC
caused by poor electric connections or faulty wiring. In this case,
careful checking of suspicious circuits may help prevent the
replacement of good parts. EC
A visual check only may not find the cause of the problems, so a
road test should be performed.
Before undertaking actual checks, take just a few minutes to talk FE
with a customer who approaches with a ABS complaint. The cus-
tomer is a very good source of information on such problems;
especially intermittent ones. Through the talks with the customer, CL
find out what symptoms are present and under what conditions
they occur.
SEF234G Start your diagnosis by looking for “conventional” problems first. MT
This is one of the best ways to troubleshoot brake problems on an
ABS controlled vehicle. Also check related Service Bulletins for
information. AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
BR-65
TROUBLE DIAGNOSIS — BASIC INSPECTION ABS
Preliminary Check
Preliminary Check NJBR0095
1 CHECK BRAKE FLUID LEVEL

Check brake fluid level in reservoir tank.
Low fluid level may indicate brake pad wear or leakage from brake line.
SBR451D
Is brake fluid filled between MAX and MIN lines on reservoir tank and/or has brake fluid been contaminated?
Yes © GO TO 2.
No © Repair. GO TO 2.
2 CHECK BRAKE LINE

Check brake line for leakage.
SBR389C
Is leakage present at or around brake lines, tubes or hoses or are any of these parts cracked or damaged?
Yes © GO TO 3.
No © Repair. GO TO 3.
BR-66
Preliminary Check (Cont’d)
3 CHECK BRAKE BOOSTER OPERATION

Check brake booster for operation and air tightness. GI
Refer to BR-19.
MA
EM
LC
EC
SBR058C
Is brake booster airtight and functioning properly?

FE
Yes © GO TO 4.
No © Replace. GO TO 4.
CL
4 CHECK BRAKE PAD AND ROTOR
Check brake pad or lining and rotor or drum.
MT
Refer to BR-27, 28, 32, 32, 34, 38.
AT
AX
SU
SBR059C
Are brake pads and rotors functioning properly? ST

Yes © GO TO 5.
No © Replace. RS
BT
HA
SC
EL
IDX
BR-67
Preliminary Check (Cont’d)
5 RECHECK BRAKE FLUID LEVEL

Check brake fluid level in reservoir tank again.
SBR451D
Is brake fluid filled between MAX and MIN lines on reservoir tank and/or has brake fluid been contaminated?
Yes © GO TO 6.
No © Fill up brake fluid.
6 CHECK WARNING LAMP ACTIVATION

Check warning lamp activation.
SBR759E
Does warning lamp turn on when ignition switch is turned “ON”?

Yes © GO TO 7.
No © Check fuse, warning lamp bulb and warning lamp circuit.
7 CHECK WARNING LAMP DEACTIVATION

Check warning lamp for deactivation after engine is started.
Does warning lamp turn off when engine is started?
Yes © GO TO 8.
No © Go to Self-diagnosis. Refer to BR-57, 59.
8 DRIVE VEHICLE
Drive vehicle at speeds over 30 km/h (19 MPH) for at least one minute.
Does warning lamp remain off after vehicle has been driven at 30 km/h (19 MPH) for at least one minute?
Yes © END
No © Go to Self-diagnosis. Refer to BR-57, 59.
BR-68
Ground Circuit Check
Ground Circuit Check NJBR0096

ABS ACTUATOR AND ELECTRIC UNIT GROUND
I
NJBR0096S04
Check continuity between ABS actuator and electric unit con-
GI
nector terminals and ground.
Continuity should exist. MA
EM
SBR045EH LC
EC
FE
CL
MT
AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
BR-69
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ABS
Malfunction Code/Symptom Chart
Malfunction Code/Symptom Chart NJBR0097
Code No. (No. of LED flashes) Malfunctioning part Reference page
12 Self-diagnosis could not detect any malfunctions. —
18 Sensor rotor BR-71
21 Front right sensor (open-circuit) BR-71
22 Front right sensor (short-circuit) BR-71
25 Front left sensor (open-circuit) BR-71
26 Front left sensor (short-circuit) BR-71
31 Rear right sensor (open-circuit) BR-71
32 Rear right sensor (short-circuit) BR-71
35 Rear left sensor (open-circuit) BR-71
36 Rear left sensor (short-circuit) BR-71
41 Actuator front right outlet solenoid valve BR-74
42 Actuator front right inlet solenoid valve BR-74
45 Actuator front left outlet solenoid valve BR-74
46 Actuator front left inlet solenoid valve BR-74
51 Actuator rear right outlet solenoid valve BR-74
52 Actuator rear right inlet solenoid valve BR-74
55 Actuator rear left outlet solenoid valve BR-74
56 Actuator rear left inlet solenoid valve BR-74
57* Power supply (Low voltage) BR-79
61 Actuator motor or motor relay BR-77
63 Solenoid valve relay BR-74
71 Control unit BR-81
Control unit power supply circuit

Warning lamp bulb circuit
ABS warning lamp stays on when
Control unit or control unit connector BR-88
ignition switch is turned on.
Solenoid valve relay stuck
Power supply for solenoid valve relay coil
ABS warning lamp stays on, during

Control unit —
self-diagnosis.
ABS warning lamp does not come on Fuse, warning lamp bulb or warning lamp circuit
BR-86
when ignition switch is turned on. Control unit
ABS warning lamp does not come on

Control unit —
during self-diagnosis.
Pedal vibration and noise — BR-85
Long stopping distance — BR-83
Unexpected pedal action — BR-82
ABS does not work. — BR-84
ABS works frequently. — BR-82
*: Under voltage that is too low, the control unit disable the ABS. It does not set the ABS in fail-safe condition. Instead, the ABS becomes
a conventional brake system. After the power supply has resumed, the warning lamp goes off, making it possible for the ABS to be
re-engaged.
BR-70
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS ABS
Wheel Sensor or Rotor
Wheel Sensor or Rotor NJBR0098

DIAGNOSTIC PROCEDURE
Malfunction code No. 21, 22, 25, 26, 31, 32, 35, 36 or 18
NJBR0098S01
GI
NOTE:
Wheel position should be identified by code No. except code No. MA
18 (sensor rotor).
1 INSPECTION START
EM
Wheel sensor inspection
LC
EC
FE
SBR476EB
CL
© GO TO 2.
MT
2 CHECK CONNECTOR
1. Disconnect connectors from control unit and wheel sensor of malfunction code No. Check terminals for damage or AT
loose connections. Then reconnect connectors.
2. Carry out self-diagnosis again.
AX
Does warning lamp activate again?
Yes © GO TO 3.
No © INSPECTION END
SU
ST
RS
BT
HA
SC
EL
IDX
BR-71
Wheel Sensor or Rotor (Cont’d)
3 CHECK WHEEL SENSOR CIRCUIT

1. Disconnect control unit connector.
2. Check resistance between control unit connector terminals.
Code No. 21 or 22 (Front RH wheel)
Terminals 4 and 5
Code No. 25 or 26 (Front LH wheel)
Terminals 6 and 7
Code No. 31 or 32 (Rear RH wheel)
Terminals 1 and 3
Code No. 35 or 36 (Rear LH wheel)
Terminals 8 and 9
Resistance: 1.44 - 1.76 kΩ
SBR477EC
Is resistance 1.44 - 1.76 kΩ?

Yes © GO TO 5.
No © GO TO 4.
4 CHECK WHEEL SENSOR

Check resistance of each sensor. (See NOTE.)
Resistance: 1.44 - 1.76 kΩ
SBR478EC
Is resistance 1.44 - 1.76 kΩ?

Yes © Repair harness and connectors between control unit connector and wheel sensor con-
nector.
No © Replace wheel sensor.
5 CHECK TIRE
Check for inflation pressure, wear and size of each tire.
Are tire pressure and size correct and is tire wear within specifications?
Yes © GO TO 6.
No © Adjust tire pressure or replace tire(s).
BR-72
Wheel Sensor or Rotor (Cont’d)
6 CHECK WHEEL BEARING

Check wheel bearing axial end play. GI
Check clearance between sensor and rotor.
Clearance:
Front MA
0.7 - 1.8 mm (0.028 - 0.071 in)
Rear
0.4 - 1.5 mm (0.016 - 0.059 in)
EM
LC
EC
FE
SBR333E
CL
MT
AT
AX
SBR069CA
SU
Is axial end play and clearance within specifications?
Yes © GO TO 7.
No © Clean sensor fixing portion, or replace sensor.
ST
7 CHECK SENSOR ROTOR
Check sensor rotor for teeth damage.
RS
Is sensor rotor free from damage?
Yes © Check control unit pin terminals for damage or the connection of control unit harness
connector. Reconnect control unit harness connector. Then retest. BT
No © Replace sensor rotor.
HA
SC
EL
IDX
BR-73
ABS Actuator Solenoid Valve or Solenoid Valve Relay
ABS Actuator Solenoid Valve or Solenoid Valve

Relay =NJBR0100
DIAGNOSTIC PROCEDURE NJBR0100S01
Malfunction code No. 41, 45, 55, 42, 46, 56, 63, 51, 52
1 INSPECTION START
Solenoid valve relay inspection
SBR761E
© GO TO 2.
2 CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT

Check 40A [c] fusible link (ABS ACTR) for ABS solenoid valve relay. For fusible link layout, refer to POWER SUPPLY
ROUTING in EL section.
Is fusible link OK?
Yes © GO TO 3.
No © GO TO 7.
3 CHECK FUSE
Check 10A fuse No. 31. For fuse layout, refer to “POWER SUPPLY ROUTING” in EL section.
Is fuse OK?
Yes © GO TO 4.
No © GO TO 9.
BR-74
ABS Actuator Solenoid Valve or Solenoid Valve Relay (Cont’d)
4 CHECK CONNECTOR
1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connection. Then reconnect GI
connector.
Does warning lamp activate again? MA
Yes © GO TO 5.
No © INSPECTION END EM
5 CHECK GROUND CIRCUIT LC

Refer to ABS ACTUATOR AND ELECTRIC UNIT in Ground Circuit Check, BR-69.
Is ground circuit OK? EC
Yes © GO TO 6.
No © Repair harness and connectors.
FE
6 CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT
CL
1. Disconnect ABS actuator and electric unit connector.
2. Check voltage between ABS actuator and electric unit connector terminal 18 and ground.
MT
AT
AX
SU
SBR052EF
Does battery voltage exist?

Yes © Replace ABS actuator and electric unit.
No © Check the following. ST
I Harness connector E1
I Harness for open or short between ABS actuator and electric unit and fusible link
If NG, repair harness or connectors. RS
7 REPLACE FUSIBLE LINK

BT
Replace fusible link.
Does the fusible link blow out when ignition switch is turned “ON”?
HA
Yes © GO TO 8.
SC
EL
IDX
BR-75
ABS Actuator Solenoid Valve or Solenoid Valve Relay (Cont’d)
8 CHECK RELAY UNIT POWER SUPPLY CIRCUIT

2. Check continuity between ABS actuator and electric unit connector terminal 18 and ground.
SBR052EF
Does continuity exist?

No © Check the following.
If NG, repair harness or connectors.
9 REPLACE FUSE
Replace fuse.
Does the fuse blow out when ignition switch is turned “ON”?
Yes © Check the following.
I Harness for open or short between ABS actuator and electric unit and fuse
BR-76
Motor Relay or Motor
Motor Relay or Motor =NJBR0101

DIAGNOSTIC PROCEDURE
Malfunction code No. 61
NJBR0101S01
GI
1 INSPECTION START
ABS motor relay inspection
MA
EM
LC
EC
FE
CL
MT
AT
AX
SBR760E
© GO TO 2. SU
2 CHECK MOTOR POWER SUPPLY CIRCUIT

Check 40A [F] fusible link (ABS MTR) for ABS motor relay. For fusible link layout, refer to POWER SUPPLY ROUTING in
EL section.
ST
Is fusible link OK?
Yes © GO TO 3.
RS
No © GO TO 6.
3 CHECK CONNECTOR
BT
1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connection. Then reconnect
connectors. HA
SC
Yes © GO TO 4.
EL
IDX
BR-77
Motor Relay or Motor (Cont’d)
4 CHECK MOTOR RELAY POWER SUPPLY CIRCUIT

SBR055EF

Yes © GO TO 5.
5 CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT

Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check, BR-69.
Is ground circuit OK?
I Harness for open or short between ABS actuator and electric unit and ground
6 REPLACE FUSIBLE LINK

Replace fusible link.
Does the fusible link blow out when ignition switch is turned “ON”?
Yes © GO TO 7.
BR-78
Motor Relay or Motor (Cont’d)
7 CHECK ABS ACTUATOR MOTOR POWER SUPPLY CIRCUIT

1. Disconnect battery cable and ABS actuator and electric unit connector. GI
MA
EM
LC
SBR055EF
EC
Yes © Check ABS actuator and electric unit pin terminals for damage or the connection of ABS FE
actuator and electric unit harness connector. Reconnect ABS actuator and electric unit
harness connector. Then retest.
CL
I Harness for open or short between ABS actuator and electric unit and fusible link MT
AT
AX
SU
Low Voltage NJBR0102 ST

1 INSPECTION START
RS
ABS actuator and electric unit power supply and ground circuit inspection
BT
HA
SC
EL
SBR625E
© GO TO 2. IDX
BR-79
Low Voltage (Cont’d)
2 CHECK CONNECTOR
1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connections. Then recon-
nect connector.
Yes © GO TO 3.
3 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

SBR058EH
Does battery voltage exist when ignition switch is turned ON?

Yes © GO TO 4.
No © GO TO 5.
4 CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND

Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check, BR-69.
Is ground circuit OK?
OK © Check ABS actuator and electric unit pin terminals for damage or the connection of ABS
NG © Check the following.
5 CHECK FUSE
Check 10A fuse 31 (Engine control) for control unit. Refer to POWER SUPPLY ROUTING in EL section.
Is fuse OK?
Yes © GO TO 6.
No © Replace fuse.
BR-80
Low Voltage (Cont’d)
6 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

Check continuity between battery and ABS actuator and electric unit connector terminal 15. GI
Yes © Check battery. Refer to BATTERY in EL section. MA
I Harness for open or short between ABS actuator and electric unit and fuse EM
LC
Control Unit NJBR0103
EC
1 INSPECTION START
FE
ABS actuator and electric unit power supply and ground circuit inspection
CL
MT
AT
AX
SBR626E
© GO TO 2.
SU
2 CHECK CONNECTOR
Check terminals for damage or loose connections and replace. Then reconnect connector.
ST
Yes © GO TO 3.
RS
3 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT BT

Check voltage. Refer to “3. CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT” in “Low Voltage”,
BR-79. HA
Does battery voltage exist when ignition switch is turned ON?
Yes © GO TO 4. SC
No © Repair.
EL
4 CHECK WARNING LAMP INDICATION
Does warning lamp indicate code No. 71 again?
IDX
No © Inspect the system according to the code No.
BR-81
TROUBLE DIAGNOSES FOR SYMPTOMS ABS
1. ABS Works Frequently
1. ABS Works Frequently NJBR0104
1 CHECK BRAKE FLUID PRESSURE

Check brake fluid pressure distribution.
Is brake fluid pressure distribution normal?
Yes © GO TO 2.
No © Perform Preliminary Check. Refer to BR-66.

1. Check wheel sensor connector for terminal damage or loose connections.
2. Perform wheel sensor mechanical check.
Refer to “Wheel Sensor or Rotor”, BR-71.
Are wheel sensors functioning properly?
Yes © GO TO 3.
No © Repair.
3 CHECK FRONT AXLE

Check front and rear axles for excessive looseness. Refer to AX section, “Front Wheel Bearing”, “ON-VEHICLE SERVICE”
and “Rear Wheel Bearing”, “ON-VEHICLE SERVICE”.
Is front axle installed properly?
Yes © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”,
BR-82.
No © Repair.
2. Unexpected Pedal Action NJBR0105
1 CHECK BRAKE PEDAL STROKE

Check brake pedal stroke. Is stroke excessively large?
SBR540A
Yes © Perform Preliminary Check. Refer to BR-66.

No © GO TO 2.
BR-82
2. Unexpected Pedal Action (Cont’d)
2 CHECK CONNECTOR AND PERFORMANCE

1. Disconnect ABS actuator and electric unit connector. GI
2. Check whether brake is effective.
OK or NG
MA
Yes © GO TO 3.
No © Perform Preliminary Check. Refer to BR-66.
EM
Ensure warning lamp remains off while driving. LC
EC
FE
CL
SBR759E MT
Is warning lamp turned off?
Yes © GO TO 4. AT
No © Carry out self-diagnosis. Refer to BR-57, BR-59.
AX
1. Check wheel sensor connector for terminal damage or loose connection. SU
2. Perform wheel sensor mechanical check.
Is wheel sensor mechanism OK?
Yes © Check ABS actuator and electric unit pin terminals for damage or the connection of ABS
ST
No © Repair.
RS
BT
HA
3. Long Stopping Distance NJBR0106

SC
1 CHECK CONNECTOR AND PERFORMANCE
1. Cancel ABS by disconnecting ABS actuator and electric unit connector. EL
2. Check whether stopping distance is still long.
OK or NG IDX
OK © Perform Preliminary Check and air bleeding.
NG © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”,
BR-82.
BR-83
3. Long Stopping Distance (Cont’d)
NOTE:
Stopping distance may be longer than vehicles without ABS when
road condition is slippery.
4. ABS Does Not Work NJBR0107

Does the ABS warning lamp activate?
Yes © Carry out self-diagnosis. Refer to BR-57, BR-59.
No © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”,
BR-82.
NOTE:
ABS does not work when vehicle speed is under 10 km/h (6 MPH).
BR-84
5. Pedal Vibration and Noise
5. Pedal Vibration and Noise =NJBR0108
1 INSPECTION START GI
Pedal vibration and noise inspection
MA
EM
LC
EC
SAT797A
© GO TO 2.
FE
2 CHECK SYMPTOM
1. Apply brake.
CL
2. Start engine.
Does the symptom appear only when engine is started? MT
Yes © Carry out self-diagnosis. Refer to BR-57, BR-59.
No © GO TO 3. AT
3 RECHECK SYMPTOM
AX
Does the symptom appear when electrical equipment switches (such as headlamp) are operated?
Yes © GO TO 4.
SU
No © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”,
BR-82.

Check wheel sensor shield ground. For location of shield ground, refer to wiring diagram and “HARNESS LAYOUT” in EL ST
section.
Is wheel sensor shield grounded properly?
RS
Yes © Check ABS actuator and electric unit pin terminals for damage or the connection of ABS
harness connector. Then retest. BT
No © Repair.
NOTE: HA
ABS may operate and cause vibration under any of the following
conditions.
I Applying brake gradually when shifting or operating clutch. SC
I Low friction (slippery) road.
I High speed cornering. EL
I Driving over bumps and pot holes.
I Engine speed is over 5,000 rpm with vehicle stopped.
IDX
BR-85
6. ABS Warning Lamp Does Not Come On When Ignition Switch Is Turned On
6. ABS Warning Lamp Does Not Come On

When Ignition Switch Is Turned On =NJBR0109
1 INSPECTION START
Warning lamp circuit inspection
SBR762E
© GO TO 2.
2 CHECK FUSE
Check 10A fuse No. 30 for warning lamp. For fuse layout, refer to “POWER SUPPLY ROUTING” in EL section.
Is fuse OK?
Yes © GO TO 3.
No © Replace fuse.
3 CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT

1. Install 10A fuse.
3. Check voltage between control unit connector terminal 10 and ground after turning ignition switch “ON”.
SBR628E
Does battery voltage exist after turning ignition switch “ON”?

Yes © GO TO 5.
No © GO TO 4.
BR-86
6. ABS Warning Lamp Does Not Come On When Ignition Switch Is Turned On (Cont’d)

Disconnect ABS actuator and electric unit connector. GI
MA
EM
LC
SBR759E EC
Does the ABS warning lamp activate?
Yes © GO TO 6. FE
No © GO TO 5.
CL
5 CHECK HARNESS FOR SHORT
2. Check voltage between ABS actuator and electric unit connector terminal 10 and ground. MT
AT
AX
SU
SBR144EF

Yes © Check combination meter. Refer to WARNING LAMPS in EL section. ST
No © Repair harness and connectors between fuse and ABS actuator and electric unit connec-
tor terminal 10.
RS
6 CHECK HARNESS CONNECTOR
Check ABS actuator and electric unit pin terminals for damage or connection of ABS actuator and electric unit harness
BT
connector. Reconnect ABS actuator and electric unit harness connector. Then reset.
OK © INSPECTION END HA
NG © Replace ABS actuator and electric unit.
SC
EL
IDX
BR-87
7. ABS Warning Lamp Stays On When Ignition Switch Is Turned On
7. ABS Warning Lamp Stays On When Ignition

Switch Is Turned On =NJBR0110
1 INSPECTION START
ABS control unit inspection
SBR763E
© GO TO 2.
2 CHECK WARNING LAMP

2. Connect suitable wire between ABS actuator and electric unit connector terminal 10 and ground.
SBR146EE
Does warning lamp activate?

Yes © GO TO 3.
No © Repair combination meter. Check the following.
I Harness for open or short between ABS actuator and electric unit and fuse
If NG, repair harness or connector.
3 CHECK HARNESS CONNECTOR

Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness
connector. Reconnect ABS actuator and electric unit harness connector. Then retest.
OK © INSPECTION END
NG © GO TO 4.
BR-88
7. ABS Warning Lamp Stays On When Ignition Switch Is Turned On (Cont’d)
4 CHECK ABS MOTOR GROUND

1. Turn ignition switch “OFF”. GI
MA
EM
LC
EC
SBR147EC
Does continuity exist? FE

No © Check the following. CL
If NG, repair harness or connector. MT
AT
AX
SU
ST
RS
BT
HA
SC
EL
IDX
BR-89
NJBR0111
REMOVAL AND INSTALLATION ABS
CAUTION:
Be careful not to damage sensor edge and sensor rotor teeth.
When removing the front or rear wheel hub assembly, first
remove the ABS wheel sensor from the assembly. Failure to
do so may result in damage to the sensor wires making the
sensor inoperative.
Wheel Sensors NJBR0111S01
SBR902D
BR-90
ABS Actuator and Electric Unit
ABS Actuator and Electric Unit NJBR0111S10
GI
MA
EM
LC
EC
FE
CL
MT
AT
SBR630E
AX
REMOVAL NJBR0111S1001 SU
1. Disconnect battery cable.
2. Drain brake fluid.
3. Remove mounting bracket fixing bolts and nuts.
4. Disconnect connector, brake pipes and remove fixing nuts.
INSTALLATION ST
NJBR0111S1002
CAUTION:
After installation, refill brake fluid. Then bleed air.
RS
1. Connect brake pipes temporarily.
2. Tighten fixing bolts and nuts.
3. Tighten brake pipes. BT
4. Connect connector and battery cable.
HA
SC
EL
IDX
BR-91
Sensor Rotor
Sensor Rotor NJBR0111S02

REMOVAL NJBR0111S0201
1. Remove the drive shaft and rear wheel hub. Refer to “Drive
Shaft” and “Wheel Hub” in AX section.
2. Remove the sensor rotor using suitable puller, drift and bear-
ing replacer.
SBR984C
SBR873CA
INSTALLATION NJBR0111S0202
Install the sensor rotor. For front sensor rotor, use hammer and
wooden block. For rear sensor rotor, use suitable drift and press.
I Always replace sensor rotor with new one.
SBR985C
I Pay attention to the dimension of rear sensor rotor as show in

figure.
h: 17.7 - 18.7 mm (0.697 - 0.736 in)
SBR986C
BR-92
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
General Specifications NJBR0077

Unit: mm (in)
GI
Except for
Applied model For Europe
Europe
Engine QG15DE
Except
All
MA
QG15DE
ABS Without ABS Optional —

EM
Brake model CL25VG CL25VBG CL25VA
Cylinder bore diameter 57.2 (2.252)

LC
125.6 ×
Front Pad 46.0 ×
113.1 × 45.5 × 11.0
Length × width × thick- 108.8 × 47.7 × 11.0 (4.28 × 1.878 × 0.433) 11.0 (4.94
brake
ness
(4.45 × 1.791 × 0.433)
× 1.811 ×
EC
0.433)
Rotor outer diameter × FE

257 × 22 (10.12 × 0.87) 280 × 22 (11.02 × 0.87)
thickness
Body Sedan Hatchback —

CL
Grade LX Except LX —
ABS Without ABS With ABS — —

MT
LT20N
Brake model LT20N CL9HC CL9HCG drum
brake
AT
33.96 17.46
Cylinder bore diameter 17.46 (0.6874) 33.9 (1.335)
(1.3370) (0.6874)
Rear 79.8 × 195 × 35 AX

brake Lining or pad 38.5 × 9.3 × 4.5
195 × 35 × 4.5 (7.68 ×
Length × width × thick- 89.1 × 39.5 × 10.0 (3.508 × 1.555 × 0.394) (3.142 × (7.68 ×
1.38 × 0.18)
ness 1.516 × 1.38 × SU
0.366) 0.18)
Drum inner diameter 258 × 9

203.2
or rotor outer diameter 203.2 (8.00) 258 × 9 (10.16 × 0.35) (10.16 ×
(8.00)
× thickness 0.35)
Master
cylinder
Cylinder bore diameter 23.81 (15/16) ST
Dual proportioning valve
Valve model
[Except 4-door Sedan for Europe (RHD with optional ABS, and LHD with gasoline engine and optional ABS)]
Control RS
valve Split point
kPa (bar, kg/cm2, psi) 3,923 (39.2, 40, 569) × 0.4
× reducing ratio
BT
Applied model For Europe Except for Europe
Body Sedan Hatchback Sedan HA

Engine QG15DE, QG18DE YD22DDT QG15DE, QG18DE YD22DDT Gasoline YD22DD
ABS Optional
Without
ABS
— Optional — SC
Booster model M215T S255 M215T S255 M210T S255
Brake 255
EL
Dia- Primary 230 (9.06) 255 (10.04) 230 (9.06) 255 (10.04) 230 (9.06)
booster (10.04)
phragm
diameter
Secondary 205 (8.07) — 205 (8.07) — 180 (7.09) — IDX
Recommended brake fluid DOT 3 or DOT 4
BR-93
SERVICE DATA AND SPECIFICATIONS (SDS)
Disc Brake
Disc Brake NJBR0078

Unit: mm (in)
Brake model CL25A, CL25VG, CL25VBG CL9HCG
Pad wear limit Minimum thickness 2.0 (0.079) 2.0 (0.079)
Maximum runout 0.07 (0.0028) 0.07 (0.0028)

Rotor repair limit
Minimum thickness 20.0 (0.787) 9 (0.35)
Drum Brake NJBR0135

Unit: mm (in)
Brake model LT20N
Lining wear limit Minimum thickness 1.5 (0.059)
Maximum inner diameter 204.5 (8.051)

Drum repair limit
Maximum out-of-round 0.03 (0.0012)
Brake Pedal NJBR0079

Unit: mm (in)
M/T 156.0 - 166.0 (6.14 - 6.54)

LHD
A/T 165.0 - 175.0 (6.50 - 6.89)
Free height “H”*
M/T 155.0 - 165.0 (6.10 - 6.50)
RHD
A/T 164.0 - 174.0 (6.46 - 6.85)
Clearance “C” between pedal stopper and threaded end of stop lamp switch or brake switch 0.74 - 1.96 (0.0291 - 0.0772)
*: Measured from surface of dash panel to surface of pedal pad
Parking Brake NJBR0080
Type Center lever
Sedan 8-9
Number of notches
[under force of 196 N (20 kg, 44 lb)]
Hatchback 4-6
Number of notches
1
when warning lamp switch comes on
BR-94

Brake System: Operating Check Airtight Check

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Brake System: Operating Check Airtight Check

Uploaded by

Copyright:

Available Formats

BRAKE SYSTEM GI

PRECAUTIONS ...............................................................3 OPERATING CHECK ...............................................19

Supplemental Restraint System (SRS) “AIR

Precautions for Brake System NJBR0002 ST

Wiring Diagrams and Trouble Diagnosis NJBR0003

Commercial Service Tools NJBR0004

Tool name Description GI

Brake fluid pressure Measuring brake fluid pressure

Rotor or drum deflection —

Rotor or drum rust —

Rotor thickness variation BR-29, 38

Drum out of round BR-32

DRIVE SHAFT NVH in FA section

AXLE AND SUSPENSION NVH in FA section

TIRES NVH in FA, RA section

ROAD WHEEL NVH in FA section

STEERING NVH in ST section

Checking Brake Fluid Level NJBR0006

Brake Burnishing Procedure NJBR0036

Bleeding Brake System NJBR0009

I Bleed air in the following order.

Hydraulic Circuit NJBR0010

Removal and Installation NJBR0015

1. Reservoir cap 5. Cylinder body 8. Secondary piston assembly

2. Remove valve stopper while piston is pushed into cylinder.

2. Install stopper cap.

1. Reservoir cap 5. Cylinder body 8. Secondary piston assembly

2. Install piston stopper pin while piston is pushed into cylinder. SC

On-vehicle Service NJBR0023

Removal and Installation NJBR0027

Connect to engine side Vacuum should not exist. AX

1. Remove parts shown below.

5. Remove vacuum pump and cylinder head rear cover assem-

3. Install rear cam sprocket.

1. Main pin 7. Inner pad 13. Main pin bolt

1. Main pin 7. Inner pad 13. Main pin bolt

Pad Replacement NJBR0029

1. Boot 6. Shoe hold-down pin 11. Retainer ring

5. Remove retainer ring with a suitable tool. Then separate toggle

Inspection — Wheel Cylinder NJBR0130

Wheel Cylinder Overhaul NJBR0131

Inspection — Drum NJBR0132

Inspection — Lining NJBR0133

1. Cable guide 11. Outer shim 21. Snap ring A

Pad Replacement NJBR0037

6. When installing new pads, push piston into cylinder body by

7. Adjust the piston to the right angle as shown in the figure. SC

7. Install adjuster, bearing, washers and ring A with a suitable

8. Insert piston seal into groove on cylinder body.

10. Fit toggle lever, return spring and cable guide.

Removal and Installation NJBR0045

6. Remove lock plate and disconnect cable (disc brake only).

3. Pull control lever with specified amount of force. Check lever

4. Bend warning lamp switch plate to ensure: SC

1. Inlet solenoid valve 4. Pump 6. Bypass check valve

System Components NJBR0086

CONTROL UNIT NJBR0087S02

ABS ACTUATOR AND ELECTRIC UNIT NJBR0087S03

Inlet solenoid Outlet solenoid

Master cylinder brake fluid pressure is directly

Hydraulic circuit is shut off to hold the caliper brake

Caliper brake fluid is sent to reservoir via the outlet

Pressure Master cylinder brake fluid pressure is transmitted