Tfbrk-We-1211th 1st WSMW 120 TF Tis 12tf

2012MY
WORKSHOP MANUAL
BRAKE
No.TFBRK-WE-1211TH
67209_Maegaki 2011.7.22 10:14 AM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0 Introduction
14A Service Information Guide
14B Vehicle Information
1 ENGINE 15B Maintenance Information
15C Functional Inspection
15D Symptom
15E DTC Information
1A Engine Control
1B Mechanical
1C Fuel System
1D Cooling
1E Lubrication
1F Induction
1G Exhaust
1H Aux. Emission Control Devices
1I Speed Control Systems
1J Electrical
2 SUSPENSION 16B Maintenance Information
16D Symptom
2B Front Suspension
2C Rear Suspension
2D Wheel, Tire System
3 DRIVELINE, AXLE 17B Maintenance Information
17D Symptom
17E DTC Information
3A Driveline Control
3B Differentials
3C Drive Shaft System
3D Transfer Case
4 BRAKES 18B Maintenance Information
18D Symptom
18E DTC Information
4A Brake Control
4B Brake System
4C Parking Brake System
4D ABS
5 TRANSMISSION, TRANSAXLE 19B Maintenance Information
19D Symptom
19E DTC Information
5A Transmission Control
5B Automatic
5C Manual
5E Clutch System
6 STEERING 20B Maintenance Information
20D Symptom
6B Power Assisted System
67209_Maegaki 2011.7.22 10:14 AM ページ 2
Section Sub Section

7 HVAC 21B Maintenance Information
21D Symptom
7B Heater, Ventilator, Airconditioner
8 RESTRAINTS 22B Maintenance Information
22D Symptom
22E DTC Information
8A SRS Control
8B Air Bag Systems
8C Seat Belt Systems
9 BODY, CAB, ACCESSORIES 23B Maintenance Information
23D Symptom
9A Lighting Systems
9B Wiper, Washer Systems
9C Electrical Control, Entertainment
9E Instrumentation, Driver Info.
9G Hood, Fenders, Doors
9H Cab Structure
9I Seats
9J Security and Locks
9L Exterior, Interior Trim
9P Unibody Sub-frames
9T Glass, Windows, Mirrors
10 BODY CONTROL 36B Maintenance Information
36D Symptom
36E DTC Information
10I Body Control
10 SECURITY AND LOCKS CONTROL 42B Maintenance Information
42E DTC Information
10S Security and Locks Control
11 FRAME 24B Maintenance Information
- ETM - Using the Wiring Diagram
- Power System
- Engine
- Chassis
- Brake
- Safety
- Driver Assist
- Accessory
- Light
- Data Communications
- Location Diagram
- Connector List
Maintenance Information (All models) 18B-1
Description Brakes
Maintenance Information
(All models)
Table of Contents
Maintenance precautions of brake.................................18B-2
Function, structure, operation of brake.........................18B-4
Primary specifications of brake...................................18B-37
Introduction to the trouble diagnosis of brake.............18B-38
18B-2 Maintenance Information (All models)
Maintenance precautions of brake

1. Maintenance precautions of brake equipment is attached, and remove it from the vehicle if it
is.
Precautions for general maintenance
If the problem has not been resolved after removing the
Make sure to follow the precautions below when
equipment, perform the diagnosis using the regular
maintaining or diagnosing the ABS or other vehicle
procedure.
control systems.
When welding the vehicle using an electric arc welder, Caution：
remove the EHCU connector before welding. ・ Make sure that commercial electronic
Do not connect or disconnect the EHCU connector when equipment is attached to a circuit that is not
the ignition switch is in the ON position. involved with the circuits for the power,
As the EHCU cannot be disassembled, never loosen the ground, and electronic control system.
bolts or plugs of the EHCU.
Take sufficient care so that foreign matter, dust, and Damage caused by electrostatic discharge
metal dust etc. do not enter the oil pressure circuit when As the electronic components used in the electronic
the brake inspection or maintenance is performed. control system are designed to operate at extremely low
As this inspection uses a drum tester and is performed voltages, they can be easily damaged by electrostatic
with the vehicle jacked up, rotating only the rear wheels discharge, and some types of electronic components can
causes the EHCU to judge the sensor to be be damaged by static electricity of 100 V or less, which
malfunctioning, resulting in the ABS warning light cannot be felt by a person. Note that a voltage of 4000 V
lighting up. In this case, as the system is normal, clear the is required for a person to be able to detect electrostatic
DTC after the inspection. Turn the ignition switch ON discharge.
again to confirm that the ABS warning light does not There are various ways a person can build up an
illuminate. electrostatic charge. The most common way to build up
an electrostatic charge is through methods based on
Use of circuit testing tools friction or induction.
Unless instructed in the diagnostic procedures, do not use An example of when a person builds an electrostatic
a test light. When a probe connector is required in the charge by friction is when they slide across the seat of the
diagnostic procedures, use the connector test adapter kit vehicle.
5-8840-2835-0. A person wearing insulated shoes can build an
Safety precautions electrostatic charge by induction if they momentarily
When performing an inspection using the scan tool with touch the ground while standing near a highly charged
the engine is running, in a closed location such as a object. A charge of the same polarity flows out, and with
garage, make sure to adequately ventilate the area to a highly opposing polarity, that person becomes
ensure you do not breathe in the exhaust gas. Take electrostatically charged. As static electricity causes
adequate care as the exhaust gas is highly poisonous, and damage, be careful when handling or testing electronic
inhaling of it can lead to fainting or death. components.
Before performing a vehicle inspection test using the scan Caution：
tool, firmly engage the parking brake, and steady the
・ To prevent damages caused by electrostatic
vehicle using chock blocks.
discharge, do not touch the connector pins of
Commercial electronic equipment the control unit, or the electronic components
Commercial electronic equipment refers to commercially soldered onto the circuit board of the control
available electronic equipment attached to the vehicle unit.
after it has been shipped from the factory. Take care, as ・ Do not open the packaging of a replacement
such equipment is not taken into particular consideration part until the preparations for installation of the
at the vehicle design stage. replacement part are completed to prevent
Commercial electronic equipment may cause damage by static electrical discharge.
malfunctions in the electronic control system, even if the
・ To prevent damages caused by electrostatic
equipment is properly attached. Commercial electronic
discharge, connect the packaging to a properly
equipment includes devices not connected to the
working ground connection of the vehicle when
electronic system of the vehicle, such as mobile
removing a part from its packaging.
telephones or radios.
Therefore when diagnosing electronic system problems, ・ To prevent damages caused by electrostatic
first confirm whether such commercial electronic discharge, touch a properly working ground
before attaching the part when handling a part
while sliding across the seat, sitting down from

a standing position, or walking a certain
distance.
Control unit maintenance precaution
The control unit has been designed to withstand the
regular current load associated with vehicle operation.
Make sure the circuit is not overload. When performing
open circuit or short circuit tests, do not ground or apply
voltage to the circuit of the control unit, unless otherwise
instructed. When performing these circuit tests, make
sure to use a DMM with a high input impedance.
When it is clear that there is a failure in the control unit,
make sure to confirm that there are no problems outside
of the control unit before replacing it. If you neglect to do
this, in cases where the control unit was damaged due to a
short circuit in the output circuit, for example, the
replaced control unit will also be damaged.
Driving precautions
The driving precautions are as follows.
Caution：
・ On steep inclines, the vehicle may move if the
brake pedal is not applied enough. It is
necessary to apply the brake pedal more firmly
in this case.
・ Make sure to use the parking brake when
parking the vehicle at an inclination of 10 % or
more.
・ Make sure to apply the parking brake when
leaving the driver seat.
・ Apply the parking brake when parking the
vehicle for an extended period.
・ After adjusting the play in the clutch pedal,
make sure to perform initial adjustment.
・ In order to ensure safety should the electrical
system and service brake system happen to
fail, make sure to use chock blocks when on
inclined roads, to ensure the vehicle can be
parked with only the parking brake.
Function, structure, operation of brake

1. Function, structure, operation of brake the driver to recover the vehicle in the stable condition by
restraining the engine output, correcting the vehicle
Overview of ABS/EBD/TCS/ESC
posture through the required wheel brake control, and
The ABS, TCS and EBD are systems for maintaining the
calling the driver's attention with the indication light
stability and handleability of the vehicle by preventing
when it detects an unstable vehicle condition due to a
wheel lock-up and slipping when accelerating and
sudden change in the vehicle posture while running.
stopping the vehicle.
When a system abnormality occurs, the fail-safe function Each function of the brake control
is activated to return the vehicle to a condition without
Note：
the ABS, TCS, and EBD, and the warning light turns on.
The ESC advances the ABS, and adds the steering angle ・ When 4L (4WD Low) is selected for the
sensor, yaw rate sensor, back and forth/horizontal G running mode, the ESC is deactivated, and the
sensors and pressure sensor. This is a system that helps ESC OFF indication light turns on.
Operation of the brake control function

Running mode
ABS EBD TCS ESC
2H (2WD) ○ ○ ○ ○
4H (4WD high) ○ ○ ○ ○
4L (4WD low) ○ ○ ○ ×
Components
1. EHCU 4. Left front wheel speed sensor

2. Right rear wheel speed sensor 5. Right front wheel speed sensor
3. Left rear wheel speed sensor
1. Instrument panel cluster 5. Yaw rate sensor (vehicles with ESC)

2. ESC OFF switch (vehicles with ESC) 6. ECM
3. Steering angle sensor (vehicles with ESC) 7. TCCM
4. Stoplight switch
Component description Electronic control unit

Outputs the ABS control signal to the hydraulic unit by
Wheel speed sensor
processing the signals from each sensor.
The wheel speed sensor detects the vehicle speed of each
Hydraulic unit
of 4 wheels.
Controls the brake fluid pressure for each of 4 wheels
Yaw rate sensor (vehicles with ESC) upon reception of the signal from the control unit.
Detects the rotating angular speed and the front, rear, left
ECM (vehicles with ESC)
and right accelerations of the vehicle.
Performs the engine output control in accordance with the
Steering angle sensor (vehicles with ESC) signal from the electronic control unit when the TCS and
Detects the steering angle and direction. ESC are operating.
Stoplight switch Instrument panel cluster
Detect the operation status of the brake. Indicates the system operation status and any error
occurrence in the system through each indication/warning
ESC OFF switch (vehicles with ESC)
light in the instrument panel cluster.
The operations of the TCS and ESC can be stopped by
operating the switch. Functions of ABS/EBD/TCS/ESC
TCCM ABS
The TCCM detects free-lock condition of the center The ABS appropriately controls the brake fluid pressure
differential. by retaining/reducing/increasing the brake fluid pressure
while braking based on the signals from the wheel speed
EHCU
sensor using the EHCU.
Master cylinder pressure sensor (vehicles with ESC)
The EHCU calculates the wheel speed, wheel
Detects the brake fluid pressure from the master cylinder.
acceleration/deceleration, and vehicle speed using signals
from the wheel speed sensor. When the brake has been 8. Front braking force
applied while the vehicle being driven, and if the wheel
speed is excessively decreasing in comparison with the TCS functions (vehicles with ESC)
vehicle speed, the system will determine that the wheels Excessive opening of the throttle at startup or
are destined to lock. When the system determines such acceleration on a slippery road surface may cause
abnormal differences in speeds that exceeds specified slippage of the driving wheel due to excessive torque,
values, the brake fluid pressure will be retained. leading to impaired startup acceleration and
If the wheel speed decreases further in this condition, the maneuverability. TCS is a system that suppresses the
system determines that the wheels tends towards locking, slippage of driving wheels by means of brake oil pressure
and reduces the brake fluid pressure. If the system control and driving force control of the driving wheels
determines that wheel locking has been avoided after this, and generates driving force corresponding to the road
it repeats retaining/increasing the brake fluid pressure. surface to ensure vehicle's startup acceleration, ability to
hold a straight line and turning stability.
EBD
EBD is a system for appropriately controlling the front ESC (vehicles with ESC)
and rear braking force distribution according to the load The ESC ensures stability of vehicle's turning direction.
movement due to deceleration and changes in the load Due to accidental conditions such as road conditions,
state of the vehicle. The braking force distribution of the vehicle speed and emergency turning or external factors,
front wheels and rear wheels when braking is controlled over steer (strong side skid of rear wheels) and under
by the EHCU. steer (side skid of front wheels) are likely to occur. When
The EHCU detects the amount the brake pedal is applied the ESC detects such condition, it mitigates strong side
using signals from the master cylinder pressure sensor, skid of rear or front wheels by means of brake oil
and starts EBD control. When EBD control starts, the pressure control and driving force control of each wheel
EHCU calculates the most suitable braking force for each to ensure stability.
wheel based on signals from each wheel speed sensor, Caution：
and controls the hydraulic unit.
・ When 4L (4WD low) is selected as the running
mode, the ESC does not operate.
ESC control
The ESC detects vehicle conditions based on signals from
various sensors including the yaw rate sensor at vehicle
speed of 15 km/h (9 mph) or higher, and controls the
brake oil pressure and engine output.
ESC operations
In case of the over steer
When the electronic control unit determines the over
steer, it applies braking force to the wheels at the outer
side of turning and to the rear wheel at the inner side in
accordance with the degree of the over steer to cause
stabilization moment toward the outer side of turning and
represses the side skid of rear wheels to put the vehicle in
neutral steer state.
In case of the under steer
1. Rear braking force When the electronic control unit determines the under
2. Ideal distribution without load steer, it represses the driving force and applies braking
3. Ideal distribution with load force to the front and rear wheels in accordance with the
4. When loading degree of the under steer to cause stabilization moment
5. EBD control toward the turning direction and then represses the side
6. Without load skid of front wheels to put the vehicle in neutral steer
7. EBD non-control state.
1. Neutral steer 4. In case of the over steer

2. Correction
3. In case of the under steer
Rolling prevention function It also determines whether or not to operate the brake
When large horizontal G on the vehicle is generated and depending on the magnitude of detected horizontal G and
the vehicle becomes unstable as the gradient angle of the applies necessary braking force to each wheel.
vehicle becomes large, this function alerts the driver and
represses the engine output.
1. Horizontal G
Wheel speed sensors

The wheel speed sensors use a hall IC type sensor. The
wheel speed sensors for the front wheels are installed in
the knuckle, and the wheel speed sensors for the rear
wheels are installed on the brake back plate. Voltage is
generated in the sensor by the turning of the sensor rotor
firmly fitted into the hubs of the front and rear wheels.
The frequency of this voltage changes proportionately to
the rotor speed, thereby enabling the wheel speed to be
detected.
1. Wheel speed sensor

2. Sensor rotor
Yaw rate sensor (vehicles with ESC)

Solid state yaw rate sensor and G sensor are integrated
and placed beneath the center of the instrument panel to
detect the rotating angular speed and deceleration speed.
The yaw rate sensor detects capacitance change at the
sensor part caused by rotation in vertical axis direction of
the vehicle as vehicle's rotating angular speed (yaw rate).
An exclusive IC is employed for vibrating the sensor unit
and processing signals to ensure reliability together with
miniaturization.
As for G sensor, capacitance at the sensor part changes
when the vehicle speed is decelerated and this change is
measured and replaced by electric signals. 2 G sensors
installed at an angle of 45 degrees toward the cross
direction of the vehicle detects any deceleration in
horizontal direction.
1. Detection gear
ESC OFF switch (vehicles with ESC)

In an attempt to escape from any quagmire or snow,
depressing the accelerator with the TCS or ESC operating
may limit the driving force and make the escape difficult.
The TCS and ESC can be deactivated by operating the
ESC OFF switch.
1. G sensor
2. Yaw rate sensor
3. Yaw rate sensor assembly
Steering angle sensor (vehicles with ESC)

The steering angle sensor is placed in the steering column
part to detect the steering angle and steering direction.
The sensor part is equipped with 2 sets of magnetic
resistance elements that detect rotation of magnets in the
detection gear and change of magnetic resistance caused
by rotation of the detection gear is detected as steering
rotation.
1. TCS OFF indication light

2. ESC OFF indication light
3. ESC OFF switch
Switch operations (vehicles with ESC)

When 2H (2WD) or 4H (4WD high) is selected for
running mode
･Pushing the ESC OFF switch briefly switches it to the
TCS OFF mode in which the TCS is deactivated. Also,
the TCS OFF indication light in the instrument panel
cluster illuminates at this time.
･Pressing and holding the ESC OFF switch for about 5 the TCS OFF mode in which the TCS is deactivated.
seconds or longer with the vehicle stopped switches it to Also, the TCS OFF indication light in the instrument
the ESC OFF mode in which the TCS and ESC are panel cluster illuminates at this time.
deactivated. Also, the TCS OFF and ESC OFF indication
･The TCS off mode is canceled by pushing the ESC OFF
lights in the instrument panel cluster illuminate at this
switch briefly or turning the ignition switch OFF.
time.
Note：
･Each mode can be canceled by pushing the ESC OFF
switch briefly or turning the ignition switch OFF. ・ When the ESC OFF switch is pressed and
held for 10 seconds or longer, it returns to the
When 4L (4WD low) is selected for running mode normal mode.
･The ESC function stops operating.
･Pressing and holding the ESC OFF switch for about 5
seconds or longer with the vehicle stopped switches it to
Control allowed/prohibited Indication light

Running mode Operation Engine Brake Engine Brake
TCS OFF ESC OFF
TCS TCS ESC ESC
No ○ ○ ○ ○ Turning off Turning off
Short press × ○ ○ ○ Lighting Turning off
2H (2WD), 4H
(4WD high) Long press
(5 seconds or × × × × Lighting Lighting
longer)
No × ○ × × Turning off Lighting
Short press × ○ × × Turning off Lighting
4L (4WD low) Long press
(5 seconds or × × × × Lighting Lighting
longer)
Warning light, indication light Model without multi-information display
Model with multi-information display

1. ESC warning light (vehicles with ESC) 3. Brake warning light

2. ABS warning light
Brake warning light The hydraulic unit is comprised of the motor, plunger
Illuminates for 3 seconds when the ignition switch is pump, gear pump (vehicles with ESC), master cylinder
turned ON. pressure sensor (vehicles with ESC) and solenoid valves.
It illuminates when normal brake performance may be
Excluding vehicles with ESC
impaired due to a failure in the EHCU, etc.
･Illuminates when the brake fluid level is lowered.
･Illuminates in case of charging system failure.
･Illuminates in case of EBS function failure.
･Illuminates when the parking brake is not released.
ABS warning light
Illuminates for 3 seconds when the ignition switch is
turned ON.
Illuminates when a failure occurs in the ABS.
In the self-diagnosis mode, it indicates a DTC by
blinking.
ESC warning light (vehicles with ESC)
Illuminates for 3 seconds when the ignition switch is
turned ON.
It blinks when the TCS and ESC are activated.
Illuminates when a failure occurs in the ESC.
EHCU
The EHCU consists of the control unit and hydraulic unit.
Vehicles with ESC
The control unit is comprised of an ABS/EBD control
part, ABS/EBD/TCS control (vehicles with ESC),
abnormality detection part, and failsafe part. It drives the
hydraulic unit, etc. based on the signals from the various
sensors, and it, on the other hand, has the function to stop
the ABS/EBD control using the failsafe function to return
it to the regular braking when an abnormality occurs in
the system. It also has a self-diagnosing function, which
displays the defective areas when performing trouble
diagnosis.
1. Hydraulic unit section
2. Electronic control unit section
EHCU operations
Note：
・ Hydraulic circuits diagram
1. Inlet valve 8. Reservoir

2. Inlet valve 9. Pump
3. Brake pressure sensor 10. Outlet valve
4. Motor 11. Outlet valve
5. Outlet valve 12. Right front brake
6. Inlet valve 13. Left front brake
7. Rear brake
Note：
・ Hydraulic circuits diagram (vehicles with ESC)
1. Inlet valve 11. Outlet valve

2. Master cylinder cut valve 1 12. Left rear brake
3. Inlet valve 13. Right rear brake
4. Damper chamber 14. Reservoir
5. Brake pressure sensor 15. Pump
6. Motor 16. Outlet valve
7. Outlet valve 17. Outlet valve
8. Inlet valve 18. Right front brake
9. Master cylinder cut valve 2 19. Left front brake
10. Inlet valve
Inlet and outlet valves The master cylinder pressure sensor is integrated into the
Switch the brake oil pressure circuit among the 3 modes hydraulic unit section and outputs the master cylinder
of pressure increase, maintain and pressure reduction by pressure signal to the electronic control unit.
operating the inlet and outlet valves based on the control
ABS/EBD operations
signals from the electronic control unit.
Note：
Master cylinder cut valve (vehicles with ESC)
Controls the valve opening status, adjusts the oil pressure ・ Hydraulic circuits diagram
generated in the pump and generates control oil pressure Normal
corresponding to the operation status.
Master cylinder pressure sensor
Pressure increase
Maintain
Pressure reduction
Operation description
ABS control
Valve operation status Non-control Pressure increase Pressure reduction
Maintain mode
mode mode
Off (pressure
Inlet valve Off (open) On (close) On (close)
adjustment)
Outlet valve Off (close) Off (close) Off (close) On (open)
ABS/EBD operations (vehicles with ESC) Normal
Note：
・ Hydraulic circuits diagram
Pressure increase
Hold
Pressure reduction
ABS control
Valve operation status Non-control Pressure increase Pressure reduction
Hold mode
mode mode
Master cylinder cut valve 1 Off (open) Off (open) Off (open) Off (open)
Master cylinder cut valve 2 Off (open) Off (open) Off (open) Off (open)
Off (pressure
adjustment)
Outlet valve Off (close) Off (close) Off (close) On (open)
TCS operation Note：
The TCS control applies the brake by leading oil pressure ・ Hydraulic circuits diagram
generated in the pump in the hydraulic unit into the wheel
cylinder of the driving wheel and prevents slippage of 2WD
vehicle wheel due to driving force.
4WD
TCS control
Valve operation status Non-control Pressure Pressure
Hold mode
increase mode reduction mode
On (pressure On (pressure On (pressure
Master cylinder cut valve 1 Off (open)
adjustment) adjustment) adjustment)
On (pressure On (pressure On (pressure
Master cylinder cut valve 2 Off (open)
adjustment) adjustment) adjustment)
MAX oil pressure wheel for 2- Inlet valve Off (open) Off (open) Off (open) Off (open)
wheel control in the same system,
or control wheel for 1-wheel Outlet valve Off (close) Off (close) Off (close) Off (close)
control in the same system
MIN oil pressure wheel for 2-wheel Inlet valve Off (open) Off (open) On (close) On (close)
control in the same system Outlet valve Off (close) Off (close) Off (close) On (open)
Inlet valve Off (open) On (close) On (close) On (close)
Non-control wheel
Outlet valve Off (close) Off (close) Off (close) Off (close)
ESC operations In case of the under steer
It prevents side skid of front wheels by introducing oil
In case of the over steer
pressure generated in the pump in the hydraulic unit into
It prevents side skid of rear wheels by introducing oil
the wheel cylinder of each wheel to control the brake oil
pressure generated in the pump in the hydraulic unit into
pressure.
the wheel cylinder of each wheel to control the brake oil
In case of the under steer, it activates braking of both rear
pressure.
wheels, and the front wheel on the outer side of turning as
In case of the over steer, it activates braking of front and
necessary.
rear wheels of the outer side of turning.
In the illustration, right and left front brake, control wheel Note：
for left rear brake and non-control wheel for right rear ・ Hydraulic circuits diagram
brake are used as an example.
ESC control
Valve operation status Pressure increase Pressure
Maintain mode
mode reduction mode
Master cylinder cut valve On (close) On (close) On (close)
Control wheel
Control system Outlet valve Off (close) Off (close) On (open)
Control wheel
Outlet valve Off (close) Off (close) On (open)
Master cylinder cut valve On (close) On (close) On (close)
Control system Inlet valve Off (open) On (close) On (close)
Control wheel
(diagonal Outlet valve Off (close) Off (close) On (open)
wheels) Non-control Inlet valve On (close) On (close) On (close)
wheel Outlet valve On (open) On (open) On (open)
Note： Excluding vehicles with ESC
・ General circuit diagram
Excluding vehicles with ESC
No. Pin function No. Pin function

1 Ground (solenoid valve) 18 Wheel speed sensor front left signal
2 Not used 19 Wheel speed sensor front left 12 volts reference
3 Not used 20 Not used
5 Wheel speed sensor rear left 12 volts reference 22 Vehicle speed signal output
6 Wheel speed sensor front right signal 23 Not used

7 Wheel speed sensor front right 12 volts reference 24 Battery voltage (motor)
8 Not used 25 CAN high signal
11 Not used 28 Brake switch signal
12 Battery voltage (solenoid valve) 29 Not used
13 Ground (motor) 30 Not used
14 CAN low signal 31 Not used
15 Not used 32 Diagnostic request switch
16 Wheel speed sensor rear right signal 33 Not used
17 Wheel speed sensor rear right 12 volts reference 34 Ignition voltage
Vehicles with ESC
Vehicles with ESC
No. Pin function No. Pin function

1 Ground (solenoid valve) 18 Wheel speed sensor front left signal
2 Brake switch signal 19 Wheel speed sensor front left 12 volts reference
3 CAN low 2 signal (local) 20 Not used
4 Wheel speed sensor rear left signal 21 Not used
5 Wheel speed sensor rear left 12 volts reference 22 Not used
6 Wheel speed sensor front right signal 23 Not used
7 Wheel speed sensor front right 12 volts reference 24 Battery voltage (motor)
8 Not used 25 CAN high signal
11 Vehicle speed signal output 28 Not used
12 Battery voltage (solenoid valve) 29 Not used
13 Ground (motor) 30 ESC OFF switch signal
14 CAN low signal 31 Not used
15 CAN high 2 signal (local) 32 Not used
16 Wheel speed sensor rear right signal 33 Diagnostic request switch
17 Wheel speed sensor rear right 12 volts reference 34 Ignition voltage
Note：
・ Front disc brake
Note：
・ Rear drum brake
Note：
・ Rear wheel cylinder
Note：
・ Blend proportioning valve
Note：・ With the blend proportioning valve

・ Brake piping diagram
Note：
・ Model with ABS
Note：
・ Model with ESC
Note：
・ Vacuum servo with master cylinder
Note： 1. Engine side

・ Vacuum hose 2. Check valve
Caution：
・ When attaching the vacuum hose, make sure
the arrow painted on the hose is pointing to the
engine side.
Structure of the blend proportioning valve rout 1 on the master cylinder side. Then it overcomes
spring operational force and fluid pressure, and affects
For bypass valve, seal the routes 1 and 2 and use a seal to
the wheel cylinder seal. The piston is pressed to the right
the piston end. The spring is pressed against the piston
and it consequently opens up the routes 1 and 2 to cancel
and spring seal is pressed against the cylinder end surface
the P-valve operation. Next, the master cylinder fluid
in order to effectively seal the routes 1 and 2.
pressure and wheel cylinder fluid pressure affect the same
Operation of the blend proportioning valve surface of the seal up to the point C and therefore they are
decreased at the same rate. However, due to the act of
P-valve operation by the master cylinder pressure does
spring on the wheel cylinder side, the wheel cylinder
not change up to the first and second brake points. When
fluid pressure maintains balance with the lower master
the master cylinder fluid pressure reaches to the second
cylinder fluid pressure with the pressure difference
brake point, the fluid pressure compress the seal (which
caused by this spring.
branches into the routes 1 and 2) and goes through the
1. Route 1 6. Route 2
2. From the master cylinder 7. Bypass valve
3. Seal 8. Spring
4. Piston 9. P-valve
5. To the wheel cylinder
Note： 3. Point C
・ Characteristic curves
Note：
・ If there is any fluid leakage or other failure,
replace the defective blend proportioning
valve.
The blend proportioning valve is set in the
engine room.
Caution：
・ Blend proportioning valve cannot be repaired
and must be replaced as a complete
assembly.
1. The first brake point

2. The second brake point
Primary specifications of brake

1. Primary specifications of brake Note：
・ Primary specifications of the brake
4x2 LOW RIDE 4x2 HIGH RIDE, 4x4

Front disc brake
Cylinder type Pin slide
Disc outer diameter ： 280 mm { 11.02 in } ： 300 mm { 11.81 in }
Disc thickness ： 27 mm { 1.06 in }
Piston diameter ： 44.45 mm { 1.75 in } x2
Adjustment method Automatic adjustment
Rear drum brake
Type Leading/trailing
Drum inner diameter ： 254 mm { 10.00 in } ： 295 mm { 11.61 in }
Brake lining dimensions 244 x 50 x 4.3 283 x 50 x 4.6
(length x width x thickness) (9.61 x 1.97 x 0.17) (11.14 x 1.97 x 0.18)
Adjustment method Automatic adjustment
Wheel cylinder inner diameter ： 25.4 mm { 1.00 in } ： 23.8 mm { 0.94 in }
Master cylinder
Type Split
Bore diameter ： 22.2 mm { 0.87 in }
Piston stroke
29+16 (1.14+0.63)
(primary + secondary)
Vacuum servo
Diaphragm diameter ： 266 mm { 10.47 in }
Power cylinder stroke ： 50 mm { 1.97 in }
Pedal ratio 3.1
Blend proportioning valve (without Blend proportioning valve (without
Balance type
ABS)/EBD (with ABS) ABS)/EBD (with ABS, with ESC)
Note：
・ Primary specifications of the parking brake
Type Leading/trailing
Drum inner diameter 254 mm (10.0 in) or 295 mm (11.61 in)
6 - 9 notches, bucket seat
Parking brake lever stroke 8 - 14 notches, bench seat
When pulled with a force of 294 N (30 kg/66 lb)
Introduction to the trouble diagnosis of brake

1. Introduction to the trouble diagnosis of brake
Description of diagnosis
The ABS, EBD, TCS, and ESC failure symptoms are
divided into symptoms that can be detected with DTCs
along with lighting of the ABS warning light, brake
warning light and ESC warning light, and symptoms that
the driver can detect as vehicle problems.
Continue the diagnosis in accordance with the inspection
of the ABS control system.
Check if the warning light operates properly and check
for a DTC using a scan tool.
Note：
・ The DTC display of the scan tool shows digit
structure (alphabet + 4 digits + 2 digits) like
DTC C00350F.
・ The final 2 digits of FTB show additional
information on problems.
Note：
About self diagnosis ・ When there is a problem, the flash code is
The EHCU has a self-diagnosing function, which repeatedly displayed. When there are multiple
performs the check operations when the system is started, DTCs detected, they are displayed in
to determine whether there are any system abnormalities ascending order of codes.
and which areas are defective. If an abnormality is
detected, it turns on the ABS warning light, brake
warning light, and ESC warning light to inform the driver
of the abnormality, and records a DTC.
Caution：
・ The illuminated warning light is turned off each
time the ignition switch is turned OFF, but the
DTC continues to be stored until the clearing
operation is performed. For intermittent
problems or problems occurring when the
vehicle is driven, the control unit determines
that the system is normal when the ignition
switch is turned from OFF to ON, and a normal
illumination pattern may be indicated. Perform
an inspection/repair according to the trouble
diagnosis flow.
Reading blinking DTCs
The vehicle must be stopped. Vehicle speed of 3 km/h (2
mph) or lower. Method for clearing DTC
The flash code is displayed with blinking of the ABS Use the following method to clear the DTCs without
warning light when the pin No. 12 and pin No. 4 or pin using a scan tool.
No. 5 of the DLC are short-circuited and then the ignition Short-circuit the pin No. 12 and pin No. 4 or pin No. 5 of
switch is turned ON. the DLC and then turn the ignition switch ON. Turn the
brake switch ON/OFF at least 8 times within 5 seconds
Note： after the ABS warning light starts blinking.
・ When the status is normal, the display is
shown as follows.
Functional Inspection (All models) 18C-1
Description Brakes
Functional Inspection
(All models)
Table of Contents
Brake basic inspection...................................................18C-2
Diagnostic system check- ABS/EBD/TCS/ESC controls
.......................................................................................18C-3
Lost communication with the EHCU............................18C-4
Check ABS, EBD, ESC warning light inoperative.......18C-5
Check ABS, EBD, ESC warning light always on.........18C-6
Hydraulic unit operation system check.........................18C-7
ESC OFF switch circuit system check..........................18C-8
18C-2 Functional Inspection (All models)
Brake basic inspection

1. Brake basic inspection description of function
Since the ABS/EBD/TCS/ESC control system controls
the brake, a mechanical inspection for the brake and
inspection for the brake system and vacuum system are
required.
2. Brake basic inspection inspection
Inspection when there may be a problem in the brake unit
or brake system, etc.
1. Inspect the amount of brake fluid.
2. If the brake fluid is insufficient, refill the brake fluid.
3. Inspect the piping of the brake system.
Note：
・ There should be no vacuum leak.
・ There should be no fluid leakage.
4. If a problem is discovered, repair or replace.
5. Inspect the brake booster.
Note：
・ There should be no vacuum leak.
・ There should be no operation failure.
7. Inspect the brake fluid tank.
Note：
・ There should be no fluid leakage.
9. Inspect the wheel brake.
Note：
・ There should be no abnormal worn.
11. Attach all components, and confirm that all
components are properly attached.
Diagnostic system check- ABS/EBD/TCS/ESC controls

1. Diagnostic system check- ABS/EBD/TCS/ESC 10. Inspect whether uneven braking occurs while ABS
controls description of function works.
The ABS/EBD/TCS/ESC control system check is the 11. Inspect whether ABS works frequently but the brake
starting point of all vehicle running status diagnosis. is not effective or TCS operates frequently.
Before using this procedure, perform a careful visual
12. Inspect whether a malfunction of the ESC exists.
inspection to confirm that the EHCU, connectors, a
power source and ground terminals are all clean and 13. Inspect whether brake pedal feeling is abnormal.
tightened properly. This check is the method for checking
14. Inspect whether operation sounds are heard from the
problems caused by malfunctions in the ABS control
hydraulic unit even though the brake is not applied.
system according to each function.
15. Inspect whether the wheels lock when braking.
2. Diagnostic system check- ABS/EBD/TCS/ESC
controls inspection
Inspection for determining the failure location in the ABS
control system
1. Turn ON the ignition switch.
2. Check the brake warning light, the ABS warning
light, and the ESC warning light.
Note：
・ The warning light turns off after lighting for 3
seconds.
3. If the warning light does not illuminate, inspect the
brake, ABS, and ESC warning lighting circuit
system.
4. Turn OFF the ignition switch.
5. Connect a scan tool to the DLC.
7. Check for a DTC using a scan tool.
Note：
・ When a DTC beginning with "U" has been
detected, or abnormal signals have been
received from other ECUs, it indicates that
there is no communication with other ECUs.
・ If DTC C0550 has been detected, inspect the
applicable DTC.
・ If another DTC has been detected, inspect the
applicable DTC.
・ When multiple DTCs are set, diagnose a DTC
starting with the one that has a smaller number
unless otherwise instructed in the diagnostic
steps.
8. Confirm that the brake warning light, the ABS
warning light, and the ESC warning light turn on.
9. When the lights illuminate, refer to Inspection of
ABS, EBD, and ESC warning light lighting circuit
system (does not go off) to inspect it.
Lost communication with the EHCU

1. Lost communication with the EHCU description of Note：
function ・ There should be no open circuit or high
The ECM, EHCU, TCM, TCCM, SRS control unit, ICU, resistance.
BCM, and instrument panel cluster communicate with a 17. If a problem is found, repair the CAN Low circuit.
scan tool via the CAN communication circuit. The
EHCU, ECM, TCM, TCCM, auto A/C control unit, SRS 18. Inspect the CAN High circuit between the EHCU
control unit, immobilizer control unit, BCM, instrument and DLC.
panel cluster, DRM, and EGR control unit communicate Note：
with each other via the same CAN communication
・ There should be no open circuit or high
circuit. The CAN terminating resistor is attached to the
resistance.
ECM and instrument panel cluster.
19. If a problem is found, repair the CAN High circuit.
2. Lost communication with the EHCU inspection
20. When the CAN circuit is normal, replace the EHCU.
1. Check for a poor connection on the EHCU harness
connector. Refer to "4.Brakes 4D.ABS(All models)
EHCU removal".
2. If a problem is found, repair the harness connector
connection. Refer to "4.Brakes 4D.ABS(All models)
EHCU installation".
3. Inspect the ABS 10A fuse.
21. Write the vehicle information into the EHCU.
4. If a problem is found, replace the fuse.
Refer to "4.Brakes 4D.ABS(All models)
Note： EHCU setting".
・ If the fuse blows again, repair the cause of the
blown fuse.
5. Disconnect the harness connector from the EHCU.
7. Connect a test light to the EHCU harness connector
ignition power circuit.
8. If the test light does not turn on, repair the open
circuit of ignition power circuit.
9. Inspect the EHCU ground circuit.
Note：
・ There should be no open circuit.
10. If a problem is found, repair the ground circuit.
11. Disconnect a scan tool from the DLC.
12. Measure the resistance value between the DLC CAN
High circuit and CAN Low circuit.
Standard： 50 to 70 Ω
13. If the resistance value is not the standard value,
disconnect the harness connector from the EHCU.
14. Check for a poor connection on the EHCU harness
connector.
15. If a problem is found, repair the harness connector.
16. Inspect the CAN Low circuit between the EHCU and
DLC.
Check ABS, EBD, ESC warning light inoperative

1. Check ABS, EBD, ESC warning light inoperative 11. If the test light does not turn on, repair any open
description of function circuit or high resistance in the instrument panel
cluster battery power supply circuit between the
The brake, ABS, and ESC warning lights illuminate when
battery and the instrument panel cluster.
the ignition switch is turned ON, and turn OFF
afterwards. When the EHCU detects the ignition switch 12. Connect a test light between the ignition power
"ON" signal, it turns on the brake, ABS, and ESC supply terminal of the instrument panel cluster
warning lights for 3 seconds for lighting check. The harness connector and the frame ground.
subsequent control of each light is performed by the
13. If the test light does not turn on, repair any open
EHCU through sending light operation requests to the
circuit or high resistance in the instrument panel
instrument panel cluster via CAN communication.
cluster ignition power supply circuit between the
Note： battery and the instrument panel cluster.
・ Function of the warning light 14. Connect a test light between the battery power
The brake warning light, the ABS warning light, and the supply terminal of the instrument panel cluster
ESC warning light inform the driver that a malfunction harness connector and the ground terminal.
has occurred and the vehicle needs to be inspected and 15. When the test light does not turn on, repair any open
repaired as soon as possible. circuit or high resistance in the instrument panel
When the brake warning light, the ABS warning light, cluster ground circuit between the instrument panel
and the ESC warning light remain on in response to the cluster and the frame ground.
instruction from the EHCU, a DTC has been detected.
16. If the circuit is normal, replace the instrument panel
Note： cluster.
・ Lighting condition of the warning light
17. Restore the vehicle.
The warning light lights up for 3 seconds after the
ignition switch is turned ON.
If the EHCU detects a malfunction, it remains on. 19. Confirm that the warning light and the indication
light turn on for 3 seconds.
2. Check ABS, EBD, ESC warning light inoperative
inspection
1. Inspect the ABS, EBD, TCS, and ESC control
system.
2. Check for a DTC using the scan tool.
3. If a DTC has been detected, perform diagnosis for
the DTC.
4. Inspect whether other lights in the instrument panel
cluster are lighting.
5. If it does not turn on, inspect the Meter 10 A fuse.
Note：
・ If the fuse is wire-melted again, repair the
cause of fuse meltdown.
8. Disconnect the harness connector from the
instrument panel cluster.
10. Connect a test light between the battery power
supply terminal of the instrument panel cluster
harness connector and the frame ground.
Check ABS, EBD, ESC warning light always on

1. Check ABS, EBD, ESC warning light always on 8. Turn ON the ignition switch.
description of function
9. Measure the voltage value between the instrument
The brake, ABS, and ESC warning lights illuminate when panel cluster CAN low circuit and the frame ground.
the ignition switch is turned ON, and turn OFF
10. Measure the voltage value between the instrument
afterwards. When the EHCU detects the ignition switch
panel cluster CAN low circuit and the frame ground.
"ON" signal, it turns on the brake, ABS, and ESC
warning lights for 3 seconds for lighting check. The 11. Measure the voltage value between the instrument
control of each light is performed by the EHCU through panel cluster CAN high circuit and the frame ground.
sending light operation requests to the instrument panel
12. Confirm whether the both voltages are within the
cluster via CAN communication.
standard value range.
Note： standard： 1.5 to 3.5 V
・ Function of the warning light
13. If the voltage is without the specified range, inspect
The brake warning light, the ABS warning light, and the the CAN low and CAN high circuits of the
ESC warning light inform the driver that a malfunction instrument panel cluster for a short circuit.
has occurred and the vehicle needs to be inspected and
repaired as soon as possible. 14. If a problem is found, repair the harness connector.
When the brake warning light, the ABS warning light, 15. If the harness connector is normal, replace the
and the ESC warning light remain on in response to the instrument panel cluster.
instruction from the EHCU, a DTC has been detected.
Note：
17. Connect the harness connector to the instrument
・ Lighting condition of the warning light panel cluster.
The warning light lights up for 3 seconds after the 18. Disconnect the harness connector from the EHCU.
ignition switch is turned ON.
If the EHCU detects a malfunction, it remains on. 19. Turn ON the ignition switch.
2. Check ABS, EBD, ESC warning light always on 20. Measure the voltage value between the EHCU CAN
inspection low circuit and the frame ground.
1. Check for a DTC using the scan tool. 21. Measure the voltage value between the EHCU CAN
high circuit and the frame ground.
2. If a DTC has been detected, perform diagnosis for
the DTC. 22. Confirm whether the both voltages are within the
standard value range.
standard： 1.5 to 3.5 V
4. Disconnect the connectors from all ECUs that are
connected to the CAN circuit. 23. When the voltage value is outside the standard value
range, inspect the CAN low and CAN high circuits
5. Inspect the CAN high circuit and the CAN low of the EHCU for a short circuit.
circuit between individual units.
Note：
・ There should not be a short circuit with the 25. If the harness connector is normal, replace the
power supply circuit. EHCU.
・ There should be no short circuit with the low 26. Write the vehicle information into the EHCU.
reference circuit. Note：
・ There should be no short circuit with metal ・ To turn off the ESC warning light, the 0-point
components such as a frame. learning of the steering angle sensor through
・ There should be no short circuit between the driving is required.
CAN high circuit and the CAN low circuit.
6. If a problem is found, repair the CAN high circuit
and the CAN low circuit.
29. Confirm that the warning light turns off after lighting
7. Connect the harness connector to the EHCU.
for 3 seconds.
Hydraulic unit operation system check

1. Hydraulic unit operation system check description of
function
Each menu is used to inspect the status of the hydraulic
unit. When no DTC is detected, these inspections are
used to diagnose failure locations.
If a DTC is detected, the inspections using these menus
are useful to distinguish mechanical failures and electrical
failures.
2. Hydraulic unit operation system check inspection
1. Lift up the 4 wheels.
2. Release the parking brake.
5. Conduct the ABS/ESC actuator test with a scan tool.
Note：
・ Left front wheel speed
・ Right front wheel speed
・ Left rear wheel speed
・ Right rear wheel speed
6. Confirm that the wheel being tested rotates by hand.
7. There should be no open circuit or high resistance
between the EHCU and the ESC OFF switch.
ESC OFF switch circuit system check

1. ESC OFF switch circuit system check description of 18. Restore the vehicle.
function
The TCS and ESC can be deactivated by operating the
Note：
ESC OFF switch.
When the ESC OFF switch is turned ON, the ground ・ To turn off the ESC warning light, the 0-point
circuit is established, and the EHCU detects the "OFF" learning of the steering angle sensor through
signal. driving is required.
The EHCU recognizes the status of the ESC OFF switch Refer to "4.Brakes 4D.ABS(All models)
by detecting the voltage changes and change time caused EHCU setting".
by the "ON/OFF" status of the ESC OFF switch.
20. Press the ESC OFF switch briefly.
2. ESC OFF switch circuit system check inspection
21. Confirm that the TCS OFF light turns on, and the
Inspection performed when there may be a problem in the TCS Driver Intent display shows "OFF".
locations relating to the ESC OFF switch system
22. If it does not turn on, replace the instrument panel
1. Press the ESC OFF switch for 5 seconds or longer. cluster.
2. Confirm whether the TCS OFF indication light turns 23. Write the vehicle information into the instrument
on. panel cluster.
3. If it does not light up, turn the ignition switch OFF. Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
4. Connect a scan tool to the DLC. Driver Info.(All models) Instrument panel
cluster setting".
6. Check the TCS Driver Intent display a the scan tool.
7. Confirm if the TCS Driver Intent display shows
"OFF" when the ESC OFF switch is pressed briefly.
8. When the TCS Driver Intent display shows "ON",
turn the ignition switch OFF.
9. Inspect the ESC OFF switch circuit.
Note：
resistance between the EHCU and the ESC
OFF switch.
resistance between the ESC OFF switch and
the ground terminal.
10. If a problem is found, repair the circuit.
11. Inspect the ESC OFF switch harness connector.
Note：
・ There should be no contact failure.
12. Inspect the ESC OFF switch.
13. If a problem is found, replace the ESC OFF switch.
15. Press the ESC OFF switch briefly.
16. Confirm that the TCS OFF light turns on, and the
TCS Driver Intent display shows "OFF".
17. If it does not turn on, replace the ECM.
Symptom (All models) 18D-1
Description Brakes
Symptom
(All models)
Table of Contents
Intermittent conditions of brake....................................18D-2
Wheels lock when braking............................................18D-5
Uneven braking occurs while ABS works....................18D-6
Brake pedal feeling is abnormal....................................18D-7
Brake operation sounds are heard from the hydraulic unit
even though the brake is not applied.............................18D-9
One wheel locks..........................................................18D-10
Dragging brakes..........................................................18D-11
Brake abnormal noise..................................................18D-12
Bake does not work efficiently...................................18D-13
Brake pedal pulsates....................................................18D-14
Stepping power of the brake pedal is large.................18D-15
Stroke of the brake pedal is abnormal.........................18D-16
Defective straight driving............................................18D-17
ABS works frequently but the brake is not effective or TCS
operates frequently......................................................18D-18
ESC does not work efficiently....................................18D-19
18D-2 Symptom (All models)
Intermittent conditions of brake

1. Intermittent conditions of brake description of happens indicates that there is an abnormality in the
symptom circuit being monitored.
Note： Test for improper installation of electronic equipment
・ Preliminary inspections before starting such as a light or mobile phone if an intermittent
condition exists from the beginning and continues to
Before starting the intermittent inspections, perform ABS exist.
control system check to verify that all the following Any of the following may cause an intermittent lighting
conditions are satisfied. of the ABS warning light with no stored DTC.
Each light operate normally.
Any DTC has not been detected. The EHCU grounds are loose or dirty.
The scan tool data is within the normal range of operation The ABS warning light circuit intermittently has an open
values. or short to ground.
Electrical system interference caused by a malfunctioning
Note： relay, motor, or switch. These electrical components can
・ Visual inspection cause a large electrical surge. Normally, the problem
occurs when the malfunctioning component operates.
Some of the symptom corrective procedures require
There is a diode with an open circuit.
careful visual and physical inspections. This step is
extremely important. Problems may be corrected just by The following diagnosis shows possible causes for each
carrying out the visual and physical inspections without problem. The order of these procedures is not important.
performing any further inspection, which leads to saving If no abnormality is seen in the scan tool readings,
valuable time. Confirm the following points. proceed in a logical order, starting with items that are
The EHCU grounds are clean, tight, and in their proper easiest to check, or those that are most likely.
location.
The problem is not currently present but is stored in the
The EHCU harness wiring and terminals are properly
DTC history. Or, there is a customer complaint, but the
connected without any pinching or open circuits.
symptom cannot currently be reproduced because the
Note： problem is not DTC related.
・ Intermittent Note：
If an intermittent condition exists, inspect for improper ・ Preliminary inspection
installation of electrical components. Inspect aftermarket
Before starting, perform the preliminary inspection and
add-on electrical devices, lights, and mobile phones.
the visual inspection.
Confirm that no commercial equipment is connected to
the CAN communication circuit. If an intermittent Note：
condition cannot be located, the communication signal of ・ Harness and connector
a mobile phone may be causing the condition.
Even if a problem occurs, the ABS, ESC, and brake Many of the circuits that are open-circuit or shorted
warning lights might not illuminate, and a DTC might not intermittently are affected by movement of harnesses and
be stored. In most cases, a faulty electrical connection or connectors caused by vibration, engine torque, bumps,
wiring is causing an intermittent failure. Perform careful rough pavement, etc. Test for this type of condition by
visual and physical inspections on the connector that is performing the applicable procedure from the following
suspected to have an abnormality for the following list.
conditions. Move the related connectors and wiring while monitoring
the relevant scan tool data.
Improper connection of connector. Move the related connectors and wiring, and observe the
Loosening of terminal. operation of the component while commanding "ON" and
Damaged or improperly formed terminal. "OFF" to the component with the scan tool.
Repair or replace the connector terminal in the problem With the engine running, move related connectors and
circuit in order to ensure the proper contact tension. wiring while monitoring engine operation.
Remove the terminal from the connector body in order to When moving the harness or connector affects the data
inspect for a poor terminal-to-wire connection. display, component,system operation or engine operation,
Connect the DMM to the circuit suspected for an inspect and repair the harness or connectors as necessary.
abnormality, and perform a road test for the vehicle. An Note：
abnormal reading that occurs when a malfunction
・ Electrical connection or wiring
In most of cases, a poor electrical connection, loosened component or connection is low, or only when the
terminal or wiring problem causes an intermittent temperature of component or connection is high.
condition. Perform the following inspections. If the intermittent condition is related to heat, check the
Inspect for poor mating of the connector halves, or data relating to the following items.
terminals improperly seated in the connector body. High ambient temperatures.
Inspect for improperly formed or damaged terminals. Heat generated by the underhood and the engine.
Test for a loosened terminal. Heat generated in a circuit due to poor connections or a
Inspect for poor terminal to wire connections including high electrical load.
terminals bent by insulation. This requires removing the Conditions of loads, towing, etc. are higher than normal.
terminals from the connector body. If the intermittent is caused by low temperature, check
Inspect for corrosion and water intrusion. Worn or the data relating to the following items.
damaged insulation can allow moisture to enter the Low ambient temperature. If the temperature is extremely
wiring. The conductor can corrode inside the insulation, low, a connection or component may freeze. Test for
with little visible evidence. Check for any swollen or stiff water intrusion.
section of the wire in the circuit suspected for an The symptom occurs only on a cold start.
abnormality. The condition goes away when the vehicle warms up.
Inspect for wires that are broken inside the insulation. Based on the information from the customer, determine if
Inspect the harness for a pinching caused by wiring, the failure is caused by temperature.
disconnection and worn.
Note：
Confirm that the wiring does not come in contact with a
hot exhaust component. ・ EMI and electrical noise
Note： Some electrical components and circuits are sensitive to

EMI or other types of electrical noises. Inspect for the
・ The power supply and GND of the control unit,
following conditions.
the power supply and GND of the components
Whether the harnesses are placed too close to the high-
Poor power source or ground connections can cause voltage or high-current devices such as injection
widely varying symptoms. components, motors, generators, etc. These components
Test all control module power supply circuits. Many may generate electrical noises which interfere with
vehicles have multiple circuits supplying power to the normal circuit operations.
control module. Other components in the system have Electrical system interference caused by malfunctioning
separate power supply circuits that may also need to be relays, and switches or solenoids controlled by the
tested. Inspect the connections of the fuses and EHCU. This may cause a large electrical surge to be
connectors for the module and components, as well as generated.
other intermediate connections between the power source Normally, the problem occurs when the malfunctioning
and the module and components. A test light or the DMM component operates.
is capable of displaying whether or not any voltage is Improper installation of non-factory or commercial
present, but neither of them has the ability to test whether electronic equipment such as lights, 2-way radios,
sufficient current is flowing in the circuit. Confirm amplifiers, electric motors, remote starters, alarm
whether the circuit can secure the current necessary to systems, mobile phones, etc. Electromagnetic disturbance
operate the components. may occur while these electronic equipment are in use,
Test all of the ground circuits for the system and control but not while they are not in use.
module. The control module may have multiple ground Test the generator for a malfunctioning rectifier bridge
circuits. Other components in the system have separate that may be allowing A/C noises into the electrical
grounds that may also need to be tested. Inspect the system.
ground connections for contamination and improper
Note：
tightening. Inspect the connections of the components,
and those in splice packs, where applicable. Confirm ・ Duplicating failure conditions
whether the circuit can secure the current necessary to If none of the above tests is successful, try to duplicate
operate the components. and record the failure condition.
Note： As for the method, it is recommended to drive the vehicle
with the DMM connected to the circuit suspected for an
・ Temperature sensitivity
abnormality. If an abnormality is seen in the reading on
An intermittent condition may occur when a component the DMM when the problem occurs, the problem may
or connection reaches the normal operating temperature. possibly be identified.
The condition may occur only when the temperature of
Note：
・ Snapshot of the scan tool
The scan tool can obtain snapshots of the parameters
available via the serial data.
The snapshot function records live data over a period of
time. The recorded data can be replayed and analyzed.
The scan tool also has the graphing function, and can
graph a parameter alone or in combination with other
parameters for comparison. The snapshot can be triggered
manually at the time the symptom is noticed, or set up in
advance to be triggered when a DTC sets. An abnormal
value captured in the recorded data may point a system or
component that needs to be investigated further.
Wheels lock when braking

1. Wheels lock when braking description of symptom
The wheels lock when braking.
2. Wheels lock when braking diagnostics
1. Confirm whether the ABS operates.
Note：
・ It does not operate when the vehicle speed is
at or below 10 km/h (6 mph).
2. If the ABS does not operate, inspect the applicable
wheel speed sensor circuit.
3. Inspect the valve GND circuit between the EHCU
and the GND.
Note：
resistance.
4. Inspect the motor GND circuit between the EHCU
and the GND.
Note：
resistance.
5. Replace the EHCU.
EHCU removal".
EHCU installation".
6. Set the vehicle information on the EHCU.
EHCU setting".
7. Perform 0-point learning of the steering angle sensor.
Refer to "4.Brakes 4D.ABS(All models) Steering angle
sensor setting".
9. Perform a test-run.
Note：
・ If a DTC has been detected, inspect the
applicable DTC.
Uneven braking occurs while ABS works

1. Uneven braking occurs while ABS works description Note：
of symptom ・ Because different wheel speed values may be
Uneven braking occurs while ABS works. displayed for the front and rear for vehicles
that have different radius tires set for the front
2. Uneven braking occurs while ABS works diagnostics and rear wheels, check the speed after
Note： running the vehicle at a constant speed for a
short period of time.
・ The following is the diagnosis when not using
a scan tool. 12. If a problem is found, inspect the applicable wheel
speed sensor circuit.
1. Inspect the installation condition of the wheel speed
sensor. 13. Inspect the brake pipe.
2. If a problem is found, repair the installation Note：
condition of the wheel speed sensor. ・ The connection should be correct.
3. Inspect the wheel speed sensor. 14. Replace the EHCU.
Note： Refer to "4.Brakes 4D.ABS(All models)
・ There should be no foreign matter attached on EHCU removal".
the wheel speed sensors.
4. Inspect the sensor rotor. EHCU installation".
Note： 15. Set the vehicle information on the EHCU.
・ There should be no foreign matter attached on Refer to "4.Brakes 4D.ABS(All models)
the sensor rotor. EHCU setting".
5. Inspect the wheel speed sensor circuit. 16. Perform 0-point learning of the steering angle sensor.
6. Inspect the brake pipe. Refer to "4.Brakes 4D.ABS(All models) Steering angle
Note： sensor setting".
・ The connection should be correct. 17. Restore the vehicle.
7. Replace the EHCU. 18. Perform a test-run.
Refer to "4.Brakes 4D.ABS(All models) 19. Check for a DTC using a scan tool.
EHCU removal".
Note：
Refer to "4.Brakes 4D.ABS(All models) ・ If a DTC has been detected, inspect the
EHCU installation". applicable DTC.
EHCU setting".
Note：
・ The following is the diagnosis when using a
scan tool.
11. Check the wheel speed display using the scan tool.
Note：
・ Perform the procedure for each wheel.
Confirm whether the lowest speed of all the wheel speed
displays are at or below 4 km/h (2 mph) and stable.
Brake pedal feeling is abnormal

1. Brake pedal feeling is abnormal description of 18. Connect a test cable with fuse between the terminals
symptom of the stoplight switch harness connector.
Brake pedal feeling is abnormal. 19. Check the stoplight.
2. Brake pedal feeling is abnormal diagnostics 20. If the stoplights, replace the stoplight switch.
1. The brake pedal is depressed. Refer to "9.Body, Cab, Accessories 9A.Lighting
Systems(All models) Stoplight switch removal".
2. Check the stoplight.
Refer to "9.Body, Cab, Accessories 9A.Lighting
3. If the stoplight lights up, turn the ignition switch
Systems(All models) Stoplight switch installation".
OFF.
21. If the stoplight does not turn on, inspect the circuit
between the stoplight fuse and the stoplight relay.
Note：
6. The brake pedal is depressed. ・ There should be no open circuit or high
7. Measure the voltage between the stoplight switch resistance.
input signal terminal of the EHCU harness connector 22. Inspect the circuit between the stoplight relay and
and the GND. stoplight switch.
standard： 18.0 V Note：
8. If it is at or below the standard value, inspect the ・ There should be no open circuit or high
stoplight switch input signal circuit between the resistance.
EHCU and the stoplight relay.
23. Inspect the circuit between the stoplight switch and
Note： the GND.
・ There should be no open circuit or high Note：
resistance.
9. If the value is at or above the standard value, inspect resistance.
the brake fluid pressure line.
24. Inspect the brake fluid pressure piping.
Note：
Note：
・ There should be no leak or air mixing.
・ There should be no leak or air mixing.
10. If the stoplight does not turn on, turn the ignition
switch OFF.
11. Inspect the stoplight fuse.
EHCU removal".
12. If the fuse is open circuit, replace the fuse.
Note： EHCU installation".
・ If the fuse continues to be open circuit, repair 26. Set the vehicle information on the EHCU.
the cause of open circuits.
13. Replace the stoplight relay. EHCU setting".
Note： 27. Perform 0-point learning of the steering angle sensor.
・ Replace the relay with a 4WD relay or a new
relay.
sensor setting".
14. The brake pedal is depressed.
15. Check the stoplight.
16. If the stoplight lights up, replace the stoplight relay.
17. If the stoplight does not turn on, disconnect the
harness connector from the stoplight switch.
Note：
applicable DTC.
Brake operation sounds are heard from the hydraulic unit even though the brake is
not applied
1. Brake operation sounds are heard from the hydraulic 10. Perform a test-run.
unit even though the brake is not applied description
of symptom
Note：
Brake operation sounds are heard from the hydraulic unit
even though the brake is not applied. ・ If a DTC has been detected, inspect the
applicable DTC.
2. Brake operation sounds are heard from the hydraulic
unit even though the brake is not applied diagnostics
Note：
・ It is normal if it operates in the following
conditions.
The vehicle speed is 10 km/h (6 mph) or less on the first
run after starting the engine.
When downshifting is performed or the clutch is
operated.
When the vehicle is driven on a slippery road, frozen or
snowy road, or rough road.
When performing a high speed turn.
When passing over a projection such as a curbstone.
sensor.
2. If a problem is found, repair the installation
condition of the wheel speed sensor.
3. Inspect the wheel speed sensor.
Note：
・ There should be no foreign matter attached on
4. Inspect the sensor rotor.
Note：
the sensor rotor.
5. Inspect the wheel speed sensor circuit.
EHCU removal".
EHCU installation".
EHCU setting".
8. Perform 0-point learning of the steering angle sensor.
sensor setting".
One wheel locks

1. One wheel locks diagnostics
Brake booster functional failure.
Perform an operation inspection, and replace as
necessary.
Caliper assembly corrosion
Clean and replace as necessary.
Dragging brakes
1. Dragging brakes diagnostics
Improper return of the master cylinder piston.
Readjust the length of the brake booster rod, and replace
the master cylinder as necessary.
Clogging in the brake pipe or hose.
Replace.
Improper brake pedal play.
Readjust the length of the brake booster rod.
Caliper or wheel cylinder piston stuck.
Perform an inspection and cleaning. Replace as
necessary.
Defective vacuum hose or improper vacuum hose
installation.
Replace. Correct the installation.
Brake abnormal noise

1. Brake abnormal noise diagnostics
Brake pad or lining wear
Replace.
Rotor corrosion.
Repair or replace.
Bake does not work efficiently

1. Bake does not work efficiently diagnostics
Master cylinder operation failure.
Perform an operation inspection. Replace as necessary.
Brake booster operation failure.
Perform an operation inspection, and replace as
necessary.
Insufficient brake fluid.
Add the specified brake fluid. Inspect for fluid leakage.
Air intrusion in the fluid pressure system.
Remove the air from the fluid pressure system.
Brake pedal pulsates

1. Brake pedal pulsates diagnostics
Large amount of side fluctuation in the rotor.
Inspect the fluctuation of the rotor and replace it if it
exceeds the standard value.
Large rotor thickness variation.
Inspect the rotor thickness variation and replace if it
exceeds the standard value.
Excessive play in the hub bearing axis direction.
Replace.
Pad installation orientation reversed
Replace the pad. Repair the rotor as necessary.
Excessive brake drum wear
Measure the inner diameter of the drum, and perform
polishing or sanding. Replace when it exceeds the
standard value.
Stepping power of the brake pedal is large

1. Stepping power of the brake pedal is large diagnostics
Brake booster malfunction.
Perform an operation inspection for the booster. Replace
as necessary.
Fluid pressure system abnormality.
Inspect and repair the fluid pressure system.
Caliper or wheel cylinder piston stuck or operation
failure.
Disassemble and reassemble the caliper or wheel
cylinder.
Brake booster vacuum leakage.
Inspect the vacuum hose for damage and looseness.
Brake pad or lining failure.
Replace.
Stroke of the brake pedal is abnormal

1. Stroke of the brake pedal is abnormal diagnostics
Fluid pressure system abnormality.
Inspect and repair the fluid pressure system.
Insufficient brake fluid.
Add the specified brake fluid. Inspect for fluid leakage.
Air intrusion in the fluid pressure system.
Remove the air from the fluid pressure system.
Defective straight driving

1. Defective straight driving diagnostics
Improper tire air pressure
Adjust the tire air pressure to the specified value evenly
on the left and right.
Poor wheel alignment.
Inspect and adjust the wheel alignment.
Tire sizes on the same axle are not the same
Match the size of tires on the same axle.
Clogging in the brake pipe or hose.
Replace.
Caliper or wheel cylinder assembly malfunction.
Inspect the caliper or wheel cylinder assembly for
freezing, sticking and operation failure.
Pad or lining damage or failure
Replace it as assembly.
Loosened sections in the suspension
Inspect each of installation section in the suspension and
tighten them to the specified torque.
Loosened brake caliper.
Inspect the installation bolt, and tighten it to the specified
torque.
ABS works frequently but the brake is not effective or TCS operates frequently
1. ABS works frequently but the brake is not effective or 14. Turn OFF the ignition switch.
TCS operates frequently description of symptom
ABS works frequently but the brake is not effective or
16. Check the wheel speed display using the scan tool.
TCS operates frequently.
Note：
2. ABS works frequently but the brake is not effective or
TCS operates frequently diagnostics ・ Perform the procedure for each wheel.
Note： Confirm whether the lowest speed of all the wheel speed
displays are at or below 4 km/h (2 mph) and stable.
・ The following is the diagnosis when not using
a scan tool. 17. If a problem is found, replace the applicable wheel
speed sensor.
1. Inspect the tire.
Refer to "4.Brakes 4D.ABS(All models) Front wheel
2. If a problem is not found, replace the tire.
speed sensor removal".
3. Inspect the front and rear brake distribution of the
vehicle.
speed sensor installation".
4. If a problem is found, repair or replace the relevant
Refer to "4.Brakes 4D.ABS(All models) Rear wheel
area.
5. Inspect assembly condition of parts related to the
axle.
6. If a problem is found, repair or replace the relevant
18. Perform diagnosis for when not using a scan tool.
area.
sensor. 20. Perform a test-run.
8. If a problem is found, repair the installation 21. Check for a DTC using a scan tool.
condition of the wheel speed sensor.
Note：
9. Inspect the wheel speed sensor. ・ If a DTC has been detected, inspect the
Note： applicable DTC.
Note：
the sensor rotor.
11. Inspect the wheel speed sensor circuit.
EHCU removal".
EHCU installation".
EHCU setting".
Note：
・ The following is the diagnosis when using a
scan tool.
ESC does not work efficiently

1. ESC does not work efficiently description of symptom
ESC malfunction, excess operation
2. ESC does not work efficiently diagnostics
1. Check the indication status of the TCS OFF
indication light and the ESC OFF indication light
when the ESC is not activated.
2. Confirm that the ESC OFF switch operation or the
4WD switch (4WD Low) operation has not evoked
the ESC off mode.
3. Confirm that the vehicle speed is under 15 km/h (9
mph) when the ESC does not operate.
4. When the ESC warning light turns on, check for a
DTC.
5. If it is not confirmed with DTC, check that the
specified tires are installed.
6. Inspect the mounting condition of the yaw rate
sensor.
Refer to "4.Brakes 4D.ABS(All models) Yaw rate
sensor removal".
sensor installation".
Note：
applicable DTC.
8. Check the scan tool data using a scan tool.
9. If a problem is found, repair it.
DTC Information (All models) 18E-1
Description Brakes
DTC Information
(All models)
Table of Contents
DTC C0035 (Flash Code 21, 22, 23, 24) Left Front Wheel DTC U1826 (Flash Code 84) Lost Communication with
Speed Sensor..................................................................18E-2 Yaw Rate Sensor.........................................................18E-25
DTC C0040 (Flash Code 25, 26, 27, 28) Right Front Wheel
Speed Sensor..................................................................18E-3
DTC C0045 (Flash Code 31, 32, 33, 34) Left Rear Wheel
Speed Sensor..................................................................18E-4
DTC C0050 (Flash Code 35, 36, 37, 38) Right Rear Wheel
Speed Sensor..................................................................18E-6
DTC C0110 (Flash Code 62, 68, 69) Pump Motor Control
.......................................................................................18E-8
DTC C0131 (Flash Code 72) M/C Pressure Sensor Circuit
.......................................................................................18E-9
DTC C0161 (Flash Code 19) Brake Switch Circuit, M/C
pressure sensor ............................................................18E-10
DTC C0186 (Flash Code 76) G sensor........................18E-11
DTC C0196 (Flash Code 75) Yaw Rate Sensor..........18E-12
DTC C0201 (Flash Code 63) Solenoid Relay monitor
Circuit..........................................................................18E-13
DTC C0245 (Flash Code 45) Tires of Different Size
Detection......................................................................18E-14
DTC C0550 (Flash Code 15, 41, 45, 49, 51, 55, 56, 64)
EHCU Performance.....................................................18E-15
DTC C0569 (Flash Code 13) System Configuration Error
.....................................................................................18E-16
DTC C0710 (Flash Code 71,73) Steering angle sensor
.....................................................................................18E-17
DTC C0800 (Flash Code 66, 67, 77, 78) System Voltage
.....................................................................................18E-18
DTC U0073 (Flash Code 16) Control Module
Communication Bus Off..............................................18E-19
Communication Bus Off - Local CAN........................18E-20
DTC U0100 (Flash Code 81) Lost Communication with
ECM.............................................................................18E-21
TCM.............................................................................18E-22
TCCM..........................................................................18E-23
Steering angle sensor...................................................18E-24
18E-2 DTC Information (All models)
DTC C0035 (Flash Code 21, 22, 23, 24)

Left Front Wheel Speed Sensor
1. DTC C0035 description of DTC DTC C003500
The ABS warning light turns on.
DTC C003506 (Flash Code 21) FL Wheel Speed Sensor
When both of the rear wheels are abnormal, the brake
Circuit malfunction
warning light turns on.
DTC C003500 (Flash Code 22) FL Abnormal wheel The ESC warning light turns on.
speed variation A The EHCU prohibits the ABS control. However, when
the ABS control is in progress, it is gradually returned to
DTC C003518 (Flash Code 23) FL Abnormal wheel
a normal status. Also, when only the front left wheel is
speed variation B
abnormal, the controls for the front right wheel and the
DTC C00350F (Flash Code 24) FL Abnormal wheel rear wheels are continued.
speed variation C The EHCU prohibits the TCS control. However, when
DTC C003506 the TCS control is in progress, the control is continued
The EHCU calculates the wheel speed based on the pulse without using the signals received from the wheel speed
signal from the wheel speed sensor. When the EHCU sensor. Also, when two or more wheels are abnormal, it
detects an abnormality of the front left wheel speed is gradually returned to a normal status.
sensor circuit, the DTC is set. The EHCU prohibits the ESC control. However, when
the ESC control is in progress, it is gradually returned to
DTC C003500/C003518/C00350F a normal status.
The EHCU monitors the pulse signals from the wheel The EHCU permits the EBD control. However, when
speed sensors. When the EHCU detects an abnormal both of the rear wheels are abnormal or one of the rear
pulse signal from the front left wheel speed sensor, the wheels and both of the front wheels are abnormal, the
DTC is set. control is prohibited.
2. DTC C0035 condition for setting the DTC DTC C003518
The ignition switch is ON. The ABS warning light turns on.
The EHCU system voltage is between 10 and 16 V. When both of the rear wheels are abnormal, the brake
When any of the following conditions is met. warning light turns on.
The ESC warning light turns on.
DTC C003506 The EHCU prohibits the ABS control.
When the EHCU detects an open circuit in the front left The EHCU prohibits the TCS control.
wheel speed sensor circuit. The EHCU prohibits the ESC control.
When the EHCU detects a low power supply voltage The EHCU permits the EBD control depending on the
status of the front left wheel speed sensor. failure condition. However, when both of the rear wheels
DTC C003500 are abnormal or one of the rear wheels and both of the
When the EHCU detects a non-pulse state of the front left front wheels are abnormal, the control is prohibited.
wheel speed sensor signal under a particular condition. DTC C00350F
DTC C003518 The ABS warning light turns on.
When the EHCU detects a non-pulse state of the front left When both of the rear wheels are abnormal, the brake
wheel speed sensor signal under a particular condition. warning light turns on.
When the EHCU detects a change in the wheel speed The ESC warning light turns on.
exceeding a specific condition on the front left wheel. The EHCU prohibits the ABS control depending on the
failure condition. However, when the ABS control is in
DTC C00350F progress, it is gradually returned to a normal status. Also,
When the EHCU detects a change in the wheel speed when only the front left wheel is abnormal, the controls
exceeding a specific condition on the front left wheel. for the front right wheel and the rear wheels are
Or, when it detects a non-pulse state when the vehicle continued.
starts moving. The EHCU prohibits the TCS control.
When the EHCU detects ABS activation on the front left The EHCU prohibits the ESC control.
wheel for 45 seconds or longer. The EHCU permits the EBD control. However, when
Or, when it detects noise failure. both of the rear wheels are abnormal or one of the rear
3. DTC C0035 action taken when the DTC sets wheels and both of the front wheels are abnormal, the
control is prohibited.
DTC C003506
DTC C0040 (Flash Code 25, 26, 27, 28)

Right Front Wheel Speed Sensor
DTC C004000
DTC C004006 (Flash Code 25) FR Wheel Speed Sensor
Circuit malfunction
DTC C004000 (Flash Code 26) FR Abnormal wheel warning light turns on.
speed variation A The ESC warning light turns on.
The EHCU prohibits the ABS control. However, when
DTC C004018 (Flash Code 27) FR Abnormal wheel
speed variation B
a normal status. Also, when only the front right wheel is
DTC C00400F (Flash Code 28) FR Abnormal wheel abnormal, the controls for the front left wheel and the rear
speed variation C wheels are continued.
DTC C004006 The EHCU prohibits the TCS control. However, when
The EHCU calculates the wheel speed based on the pulse the TCS control is in progress, the control is continued
signal from the wheel speed sensor. When the EHCU without using the signals received from the wheel speed
detects an abnormality of the front right wheel speed sensor. Also, when two or more wheels are abnormal, it
sensor circuit, the DTC is set. is gradually returned to a normal status.
The EHCU prohibits the ESC control. However, when
DTC C004000/C004018/C00400F the ESC control is in progress, it is gradually returned to
The EHCU monitors the pulse signals from the wheel a normal status.
speed sensors. When the EHCU detects an abnormal The EHCU permits the EBD control. However, when
pulse signal from the front right wheel speed sensor, the both of the rear wheels are abnormal or one of the rear
DTC is set. wheels and both of the front wheels are abnormal, the
2. DTC C0040 condition for setting the DTC control is prohibited.
The ignition switch is ON. DTC C004018

The EHCU system voltage is between 10 and 16 V. The ABS warning light turns on.
When any of the following conditions is met. When both of the rear wheels are abnormal, the brake
DTC C004006 The ESC warning light turns on.
When the EHCU detects an open circuit in the front right The EHCU prohibits the ABS control.
wheel speed sensor circuit. The EHCU prohibits the TCS control.
When the EHCU detects a low power supply voltage The EHCU prohibits the ESC control.
status of the front right wheel speed sensor. The EHCU permits the EBD control depending on the
DTC C004000 failure condition. However, when both of the rear wheels
When the EHCU detects a non-pulse state of the front are abnormal or one of the rear wheels and both of the
right wheel speed sensor signal under a particular front wheels are abnormal, the control is prohibited.
condition. DTC C00400F
DTC C004018 The ABS warning light turns on.
When the EHCU detects a non-pulse state of the front When both of the rear wheels are abnormal, the brake
right wheel speed sensor signal under a particular warning light turns on.
condition. The ESC warning light turns on.
When the EHCU detects a change in the wheel speed The EHCU prohibits the ABS control depending on the
exceeding a specific condition on the front right wheel. failure condition. However, when the ABS control is in
progress, it is gradually returned to a normal status. Also,
DTC C00400F when only the front right wheel is abnormal, the controls
When the EHCU detects a change in the wheel speed for the front left wheel and the rear wheels are continued.
exceeding a specific condition on the front right wheel. The EHCU prohibits the TCS control.
Or, when it detects a non-pulse state when the vehicle The EHCU prohibits the ESC control.
starts moving. The EHCU permits the EBD control. However, when
When the EHCU detects the ABS activation on the front both of the rear wheels are abnormal or one of the rear
right wheel for 45 seconds or longer. wheels and both of the front wheels are abnormal, the
Or, when it detects noise failure. control is prohibited.
3. DTC C0040 action taken when the DTC sets
DTC C0045 (Flash Code 31, 32, 33, 34)

Left Rear Wheel Speed Sensor
DTC C004506 (Flash Code 31) RL Wheel Speed Sensor
Circuit malfunction
DTC C004500 (Flash Code 32) RL Abnormal wheel The ESC warning light turns on.
speed variation A The EHCU prohibits the ABS control. However, when
DTC C004518 (Flash Code 33) RL Abnormal wheel
a normal status. Also, when only the rear left wheel is
speed variation B
abnormal, the controls for the rear right wheel and the
DTC C00450F (Flash Code 34) RL Abnormal wheel front wheels are continued. When both of the rear wheels
speed variation C are abnormal, the controls for all of the four wheels are
DTC C004506 prohibited.
The EHCU calculates the wheel speed based on the pulse The EHCU prohibits the TCS control. However, when
signal from the wheel speed sensor. When the EHCU the TCS control is in progress, the control is continued
detects an abnormality of the rear left wheel speed sensor without using the signals received from the wheel speed
circuit, the DTC is set. sensor. Also, when two or more wheels are abnormal, it
is gradually returned to a normal status.
DTC C004500/C004518/C00450F The EHCU prohibits the ESC control. However, when
The EHCU monitors the pulse signals from the wheel the ESC control is in progress, it is gradually returned to
speed sensors. When the EHCU detects an abnormal a normal status.
pulse signal from the rear left wheel speed sensor, the The EHCU permits the EBD control. However, when
DTC is set. both of the rear wheels are abnormal or one of the rear
2. DTC C0045 condition for setting the DTC wheels and both of the front wheels are abnormal, the
The ignition switch is ON.
The EHCU system voltage is between 10 and 16 V. DTC C004518
When any of the following conditions is met. The ABS warning light turns on.
DTC C004506 warning light turns on.
When the EHCU detects an open circuit in the rear left The ESC warning light turns on.
wheel speed sensor circuit. The EHCU prohibits the ABS control.
When the EHCU detects a low power supply voltage The EHCU prohibits the TCS control.
status of the rear left wheel speed sensor. The EHCU prohibits the ESC control.
DTC C004500 The EHCU permits the EBD control depending on the
When the EHCU detects a non-pulse state of the rear left failure condition. However, when both of the rear wheels
wheel speed sensor signal under a particular condition. are abnormal or one of the rear wheels and both of the
front wheels are abnormal, the control is prohibited.
DTC C004518
When the EHCU detects a non-pulse state of the rear left DTC C00450F
wheel speed sensor signal under a particular condition. The ABS warning light turns on.
When the EHCU detects a change in the wheel speed When both of the rear wheels are abnormal, the brake
exceeding a specific condition on the rear left wheel. warning light turns on.
DTC C00450F The EHCU prohibits the ABS control depending on the
When the EHCU detects a change in the wheel speed failure condition. However, when the ABS control is in
exceeding a specific condition on the rear left wheel. progress, it is gradually returned to a normal status. Also,
Or, when it detects a non-pulse state when the vehicle when only the rear left wheel is abnormal, the controls for
starts moving. the rear right wheel and the front wheels are continued.
When the EHCU detects the ABS activation on the rear When both of the rear wheels are abnormal, the controls
left wheel for 45 seconds or longer. for all of the four wheels are prohibited.
Or, when it detects noise failure. The EHCU prohibits the TCS control.
3. DTC C0045 action taken when the DTC sets The EHCU prohibits the ESC control.
The EHCU permits the EBD control. However, when
DTC C004506 both of the rear wheels are abnormal or one of the rear
wheels and both of the front wheels are abnormal, the
DTC C0050 (Flash Code 35, 36, 37, 38)

Right Rear Wheel Speed Sensor
DTC C005000
DTC C005006 (Flash Code 35) RR Wheel Speed Sensor
Circuit malfunction
DTC C005000 (Flash Code 36) RR Abnormal wheel warning light turns on.
speed variation A The ESC warning light turns on.
The EHCU prohibits the ABS control. However, when
DTC C005018 (Flash Code 37) RR Abnormal wheel
speed variation B
a normal status. Also, when only the rear right wheel is
DTC C00500F (Flash Code 38) RR Abnormal wheel abnormal, the controls for the rear left wheel and the front
speed variation C wheels are continued. When both of the rear wheels are
DTC C005006 abnormal, the controls for all of the four wheels are
The EHCU calculates the wheel speed based on the pulse prohibited.
signal from the wheel speed sensor. When the EHCU The EHCU prohibits the TCS control. However, when
detects an abnormality of the rear right wheel speed the TCS control is in progress, the control is continued
sensor circuit, the DTC is set. without using the signals received from the wheel speed
sensor. Also, when two or more wheels are abnormal, it
DTC C005000/C005018/C00500F is returned to the normal status gradually.
The EHCU monitors the pulse signals from the wheel The EHCU prohibits the ESC control. However, when
speed sensors. When the EHCU detects an abnormal the ESC control is in progress, it is returned to the normal
pulse signal from the rear right wheel speed sensor, the status gradually.
DTC is set. The EHCU permits the EBD control. However, when
2. DTC C0050 condition for setting the DTC both of the rear wheels are abnormal or one of the rear
The ignition switch is ON. control is prohibited.
The EHCU system voltage is between 10 and 16 V.
When any of the following conditions is met. DTC C005018
DTC C005006 When both of the rear wheels are abnormal, the brake
When the EHCU detects an open circuit in the rear right warning light turns on.
wheel speed sensor circuit. The ESC warning light turns on.
When the EHCU detects a low power supply voltage The EHCU prohibits the ABS control.
status of the rear right wheel speed sensor. The EHCU prohibits the TCS control.
DTC C005000 The EHCU prohibits the ESC control.
When the EHCU detects a non-pulse state of the rear The EHCU permits the EBD control depending on the
right wheel speed sensor signal under a particular failure condition. However, when both of the rear wheels
condition. are abnormal or one of the rear wheels and both of the
front wheels are abnormal, the control is prohibited.
DTC C005018
When the EHCU detects a non-pulse state of the rear DTC C00500F
right wheel speed sensor signal under a particular The ABS warning light turns on.
condition. When both of the rear wheels are abnormal, the brake
When the EHCU detects a change in the wheel speed warning light turns on.
exceeding a specific condition on the rear right wheel. The ESC warning light turns on.
The EHCU prohibits the ABS control depending on the
DTC C00500F failure condition. However, when the ABS control is in
When the EHCU detects a change in the wheel speed progress, it is gradually returned to a normal status. Also,
exceeding a specific condition on the rear right wheel. when only the rear right wheel is abnormal, the controls
Or, when it detects a non-pulse state when the vehicle for the rear left wheel and the front wheels are continued.
starts moving. When both of the rear wheels are abnormal, the controls
When the EHCU detects the ABS activation on the rear for all of the four wheels are prohibited.
right wheel for 45 seconds or longer. The EHCU prohibits the TCS control.
Or, when it detects noise failure. The EHCU prohibits the ESC control.
The EHCU permits the EBD control. However, when
both of the rear wheels are abnormal or one of the rear
DTC C0110 (Flash Code 62, 68, 69)

Pump Motor Control
1. DTC C0110 description of DTC
DTC C011004 (Flash Code 68,69) Motor relay
malfunction or Open/short circuit detection
DTC C011061 (Flash Code 62) Motor lock detection
DTC C011004
The EHCU monitors the internal motor drive circuit.
When the EHCU detects a motor drive circuit
abnormality, the DTC is set.
DTC C011016
The EHCU monitors the internal motor drive circuit. If
the EHCU detects any motor abnormality, the DTC is set.
2. DTC C0110 condition for setting the DTC
DTC C011004
When any of the following conditions is met.
The EHCU detects the motor drive circuit OFF status
when the motor relay ON command is executed.
The EHCU detects the motor drive circuit ON status
when the motor relay OFF command is executed.
The EHCU detects an open circuit in the motor drive
circuit when the motor relay OFF command is executed.
DTC C011016
When the EHCU detects an abnormal voltage level in the
hydraulic motor control circuit while the motor check at
startup is running.
DTC C011004
The brake warning light turns on.
The EHCU prohibits the ABS control.
The EHCU prohibits the EBD control.
The EHCU prohibits the TCS control.
The EHCU prohibits the ESC control.
DTC C011016
DTC C0131 (Flash Code 72)

M/C Pressure Sensor Circuit
DTC C013100 (Flash Code 72) M/C pressure sensor
circuit malfunction
DTC C01315A (Flash Code 72) M/C pressure sensor
output rise malfunction
The EHCU monitors the internal master cylinder pressure
sensor signal. When the EHCU detects an abnormality
with the master cylinder pressure sensor signal, the DTC
is set.
DTC C013100
When the EHCU detects an abnormal voltage value due
to an open circuit or short circuit.
When the EHCU detects a stuck pressure value or
abnormality.
When the EHCU detects noise failure of the pressure
value.
DTC C01315A
When the EHCU detects that the deceleration speed
calculated from the vehicle speed deviates from the
normal value.

Brake Switch Circuit, M/C pressure sensor
DTC C016100 (Flash Code 19) Brake switch circuit
malfunction / M/C pressure sensor zero point output
malfunction (with ESC model)
The operation signal of the brake switch is input into the
EHCU. When the EHCU detects an abnormality with the
operation signal of the brake switch, the DTC is set. Also,
when the EHCU detects a 0-point error in the master
cylinder pressure sensor by comparing the brake switch
signal with the master cylinder pressure sensor signal, the
DTC is set.
When the EHCU detects that the signal voltage of the
master cylinder pressure sensor is less than 0.27 V.
When the EHCU detects that the master cylinder pressure
sensor signal voltage exceeds 0.86 V with the brake
switch OFF.
When the EHCU detects an open circuit in the brake
switch circuit.
When the EHCU detects that the brake switch is stuck
"ON".
The ABS warning light turns on depending on the failure
condition.
failure condition.
The EHCU permits the EBD control depending on the
failure condition.

G sensor
1. DTC C0186 description of DTC DTC C01865A
DTC C01863B (Flash Code 76) G sensor data internal
invalid malfunction
DTC C018600 (Flash Code 76) G sensor stuck detection, The EHCU prohibits the TCS control.
G sensor output malfunction detection The EHCU prohibits the ESC control.
The EHCU permits the EBD control.
DTC C01865A (Flash Code 76) G sensor output
malfunction, G sensor short/open malfunction detection Note：
In a vehicle with the ESC, the EHCU receives signals ・ Vehicles without ESC
from the yaw rate sensor via the CAN communication. DTC C01865A
The G sensor is built into the yaw rate sensor. The ABS warning light turns on.
In a vehicle without the ESC, analog communication is The EHCU prohibits the ABS control.
made, and the G sensor is built into the EHCU. The EHCU permits the EBD control.
The EHCU monitors the signal of the G sensor. When the
EHCU detects an abnormal G sensor signal, the DTC is
set.
DTC C01863B
When the EHCU detects an abnormal signal from the G
sensor.
DTC C018600
When the EHCU detects a stuck G sensor value no 1-axis
variation.
When the EHCU detects 2-axis clamp failure of the G
sensor.
When the EHCU detects a stuck G sensor value.
When the EHCU detects G sensor output failure.
When the EHCU detects continuous large cant failure.
DTC C01865A
When the EHCU detects abnormal output when the
vehicle is stopped.
Note：
・ Vehicles without ESC
DTC C01865A
When the EHCU detects an open circuit or short circuit
of the G sensor.
DTC C01863B
DTC C018600
The ABS warning light turns on depending on the failure
condition.
failure condition.
The EHCU permits the EBD control depending on the
failure condition.

Yaw Rate Sensor
1. DTC C0196 description of DTC The EHCU prohibits the ABS control.
DTC C01963B (Flash Code 75) Yaw rate sensor data
invalid status
DTC C019628 (Flash Code 75) Yaw rate sensor
oscillation malfunction
DTC C019671 (Flash Code 75) Yaw rate sensor output
malfunction A
DTC C019600 (Flash Code 75) Yaw rate sensor output
malfunction B
DTC C019603 (Flash Code 75) Yaw rate sensor Power
source voltage malfunction
The EHCU performs the CAN communication with the
yaw rate sensor to receive the yaw rate signals required
for the control. The G sensor is built into the yaw rate
sensor.
When the yaw rate signal deviates from a certain range,
the DTC is set.
DTC C01963B
When the EHCU detects an abnormal signal from the
yaw rate sensor.
DTC C019628
When the EHCU detects a startup abnormality of the yaw
rate sensor.
DTC C019671
When the EHCU detects abnormal output of the yaw rate
sensor.
DTC C019600
When the EHCU detects abnormal zero point of the yaw
rate sensor.
When the EHCU detects abnormal gain of the yaw rate
sensor.
DTC C019603
When the EHCU detects abnormal power supply voltage
of the yaw rate sensor.
DTC C01963B
DTC C019628
DTC C019671
DTC C019600
DTC C019603

Solenoid Relay monitor Circuit
DTC C020100 (Flash Code 63) Solenoid relay monitor
malfunction
The EHCU monitors the internal solenoid relay and drive
circuit. When the EHCU detects a solenoid relay
abnormality or drive circuit stuck "OFF", the DTC is set.
When the EHCU detects the solenoid drive circuit OFF
status while the solenoid relay ON command is being
executed.

Tires of Different Size Detection
DTC C024500 (Flash Code 18) Tires of different size
detection
The EHCU calculates the wheel speed according to the
pulse signal from the wheel speed sensor. When the
EHCU detects a state where the difference between the
average wheel speed of front wheels and the average
wheel speed of rear wheels is large, the DTC is set.
When a difference between average wheel speeds of front
and rear wheels is detected.
DTC C0550 (Flash Code 15, 41, 45, 49, 51, 55, 56, 64)
EHCU Performance
DTC C055000 (Flash Code 15,41,45,49,51,55,56,64)
EHCU performance
This diagnosis applies to a monitor circuit abnormality
inside the EHCU.
The EHCU monitors the drive circuit and monitor circuit
inside the ECU. When the EHCU detects an abnormality
in the drive or monitor circuit, the DTC is set.
When the EHCU detects an abnormality in the internal
CPU.

System Configuration Error
DTC C056900 (Flash Code 13) Configuration
information not identified malfunction (System
Configuration Error)
The ESC records and controls vehicle information
necessary for control.
When an abnormality in vehicle information is detected,
the DTC is set.
In addition, the DTC is set when the EHCU is replaced.
When the EHCU detects that the vehicle data in the
EEPROM inside the EHCU remains as its initial values.
When the EHCU detects an error in the vehicle data in
the EEPROM inside the EHCU.
DTC C0710 (Flash Code 71,73)

Steering angle sensor
DTC C07104B (Flash Code 71) Steering angle sensor
center position invalid malfunction
DTC C071071 (Flash Code 73) Steering sensor internal
malfunction
DTC C071000 (Flash Code 73) Steering angle sensor
signal malfunction
DTC C07104B
The EHCU learns and records the zero point of the
steering angle sensor.
When the zero point of the steering angle sensor is not
learned, the EHCU sets the DTC.
DTC C071071
DTC C071000
The EHCU performs the CAN communication between
the steering angle sensors to receive the steering angle
signals required for the control. When an abnormality is
found with the steering angle signal or when the signal
deviates from a certain range, the DTC is set.
The voltage of the CAN circuit is normal.
DTC C07104B
When the EHCU detects that the zero point of the
steering angle sensor is not learned.
DTC C071071
DTC C071000
When the EHCU detects an abnormal signal from the
DTC C0800 (Flash Code 66, 67, 77, 78)

System Voltage
DTC C080003 (Flash Code 66,67,77) Voltage drop
detection
DTC C080007 (Flash Code 78) High voltage
The EHCU monitors the system voltage. When the
EHCU power supply voltage is abnormally low, or a high
ignition power source is detected, the DTC is set.
DTC C080003
When the EHCU detects an abnormality of the solenoid
relay monitor.
When the EHCU detects an abnormality of the motor
relay monitor.
When the EHCU detects a decrease in the ignition power
source voltage.
When the EHCU detects a decrease in the power source
voltage of the wheel speed sensor.
DTC C080007
When the EHCU detects high system voltage.
DTC U0073 (Flash Code 16)

Control Module Communication Bus Off
1. DTC U0073 description of DTC
DTC U007300 (Flash Code 16) Control module
communication Bus off
The EHCU, ECM, TCM, TCCM, auto A/C control unit,
SRS control unit, immobilizer control unit, BCM,
instrument panel cluster and DRM communicate the
control information and the diagnostic information via the
CAN communication. The EHCU monitors the CAN
operational status by expecting a constant message flow
from each module. When the EHCU detects an
abnormality in the CAN communication circuit, the DTC
is set.
2. DTC U0073 condition for setting the DTC
When the EHCU detects the CAN Bus OFF status 10
times or more within 10 seconds.
3. DTC U0073 action taken when the DTC sets

Control Module Communication Bus Off - Local CAN
DTC U007400 (Flash Code 17) Control module
communication Bus off - Local CAN
The EHCU, the yaw rate sensor and the steering angle
sensor communicate the control information and
diagnosis information via the local CAN communication.
The EHCU monitors the CAN operational status by
expecting a constant message flow from each sensor.
When the EHCU detects an abnormality in the local CAN
communication circuit, the DTC is set.
When the CAN Bus "OFF" state is detected.

Lost Communication with ECM
DTC U010000 (Flash Code 81) Communication
malfunction with ECM
DTC U010071 (Flash Code 81) ECM information invalid
error
The EHCU and the ECM communicate the control
information via the CAN communication. The EHCU
monitors the CAN operational status by expecting a
constant message flow from the ECM.
When the EHCU fails to receive an expected message
from the ECM, the DTC is set.
DTC U010000
When the EHCU detects that the CAN Bus messages
from the ECM are not being received.
DTC U010071
When the EHCU detects an abnormality of the
accelerator pedal position.

Lost Communication with TCM
malfunction with transmission TCM
DTC U010171 (Flash Code 82) TCM information invalid
error
The EHCU and the TCM communicate the control
constant message flow from the TCM.
from the TCM, the DTC is set.
DTC U010100
from the TCM are not being received.
DTC U010171
When the EHCU detects an abnormality of the gear
position.

Lost Communication with TCCM
malfunction with transfer TCCM
DTC U010271 (Flash Code 83) TCCM information
invalid error
The EHCU and the TCCM communicate the control
constant message flow from the TCCM.
from the TCCM, the DTC is set.
DTC U010200
from the TCCM are not being received.
DTC U010271
When the EHCU detects an abnormality of the transfer
case range.

Lost Communication with Steering angle sensor
DTC U012600 (Flash Code 85) Steering angle sensor
communication malfunction
The EHCU and the steering angle sensor communicate
the control information and diagnosis information via the
local CAN communication. The EHCU monitors the
CAN operational status by expecting a constant message
flow from the steering angle sensor.
from the steering angle sensor, the DTC is set.
from the steering angle sensor are not being received.

Lost Communication with Yaw Rate Sensor
DTC U182600 (Flash Code 84) Yaw rate sensor
communication malfunction
The EHCU and the yaw rate sensor communicate the
control information and diagnosis information via the
local CAN communication. The EHCU monitors the
CAN operational status by expecting a constant message
flow from the yaw rate sensor.
from the yaw rate sensor, the DTC is set.
from the yaw rate sensor are not being received.
Brake Control (ABS/ESC) 4A-1
Brake Control
Brake Control
(ABS/ESC)
Table of Contents
DTC C0035 (Flash Code 21, 22, 23, 24) Left Front Wheel
Speed Sensor...................................................................4A-2
DTC C0040 (Flash Code 25, 26, 27, 28) Right Front Wheel
Speed Sensor...................................................................4A-4
DTC C0045 (Flash Code 31, 32, 33, 34) Left Rear Wheel
Speed Sensor...................................................................4A-6
DTC C0050 (Flash Code 35, 36, 37, 38) Right Rear Wheel
Speed Sensor...................................................................4A-8
DTC C0110 (Flash Code 62, 68, 69) Pump Motor Control
.......................................................................................4A-10
DTC C0131 (Flash Code 72) M/C Pressure Sensor Circuit
.......................................................................................4A-11
DTC C0161 (Flash Code 19) Brake Switch Circuit, M/C
pressure sensor..............................................................4A-12
DTC C0186 (Flash Code 76) G sensor.........................4A-14
DTC C0196 (Flash Code 75) Yaw Rate Sensor............4A-15
DTC C0201 (Flash Code 63) Solenoid Relay monitor
Circuit............................................................................4A-16
DTC C0245 (Flash Code 45) Tires of Different Size
Detection.......................................................................4A-17
DTC C0550 (Flash Code 15, 41, 45, 49, 51, 55, 56, 64)
EHCU Performance......................................................4A-18
DTC C0569 (Flash Code 13) System Configuration Error
.......................................................................................4A-19
DTC C0710 (Flash Code 71,73) Steering angle sensor 4A-20
DTC C0800 (Flash Code 66, 67, 77, 78) System Voltage
.......................................................................................4A-21
Communication Bus Off...............................................4A-22
Communication Bus Off - Local CAN.........................4A-24
ECM..............................................................................4A-25
TCM..............................................................................4A-26
TCCM...........................................................................4A-27
Steering angle sensor.....................................................4A-28
Yaw Rate Sensor...........................................................4A-29
4A-2 Brake Control (ABS/ESC)
DTC C0035 (Flash Code 21, 22, 23, 24)

Left Front Wheel Speed Sensor
1. DTC C0035 diagnostics Refer to "4.Brakes 4D.ABS(All models) Front wheel
Note：
・ For DTCs C003500, C00350F and C003518, 12. Inspect the front left wheel speed sensor.
go to step 19. Refer to "4.Brakes 4D.ABS(All models) Front wheel
1. Turn OFF the ignition switch. speed sensor inspection".
2. Disconnect the harness connector from the front left 13. If a problem is found, replace the front left wheel
wheel speed sensor. speed sensor.
3. Turn ON the ignition switch. Refer to "4.Brakes 4D.ABS(All models) Front wheel
4. Measure the voltage between the power supply
terminal of the front left wheel speed sensor harness Refer to "4.Brakes 4D.ABS(All models) Front wheel
connector and the frame ground. speed sensor installation".
Standard： 8 to 16 V 14. Inspect the front left wheel speed sensor harness
connector for poor connections.
5. If the voltage value is outside the specified range,
inspect the power supply circuit between the EHCU 15. If a problem is found, repair the harness connector.
and the front left wheel speed sensor. 16. Disconnect the harness connector from the EHCU.
Note： 17. Inspect the EHCU harness connector for poor
・ There should be no short circuit with any other connections.
circuit.
・ There should be no short to metal components
such as a frame. 19. If the harness connector is normal, replace the
EHCU.
・ There should not be an open or high
resistance. Refer to "4.Brakes 4D.ABS(All models)
EHCU removal".
6. If a problem is found, repair the power supply circuit
of the front left wheel speed sensor. Refer to "4.Brakes 4D.ABS(All models)
EHCU installation".
7. If the voltage is within the specified range, measure
the voltage between the signal terminal of the front 20. Write the vehicle information into the EHCU.
left wheel speed sensor harness connector and the
frame ground.
EHCU setting".
22. If a problem is found, repair or replace the tire.
inspect the signal circuit between the EHCU and the
front left wheel speed sensor. 23. Inspect the power supply circuit between the EHCU
and the front left wheel speed sensor for high
Note： resistance.
・ There should be no short circuit to the battery
or ignition power supply circuit. 24. If a problem is found, repair the power supply
circuit.
such as a frame. 25. Inspect the signal circuit between the EHCU and the
・ There should not be an open or high front left wheel speed sensor for high resistance.
resistance. 26. If a problem is found, repair the signal circuit.
9. If a problem is found, repair the signal circuit of the 27. Visually inspect the front left wheel speed sensor.
front left wheel speed sensor.
Note：
10. Turn OFF the ignition switch. ・ There should be no damage.
11. Remove the front left wheel speed sensor. ・ There should be no improper installation.
28. If a problem is found, repair it. Refer to "4.Brakes 4D.ABS(All models) Steering angle
sensor setting".
29. Visually inspect the sensor rotor.
2. DTC C0035 confirm resolution
Note：
・ There should be no damage. 1. Clear the DTC with the scan tool.
・ There should be no improper installation. 2. Turn OFF the ignition switch.
30. If a problem is found, repair it. 3. Start the engine.
31. Inspect between the front left wheel speed sensor and 4. Perform a test-run.
the sensor rotor.
5. Using the scan tool, verify that DTCs have not been
Note： detected.
・ The gap should be correct.
・ There should be no foreign matter.
・ There should be no electromagnetic
interference in the front left wheel speed
sensor circuit.
32. Remove the front left wheel speed sensor.
33. Inspect the front left wheel speed sensor.
speed sensor inspection".
34. If a problem is found, replace the front left wheel
speed sensor.
35. Inspect the front left wheel speed sensor harness
38. Inspect the EHCU harness connector for poor
connections.
40. If the harness connector is normal, replace the
EHCU.
EHCU removal".
EHCU installation".
EHCU setting".
42. Perform the 0-point learning of the steering angle
sensor.
DTC C0040 (Flash Code 25, 26, 27, 28)

Right Front Wheel Speed Sensor
1. DTC C0040 diagnostics Refer to "4.Brakes 4D.ABS(All models) Front wheel
Note：
・ For DTCs C004000, C00400F and C004018, 12. Inspect the front right wheel speed sensor.
go to step 19. Refer to "4.Brakes 4D.ABS(All models) Front wheel
2. Disconnect the harness connector from the front 13. If a problem is found, replace the front right wheel
right wheel speed sensor. speed sensor.
3. Turn ON the ignition switch. Refer to "4.Brakes 4D.ABS(All models) Front wheel
terminal of the front right wheel speed sensor Refer to "4.Brakes 4D.ABS(All models) Front wheel
harness connector and the frame ground. speed sensor installation".
Standard： 8 to 16 V 14. Inspect the front right wheel speed sensor harness
and the front right wheel speed sensor. 16. Disconnect the harness connector from the EHCU.
circuit.
EHCU.
EHCU removal".
of the front right wheel speed sensor. Refer to "4.Brakes 4D.ABS(All models)
EHCU installation".
the voltage between the signal terminal of the front 20. Write the vehicle information into the EHCU.
right wheel speed sensor harness connector and the
frame ground.
EHCU setting".
front right wheel speed sensor. 23. Inspect the power supply circuit between the EHCU
and the front right wheel speed sensor for high
Note： resistance.
circuit.
・ There should not be an open or high front right wheel speed sensor for high resistance.
9. If a problem is found, repair the signal circuit of the 27. Visually inspect the front right wheel speed sensor.
front right wheel speed sensor.
Note：
11. Remove the front right wheel speed sensor. ・ There should be no improper installation.
sensor setting".
Note：
31. Inspect between the front right wheel speed sensor 4. Perform a test-run.
and the sensor rotor.
Note： detected.
interference in the front right wheel speed
sensor circuit.
32. Remove the front right wheel speed sensor.
33. Inspect the front right wheel speed sensor.
34. If a problem is found, replace the front right wheel
speed sensor.
35. Inspect the front right wheel speed sensor harness
connections.
EHCU.
EHCU removal".
EHCU installation".
EHCU setting".
sensor.
DTC C0045 (Flash Code 31, 32, 33, 34)

Left Rear Wheel Speed Sensor
1. DTC C0045 diagnostics Refer to "4.Brakes 4D.ABS(All models) Rear wheel
Note：
・ For DTCs C004500, C00450F and C004518, 12. Inspect the rear left wheel speed sensor.
go to step 19. Refer to "4.Brakes 4D.ABS(All models) Rear wheel
2. Disconnect the harness connector from the rear left 13. If a problem is found, replace the rear left wheel
3. Turn ON the ignition switch. Refer to "4.Brakes 4D.ABS(All models) Rear wheel
terminal of the rear left wheel speed sensor harness Refer to "4.Brakes 4D.ABS(All models) Rear wheel
Standard： 8 to 16 V 14. Inspect the rear left wheel speed sensor harness
and the rear left wheel speed sensor. 16. Disconnect the harness connector from the EHCU.
circuit.
EHCU.
EHCU removal".
of the rear left wheel speed sensor. Refer to "4.Brakes 4D.ABS(All models)
EHCU installation".
the voltage between the signal terminal of the rear 20. Write the vehicle information into the EHCU.
left wheel speed sensor harness connector and the
frame ground.
EHCU setting".
rear left wheel speed sensor. 23. Inspect the power supply circuit between the EHCU
and the rear left wheel speed sensor for high
Note： resistance.
circuit.
・ There should not be an open or high rear left wheel speed sensor for high resistance.
9. If a problem is found, repair the signal circuit of the 27. Visually inspect the rear left wheel speed sensor.
rear left wheel speed sensor.
Note：
11. Remove the rear left wheel speed sensor. ・ There should be no improper installation.
sensor setting".
Note：
31. Inspect between the rear left wheel speed sensor and 4. Perform a test-run.
the sensor rotor.
Note： detected.
interference in the rear left wheel speed
sensor circuit.
32. Remove the rear left wheel speed sensor.
33. Inspect the rear left wheel speed sensor.
34. If a problem is found, replace the rear left wheel
speed sensor.
35. Inspect the rear left wheel speed sensor harness
connections.
EHCU.
EHCU removal".
EHCU installation".
EHCU setting".
sensor.
DTC C0050 (Flash Code 35, 36, 37, 38)

Right Rear Wheel Speed Sensor
1. DTC C0050 diagnostics Refer to "4.Brakes 4D.ABS(All models) Rear wheel
Note：
・ For DTCs C005000, C00500F and C005018, 12. Inspect the rear right wheel speed sensor.
go to step 19. Refer to "4.Brakes 4D.ABS(All models) Rear wheel
2. Disconnect the harness connector from the rear right 13. If a problem is found, replace the rear right wheel
3. Turn ON the ignition switch. Refer to "4.Brakes 4D.ABS(All models) Rear wheel
terminal of the rear right wheel speed sensor harness Refer to "4.Brakes 4D.ABS(All models) Rear wheel
Standard： 8 to 16 V 14. Inspect the rear right wheel speed sensor harness
and the rear right wheel speed sensor. 16. Disconnect the harness connector from the EHCU.
circuit.
EHCU.
EHCU removal".
of the rear right wheel speed sensor. Refer to "4.Brakes 4D.ABS(All models)
EHCU installation".
the voltage between the signal terminal of the rear 20. Write the vehicle information into the EHCU.
right wheel speed sensor harness connector and the
frame ground.
EHCU setting".
rear right wheel speed sensor. 23. Inspect the power supply circuit between the EHCU
and the rear right wheel speed sensor for high
Note： resistance.
circuit.
・ There should not be an open or high rear right wheel speed sensor for high resistance.
9. If a problem is found, repair the signal circuit of the 27. Visually inspect the rear right wheel speed sensor.
rear right wheel speed sensor.
Note：
11. Remove the rear right wheel speed sensor. ・ There should be no improper installation.
sensor setting".
Note：
31. Inspect between the rear right wheel speed sensor 4. Perform a test-run.
and the sensor rotor.
Note： detected.
interference in the rear right wheel speed
sensor circuit.
32. Remove the rear right wheel speed sensor.
33. Inspect the rear right wheel speed sensor.
34. If a problem is found, replace the rear right wheel
speed sensor.
35. Inspect the rear right wheel speed sensor harness
connections.
EHCU.
EHCU removal".
EHCU installation".
EHCU setting".
sensor.
DTC C0110 (Flash Code 62, 68, 69)

Pump Motor Control
1. DTC C0110 diagnostics 1. Clear the DTC with the scan tool.
Note： 2. Turn OFF the ignition switch.
・ For DTC C011061, go to step 12. 3. Start the engine.
1. Turn OFF the ignition switch. 4. Perform a test-run.
2. Disconnect the harness connector from the EHCU. 5. Using the scan tool, verify that DTCs have not been
3. Inspect the EHCU harness connector for poor detected.
connections.
6. Measure the voltage between the motor power
supply terminal of the EHCU harness connector and
the frame ground.
standard： 10 to 16 V
inspect the motor power supply circuit between the
ABS/ESC 50 A slow blow fuse and the EHCU.
Note：
resistance.
8. If a problem is found, repair the power supply
circuit.
9. Measure the voltage between the motor power
supply terminal and the GND terminal of the EHCU
harness connector.
standard： 10 to 16 V
10. When the voltage value is outside the standard value
range, inspect the motor ground circuit between the
EHCU and the frame ground.
Note：
resistance.
11. If a problem is found, repair the motor ground
circuit.
EHCU removal".
EHCU installation".
EHCU setting".

M/C Pressure Sensor Circuit
1. DTC C0131 diagnostics
connections.
EHCU.
EHCU removal".
EHCU installation".
EHCU setting".
1. Clear the DTC with the scan tool.
detected.

Brake Switch Circuit, M/C pressure sensor
1. DTC C0161 diagnostics Note：
1. Observe the Master Cylinder Pressure Sensor Input ・ Observe the display under each condition by
display and the Brake Switch on the scan tool. following the table below.
Brake pedal Brake Switch display Master Cylinder Pressure Sensor Input display
OFF OFF ： 0.4 to 0.6 V
Press the pedal to the end of the
From OFF to ON ： 0.4 to 0.6 V
free travel.
Fully press the pedal. ON ： 0.5 to 4.5 V Increases within the range
Note： 15. Connect a test cable with fuse between the terminals
・ For the STP-switch open circuit malfunction of the brake switch harness connector.
and STP-switch ON Stuck malfunction, go to 16. Observe the Brake Switch display on the scan tool.
step 26.
Note：
2. If a problem is found in the Master Cylinder Pressure
・ The Brake Switch display shows "ON".
Sensor Input display, replace the EHCU.
17. If the Brake Switch display is normal, inspect the
brake switch harness connector for a contact failure.
EHCU removal".
EHCU installation". 19. If the harness connector is normal, replace the brake
switch.
EHCU setting".
4. If a problem is found in the Brake Switch display,
inspect the stoplight fuse.
20. If a problem is found in the Brake Switch display,
5. If a problem is found, inspect the stoplight fuse
inspect the power supply circuit between the
circuit for a short circuit.
stoplight fuse and the brake switch.
6. If a problem is found, repair the stoplight fuse
Note：
circuit.
7. Verify that the brake switch is adjusted correctly. resistance.
8. If a problem is found, adjust it. 21. If a problem is found, repair the power supply
9. Operate the brake pedal. circuit.
10. Verify that the stoplight illuminates. 22. When the circuit is normal, inspect the EHCU
harness connector for poor connections.
11. When the stoplight does not turn on, inspect the
brake switch signal circuit between the brake switch 23. If a problem is found, repair the harness connector.
and the stoplight. 24. If the harness connector is normal, replace the
Note： EHCU.
・ There should not be an open or high Refer to "4.Brakes 4D.ABS(All models)
resistance. EHCU removal".
12. If a problem is found, repair the signal circuit. Refer to "4.Brakes 4D.ABS(All models)
EHCU installation".
13. Disconnect the brake switch harness connector.
Refer to "4.Brakes 4D.ABS(All models) 42. If a problem is found in the Brake Switch display,
EHCU setting". inspect the power supply circuit between the
stoplight fuse and the brake switch.
26. Inspect the stoplight fuse.
Note：
27. If a problem is found, inspect the stoplight fuse
circuit for a short circuit. ・ There should not be an open or high
resistance.
28. If a problem is found, repair the stoplight fuse
・ There should be no short circuit with a metal
circuit.
component such as the frame.
29. Verify that the brake switch is adjusted correctly.
30. If a problem is found, adjust it. circuit.
31. Operate the brake pedal. 44. When the circuit is normal, inspect the EHCU
harness connector for poor connections.
32. Verify that the stoplight illuminates.
Note：
・ The stoplight should turn ON when the brake 46. If the harness connector is normal, replace the
pedal is depressed and turn OFF when the EHCU.
brake pedal is released. Refer to "4.Brakes 4D.ABS(All models)
・ Brake pedal play should be appropriate. EHCU removal".
33. If a problem is found with the stoplight lighting state, Refer to "4.Brakes 4D.ABS(All models)
inspect the brake switch signal circuit between the EHCU installation".
brake switch and the EHCU.
Note：
・ There should not be an open or high EHCU setting".
resistance.
sensor.
or ignition power supply circuit.
34. If a problem is found, repair the signal circuit.
sensor setting".
35. Disconnect the brake switch harness connector.
37. Connect a test cable with fuse between the terminals
of the brake switch harness connector.
3. Start the engine.
38. Observe the Brake Switch display on the scan tool.
Note：
・ The Brake Switch display should indicate "ON" 5. Using the scan tool, verify that DTCs have not been
when the test cable is connected and "OFF" detected.
when the test cable is disconnected.
39. If the Brake Switch display is normal, inspect the
brake switch harness connector for a contact failure.
41. If the harness connector is normal, replace the brake
switch.

G sensor
1. DTC C0186 priority DTC 13. If the harness connector is normal, replace the yaw
rate sensor.
DTC U0074
DTC U1826
sensor removal".
Note： sensor installation".
・ Excluding vehicles with ESC 14. Clear the DTC with a scan tool.
1. Replace the EHCU. 15. Turn OFF the ignition switch.
Refer to "4.Brakes 4D.ABS(All models) 16. Start the engine.
EHCU removal".
17. Perform a test-run at 30 km/h (19 mph) or higher.
EHCU installation". 18. Use a scan tool to confirm that a DTC has not been
detected.
2. Write the VIN into the EHCU.
19. When a DTC is detected, replace the EHCU.
EHCU setting". Refer to "4.Brakes 4D.ABS(All models)
EHCU removal".
Note：
・ Model with ESC
EHCU installation".
3. Inspect the ABS 10 A fuse.
Note： EHCU setting".
・ If the fuse has blown repeatedly, repair the 3. DTC C0186 confirm resolution
cause of the blown fuse.
5. Inspect the power supply circuit between the ABS 10
A fuse and yaw rate sensor. 2. Turn OFF the ignition switch.
Note： 3. Operate vehicle with the vehicle speed above 30 km/

h (19 mph).
resistance. 4. Using the scan tool, verify that DTCs have not been
detected.
circuit.
7. Inspect the yaw rate sensor ground circuit between
the yaw rate sensor and the frame ground.
Note：
resistance.
8. If a problem is found, repair the yaw rate sensor
ground circuit.
9. If the DTC C0186 is detected, inspect the installation
condition of the yaw rate sensor.
10. If a problem is detected, repair it.
11. Inspect the yaw rate sensor harness connector for
poor connections.

Yaw Rate Sensor
1. DTC C0196 priority DTC 5. Using the scan tool, verify that DTCs have not been
detected.
DTC U0074
DTC U0126
1. If the DTC C0196 is detected, inspect the installation
condition of the yaw rate sensor.
2. If a problem is detected, repair it.
3. Inspect the ABS 10 A fuse.
Note：
・ If the fuse has blown repeatedly, repair the
A fuse and yaw rate sensor.
Note：
resistance.
circuit.
7. Inspect the yaw rate sensor ground circuit between
the yaw rate sensor and the frame ground.
Note：
resistance.
8. If a problem is found, repair the yaw rate sensor
ground circuit.
9. Inspect the yaw rate sensor harness connector for
poor connections.
11. If the harness connector is normal, replace the yaw
rate sensor.
sensor removal".

Solenoid Relay monitor Circuit
3. Measure the voltage value between the EHCU
harness connector solenoid valve power supply
circuit and the frame ground.
Standard： 10.0 V
4. When the value is at or below the standard value,
inspect the ABS/ESC 30 A slow blow fuse.
5. If a problem is found, inspect the slow blow fuse
circuit.
6. If any short circuit is found in the circuit, repair it.
7. Inspect the solenoid valve power supply circuit
between the ABS/ESC 30 A slow blow fuse and the
EHCU.
Note：
resistance.
circuit.
9. When the value is at or above the standard value,
inspect the EHCU harness connector for a contact
failure.
EHCU.
EHCU removal".
EHCU installation".
EHCU setting".
detected.

Tires of Different Size Detection
3. When the tires are normal, replace the EHCU.
EHCU removal".
EHCU installation".
EHCU setting".
detected.
DTC C0550 (Flash Code 15, 41, 45, 49, 51, 55, 56, 64)
EHCU Performance
EHCU removal".
EHCU removal".
EHCU setting".
detected.

System Configuration Error
EHCU setting".
Note：
・ After writing, confirm that the Base Model
Number display and the Part Number display
are correct on the module information screen.
4. Check for DTCs with the scan tool.
5. If the DTC C0569 is detected, replace the EHCU.
EHCU removal".
EHCU installation".
EHCU setting".
detected.
DTC C0710 (Flash Code 71,73)

1. DTC C0710 priority DTC 15. If a problem is found, repair the harness connector.
DTC U0074 16. If the harness connector is normal, replace the
DTC U0126
sensor removal".
1. When a DTC C07104B is detected, drive the vehicle
and perform 0-point learning of the steering angle
sensor.
17. If the steering angle sensor has been replaced,
Note：
perform the 0-point learning of steering angle
・ DTC C07104B is cleared once the 0-point sensor .
learning of the steering angle sensor is
completed. Refer to "4.Brakes 4D.ABS(All models) Steering angle
sensor setting".
3. Operate vehicle with the vehicle speed above 35 km/
6. If the DTC C0710 is detected, inspect the installation h (22 mph).
condition of the steering angle sensor.
7. If a problem is detected, repair it. detected.
8. Inspect the ABS 10 A fuse and ESC 10 A fuse.
Note：
・ If the fuse has blown repeatedly, repair the
A fuse and the steering angle sensor and the power
supply circuit between the ESC 10 A fuse and the
Note：
resistance.
circuit.
12. Inspect the steering angle sensor ground circuit
between the steering angle sensor and the frame
ground.
Note：
resistance.
13. If a problem is found, repair the steering angle sensor
ground circuit.
14. Inspect the steering angle sensor harness connector
for a contact failure.
DTC C0800 (Flash Code 66, 67, 77, 78)

System Voltage
1. DTC C0800 diagnostics 18. If a problem is found, replace the fuse.
1. Inspect the charging system. 19. Inspect the ignition power supply circuit between the
ABS 10 A fuse and EHCU.
2. If a problem is found, repair the charging system.
Note：
4. Disconnect the harness connector from the EHCU. resistance.
5. Measure the voltage value between the motor power 20. If a problem is found, repair the ignition power
supply circuit and the ground circuit of the EHCU supply circuit.
harness connector.
21. Inspect the ground circuit between the EHCU and
Standard： 10.0 V the frame ground.
6. When the value is at or below the standard value, Note：
inspect the ABS/ESC 50 A slow blow fuse.
7. If a problem is found, replace the slow blow fuse. resistance.
8. Inspect the motor power supply circuit between the 22. If a problem is found, repair the ground circuit.
ABS/ESC 50 A slow blow fuse and EHCU.
23. When the circuit is normal, inspect the EHCU
Note： harness connector for a contact failure.
・ There should be no open circuit or high 24. If a problem is found, repair the harness connector.
resistance.
25. When the harness connector is normal, replace the
9. If a problem is found, repair the motor power supply EHCU.
circuit.
10. Measure the voltage value between the solenoid EHCU removal".
valve power supply circuit and the ground circuit of
the EHCU harness connector. Refer to "4.Brakes 4D.ABS(All models)
EHCU installation".
Standard： 10.0 V
inspect the ABS/ESC 30 A slow blow fuse. Refer to "4.Brakes 4D.ABS(All models)
EHCU setting".
12. If a problem is found, replace the slow blow fuse.
13. Inspect the solenoid valve power supply circuit
between the ABS/ESC 30 A slow blow fuse and the 1. Clear the DTC with the scan tool.
EHCU. 2. Turn OFF the ignition switch.
Note： 3. Perform a test-run.
resistance.
detected.
14. If a problem is found, repair the solenoid valve
power supply circuit.
16. Measure the voltage value between the ignition
power supply circuit and the ground circuit of the
EHCU harness connector.
Standard： 10.0 V
inspect the ABS 10 A fuse.

Control Module Communication Bus Off
1. DTC U0073 diagnostics Refer to "5.Transmission, Transaxle
5B.Automatic(TB-50LS) TCM installation".
20. Write the vehicle information into the TCM.
2. Disconnect the harness connector from the DRM.
Refer to "5.Transmission, Transaxle
5B.Automatic(TB-50LS) TCM setting".
5. When a DTC is not detected, replace the DRM.
22. Connect the harness connector to the TCM.
Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
23. Disconnect the harness connector from the ICU.
Driver Info.(All models) DRM removal".
Driver Info.(All models) DRM installation". 25. Check for DTCs with the scan tool.
6. Turn OFF the ignition switch. 26. When a DTC is not detected, replace the ICU.
7. Connect the harness connector to the DRM. Refer to "9.Body, Cab, Accessories 9J.Security and
Locks(All models) ICU removal".
8. Disconnect the harness connector from the ECM.
Refer to "9.Body, Cab, Accessories 9J.Security and
Locks(All models) ICU installation".
27. Set the authentication information into the ICU.
11. When a DTC is not detected, replace the ECM.
Refer to "9.Body, Cab, Accessories 9J.Security and
Refer to "1.Engine 1J.Electrical(4JJ1) ECM removal". Locks(All models) ICU setting".
Refer to "1.Engine 1J.Electrical(4JJ1) 28. Turn OFF the ignition switch.
ECM installation".
29. Connect the harness connector to the ICU.
Refer to "1.Engine 1J.Electrical(4JK1)
ECM removal".
instrument panel cluster.
ECM installation".
12. Set the immobilizer function and injector ID code
into the ECM. 33. When a DTC is not detected, replace the instrument
panel cluster.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM setting".
Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
Driver Info.(All models) Instrument panel
13. Perform the unit difference learning of fuel supply cluster removal".
pumps on the ECM.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM writing". Driver Info.(All models) Instrument panel
cluster installation".
Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
35. Connect the harness connector to the instrument
15. Connect the harness connector to the ECM.
panel cluster.
16. Disconnect the harness connector from the TCM.
36. Disconnect the harness connector from the auto A/C
17. Turn ON the ignition switch. control unit.
18. Check for DTCs with the scan tool. 37. Turn ON the ignition switch.
19. When a DTC is not detected, replace the TCM. 38. Check for DTCs with the scan tool.
5B.Automatic(TB-50LS) TCM removal".
39. When a DTC is not detected, replace the auto A/C 60. Disconnect the harness connector from the BCM.
control unit.
41. Connect the harness connector to the auto A/C
63. When a DTC is not detected, replace the BCM.
control unit.
42. Disconnect the harness connector from the TCCM.
Driver Info.(All models) BCM removal".
44. Check for DTCs with the scan tool. Driver Info.(All models) BCM installation".
45. When a DTC is not detected, replace the TCCM. 64. Set the vehicle information into the BCM.
Refer to "3.Driveline, Axle 3D.Transfer Case(All Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
models) TCCM removal". Driver Info.(All models) BCM setting".
Refer to "3.Driveline, Axle 3D.Transfer Case(All 65. When a DTC is detected, inspect the CAN low and
models) TCCM installation". CAN high circuits.
46. Turn OFF the ignition switch. Note：
47. Connect the harness connector to the TCCM. ・ There should be no short circuit to the battery
48. Disconnect the harness connector from the EGR
valve.
resistance.
49. Turn ON the ignition switch. ・ There should be no short circuit between CAN
50. Check for DTCs with the scan tool. circuits.
51. If a DTC is not detected, replace the EGR valve. ・ There should be no short circuit to the low
reference circuit.
Refer to "1.Engine 1H.Aux. Emission Control ・ There should be no short circuit with a metal
Devices(4JJ1) EGR valve removal". component such as the frame.
Refer to "1.Engine 1H.Aux. Emission Control 66. If a problem is found, repair the CAN circuit.
Devices(4JJ1) EGR valve installation".
67. When the CAN circuit is normal, replace the EHCU.
Refer to "1.Engine 1H.Aux. Emission Control
Devices(4JK1) EGR valve removal". Refer to "4.Brakes 4D.ABS(All models)
EHCU removal".
Refer to "1.Engine 1H.Aux. Emission Control
Devices(4JK1) EGR valve installation". Refer to "4.Brakes 4D.ABS(All models)
EHCU installation".
53. Connect the harness connector to the EGR valve.
54. Disconnect the harness connector from the SRS EHCU setting".
control unit.
2. DTC U0073 confirm resolution
2. Turn OFF the ignition switch for more than 30
57. When a DTC is not detected, replace the SRS control seconds.
unit.
Refer to "8.Restraints 8B.Air Bag Systems(All models)
SRS control unit removal". 4. Perform a test-run.
Refer to "8.Restraints 8B.Air Bag Systems(All models) 5. Using the scan tool, verify that DTCs have not been
SRS control unit installation". detected.
59. Connect the harness connector to the SRS control
unit.

Control Module Communication Bus Off - Local CAN
1. DTC U0074 diagnostics 15. When the CAN circuit is normal, replace the EHCU.
1. Turn OFF the ignition switch. Refer to "4.Brakes 4D.ABS(All models)
EHCU removal".
2. Disconnect the harness connector from the steering
angle sensor. Refer to "4.Brakes 4D.ABS(All models)
EHCU installation".
5. When a DTC is not detected, replace the steering
EHCU setting".
angle sensor.
sensor removal". 1. Clear the DTC with the scan tool.
Refer to "4.Brakes 4D.ABS(All models) Steering angle 2. Turn OFF the ignition switch for more than 30
sensor installation". seconds.
6. If the steering angle sensor has been replaced, 3. Start the engine.
perform the 0-point learning.
sensor setting".
detected.
8. Connect the harness connector of the steering angle
sensor.
9. Disconnect the harness connector from the yaw rate
sensor.
12. When a DTC is not detected, replace the yaw rate
sensor.
sensor removal".
13. Inspect the CAN low and CAN high circuits.
Note：
resistance.
・ There should be no short circuit between CAN
circuits.
・ There should be no short circuit to the low
reference circuit.
・ There should be no short circuit with a metal
component such as the frame.
14. If a problem is found, repair the CAN circuit.

Lost Communication with ECM
1. DTC U0100 priority DTC Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
DTC U0073 15. Perform the unit difference learning of fuel supply
pumps on the ECM.
2. DTC U0100 diagnostics
Refer to "1.Engine 1J.Electrical(4JJ1) ECM writing".
1. Using the scan tool, communicate with the ECM.
Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
2. If it does not communicate with the ECM is not
possible, check the engine control system. 16. Clear the DTC with a scan tool.
3. Turn OFF the ignition switch. 17. Turn OFF the ignition switch.
4. Disconnect the harness connector from the ECM. 18. Turn ON the ignition switch.
5. Measure the voltage value between the ECM harness 19. Check for a DTC using a scan tool.
connector CAN low circuit and the frame ground.
20. When a DTC U0100 is detected, replace the EHCU.
6. Measure the voltage value between the ECM harness
connector CAN high circuit and the frame ground.
EHCU removal".
7. When the value is outside the standard value range, EHCU installation".
inspect the CAN high circuit between the EHCU and
the ECM.
Note：
EHCU setting".
resistance. 3. DTC U0100 confirm resolution
8. If a problem is found, repair the CAN high circuit. 1. Clear the DTC with the scan tool.
9. Inspect the CAN low circuit between the EHCU and 2. Turn OFF the ignition switch.
the ECM. 3. Turn ON the ignition switch.
Note： 4. Using the scan tool, verify that DTCs have not been
・ There should be no open circuit or high detected.
resistance.
10. If a problem is found, repair the CAN low circuit.
11. When the value is within the standard value, inspect
the ECM harness connector for a contact failure.
13. If the harness connector is normal, replace the ECM.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM removal".
Refer to "1.Engine 1J.Electrical(4JJ1)
ECM installation".
ECM removal".
ECM installation".
14. Set the immobilizer function and injector ID code
into the ECM.
Refer to "1.Engine 1J.Electrical(4JJ1) ECM setting".

Lost Communication with TCM
1. DTC U0101 priority DTC 18. Check for a DTC using a scan tool.
DTC U0073 19. When a DTC U0101 is detected, replace the EHCU.
2. DTC U0101 diagnostics Refer to "4.Brakes 4D.ABS(All models)
EHCU removal".
1. Using the scan tool, communicate with the TCM.
2. If it does not communicate with the TCCM, check
EHCU installation".
the transfer control system.
4. Disconnect the harness connector from the TCM.
EHCU setting".
5. Measure the voltage value between the TCM harness
connector CAN low circuit and the frame ground.
6. Measure the voltage value between the TCM harness
connector CAN high circuit and the frame ground. 2. Turn OFF the ignition switch.
standard： 1.5 to 3.5 V 3. Turn ON the ignition switch.
7. When the value is outside the standard value range, 4. Using the scan tool, verify that DTCs have not been
inspect the CAN high circuit between the EHCU and detected.
the TCM.
Note：
resistance.
8. If a problem is found, repair the CAN high circuit.
9. Inspect the CAN low circuit between the EHCU and
the TCM.
Note：
resistance.
the TCM harness connector for a contact failure.
13. If the harness connector is normal, replace the TCM.
5B.Automatic(TB-50LS) TCM removal".
5B.Automatic(TB-50LS) TCM installation".
14. Write the vehicle information into the TCM.
5B.Automatic(TB-50LS) TCM setting".
15. Clear the DTC with a scan tool.

Lost Communication with TCCM
1. DTC U0102 priority DTC 18. When a DTC U0102 is detected, replace the EHCU.
DTC U0073 Refer to "4.Brakes 4D.ABS(All models)
EHCU removal".
1. Using the scan tool, communicate with the TCCM.
EHCU installation".
2. If it does not communicate with the TCCM, check
the transfer control system.
EHCU setting".
4. Disconnect the harness connector from the TCCM.
5. Measure the voltage value between the TCCM
harness connector CAN low circuit and the frame
ground. 2. Turn OFF the ignition switch.
6. Measure the voltage value between the TCCM 3. Turn ON the ignition switch.
harness connector CAN high circuit and the frame
ground.
detected.
7. When the value is outside the standard value range,
inspect the CAN high circuit between the EHCU and
the TCCM.
Note：
resistance.
8. If a problem is found, repair the CAN high circuit.
the TCCM.
Note：
resistance.
the TCCM harness connector for a contact failure.
TCCM.
Refer to "3.Driveline, Axle 3D.Transfer Case(All
models) TCCM removal".
Refer to "3.Driveline, Axle 3D.Transfer Case(All
models) TCCM installation".

Lost Communication with Steering angle sensor
1. DTC U0126 priority DTC 13. Clear the DTC with a scan tool.
DTC U0074 14. Turn OFF the ignition switch.
2. DTC U0126 diagnostics 15. Turn ON the ignition switch.
1. Turn OFF the ignition switch. 16. Check for a DTC using a scan tool.
2. Disconnect the harness connector from the steering 17. When a DTC U0126 is detected, replace the EHCU.
angle sensor.
3. Measure the voltage value between the steering EHCU removal".
angle sensor harness connector local CAN low
circuit and the frame ground.
EHCU installation".
4. Measure the voltage value between the steering
angle sensor harness connector local CAN high
circuit and the frame ground. Refer to "4.Brakes 4D.ABS(All models)
EHCU setting".
inspect the local CAN high circuit between the 1. Clear the DTC with the scan tool.
EHCU and the steering angle sensor.
Note： 3. Turn ON the ignition switch.
resistance. 4. Using the scan tool, verify that DTCs have not been
detected.
6. If a problem is found, repair the local CAN high
circuit.
Note：
resistance.
8. If a problem is found, repair the local CAN low
circuit.
the steering angle sensor harness connector for a
contact failure.
sensor removal".
12. If the steering angle sensor has been replaced,
perform the 0-point learning.
sensor setting".

Lost Communication with Yaw Rate Sensor
1. DTC U1826 priority DTC 16. When a DTC U1826 is detected, replace the EHCU.
DTC U0074 Refer to "4.Brakes 4D.ABS(All models)
EHCU removal".
EHCU installation".
2. Disconnect the harness connector from the yaw rate
sensor.
3. Measure the voltage value between the yaw rate
EHCU setting".
sensor harness connector local CAN low circuit and
the frame ground. 3. DTC U1826 confirm resolution
4. Measure the voltage value between the yaw rate 1. Clear the DTC with the scan tool.
sensor harness connector local CAN high circuit and
the frame ground.
detected.
inspect the local CAN high circuit between the
EHCU and the yaw rate sensor.
Note：
resistance.
6. If a problem is found, repair the local CAN high
circuit.
7. Inspect the local CAN low circuit between the
EHCU and yaw rate sensor.
Note：
resistance.
8. If a problem is found, repair the local CAN low
circuit.
the yaw rate sensor harness connector for a contact
failure.
11. If the harness connector is normal, replace the yaw
rate sensor.
sensor removal".
Brake System (All models) 4B-1
Brakes
Brake System
(All models)
Table of Contents
Brake master cylinder......................................................4B-2
removal.......................................................................4B-2
disassembly.................................................................4B-3
reassembly..................................................................4B-4
installation...................................................................4B-5
Brake booster assembly...................................................4B-9
removal.......................................................................4B-9
installation.................................................................4B-10
Front disc brake.............................................................4B-15
removal.....................................................................4B-15
disassembly...............................................................4B-18
inspection..................................................................4B-19
reassembly................................................................4B-22
installation.................................................................4B-25
Rear brake drum............................................................4B-34
disassembly...............................................................4B-34
inspection..................................................................4B-36
reassembly................................................................4B-38
Brake pedal....................................................................4B-46
removal.....................................................................4B-46
installation.................................................................4B-47
Disc brake pad...............................................................4B-49
removal.....................................................................4B-49
installation.................................................................4B-51
Supplementary Information...........................................4B-54
4B-2 Brake System (All models)
Brake master cylinder
removal
1. Brake pipe disconnect
1. Disconnect the brake pipe from the brake master
cylinder.
Caution：
・ Be careful never to spill the brake fluid on
painted surfaces because the fluid will damage
the paint.
2. Brake master cylinder removal

1. Remove the brake master cylinder from the brake
booster assembly.
disassembly
1. Cap removal
1. Remove the cap from the reservoir tank.
2. Remove the diaphragm from the reservoir tank.
3. Remove the filter from the reservoir tank.
reassembly
1. Cap installation
1. Install the filter to the reservoir tank.
2. Install the diaphragm to the reservoir tank.
3. Install the cap to the reservoir tank.
installation Note：
・ Filling up the reservoir tank
1. Brake master cylinder installation
Caution：
1. Install the brake master cylinder to the brake booster
・ Use only the specified brake fluid.
assembly.
・ Do not use any brake fluid that contains
Note： petroleum components.
・ Apply 0.2 g {0.007 oz} silicon grease or
Note：
equivalent to the cylinder shell of the brake
booster assembly. ・ Doing so may cause expansion or distortion of
the rubber parts in the hydraulic brake system.
Tightening torque： 10 to 16 N・m { 1.0 to 1.6 kgf・m /
89 to 142 lb・in } Caution：
・ Do not use any brake fluid container that
contains petroleum components or that is wet
with water.
Note：
・ If water mixes in the brake fluid, its boiling
point decreases.
・ Put a cover on every container to prevent
contaminations.
Caution：
・ Refill the fluid in the reservoir tank when the
engine is cold.
・ Be careful never to spill the brake fluid on the
the paint.
・ Refill the fluid in the reservoir tank to the MAX
mark to prevent air from mixing in.
2. Brake pipe connect ・ Be careful for the fluid not to overflow.
1. Connect the brake pipe to the brake master cylinder. ・ Clean the reservoir tank before removing the
cap to prevent dirt, etc. from entering the tank.
10 to 14 lb・ft } Note：
・ Refill the brake fluid to the MAX mark of the
reservoir tank as necessary.
・ Use the brake fluid DOT3.
・ Brake fluid leakage
・ With the engine idling, set the shift lever to
neutral, and continue depressing the brake
pedal with a constant amount of pressure.
・ If the pedal stroke gradually increases, there
may be fluid leakage in the oil pressure
system.
・ Visually check for oil leakage.
・ Air removal from the oil pressure system
・ Air entering the brake pipe will cause an
insufficient brake operation.
・ In the case of using the brake in a condition
where the fluid level in the reservoir tank is
extremely low, or removing the brake pipe,
3. Brake fluid air bleed conduct air removal.
・ The air removal work requires cooperation Caution：

between 2 operators. ・ During the air removal work, keep filling the
・ Be sure to engage the parking brake during reservoir tank at least half full with the fluid.
the air removal work. ・ Be sure to refill new brake fluid.
Caution：・ When refilling the fluid, be careful for the air
not to enter the fluid.
・ Conduct the air removal work with the engine
started to protect damage to the push rod seal,
and secure adequate ventilation.
・ Maintain the fluid in the reservoir tank at the
specified level before starting the air removal
work.
・ Start the air removal work with the rear wheel
cylinder that is the farthest from the master
cylinder.
Note：
・ The air removal work is necessary to remove
the air when the air enters the oil pressure
system.
・ In a condition where the brake fluid level has
dropped or when the air entered the fluid after
removing the brake pipe from the master
cylinder, air removal may be needed for all
brakes at 4 locations.
1. MAX level
・ When the brake pipe is removed at 1 brake, air 2. MIN level
removal is needed for the corresponding wheel 3. Brake fluid compartment
cylinder and caliper.
・ When the piping between the master cylinder Note：
and one of the brakes is removed, air removal ・ When installing/removing or replacing the
is needed for the brake system operating with master cylinder, follow the procedures
the removed pipe. described below. First, remove air from the
1. Apply the parking brake. master cylinder, and then, remove air from
every wheel cylinder and caliper.
Note：・ Air removal from the brake master cylinder
・ Pull the parking brake lever to a full extent.
2. Start the engine. cylinder.
Caution：
・ Be careful not to conduct the air removal work
with the engine stopped. Doing so will damage
the vacuum booster.
4. Replenish the reservoir tank with the brake fluid.
Note：
・ The brake fluid tank is shared with the clutch
fluid tank.
・ As the amount of the fluid is different between
the brake compartment and clutch
compartment depending on the partition inside
the tank, check the amount of brake fluid in the
brake compartment.
1. Rear brake pipe
2. Front brake pipe
Note：
・ Remove the rear brake pipe.
・ Inspect the fluid level and refill the fluid as
necessary.
・ If the fluid is refilled, leave the system as it is
for at least 1 minute.
6. Operate the brake pedal.
Note：
・ Slowly depress the brake pedal once and hold
it down.
・ Use a finger to completely plug the outlet of
the master cylinder that is removed from the
brake pipe, and slowly release the brake
pedal. 1. Rear brake pipe
・ Remove the finger from the outlet after the 2. Front brake pipe
brake pedal has been completely returned.
Note：
・ Repeat the process mentioned above until the
brake fluid comes out overflowing from the ・ Air removal from the caliper
outlet. 8. Drain air from the brake caliper assembly.
Caution： Note：
・ Be careful that the fluid level in the reservoir ・ Remove air from each wheel in the following
tank does not drop below the intermediate order.
level indication. ・ Right rear wheel cylinder
7. Connect the brake pipe to the brake master cylinder. ・ Left rear wheel cylinder
Note：・ Left front caliper
・ Connect the rear brake pipe. ・ Right front caliper
・ Slowly depress the brake pedal once and hold ・ If the brake fluid does not come out, it shows
it down. that air has entered the master cylinder.
・ Loosen the rear brake pipe. ・ In this case, follow steps 5 to 7 to remove air
・ Tighten the brake pipe again and slowly return from the master cylinder.
the brake pedal. ・ Apply an appropriate wrench to the bleeder
・ Repeat steps 5 to 7 mentioned above until air screw.
does not come out form the outlet when the 9. Connect the tube to the bleeder screw.
brake pipe is loosened.
Note：
Caution：・ Connect a transparent tube to the bleeder
・ Be careful never to spill the brake fluid on the screw and put the other end of the tube into a
painted surfaces because the fluid will damage transparent container containing the brake
the paint. fluid.
Note：
・ Repeat steps 5 to 7 to remove air from the
front brake pipe.
Caution：
・ After air removal of each wheel, be sure to
confirm the fluid level in the reservoir tank.
Note：
・ When air removal of all wheels is completed,
depress the brake pedal and check for a
feeling of stepping on a sponge.
・ If the feeling of stepping on a sponge exists,
the air removal procedures need to be
repeated.
Note：
・ Refill the fluid to the MAX mark as necessary.
13. Stop the engine.
Note：
Note：
・ Brake pipe and brake hose
・ Slowly depress the brake pedal 3 times with a
・ Inspect all pipes and hoses for worn, bent,
speed of once per second and hold it down.
damage, cracks, or dents.
・ If any abnormality is found, conduct a
necessary repair or replacement.
Caution：
・ Pay attention to all joint sections of pipes and
hoses, which are vulnerable to damage.
・ Be careful not to extremely twist or bend the
hose during work, and not to damage the
brake pipe when repairing or replacing the
axles, suspensions, etc.
Note：
・ Conduct leakage inspections with the brake
pedal fully depressed.
Caution：
・ If leakage is found around the joint section,
conduct re-tightening or replacement.
1. Brake pedal ・ Be sure to implement these procedures when
installing the brake pipe.
Note：・ After removing the pipe and hose, cover the
・ Loosen the bleeder screw until the brake fluid opening with a plug or tape to prevent foreign
flows in the tube. objects from entering.
・ Loosen the bleeder screw.
・ Slowly return the brake pedal.
・ Repeat steps 9 and 10 until air is completely
removed.
・ Repeat the air removal procedures at least 10
times for the front wheel and at least 15 times
for the rear wheel.
Brake booster assembly
removal 1. Remove the joint pin from the clevis.

5. Brake booster assembly removal
1. Remove the brake booster assembly from the brake
pedal bracket.
cylinder.
2. Remove the spacer from the brake booster assembly.
Caution：
・ Be careful never to spill the brake fluid on 3. Remove the gasket from the spacer.
painted surfaces because the fluid will damage 6. Vacuum hose inspection
the paint.
1. Inspect the vacuum hose.
Note：
・ Inspect the check valve installed in the
vacuum hose.
・ Blow in air from the booster side as shown in
the diagram and confirm that air goes out
smoothly.
・ Confirm that air does not go out when air is
blown in from the engine side.
2. Vacuum hose removal

1. Remove the vacuum hose from the brake booster
assembly.
3. Brake master cylinder removal
1. Remove the bracket from the brake master cylinder.
2. Remove the brake master cylinder from the brake
booster assembly.
Note：
Note：
・ When removing the brake master cylinder,
・ If any abnormality is found on the vacuum
remove the negative pressure in the brake
hose and check valve, replace them as a set.
booster in advance by disconnecting the
vacuum hose.
・ Even if only a slight negative pressure remains
when the master cylinder is removed, the
piston may bounce out and the brake fluid may
flow out.
Caution：
・ Do not hold the piston when removing the
master cylinder because the piston easily
comes out.
4. Joint pin removal
installation 2. Check valve
1. Brake booster assembly installation 4. Brake master cylinder installation

1. Install the gasket to the spacer. 1. Install the brake master cylinder to the brake booster
assembly.
2. Install the spacer to the brake booster assembly.
2. Install the bracket to the brake master cylinder.
3. Install the brake booster assembly to the brake pedal
bracket. 5. Brake pipe connect
Caution： 1. Connect the brake pipe to the brake master cylinder.
・ Do not adjust the brake booster push rod.
・ If the brake booster is damaged, replace it with
a new one for which the push rod has been
adjusted.
Note：
・ Measurement of the primary piston position on
the master cylinder side is not necessary.
2. Joint pin installation
1. Install the joint pin to the clevis.
3. Vacuum hose installation
1. Install the vacuum hose to the brake booster
assembly.
Caution：
・ Since the check valve is embedded in the
vacuum hose, during installation make sure
6. Brake fluid air bleed
the installation direction causes the arrow to
face the engine side. Note：
Note：・ Filling up the reservoir tank
・ If the vacuum hose is installed incorrectly, the Caution：
booster will not operate. ・ Use only the specified brake fluid.
Caution：・ Do not use any brake fluid that contains
・ Do not apply oil to the vacuum hose. petroleum components.
Note：
・ Doing so may cause expansion or distortion of
Caution：
with water.
Note：
point decreases.
contaminations.
Caution：
engine is cold.
1. Engine side
・ Be careful never to spill the brake fluid on the ・ When the brake pipe is removed at 1 brake, air
painted surfaces because the fluid will damage removal is needed for the corresponding wheel
the paint. cylinder and caliper.
・ Refill the fluid in the reservoir tank to the MAX ・ When the piping between the master cylinder
mark to prevent air from mixing in. and one of the brakes is removed, air removal
・ Be careful for the fluid not to overflow. is needed for the brake system operating with
the removed pipe.
・ Clean the reservoir tank before removing the
cap to prevent dirt, etc. from entering the tank. 1. Apply the parking brake.
Note： Note：
・ Refill the brake fluid to the MAX mark of the ・ Pull the parking brake lever to a full extent.
Caution：
the vacuum booster.
・ If the pedal stroke gradually increases, there 3. Remove the cap from the reservoir tank.
may be fluid leakage in the oil pressure 4. Replenish the reservoir tank with the brake fluid.
system.
Note：
fluid tank.
・ In the case of using the brake in a condition compartment depending on the partition inside
where the fluid level in the reservoir tank is the tank, check the amount of brake fluid in the
extremely low, or removing the brake pipe, brake compartment.
conduct air removal.
Caution：
・ The air removal work requires cooperation
reservoir tank at least half full with the fluid.
・ Be sure to engage the parking brake during
・ When refilling the fluid, be careful for the air
Caution：
work.
cylinder.
Note：
system.
brakes at 4 locations. 1. MAX level
2. MIN level
3. Brake fluid compartment Caution：
・ Be careful that the fluid level in the reservoir
Note：
tank does not drop below the intermediate
・ When installing/removing or replacing the level indication.
master cylinder, follow the procedures
described below. First, remove air from the 7. Connect the brake pipe to the brake master cylinder.
master cylinder, and then, remove air from Note：
every wheel cylinder and caliper.
・ Connect the rear brake pipe.
・ Air removal from the brake master cylinder
5. Disconnect the brake pipe from the brake master it down.
cylinder. ・ Loosen the rear brake pipe.
・ Tighten the brake pipe again and slowly return
the brake pedal.
・ Repeat steps 5 to 7 mentioned above until air
does not come out form the outlet when the
Caution：
the paint.
Note：
front brake pipe.
1. Rear brake pipe

2. Front brake pipe
Note：
necessary.
Note：
it down.
1. Rear brake pipe
・ Use a finger to completely plug the outlet of 2. Front brake pipe
brake pipe, and slowly release the brake Note：
pedal. ・ Air removal from the caliper
・ Remove the finger from the outlet after the
8. Drain air from the brake caliper assembly.
・ Repeat the process mentioned above until the Note：
brake fluid comes out overflowing from the ・ Remove air from each wheel in the following
outlet. order.
・ Right rear wheel cylinder
・ Left rear wheel cylinder
・ Left front caliper

・ Right front caliper
・ If the brake fluid does not come out, it shows
that air has entered the master cylinder.
・ In this case, follow steps 5 to 7 to remove air
from the master cylinder.
・ Apply an appropriate wrench to the bleeder
screw.
9. Connect the tube to the bleeder screw.
Note：
・ Connect a transparent tube to the bleeder
screw and put the other end of the tube into a
transparent container containing the brake
fluid.
1. Brake pedal
Note：
・ Loosen the bleeder screw until the brake fluid
flows in the tube.
removed.
for the rear wheel.
Caution：
10. Operate the brake pedal. Note：
Note：・ When air removal of all wheels is completed,
・ Slowly depress the brake pedal 3 times with a depress the brake pedal and check for a
speed of once per second and hold it down. feeling of stepping on a sponge.
repeated.
Note：
Note：
Caution：
Note：
Caution：
・ Be sure to implement these procedures when
・ After removing the pipe and hose, cover the
opening with a plug or tape to prevent foreign
objects from entering.
Front disc brake
removal
1. Disc wheel removal
1. Remove the disc wheel from vehicle.
2. Brake hose disconnect
1. Disconnect the brake hose from the brake caliper
assembly.
Note：
・ Remove the brake hose from the caliper by
taking off the bolt and gasket.
Caution：
・ After removing the brake hose, cover the
material from entering.
2. Remove the brake caliper assembly from the brake

support.
4. Disc brake pad removal
1. Remove the disc brake pad from the brake support.
Note：
・ Turn the caliper facing upward.
3. Brake caliper assembly removal

1. Remove the lock bolt from the brake caliper
assembly.
Note：
・ Put an alignment mark in the pad position as a
guide for installation.
1. Remove the hub cap from the front hub.
Caution：
・ Be careful not to cause scratches and
distortion to the hub tapered fitting portion
when removing the hub cap.
2. Remove the clip from the brake support.

Note：
・ Remove the pad clip.
5. Guide pin removal
1. Remove the guide pin from the brake support.
Note：
2. Remove the boot from the guide pin. ・ The following applies to 2WD high ride
6. Brake support removal suspension, 4WD.
1. Remove the brake support from the knuckle. 2. Remove the hub cap from the front hub.
Caution：
・ Be careful not to damage the brake hose when
removing the brake support.
8. Hub nut removal

Note：
・ The following applies to high ride suspension
7. Hub cap removal models except for 2WD.
Note： 1. Remove the hub nut from the knuckle.
・ The following applies to high ride suspension Note：
models except for 2WD. ・ Remove the cotter pin and then remove the
nut retainer and hub nut.
・ Remove the lock washer. Note：

9. Flange removal
models except for 2WD.
Note：
1. Remove the outer bearing from the front hub rotor
・ The following applies to 2WD high ride assembly.
suspension, 4WD.
Note：
1. Remove the flange from the front hub.
・ Remove the outer bearing inner race from the
Note： front hub rotor assembly.
・ Remove the snap ring and shim, and then 13. Front hub rotor assembly removal
remove the flange from the front hub.
1. Remove the front hub rotor assembly from the
10. Lock washer removal knuckle.
Note：
・ The following applies to 2WD high ride
suspension, 4WD.
1. Remove the lock washer from the bearing lock nut.
11. Bearing lock nut removal
Note：
suspension, 4WD.
1. Remove the bearing lock nut from the knuckle using
special tool.
SST: 5-8840-2117-0 - hub nut wrench
12. Outer bearing removal

disassembly
1. Brake caliper assembly disassembly
1. Remove the bleeder screw from the brake caliper
assembly.
Note：
・ Remove it with the cap attached.
2. Remove the piston from the brake caliper assembly.
Note：
・ Perform it before removing the dust seal.
・ Insert a piece of wood, etc. into the caliper,
blow air into the flexible hose installation hole
to pull out the piston.
Caution：
・ Be careful not to catch your finger with the
piston.
3. Remove the dust seal from the piston.

4. Remove the seal from the piston.
Note：
・ Remove the ring seal from the piston.
inspection Note：
・ Adjust the wheel bearing properly before the
1. Front disc brake inspection inspection.
1. Inspect the brake assembly. ・ Measure the amount of fluctuation with a dial
Note： gauge at a position 10 mm {0.04 in} away from
the rotor outside end on the contact surface of
・ If any worn, damage, or other abnormalities the disc brake pad.
are found during the inspection, make repairs
or replace the parts.
・ Visually inspect the following parts for worn,
bent, degradation, corrosion, abrasion,
scratches, or other abnormalities.
・ Rotor
・ Caliper body
・ Cylinder bore
・ Piston
・ Brake support
・ Lock bolt
・ Guide pin
2. Brake rotor inspection
1. Inspect the brake rotor.
Note：
・ Measure the thickness of the brake rotor. Note：
Specificati ・ Measure the parallelism of the brake rotor.
Standard value Limit
ons Limit： 0.023 mm { 0.00091 in }
： 27.0 mm { 1.063 ： 25.6 mm { 1.008
2WD Note：
in } in }
： 27.0 mm { 1.063 ： 25.0 mm { 0.984 ・ The contact surface is within 0.023 mm
4WD {0.0009 in} at a position inside the piston 10
in } in }
mm {0.04 in} from the rotor outside end.
・ Perform measurement at 8 locations or more
in a circumferential direction.
Note：
・ Measure the brake rotor fluctuation.
Limit： 0.075 mm { 0.00295 in } 3. Disc brake pad inspection
1. Inspect the disc brake pad.
Note：
・ Measure the thickness of the disc brake pad.
Standard： 10.0 mm { 0.394 in }
Limit： 1.5 mm { 0.059 in }
1. Support bracket
2. Slide pin boot
3. Slide pin (guide pin）
4. Lock bolt
5. Pad clip
6. Slide pin (lock pin）
Note： 3. Inspect the boot.

・ When the pad friction indicator makes a Note：
scratchy sound or the pad is worn to 1.8 mm ・ Replace the boot every time the caliper is
{0.071 in} or less from the shoe table, replace overhauled.
the pad.
4. Inspect the dust seal.
Caution：
Note：
・ When replacing, replace all of the 4 pads.
・ Replace the dust seal and ring seal every time
4. Guide pin inspection the caliper is overhauled.
1. Inspect the guide pin.
2. Inspect the lock pin.
Note：
・ Inspect it for sticking, worn, bending,
degradation, corrosion, abrasion, scratches, or
other abnormalities.
・ If there are abnormalities, make repairs or
replace the parts.
1. Piston
2. Caliper body
3. Dust boot
4. Ring seal
reassembly Caution：
・ Do not mix up the upper and lower sides of the
1. Brake caliper assembly reassembly dust boot.
1. Install the seal to the piston.
Note：
・ Install the ring seal to the piston.
・ Apply Castrol Red Rubber Grease or
equivalent to the ring seal, and install it to the
cylinder.
Caution：
・ Be careful the ring seal does not become
twisted.
3. Install the piston to the brake caliper assembly.

Note：
・ Apply clean brake fluid to the piston, and
install it to the caliper.
・ When inserting the piston into the cylinder, use
the finger pressure only.
Caution：
・ Do not use a tool such as a mallet or impact
wrench because it may damage the cylinder
2. Install the dust boot to the piston. wall or the ring seal.
Note： Note：
・ Apply rubber grease NIGLUBE RX-2 or ・ Confirm that the piston moves smoothly in the
equivalent in a thin layer to the inner side and cylinder.
the outside lip of the dust boot.
・ If the piston does not move or hardly moves,

overhauling or replacement of the caliper is
needed.
・ If the piston cannot be pushed in with fingers,
place a scrapped brake pad or a piece of wood
on top of the piston and use 2 large-sized C
clamps to insert the piston into the cylinder.
1. Protruding portion of the dust boot

2. Cylinder body groove
Note：
・ Confirm that the pleated portion of the dust
boot does not protrude from the piston end.
・ Pull out the piston slightly and confirm that the
boot is firmly installed to the cylinder body
1. Large-sized C clamp groove.
2. Brake pad or a piece of wood
3. Caliper
Caution：
・ Insert it slowly and evenly.
・ Do not hit the piston with a hammer, nor
wrench the piston surface with pliers, etc.
Note：
・ After inserting the piston into the cylinder, push
the dust boot peripheral toward the cylinder
body side surface to assemble them.
・ Carefully push the protruding portion of the
dust boot into the cylinder body groove.
1. Piston end
2. Dust boot pleated portion
3. Piston
4. Install the bleeder screw to the brake caliper

assembly.
80 to 115 lb・in }
5. Install the cap to the bleeder screw.

installation Note：
1. Front hub rotor assembly installation suspension, 4WD.
Note： 1. Install the bearing lock nut to the knuckle using
・ The following applies to high ride suspension special tool.
Note：
1. Install the front hub rotor assembly to the knuckle. ・ Install the bearing lock nut with its slit surface
Note： facing to the outside.
・ Fill grease in the front hub and hub cap.
： 50 g { 1.76 oz } Hub, grease filling amount
： 20 g { 0.71 oz } Hub cap, grease filling amount
1. Outer bearing
2. Inner bearing
3. Hub
4. Hub cap
Note： 1. Hub nut wrench

・ The following applies to 2WD high ride 4. Front hub rotor assembly adjustment
suspension, 4WD.
Note：
2. Install the front hub rotor assembly to the knuckle.
2. Outer bearing installation models except for 2WD.
Note： 1. Adjust the preload to a standard value.
・ The following applies to high ride suspension Note：
・ Adjust the preload for the front hub bearing.
1. Install the outer bearing to the front hub rotor ・ Tighten the spindle nut to the specified torque.
assembly.
Tightening torque： 29 N・m { 3.0 kgf・m / 21 lb・ft }
Note：
Note：
・ Install the outer bearing inner race into the
front hub rotor assembly. ・ Rotate the hub 2 or 3 turns and loosen the
nuts so that they can be turned by fingers.
3. Bearing lock nut installation
・ Fully tighten the nuts securely with fingers and
confirm that there is no play at the hub.
・ Pull one of the wheel pins with a spring scale Caution：

and measure the bearing preload. ・ If the preload is unstable, rotate the hub
・ Tighten the spindle nut until the specified several times, stop the rotation completely and
bearing preload is obtained. carry out measurement again.
・ If it is still unstable, start over the procedure to
Preload： 8.0 to 12.0 N { 0.8 to 1.2 kg / 1.8 to 2.7 lb }
turn the front hub to the left and right by
New bearing, new oil seal
several turns to stabilize the bearing for
Preload： 8.0 to 12.0 N { 0.8 to 1.2 kg / 1.8 to 2.7 lb } installation.
Reused bearing, new oil seal
5. Lock washer installation

Note：
Note：
・ Install the cotter pin to the retainer.
・ Install the cotter pin to the nut retainer. suspension, 4WD.
Caution： 1. Install the lock washer to the bearing lock nut.
・ Use a new cotter pin.
Note：
Note：・ Install it in such a way that the side with the
・ The following applies to 2WD high ride larger taper hole diameter faces the outside of
suspension, 4WD. the vehicle.
2. Adjust the preload to a standard value. ・ If the lock washer screw hole does not align
with the corresponding hole of the bearing lock
Note： nut, turn the lock washer over.
・ Adjust the preload for the front hub bearing. ・ If the hole positions still do not align, turn the
・ After tightening the hub to the specified torque bearing lock nut to adjust the hole positions to
of the nut, fully loosen the nut. best alignment.
Tightening torque： 29 N・m { 3.0 kgf・m / 21 lb・ft } ・ Tighten the lock washer installation screw
securely so that the screw head is lower than
Note： the washer surface.
・ Hook a spring scale to the wheel pin, and
gently pull it in a tangent direction. Make
adjustments by tightening the hub nut until the
preload reaches the specified value.
Renewed bearing, new oil seal
6. Flange installation 7. Hub cap installation

Note： Note：
・ The following applies to 2WD high ride ・ The following applies to 2WD high ride
suspension, 4WD. suspension, 4WD.
1. Install the flange to the front hub. 1. Install the hub cap to the front hub.
Note： Note：
・ Apply liquid gasket LOCTITE 515 or equivalent ・ Install the hub cap to the front hub with bolts.
to the flange installation surface and install the
flange to the hub.
・ Install the snap ring and shim.
2. Adjust the shim.
Note：
・ Adjust the clearance between the flange and
snap ring with the shim.
Standard： 0.0 to 0.2 mm { 0.000 to 0.008 in }
Types of adjust shims
： 0.2 mm { 0.008 in }
： 0.3 mm { 0.012 in }
： 0.5 mm { 0.020 in }
： 1.0 mm { 0.039 in }
Note：
2. Install the hub cap to the front hub.
8. Guide pin installation 2. Install the guide pin to the brake caliper assembly.
Note：
・ Apply rubber grease NIGLUBE RX-2 or
equivalent to the portions of the boot and
guide pin as shown in the diagram.
・ Apply rubber grease NIGLUBE RX-2 or
equivalent to the inside of the boot.
Caution：
・ Do not use mineral grease.
Note：
・ Install the guide pin boot securely to the guide
pin groove.
・ Pull out the guide pin slightly and confirm that
the boot is securely installed to the cylinder
body groove.
・ Move the guide pin to spread rubber grease
over the brake support groove.
Caution：
1. Install the boot to the brake support.
Note： guide pin.
・ Install it firmly to the brake support groove.
2. Install the lock bolt to the brake caliper assembly.
24 to 31 lb・ft }
9. Brake support installation

1. Install the brake support to the knuckle.
Tightening torque： 205 to 245 N・m { 20.9 to 25.0
kgf・m / 151 to 181 lb・ft } 12. Brake hose connect
Note： 1. Install the brake hose to the brake caliper assembly.
・ After installing the brake support, install the Note：
clip and pad.
・ Install the bolt and a new gasket.
21 to 29 lb・ft }
10. Disc brake pad installation

1. Install the disc brake pad to the brake support.
Note： Note：
・ After installing the clip, install the pad ・ After the installation, conduct air removal.
assembly attached with the shim.
Caution：
・ Install a new one as necessary.
・ Make sure to use a new gasket.
11. Brake caliper assembly installation ・ Insert the brake hose end into the stopper
1. Install the brake caliper assembly to the brake hole.
support.
・ Before the installation, completely remove dust ・ In the case of using the brake in a condition
and foreign material from the bolt, screw on where the fluid level in the reservoir tank is
the brake side surface, and sealing surface. extremely low, or removing the brake pipe,
Note： between 2 operators.
・ Filling up the reservoir tank ・ Be sure to engage the parking brake during
Caution： the air removal work.
・ Use only the specified brake fluid. Caution：
・ Do not use any brake fluid that contains ・ Conduct the air removal work with the engine
petroleum components. started to protect damage to the push rod seal,
Note：
work.
Caution：・ Start the air removal work with the rear wheel
・ Do not use any brake fluid container that cylinder that is the farthest from the master
contains petroleum components or that is wet cylinder.
with water.
Note：
Note：・ The air removal work is necessary to remove
・ If water mixes in the brake fluid, its boiling the air when the air enters the oil pressure
point decreases. system.
・ Put a cover on every container to prevent ・ In a condition where the brake fluid level has
contaminations. dropped or when the air entered the fluid after
Caution： removing the brake pipe from the master
・ Refill the fluid in the reservoir tank when the brakes at 4 locations.
engine is cold.
・ When the brake pipe is removed at 1 brake, air
・ Be careful never to spill the brake fluid on the removal is needed for the corresponding wheel
painted surfaces because the fluid will damage cylinder and caliper.
the paint.
・ When the piping between the master cylinder
・ Refill the fluid in the reservoir tank to the MAX and one of the brakes is removed, air removal
mark to prevent air from mixing in. is needed for the brake system operating with
・ Be careful for the fluid not to overflow. the removed pipe.
・ Clean the reservoir tank before removing the 1. Apply the parking brake.
Note：
Note：
・ Pull the parking brake lever to a full extent.
reservoir tank as necessary. 2. Start the engine.
・ Use the brake fluid DOT3. Caution：
・ Brake fluid leakage ・ Be careful not to conduct the air removal work
・ With the engine idling, set the shift lever to with the engine stopped. Doing so will damage
neutral, and continue depressing the brake the vacuum booster.
pedal with a constant amount of pressure. 3. Remove the cap from the reservoir tank.
system. Note：
・ Visually check for oil leakage. ・ The brake fluid tank is shared with the clutch
・ Air removal from the oil pressure system fluid tank.
・ Air entering the brake pipe will cause an ・ As the amount of the fluid is different between
insufficient brake operation. the brake compartment and clutch
compartment depending on the partition inside

the tank, check the amount of brake fluid in the
brake compartment.
Caution：
・ During the air removal work, keep filling the
・ Be sure to refill new brake fluid.
1. Rear brake pipe

2. Front brake pipe
Note：
necessary.
1. MAX level
Note：
2. MIN level
3. Brake fluid compartment ・ Slowly depress the brake pedal once and hold
it down.
Note：・ Use a finger to completely plug the outlet of
・ When installing/removing or replacing the the master cylinder that is removed from the
master cylinder, follow the procedures brake pipe, and slowly release the brake
described below. First, remove air from the pedal.
master cylinder, and then, remove air from ・ Remove the finger from the outlet after the
every wheel cylinder and caliper. brake pedal has been completely returned.
・ Air removal from the brake master cylinder ・ Repeat the process mentioned above until the
5. Disconnect the brake pipe from the brake master brake fluid comes out overflowing from the
cylinder. outlet.
Caution：
level indication.
7. Connect the brake pipe to the brake master cylinder.
Note：
it down.
・ Loosen the rear brake pipe.
the brake pedal.
・ Repeat steps 5 to 7 mentioned above until air Note：

does not come out form the outlet when the ・ Connect a transparent tube to the bleeder
brake pipe is loosened. screw and put the other end of the tube into a
Caution：
fluid.
the paint.
Note：
front brake pipe.

Note：
speed of once per second and hold it down.
1. Rear brake pipe

2. Front brake pipe
Note：
・ Air removal from the caliper
Note：
・ Remove air from each wheel in the following
order.
that air has entered the master cylinder. 1. Brake pedal
from the master cylinder. Note：
・ Apply an appropriate wrench to the bleeder ・ Loosen the bleeder screw until the brake fluid
screw. flows in the tube.
9. Connect the tube to the bleeder screw. ・ Loosen the bleeder screw.
removed.
・ Repeat the air removal procedures at least 10 Tightening torque： 118 N・m { 12.0 kgf・m / 87.0 lb・
times for the front wheel and at least 15 times ft }
for the rear wheel.
Caution：
Note：
repeated.
Note：
Note：
Caution：
Note：
Caution：
objects from entering.
14. Disc wheel installation
1. Install the disc wheel to vehicle.
Note：
・ Install the wheel nuts in the numbered order.
Rear brake drum
disassembly
2. Brake drum removal
1. Remove the brake drum from the brake assembly.
3. Adjust lever spring removal
1. Remove the adjust lever spring from the adjust lever.
2. Remove the adjust lever spring from the parking
lever.
4. Adjust lever removal
1. Remove the adjust lever from the brake shoe.
5. Shoe holder pin removal
1. Remove the shoe holding spring from the shoe 1. Lower spring
holder pin.
Note： 7. Adjuster assembly removal
・ Push the spring toward the brake shoe and 1. Remove the adjuster assembly from the brake shoe.
hold it. 8. Brake shoe assembly removal
・ Turn the spring to remove it from the shoe
1. Remove the brake shoe assembly from the back
holder pin.
plate.
9. Parking lever removal
1. Remove the parking lever from the brake shoe.
1. Disconnect the brake pipe from the wheel cylinder
assembly.
11. Rear wheel cylinder assembly removal
1. Remove the wheel cylinder assembly from the back
plate.
2. Remove the brake pipe from the wheel cylinder
assembly.
12. Cover removal
1. Remove the cover from the back plate.
13. Rear wheel cylinder assembly disassembly
2. Remove the shoe holder pin from the brake shoe. 1. Remove the piston assembly from the cylinder body.
6. Spring removal 2. Remove the piston cup from the piston.
1. Remove the spring from the brake shoe. 3. Remove the boot from the piston.
Note： 4. Remove the return spring from the cylinder body.
・ Remove the lower side spring.
5. Remove the cap from the bleeder screw.
・ Slide the brake shoe and the lower side spring
toward the ground. 6. Remove the bleeder screw from the cylinder body.
inspection Note：
・ In cleaning the wheel cylinder parts, make
1. Rear brake drum inspection sure to use clean brake fluid.
1. Inspect the brake assembly. Caution：
Note：・ Do not use cleaning agents consisting of
・ If any worn, damage, or other abnormalities mineral oil components such as gasoline,
are found during the inspection, make repairs kerosene, acetone, thinner, carbon
or replace the parts. tetrachloride, etc.
・ Inspect the following parts for worn, corrosion,
scuffs, scratches, rust, deterioration or other
abnormalities.
・ Brake drum
・ Back plate
・ Brake lining
・ Wheel cylinder body
・ Piston
・ Piston cup
・ Return spring
2. Brake shoe assembly inspection
1. Inspect the brake shoe assembly.
Note：
・ Thickness
Specificati 1. Inspect the piston cup.
ons
Note：
： 4.3 mm { 0.169 ： 1.0 mm { 0.039
2WD ・ Inspect it for worn, bent, degradation, fatigue,
in } in }
or other abnormalities.
： 4.6 mm { 0.181 ： 1.0 mm { 0.039
4WD
in } in }
4. Brake drum inspection
1. Standard value 1. Inspect the brake drum.

2. Limit Note：
3. Rear wheel cylinder assembly inspection ・ Measure the inner diameter of the drum.
Specificati
ons
2WD high
ride ： 295.0 mm ： 296.5 mm
suspension { 11.614 in } { 11.673 in }
and 4WD
Except for
2WD high
： 254.0 mm ： 255.5 mm
ride
{ 10.000 in } { 10.059 in }
suspension
models
Note：
・ Measure the fluctuation of the drum.
Specificati
ons
2WD high
ride
suspension
and 4WD
： 0.08 mm ： 0.15 mm
Except for { 0.0031 in } { 0.0059 in }
2WD high
ride
suspension
models
reassembly
1. Rear wheel cylinder assembly reassembly
Note：
・ Clean the disassembled parts with clean brake
fluid.
・ Use air to clean the port.
・ Inspect the part surface for dust and foreign
objects after disassembly and before
assembly.
Caution：
・ Be sure to replace the specified part with a
new one.
1. Install the piston cup to the piston.
Note：
・ Apply brake fluid to the inside of the piston. 1. Piston cup
・ Install the cup to the piston so that the opening 2. Boot
side of the cup faces the inside of the piston.
4. Install the bleeder screw to the cylinder body.
Caution：
・ Make sure to use a new one and do not mix up 53 to 71 lb・in }
the cup orientation.
5. Install the cap to the bleeder screw.

2. Install the return spring to the cylinder body.
2. Cover installation
3. Install the boot to the piston.
1. Install the cover to the back plate.
Note：
3. Rear wheel cylinder assembly installation
・ Apply brake fluid to the inside of the boot.
・ Apply rubber grease to the boot as illustrated 1. Install the wheel cylinder assembly to the back plate.
in the diagram. Tightening torque： 14 to 18 N・m { 1.4 to 1.8 kgf・m /
Caution： 10 to 13 lb・ft }
・ Make sure to use a new boot.
4. Brake pipe connect 1. Back plate sliding section

2. Brake shoe fitting section
1. Connect the brake pipe to the wheel cylinder
assembly. Caution：
Tightening torque： 13 to 19 N・m { 1.3 to 1.9 kgf・m / ・ Always use a new shoe holder pin and spring.
10 to 14 lb・ft } ・ Be careful not to damage the wheel cylinder
dust cover.
・ Be careful for the wheel cylinder piston not to
bounce off.
6. Parking lever installation
1. Install the parking lever to the brake shoe.
Note：
・ Install the parking lever, washer, and retainer
to the brake shoe on the leading side.
・ Apply grease to the sliding surface of the
parking lever.
Caution：
・ Always use a new washer and retainer.
5. Brake shoe assembly installation

1. Install the brake shoe assembly to the back plate.
Note：
・ Apply grease to the brake shoe fitting section
and the back plate sliding section.
7. Adjust lever spring installation 2. Brake shoe installation portion
3. Brake shoe installation portion
1. Install the adjust lever spring to the parking lever.
4. Adjuster rod
2. Install the adjust lever spring to the adjust lever. 5. Adjuster bolt
8. Spring installation 2. Install the spring to the adjuster assembly.
1. Install the spring to the brake shoe. 3. Install the adjuster assembly to the brake shoe.
9. Adjuster assembly installation 10. Adjust lever installation
Note： 1. Install the adjust lever to the brake shoe.
・ Clean the adjuster bolt and adjuster rod.
Note：
1. Apply the grease to the adjuster assembly. ・ Apply grease to the sliding section of the
Note： adjust lever.
・ Apply grease to the threaded portion of the ・ Install the adjust lever and ring to the brake
adjuster bolt. shoe on the trailing side.
・ Install the adjuster rod to the adjuster bolt. Caution：
・ Apply grease on the brake shoe installation ・ Always use a new ring.
portion.
11. Shoe holder pin installation
1. Install the shoe holder pin to the brake shoe.
2. Install the spring to the shoe holder pin.
12. Brake drum installation

1. Install the brake drum to the brake assembly.
Note：
・ If the wheel cylinder is removed, bleeding air
from the brake system is needed.
・ Depress the brake pedal 10 times to confirm
that there is no variation in strokes.
・ Adjust the lining gap.
Note：
1. Adjuster rod
Caution：・ Be sure to engage the parking brake during
・ Use only the specified brake fluid. the air removal work.
・ Do not use any brake fluid that contains Caution：
petroleum components.
Note： started to protect damage to the push rod seal,
・ Doing so may cause expansion or distortion of and secure adequate ventilation.
the rubber parts in the hydraulic brake system. ・ Maintain the fluid in the reservoir tank at the
Caution：
work.
with water.
cylinder.
Note：
Note：
point decreases.
・ Put a cover on every container to prevent system.
contaminations.
Caution： dropped or when the air entered the fluid after
・ Refill the fluid in the reservoir tank when the removing the brake pipe from the master
engine is cold. cylinder, air removal may be needed for all
painted surfaces because the fluid will damage ・ When the brake pipe is removed at 1 brake, air
the paint. removal is needed for the corresponding wheel
mark to prevent air from mixing in. ・ When the piping between the master cylinder
and one of the brakes is removed, air removal
・ Be careful for the fluid not to overflow.
is needed for the brake system operating with
・ Clean the reservoir tank before removing the the removed pipe.
1. Apply the parking brake.
Note：
Note：
reservoir tank as necessary. ・ Pull the parking brake lever to a full extent.
・ Use the brake fluid DOT3. 2. Start the engine.
・ Brake fluid leakage Caution：
・ With the engine idling, set the shift lever to ・ Be careful not to conduct the air removal work
neutral, and continue depressing the brake with the engine stopped. Doing so will damage
pedal with a constant amount of pressure. the vacuum booster.
system. 4. Replenish the reservoir tank with the brake fluid.
・ Visually check for oil leakage. Note：
・ Air removal from the oil pressure system ・ The brake fluid tank is shared with the clutch
・ Air entering the brake pipe will cause an fluid tank.
insufficient brake operation. ・ As the amount of the fluid is different between
・ In the case of using the brake in a condition the brake compartment and clutch
where the fluid level in the reservoir tank is compartment depending on the partition inside
extremely low, or removing the brake pipe, the tank, check the amount of brake fluid in the
conduct air removal. brake compartment.
・ The air removal work requires cooperation Caution：
between 2 operators.
・ During the air removal work, keep filling the
・ Be sure to refill new brake fluid. Note：

・ When refilling the fluid, be careful for the air ・ Remove the rear brake pipe.
not to enter the fluid. ・ Inspect the fluid level and refill the fluid as
necessary.
Note：
it down.
・ Use a finger to completely plug the outlet of
pedal.
・ Remove the finger from the outlet after the
brake fluid comes out overflowing from the
outlet.
1. MAX level Caution：
2. MIN level ・ Be careful that the fluid level in the reservoir
3. Brake fluid compartment tank does not drop below the intermediate
Note： level indication.
・ When installing/removing or replacing the 7. Connect the brake pipe to the brake master cylinder.
master cylinder, follow the procedures Note：
described below. First, remove air from the
master cylinder, and then, remove air from
every wheel cylinder and caliper. ・ Slowly depress the brake pedal once and hold
it down.
・ Air removal from the brake master cylinder
cylinder.
the brake pedal.
Caution：
the paint.
Note：
front brake pipe.
1. Rear brake pipe

2. Front brake pipe
1. Rear brake pipe 10. Operate the brake pedal.

2. Front brake pipe
Note：
Note：・ Slowly depress the brake pedal 3 times with a
・ Air removal from the caliper speed of once per second and hold it down.

Note：
order.
from the master cylinder.
・ Apply an appropriate wrench to the bleeder
screw.
9. Connect the tube to the bleeder screw.
1. Brake pedal
Note：
・ Connect a transparent tube to the bleeder Note：
screw and put the other end of the tube into a ・ Loosen the bleeder screw until the brake fluid
transparent container containing the brake flows in the tube.
fluid. ・ Loosen the bleeder screw.
removed.
for the rear wheel.
Caution：
Note：
repeated.
Note：
15. Brake drum adjustment
Note：
Note：
・ All brakes are adjusted automatically.
damage, cracks, or dents. ・ The brakes are adjusted automatically by
repeatedly depressing the brake pedal.
necessary repair or replacement. ・ After depressing and then releasing the pedal,
a click is heard from the auto adjuster of the
Caution： rear brake.
・ Pay attention to all joint sections of pipes and ・ After overhauling the rear brake assembly,
hoses, which are vulnerable to damage. conduct adjustment by following the
・ Be careful not to extremely twist or bend the procedures below.
1. Release the parking brake lever.
axles, suspensions, etc. Note：
Note：・ Move it to the complete releasing position.
・ Conduct leakage inspections with the brake 2. Loosen the adjust nut using a wrench.
pedal fully depressed. Note：
Caution：・ Loosen the adjust nut and lock nut.
・ If leakage is found around the joint section, 3. Operate the brake pedal.
・ Be sure to implement these procedures when Note：
installing the brake pipe. ・ Repeat the depressing and releasing operation
・ After removing the pipe and hose, cover the of the brake pedal until the click of the auto
opening with a plug or tape to prevent foreign adjuster is not heard.
objects from entering. ・ If the gap between the brake drum inner
diameter and brake shoe is adjusted so that
14. Disc wheel installation the gap value is unknown, the number of times
1. Install the disc wheel to vehicle. of depressing the brake pedal can be reduced.
Note： 4. Remove the brake drum from the brake assembly.
・ Install the wheel nuts in the numbered order. Note：
Tightening torque： 118 N・m { 12.0 kgf・m / 87.0 lb・・ Measure the gap between the brake drum and
ft } brake shoe.
Lining clearance： 0.25 to 0.40 mm { 0.0098 to 0.0157
in }
Note：
・ If the value does not fall in this range, check
the auto adjuster.
5. Adjust the parking brake lever.
Note：
・ Turn the adjust nut so that the parking brake
lever is pulled up 6 to 9 notches when the
lever is pulled up with the force of 294 N {30
kg/66 lb}.
・ Tighten the lock nut.
Caution：
・ Be careful for the brake not to drag.
Brake pedal
removal
1. Pedal pad removal
1. Remove the pedal pad from the brake pedal.
2. Pedal stopper removal
1. Remove the pedal stopper from the brake pedal.
3. Brake pedal removal
1. Remove the brake pedal from the brake booster
assembly.
Note：
・ Remove the stoplight switch.
・ Remove the snap pin from the brake pedal.
1. Stoplight switch
2. Pedal stopper
3. Brake pedal
4. Pedal pad
5. Snap pin
installation ： 177 to 189 mm

M/T
Pedal { 6.97 to 7.44 in }
1. Brake pedal installation height ： 180 to 192 mm
A/T
1. Install the brake pedal to the brake booster assembly. { 7.09 to 7.56 in }
Note：
・ Install the snap pin to the brake pedal.
・ Install the stoplight switch to the brake pedal.
1. Lock nut
2. Pedal free play
3. Pedal height
1. Stoplight switch Note：

2. Pedal stopper ・ Measure the pedal play after stopping the
3. Brake pedal engine and depressing the brake pedal 5 times
4. Pedal pad or more.
5. Snap pin ・ Adjust the brake pedal if the measured value
2. Pedal stopper installation falls outside the previously mentioned range.
1. Install the pedal stopper to the brake pedal. 1. Adjust the brake pedal.
3. Pedal pad installation 2. Remove the stoplight switch from the brake pedal
bracket.
1. Install the pedal pad to the brake pedal.
3. Loosen the lock nut using a wrench.
4. Brake pedal adjustment
Note：
Note：・ Loosen the push rod lock nut.
・ The push rod functions as the pedal stopper
when the pedal is fully depressed. 4. Turn the push rod.
・ Adjust the brake pedal height according to the Note：
following procedures. ・ Turn the push rod until the brake pedal
・ Measure the brake pedal height. reaches the specified height.
・ Confirm that the brake pedal has returned ・ Tighten the lock nut.
completely by observing the condition of the Tightening torque： 15 to 25 N・m { 1.5 to 2.5 kgf・m }
brake return spring.
5. Install the stoplight switch to the brake pedal
・ Measure the pedal height after starting the
bracket.
engine and depressing the accelerator pedal
several times. Caution：
Pedal free ・ The pedal height must be 45 mm {1.77 in} or
： 6 to 10 mm { 0.24 to 0.39 in } more when the pedal is depressed with a force
play
of about 490 N {50 kg/110 lb}.
Note：
・ Procedures to connect the booster rod clevis
attached with the pedal arm and to adjust the
pedal switch
・ Connect the booster rod clevis to the pedal
arm, and adjust the pedal switch installed to
the pedal bracket according to the following
procedure.
・ Set the clevis holes of the booster and master
cylinder rod to the holes in the pedal arm.
・ Insert the push rod pin from the left side of the
pedal.
・ Secure the push rod pin with the snap pin at
the right side of the pedal.
・ Turn the switch counterclockwise to release
the lock.
・ Pull the pedal arm toward the near side slightly
to prevent the pedal arm from being pushed in.
・ Hold the pedal arm with one hand and push
the whole switch in with the other hand until
the switch itself hits the pedal arm rubber after
the switch plunger is pushed.
・ Turn the switch clockwise until a click is heard
to lock the switch.
・ The switch gap is adjusted to 0.2 - 1.2 mm
{0.008 - 0.048 in}.
Disc brake pad
removal
2. Disc brake pad removal
1. Remove the lock bolt from the brake caliper
assembly.
Caution：
・ When replacing the disc brake pad, do not
remove the brake hose from the caliper.
2. Remove the disc brake pad from the brake support.

Note：
・ Remove it with the shim attached.
・ Put an alignment mark in the pad position as a
guide for installation.
Note：
・ Turn the brake caliper facing upward.
・ Remove the brake caliper from the brake
support and hold it up toward the upper link or
the frame.
Caution：
・ While the caliper is removed from the brake
support, never depress the brake pedal to
avoid the piston abruptly bouncing out.
3. Remove the clip from the brake support.

Note：
・ Dispose of the used pad clip and use a new
one.
Note：
・ When the pad friction indicator makes a
scratchy sound or the pad is worn to 1.8 mm
{0.071 in} or less from the shoe table, replace
the pad.
Caution：
・ When replacing, replace all of the 4 pads.
4. Guide pin inspection
1. Inspect the guide pin.
2. Inspect the lock pin.
Note：
・ Inspect it for sticking, worn, bending,
degradation, corrosion, abrasion, scratches, or
other abnormalities.
・ If there are abnormalities, make repairs or
1. Pad clip replace the parts.
2. Inner pad
3. Shim
4. Indicator
5. Outer pad
Note：
・ Completely remove old grease remaining
between the clip and brake support.
3. Disc brake pad inspection
1. Inspect the disc brake pad.
Note：
・ Measure the thickness of the disc brake pad.
Standard： 10.0 mm { 0.394 in }
Limit： 1.5 mm { 0.059 in }
1. Support bracket
2. Slide pin boot
3. Slide pin (guide pin）
4. Lock bolt
5. Pad clip
6. Slide pin (lock pin）
installation 2. 5.0 mm (0.20 in)

3. Section to which grease is applied
1. Disc brake pad installation 4. 5.0 mm (0.20 in)
1. Install the clip to the brake support. 5. 5.0 mm (0.20 in)
Note： Note：
・ When replacing the pad, dispose of the used ・ Install the pad assembly attached with the
clip and use a new one. shim to the brake support.
Caution：・ Align the inner pad indicator with the lower
side.
clip. ・ Align the outer pad indicator with the upper
side.
・ After assembling the pad, if grease is found
protruding again, wipe it off.
1. Lower side clip

2. Upper side clip
3. Clamp
1. Shim
2. Install the disc brake pad to the brake support. 2. Outer pad
Note： 3. Inner pad
4. Indicator
・ Apply grease to the disc brake pad.
Note：
・ Lower the brake caliper to the original position.
Caution：
・ Do not damage the brake hose by twisting or
pulling it.
1. 10.3 mm (0.41 in)

Caution： 3. Install the lock bolt to the brake caliper assembly.

・ Confirm that the dust boot does not protrude Tightening torque： 32 to 42 N・m { 3.3 to 4.3 kgf・m /
from the piston end, and then lower the 24 to 31 lb・ft }
caliper.
・ Be careful for the dust boot not to be caught
between the piston and pad.

Note：
Tightening torque： 118 N・m { 12.0 kgf・m / 87.0 lb・
ft }
Supplementary Information
1. Component Views Note：
1. Brake flexible hose 6. Slide pin, lock pin, guide pin

2. Lock bolt 7. Boot
3. Caliper assembly 8. Brake support
4. Pad assembly with shim
5. Pad clip
Note：
・ Caliper assembly
1. Caliper body 5. Bleeder screw

2. Ring seal 6. Cap
3. Dust seal
4. Piston
Note：
・ Rear drum brake
1. Cover 14. Lower spring

2. Shoe holder pin 15. Adjust lever spring
3. Wheel cylinder bolt 16. Leading shoe
4. Wheel cylinder assembly 17. Back plate
5. Pin 18. Bleeder cap
6. Trailing shoe 19. Bleeder screw
7. Spring 20. Return spring
8. Adjuster assembly 21. Piston cup
9. Lever washer 22. Piston assembly
10. Retainer 23. Piston boot
11. Parking lever 24. Adjust lever
12. Upper spring
13. Adjust lever ring
Note：
・ Brake pedal
1. Stoplight switch 4. Pedal pad

2. Stopper 5. Snap pin
3. Brake pedal assembly
Note：
・ Brake master cylinder
1. Brake pipe 3. Master cylinder assembly

2. Nut
1. Cap 4. Master cylinder

2. Diaphragm
3. Filter
Note：
・ Brake booster assembly
1. Brake booster fixing nut 6. Vacuum hose

2. Spacer 7. Master cylinder assembly
3. Gasket 8. Master cylinder fixing nut
4. Joint pin 9. Brake pipe
5. Brake booster assembly
Note：
・ Blend proportioning valve
1. Blend proportioning valve
2. Tightening Torque Views Note：

1： 9 to 13 N・m { 0.9 to 1.3 kgf・m / 80 to 115 lb・ Note：

in } ・ Rear drum brake
2： 32 to 42 N・m { 3.3 to 4.3 kgf・m / 24 to 31 lb・ft }
1： 14 to 18 N・m { 1.4 to 1.8 kgf・m / 10 to 13 lb・ft } Note：

2： 6 to 8 N・m { 0.6 to 0.8 kgf・m / 53 to 71 lb・in } ・ Brake master cylinder
1： 33 N・m { 3.4 kgf・m / 24 lb・ft } Note：

2： 15 to 25 N・m { 1.5 to 2.5 kgf・m / 11 to 18 lb・ft } ・ Blend proportioning valve
3： 21 N・m { 2.1 kgf・m / 15 lb・ft }

4： 10 to 16 N・m { 1.0 to 1.6 kgf・m / 89 to 142 lb・
in }

2： 8 N・m { 0.8 kgf・m / 71 lb・in }
3： 20 N・m { 2.0 kgf・m / 15 lb・ft }
Parking Brake System (All models) 4C-1
Brakes
Parking Brake System
(All models)
Table of Contents
Parking brake lever assembly..........................................4C-2
removal.......................................................................4C-2
installation...................................................................4C-3
Parking brake cable.........................................................4C-6
removal.......................................................................4C-6
inspection....................................................................4C-8
installation...................................................................4C-9
Supplementary Information...........................................4C-12
4C-2 Parking Brake System (All models)
Parking brake lever assembly
removal 1. Disconnect the parking brake cable from the parking

brake lever assembly.
1. Console box removal
Note：
Note：・ Disconnect the parking brake cable T-end from
・ Below is for the center console type manual the equalizer.
transmission.
1. Remove the shift lever knob from the shift lever.
Note：
・ Below is for the center console type.
2. Remove the shift console cover from the console
box.
Note：
・ Disconnect the cigarette lighter connector.
・ Below is for the 2WD center console type.
3. Remove the cover from the console box.
Note：
4. Remove the 4WD switch from the console box.
Note：
・ Below is for the center console type. 1. Parking brake lever assembly
2. Bolt
5. Remove the console box from the floor. 3. Equalizer
Note： 4. T-end
5. Parking brake cable
・ Remove the 3 clips. 6. Adjust nut
・ Open the console box cover and remove 2 7. Parking brake switch
screws. 8. Screw
・ Remove the control box backward.
4. Parking brake lever assembly removal
・ Below except for the center console type.
1. Remove the parking brake lever assembly from the
6. Remove the console cover from the instrument
floor.
panel.
Note：
・ Remove the 2 clips.
7. Remove the cup holder cover from the floor.
8. Remove the bracket from the floor.
2. Parking brake switch removal
1. Loosen the adjust nut using a wrench.
2. Remove the screw from the parking brake lever
assembly.
3. Remove the parking brake switch from the parking
brake lever assembly.
3. Parking brake cable disconnect
installation 4. Console box installation

Note：
1. Parking brake lever assembly installation
1. Install the parking brake lever assembly to the floor.
1. Install the console box to the floor.
Note：
Note：
・ Tighten the parking brake lever assembly
fixing bolt to the specified torque. ・ Install the 3 clips.
・ Open the console box cover and install 2
screws.
Note：・ Below is for the 2WD center console type.
・ Tighten the adjust nut so that the T-end of the
2. Install the cover to the console box.
parking brake cable aligns with the equalizer.
Note：
2. Parking brake cable connect
1. Apply the grease to the parking brake cable.
3. Install the 4WD switch to the console box.
Note：
Note：
・ Apply grease to the connection portion of the
parking brake cable T-end and the equalizer. ・ Below is for the center console type.
2. Connect the parking brake cable to the parking brake 4. Install the shift console cover to the console box.
lever assembly. Note：
Note：・ Connect the cigarette lighter connector.
・ Connect the parking brake cable T-end to the ・ Below is for the center console type manual
equalizer. transmission.
3. Parking brake switch installation 5. Install the shift lever knob to the shift lever.
1. Install the parking brake switch to the parking brake Note：
lever assembly. ・ Below except for the center console type.
6. Install the bracket to the floor.
7. Install the cup holder cover to the bracket.
8. Install the console cover to the instrument panel.
Note：
・ Connect the cigarette lighter connector.
・ Install the 2 clips.
5. Parking brake lever assembly adjustment
Note：
・ The brakes are adjusted automatically by
・ After depressing and releasing the pedal, a
click is heard from the auto adjuster of the rear
brake.
1. Parking brake assembly ・ After overhauling the rear brake assembly or
2. Bolt replacing the parking brake cable, conduct
3. Equalizer adjustment according to the following
4. T-end procedures.
5. Parking brake cable ・ When the parking brake cable is removed and
6. Adjust screw installed but not replaced, follow step 5.
7. Parking brake switch
8. Screw 1. Release the parking brake lever.
Note：
・ Move it to the complete releasing position.
Note：
・ Loosen the adjust nut and lock nut.
Note：
・ Repeatedly depress and release the brake
pedal until the click of the auto adjuster is not
heard.
・ If the gap between the brake drum inner
diameter and brake shoe is adjusted so that it
becomes 0.5 mm {0.020 in}, the number of
times of depressing the brake pedal can be
reduced.
4. Remove the brake drum from the brake assembly. 1. Adjust bolt
2. Adjust nut
Note： 3. Spacer
・ Measure the gap between the brake drum and 4. Parking brake cable
brake shoe.
Note：
： 0.4 mm { 0.016 in }
・ The following applies to the bench seat type.
Note：
・ If it does not fall within the range, readjust the
gap.
・ After adjusting the lining gap, adjust the
parking brake lever.
Note：
・ Turn the adjust nut to adjust so that the
parking brake lever is pulled up 6 to 9 notches
when the lever is pulled up with a force of 294
N {30 kg/66 lb}.
Caution：
・ Make sure the brake does not drag.
Note：
・ The following applies to the tray console type.
・ Remove the tray console to adjust.
1. Tray console
Note：
・ The following applies to the full cover control
type.
・ Remove the ash tray to adjust.
1. Ash tray
Parking brake cable
removal
3. Shoe holder pin removal
1. Remove the shoe holding spring from the shoe
holder pin.
Note：
・ Push the spring toward the brake shoe and
hold it.
holder pin.
1. Lower spring
5. Brake shoe assembly removal

1. Remove the brake shoe assembly from the back
plate.
lever.
7. Parking brake cable removal
1. Remove the parking brake cable from the back plate.
Note：
・ Press the lock protrusion of the cable with a 12
mm hexagonal offset box wrench and remove
2. Remove the shoe holder pin from the brake shoe. the parking brake outer cable.
・ Remove the parking brake inner cable from
4. Spring removal the parking lever.
1. Remove the spring from the brake shoe. ・ Remove the parking brake cable bolt and nut.
Note： Caution：
・ Remove the lower side spring. ・ Do not twist or bend the cable.
・ Slide the brake shoe and the lower side spring ・ Be careful for damage to the cable, which will
toward the ground. cause insufficient operation.
1. 12 mm hexagonal offset box wrench
2. Remove the parking brake cable bracket from the

leaf spring.
Note：
・ Remove the nuts that are holding the cable in
place.
3. Remove the parking brake cable from the parking
brake lever.
Note：
・ Remove the T-end of the parking brake cable
from the equalizer of the front parking brake
cable.
inspection
1. Brake shoe assembly inspection
Note：
・ Check the brake shoe assembly for worn.
・ If the lining thickness is below the limit value,
replace the brake shoe assembly.
Limit： 1.0 mm { 0.039 in }
installation
1. Parking brake cable installation
1. Apply the grease to the parking brake cable.
Note：
・ Apply multi-purpose grease to the connection
portion of the T-end of the parking brake cable
and the equalizer.
2. Install the parking brake cable to the back plate.
Note：
・ Install the inner cable to the back plate hole.
Then install the case cap of the outer cable to
the back plate.
・ Install the inner cable end to the parking brake
lever.
・ The following applies to 4x2 (except for high 1. Back plate sliding section
ride suspension). 2. Brake shoe fitting section
3. Install the parking brake cable to the bracket.
Caution：
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } ・ Always use a new shoe holder pin and spring.
Nut
・ Be careful not to damage the wheel cylinder
Note： dust cover.
・ The following applies to the 4x2 (high ride ・ Be careful for the wheel cylinder piston not to
suspension), 4x4. bounce off.
4. Install the parking brake cable to the bracket. 4. Spring installation
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Install the spring to the brake shoe.
Bolt
5. Install the parking brake cable to the parking brake
lever.
Note：
・ Install the T-end of the parking brake cable to
the equalizer of the front parking brake cable.
・ Install the retainer of the parking brake cable
with a nut.
6. Install the parking brake cable bracket to the frame.
Tightening torque： 6.5 N・m { 0.66 kgf・m / 58 lb・
in } Bolt
2. Adjust lever spring installation
2. Install the adjust lever spring to the adjust lever.
3. Brake shoe assembly installation
1. Install the brake shoe assembly to the back plate.
Note： 6. Brake drum installation
・ Apply grease to the brake shoe fitting section
and the back plate sliding section.
Note： Note：
・ If the wheel cylinder is removed, bleeding air ・ Loosen the adjust nut and lock nut.
from the brake system is needed.
・ Depress the brake pedal 10 times to confirm
that there is no variation in strokes. Note：
・ Adjust the lining gap. ・ Repeatedly depress and release the brake
pedal until the click of the auto adjuster is not
7. Disc wheel installation heard.
1. Install the disc wheel to vehicle. ・ If the gap between the brake drum inner
diameter and brake shoe is adjusted so that it
Note：
becomes 0.5 mm {0.020 in}, the number of
・ Install the wheel nuts in the numbered order. times of depressing the brake pedal can be
Tightening torque： 118 N・m { 12.0 kgf・m / 87.0 lb・ reduced.
ft } 4. Remove the brake drum from the brake assembly.
Note：
・ Measure the gap between the brake drum and
brake shoe.
： 0.4 mm { 0.016 in }
Note：
・ If it does not fall within the range, readjust the
gap.
・ After adjusting the lining gap, adjust the
parking brake lever.
Note：
・ Turn the adjust nut to adjust so that the
parking brake lever is pulled up 6 to 9 notches
when the lever is pulled up with a force of 294
N {30 kg/66 lb}.
8. Parking brake lever assembly adjustment
Caution：
Note：・ Make sure the brake does not drag.
・ The brakes are adjusted automatically by
・ After depressing and releasing the pedal, a
click is heard from the auto adjuster of the rear
brake.
・ After overhauling the rear brake assembly or
replacing the parking brake cable, conduct
adjustment according to the following
procedures.
・ When the parking brake cable is removed and
installed but not replaced, follow step 5.
1. Release the parking brake lever.
Note：
1. Adjust bolt
2. Adjust nut
3. Spacer
4. Parking brake cable
Note：
・ The following applies to the bench seat type.
1. Ash tray
Note：
・ The following applies to the tray console type.
・ Remove the tray console to adjust.
1. Tray console
Note：
・ The following applies to the full cover control
type.
・ Remove the ash tray to adjust.
・ Parking brake lever
1. Parking brake lever assembly 5. Adjust nut

2. Bolt 6. Parking brake switch
3. Equalizer
4. Front parking brake cable T-end
Note：
・ Parking brake cable
1. Equalizer 11. Spring

2. Parking brake cable T-end 12. Lever washer
3. Parking brake cable nut 13. Parking lever clip
4. Parking brake cable bolt 14. Parking lever
5. Parking brake cable 15. Parking lever clip
6. Parking brake cable bolt 16. Lower spring
7. Nut 17. Spring
8. Shoe holder pin 18. Adjust lever
9. Pin 19. Upper spring
10. Brake shoe

・ Parking brake lever
1： 1.5 N・m { 0.2 kgf・m / 13 lb・in } Note：

2： 15 N・m { 1.5 kgf・m / 11 lb・ft } ・ Parking brake cable, 4x2 (except for high ride
suspension)
1： 25 N・m { 2.5 kgf・m / 18 lb・ft } Note：

2： 6.5 N・m { 0.7 kgf・m / 58 lb・in } ・ Parking brake cable, 4x2 high ride suspension,
4x4
3： 10 N・m { 1.0 kgf・m / 89 lb・in }
1： 25 N・m { 2.5 kgf・m / 18 lb・ft }

2： 6.5 N・m { 0.7 kgf・m / 58 lb・in }
3： 25 N・m { 2.5 kgf・m / 18 lb・ft }
ABS (All models) 4D-1
Brakes
ABS
(All models)
Table of Contents
EHCU..............................................................................4D-2
removal.......................................................................4D-2
installation..................................................................4D-4
setting..........................................................................4D-8
Front sensor rotor (disc brake)........................................4D-9
removal.......................................................................4D-9
inspection..................................................................4D-11
installation................................................................4D-12
Front wheel speed sensor..............................................4D-17
removal.....................................................................4D-17
inspection..................................................................4D-19
installation................................................................4D-20
Rear wheel speed sensor...............................................4D-23
removal.....................................................................4D-23
inspection..................................................................4D-24
installation................................................................4D-25
Rear sensor rotor (drum brake).....................................4D-27
removal.....................................................................4D-27
inspection..................................................................4D-30
installation................................................................4D-31
Yaw rate sensor.............................................................4D-41
removal.....................................................................4D-41
installation................................................................4D-42
Steering angle sensor ....................................................4D-43
removal.....................................................................4D-43
installation................................................................4D-47
setting........................................................................4D-50
Supplementary Information..........................................4D-51
4D-2 ABS (All models)
EHCU
removal 2. Turn ON the ignition switch.

3. Select diagnosis.
1. EHCU safety information
4. Select the chassis.
Caution：
・ When welding the vehicle using an electrical 5. Select ABS/ESC.
arc welder, remove the EHCU from the 6. Select the programming.
vehicle.
7. Select Module Information.
・ When removing the EHCU from the vehicle,
disconnect the battery cable and connectors. Note：
・ Installation is the reverse order of the removal ・ Record the 8 digits of ESC Data File
procedure. Partnumber.
・ Do not install devices that emit powerful radio 8. Select Upload Vehicle Configuration Data.
waves such as wireless devices near the
EHCU. Note：
・ Keep water away from the EHCU. ・ Upload the vehicle data to a scan tool by
following the on-screen instructions.
・ Never loosen the screws of the EHCU.
・ Do not paint it. 3. EHCU disconnect
・ Do not allow metal objects such as 1. Disconnect the harness connector from the EHCU.
screwdrivers or tester probes directly contact 4. Brake pipe disconnect
the connector pins terminals.
・ Handle with due attention to static electricity. 1. Disconnect the brake pipe from the EHCU.
・ Do not directly apply external voltage to the Caution：
terminals. ・ After removing the brake pipe, cover the
・ Do not hold the pipe on the top of the EHCU opening with a plug or tape to prevent foreign
when handling it. objects from entering.
・ Never loosen the EHCU bolts and nuts. Note：
・ Should they be loosened, do not reuse the ・ Except for models with ABS/EBD/ESC
EHCU. ・ Loosen the 5 flare nuts to disconnect the brake
・ When replacing the EHCU, it is needed to pipe.
write the vehicle information to a new EHCU.
・ When replacing the EHCU, upload the data in
the EHCU before replacement to a scan tool,
and then remove the EHCU.
・ If communication cannot be made with a scan
tool, remove it with no change.
・ Use the same scan tool from the beginning to
the completion of a work for replacement. If a
scan tool is replaced during a work, correct
information cannot be written.
2. EHCU upload
Note：
・ The following applies to the models with the
ESC.
・ If the EHCU to be replaced is not able to
communicate with a scan tool, do not perform
this operation.
Note：
1. Connect a scan tool to the DLC. ・ The following applies to models with EHCU,
ABS/EBD/TCS/ESC.
・ Loosen the 6 flare nuts to disconnect the brake

pipe.
5. EHCU removal
1. Remove the EHCU from the frame.
Note：
・ Remove the 3 bracket-fixing bolts.
installation
Caution：
・ Make sure to use a ground bolt when installing
the ground connection.
・ Confirm that there is no dust or foreign
material when connecting the pipes.
・ Be careful not to confuse the pipe connection
destinations.
・ After installing the EHCU, bleed the brakes.
・ Use new brake fluid, and only of the specified
type.
・ When replacing the EHCU, it is needed to
2. EHCU installation
4. EHCU connect
1. Install the EHCU to the frame.
1. Connect the harness connector to the EHCU.
Tightening torque： 8 N・m { 0.8 kgf・m / 71 lb・in }
3. Brake pipe connect
Note：
1. Connect the brake pipe to the EHCU.
Caution：
Except for models with ABS/EBD/ESC
・ Use only the specified brake fluid.
・ Do not use any brake fluid that contains
petroleum components.
Note：
Caution：
with water.
Note：
point decreases.
contaminations.
Caution：
Models with ABS/EBD/TCS/ESC, wheel cylinder side
engine is cold.
Tightening torque： 20 N・m { 2.0 kgf・m / 15 lb・ft } ・ Be careful never to spill the brake fluid on the
Models with ABS/EBD/TCS/ESC, master cylinder side painted surfaces because the fluid will damage
the paint.
Note： Note：
・ Refill the brake fluid to the MAX mark of the ・ Pull the parking brake lever to a full extent.
Caution：
the vacuum booster.
・ If the pedal stroke gradually increases, there 3. Remove the cap from the reservoir tank.
may be fluid leakage in the oil pressure 4. Replenish the reservoir tank with the brake fluid.
system.
Note：
fluid tank.
・ In the case of using the brake in a condition compartment depending on the partition inside
where the fluid level in the reservoir tank is the tank, check the amount of brake fluid in the
extremely low, or removing the brake pipe, brake compartment.
Caution：
・ Be sure to engage the parking brake during
Caution：
work.
cylinder.
Note：
system.
brakes at 4 locations. 1. MAX level
・ When the brake pipe is removed at 1 brake, air 2. MIN level
removal is needed for the corresponding wheel 3. Brake fluid compartment
Note：
and one of the brakes is removed, air removal ・ When installing/removing or replacing the
is needed for the brake system operating with master cylinder, follow the procedures
the removed pipe. described below. First, remove air from the
1. Apply the parking brake. every wheel cylinder and caliper.
・ Air removal from the brake master cylinder ・ Slowly depress the brake pedal once and hold
it down.
cylinder. ・ Loosen the rear brake pipe.
the brake pedal.
Caution：
the paint.
Note：
front brake pipe.
1. Rear brake pipe

2. Front brake pipe
Note：
necessary.
Note：
it down. 1. Rear brake pipe
・ Use a finger to completely plug the outlet of 2. Front brake pipe
Note：
pedal. ・ Air removal from the caliper
・ Remove the finger from the outlet after the 8. Drain air from the brake caliper assembly.
Note：
brake fluid comes out overflowing from the
order.
outlet.
Caution：
level indication. ・ Right front caliper
7. Connect the brake pipe to the brake master cylinder.
Note：・ In this case, follow steps 5 to 7 to remove air
・ Connect the rear brake pipe. from the master cylinder.
・ Apply an appropriate wrench to the bleeder ・ Slowly return the brake pedal.
screw. ・ Repeat steps 9 and 10 until air is completely
9. Connect the tube to the bleeder screw. removed.
Note：
・ Connect a transparent tube to the bleeder for the rear wheel.
screw and put the other end of the tube into a
transparent container containing the brake Caution：
fluid. ・ After air removal of each wheel, be sure to
Note：
repeated.
Note：
Note：
Note： damage, cracks, or dents.
・ Slowly depress the brake pedal 3 times with a ・ If any abnormality is found, conduct a
speed of once per second and hold it down. necessary repair or replacement.
Caution：
Note：
Caution：
1. Brake pedal
Note： objects from entering.
flows in the tube.
setting 7. Select Download Vehicle Configuration Data.

Note：
・ Download the vehicle data to the EHCU by
Caution： following the on-screen instructions.
・ When replacing the EHCU, it is needed to
8. Select Module Information.
・ When replacing the EHCU, upload the data in Note：
the EHCU before replacement to a scan tool, ・ Confirm that the ESC Data File Partnumber
and then remove the EHCU. that was recorded before replacement of the
・ Use the same scan tool from the beginning to EHCU is downloaded.
the completion of a work for replacement. If a 9. Turn OFF the ignition switch.
scan tool is replaced during a work, correct
information cannot be written. Note：
・ Turn the ignition switch OFF for 30 seconds.
2. EHCU setting
4. EHCU setting 2nd
Note：
・ The following applies to the models with the
3. Select diagnosis. ESC.
4. Select the chassis. ・ If the EHCU to be replaced cannot
communicate with a scan tool, it is necessary
5. Select ABS/ESC.
to program the confirmed vehicle data.
6. Select the programming.
7. Select Program VIN.
Note：
・ Operate a scan tool to program the VIN to the
EHCU by following the on-screen instructions. 4. Select the chassis.
・ Input the vehicle number VIN indicated on the 5. Select ABS/ESC.
ID plate.
7. Select Vehicle Configuration Data Setting.
Note：
Note：
・ Turn the ignition switch OFF for 30 seconds.
・ Operate a scan tool to program the data to the
3. EHCU download EHCU by following the on-screen instructions.
Note： 8. Select Module Information.
・ The following applies to the models with the Note：
ESC.
・ Confirm that the programmed ESC Data File
・ If the EHCU to be replaced can communicate Partnumber is correct.
with a scan tool, download the vehicle data.
Caution：
Note：
・ Check the specification of the vehicle before
downloading. ・ Turn the ignition switch OFF for 30 seconds.

5. Select ABS/ESC.
Front sensor rotor (disc brake)
removal
2. Brake caliper assembly removal
1. Remove the brake caliper assembly from the
knuckle.
Note：
・ Remove 2 bolts from the knuckle arm rear
side.
・ Remove the brake caliper with the brake hose
attached together with the brake support.
Caution：
・ By using a wire, etc., fix and hold the brake
caliper to the frame, etc.
4. Hub nut removal
3. Hub cap removal
Note：
Note：
1. Remove the hub nut from the knuckle.
1. Remove the hub cap from the front hub.
Note：
Caution：
・ Remove the cotter pin and then remove the
・ Be careful not to cause scratches and
nut retainer and hub nut.
distortion to the hub tapered fitting portion
when removing the hub cap. ・ Remove the lock washer.
5. Flange removal
Note：
suspension, 4WD.
1. Remove the flange from the front hub.
Note：
・ Remove the snap ring and shim, and then
remove the flange from the front hub.
6. Lock washer removal
Note：
suspension, 4WD.
1. Remove the lock washer from the bearing lock nut.
7. Bearing lock nut removal
Note： Note：
・ The following applies to 2WD high ride ・ The following applies to 2WD high ride
suspension, 4WD. suspension, 4WD.
2. Remove the hub cap from the front hub. 1. Remove the bearing lock nut from the knuckle using
special tool.
1. Metal rod
2. Sensor rotor
2. Install the bolt to the front hub rotor assembly.

Note：
・ Install the disc-rotor-fixing bolt, and tighten it to
the specified torque.
Tightening torque： 103 N・m { 10.5 kgf・m / 76 lb・
8. Outer bearing removal ft }
Note：
1. Remove the outer bearing from the front hub rotor
assembly.
Note：
・ Remove the outer bearing inner race from the
front hub rotor assembly.
9. Front hub rotor assembly removal
1. Remove the front hub rotor assembly from the
knuckle.
2. Remove the bolt from the front hub rotor assembly.
Note：
・ Remove the 2 disc-rotor-fixing bolts on the
diagonal line.
10. Sensor rotor removal
1. Remove the sensor rotor from the front hub rotor
assembly.
Note：
・ Insert metal rods into the 2 bolt holes after
removing the bolts, and remove the sensor
rotor with a hammer, etc.
・ Dispose of the removed sensor rotor.
inspection
1. Sensor rotor inspection
Note：
・ Check the sensor rotor for damage or
powdered iron sticking to it.
・ Check the play of the sensor rotor.
・ Check the sensor rotor teeth for damage,
dents, etc.
・ If an abnormality is found, conduct adjustment,
repair, or replacement of the parts as
necessary.
installation ・ Conduct measurement at 4 points of every 90°

interval.
1. Sensor rotor installation
・ Confirm that the gap is within the specified
1. Install the sensor rotor to the front hub rotor range.
assembly using special tool.
Specifications Gap
Note：
2WD high ride ： 7.2 to 7.6 mm { 0.283
・ Use the sensor rotor installer and grip to install suspension and 4WD to 0.299 in }
the sensor rotor in the hub.
High ride suspension ： 7.0 to 7.4 mm { 0.276
Caution： models except for 2WD to 0.291 in }
・ Always use a new sensor rotor.
SST: 5-8840-2789-0 - sensor rotor installer
SST: 5-8840-0007-0 - grip

2. Front hub rotor assembly installation
Note：
1. Install the front hub rotor assembly to the knuckle.
Note：
・ Fill grease in the front hub and hub cap.
： 50 g { 1.76 oz } Hub, grease filling amount
： 20 g { 0.71 oz } Hub cap, grease filling amount
1. Front hub rotor assembly

2. Sensor rotor
3. Push
2. Measure the sensor rotor using the gauge.

Note：
・ Measure the gap.
1. Outer bearing
2. Inner bearing
3. Hub
4. Hub cap
Note：
suspension, 4WD.
2. Install the front hub rotor assembly to the knuckle. 1. Hub nut wrench
3. Outer bearing installation
5. Front hub rotor assembly adjustment
Note：
Note：
models except for 2WD. ・ The following applies to high ride suspension
1. Install the outer bearing to the front hub rotor
assembly. 1. Adjust the preload to a standard value.
Note： Note：
・ Install the outer bearing inner race into the ・ Adjust the preload for the front hub bearing.
front hub rotor assembly. ・ Tighten the spindle nut to the specified torque.
4. Bearing lock nut installation Tightening torque： 29 N・m { 3.0 kgf・m / 21 lb・ft }
Note： Note：
・ The following applies to 2WD high ride ・ Rotate the hub 2 or 3 turns and loosen the
suspension, 4WD. nuts so that they can be turned by fingers.
1. Install the bearing lock nut to the knuckle using ・ Fully tighten the nuts securely with fingers and
special tool. confirm that there is no play at the hub.
・ Pull one of the wheel pins with a spring scale
Note：
and measure the bearing preload.
・ Install the bearing lock nut with its slit surface
・ Tighten the spindle nut until the specified
facing to the outside.
bearing preload is obtained.
Reused bearing, new oil seal
Note： 6. Lock washer installation

・ Install the cotter pin to the retainer. Note：
・ Install the cotter pin to the nut retainer. ・ The following applies to 2WD high ride
Caution： suspension, 4WD.
・ Use a new cotter pin. 1. Install the lock washer to the bearing lock nut.
Note： Note：
・ The following applies to 2WD high ride ・ Install it in such a way that the side with the
suspension, 4WD. larger taper hole diameter faces the outside of
the vehicle.
2. Adjust the preload to a standard value.
・ If the lock washer screw hole does not align
Note： with the corresponding hole of the bearing lock
・ Adjust the preload for the front hub bearing. nut, turn the lock washer over.
・ After tightening the hub to the specified torque ・ If the hole positions still do not align, turn the
of the nut, fully loosen the nut. bearing lock nut to adjust the hole positions to
Tightening torque： 29 N・m { 3.0 kgf・m / 21 lb・ft } best alignment.
・ Tighten the lock washer installation screw
Note： securely so that the screw head is lower than
・ Hook a spring scale to the wheel pin, and the washer surface.
gently pull it in a tangent direction. Make
adjustments by tightening the hub nut until the
preload reaches the specified value.
Renewed bearing, new oil seal
Caution：
・ If the preload is unstable, rotate the hub
several times, stop the rotation completely and
carry out measurement again.
・ If it is still unstable, start over the procedure to
turn the front hub to the left and right by
several turns to stabilize the bearing for
installation.
7. Flange installation
Note：
suspension, 4WD.
1. Install the flange to the front hub.
Note：
・ Apply liquid gasket LOCTITE 515 or equivalent
to the flange installation surface and install the
flange to the hub.
・ Install the snap ring and shim.
2. Adjust the shim.
Note：
・ Adjust the clearance between the flange and
snap ring with the shim.
Standard： 0.0 to 0.2 mm { 0.000 to 0.008 in } Note：
Types of adjust shims ・ The following applies to high ride suspension
： 0.2 mm { 0.008 in }
： 0.3 mm { 0.012 in } 2. Install the hub cap to the front hub.
： 0.5 mm { 0.020 in }
： 1.0 mm { 0.039 in }
9. Brake caliper assembly installation

1. Install the brake caliper assembly to the knuckle.
8. Hub cap installation Note：
Note：・ While making sure that the flexible hose is not
・ The following applies to 2WD high ride twisted, install the brake caliper together with
suspension, 4WD. the brake support.
1. Install the hub cap to the front hub. Tightening torque： 206 to 246 N・m { 21.0 to 25.1
kgf・m / 152 to 181 lb・ft }
Note：
・ Install the hub cap to the front hub with bolts.

Note：
ft }
Front wheel speed sensor
removal
2. Front wheel speed sensor safety information
Caution：
・ If the wheel speed sensor is damaged in the
course of the maintenance works, that may
cause the following symptoms.
・ ABS abnormalities due to sensor damage
・ In case of ABS failure or ABS malfunction due
to improper sensor installation, installation/
removal of the wheel speed sensor, or
replacement of the wheel speed sensor, follow
the precautions indicated in the procedure for
the work.
1. Connector position
3. Front wheel speed sensor disconnect
2. Front speed sensor assembly
1. Disconnect the harness connector from the wheel 3. Harness bracket tightening nut
speed sensor. 4. Harness bracket tightening bolt
5. Sensor tightening bolt
4. Front wheel speed sensor removal
Note： Note：
・ The following applies to the 4x2 (high ride ・ The following applies to 4x2 (except for high
suspension), 4x4. ride suspension).
1. Remove the harness clip from the harness. 3. Remove the harness bracket from the upper link
assembly.
Note：
4. Remove the harness bracket from the knuckle.
・ Disconnect the harness clip lock indicated by
the arrow. 5. Remove the wheel speed sensor from the knuckle.
・ Remove the harness bracket. Caution：
2. Remove the wheel speed sensor from the knuckle. ・ When the wheel speed sensor body does not
come off easily due to the rust on the knuckle
Caution：
or support, use a rust penetrant, etc., and
・ When the wheel speed sensor body does not carefully remove the sensor body by shifting it
come off easily due to the rust on the knuckle little by little.
・ Be careful not to hit or step on the removed
carefully remove the sensor body by shifting it
sensor.
little by little.
・ Never perform following works.
・ Be careful not to hit or step on the removed
sensor. ・ Remove the sensor body by hammering.
・ Never perform following works. ・ Insert a flat-head screwdriver or the like into
the gap to remove it forcibly.
・ Remove the sensor body by hammering.
・ When removing the wheel speed sensor, do
・ Insert a flat-head screwdriver or the like into
not pull the harness.
・ When removing the wheel speed sensor, do Note：
not pull the harness. ・ Remove the sensor fixing bolt.
Note：
・ Remove the sensor fixing bolt.
2. Front speed sensor assembly
3. Harness bracket tightening nut
4. Harness bracket tightening bolt
inspection ・ Check for any deformation of the cylindrical

part of the sensor.
1. Front wheel speed sensor inspection
・ Check for any clearance between the sensor
1. Inspect the wheel speed sensor. resin section and the sensor mounting flange.
Note：・ Check for any deformation of the flange such
・ Inspect the voltage. as bending.
Caution：
・ When any abnormality is found, replace the
wheel speed sensor with a new one.
1. Battery, 12 V
2. DMM
3. Resistance
4. Wheel speed sensor 1. Sensor's resin collar
2. Cylindrical part of the sensor
Note：
3. Sensor resin section
・ Turn the ignition switch OFF. 4. Sensor mounting flange
・ Install the wheel speed sensor to the vehicle,
and remove the harness connector.
・ Connect a resistance of 100 Ω between the
wheel speed sensor connector 1 pin and GND.
・ Apply a voltage of 9 to 16 V to the wheel
speed sensor connector 2 pin.
・ Connect a DMM between the wheel speed
sensor connector 1 pin and GND.
・ Spin the tire at 1/2 rotation per second, and
confirm that the voltage is within the range of
standard values.
・ Standard value: 0.5 - 2.0 V
Caution：
・ Replace the wheel speed sensor if the voltage
is not within the range of standard values.
Note：
・ Inspect the sensor.
・ Inspect whether any of the following failures
exists in the appearance of the removed wheel
speed sensor.
・ Check for any damage on sensor's resin collar.
installation ・ Confirm that there is no harness interference.
1. Front wheel speed sensor preparation 3. Front wheel speed sensor installation
Note： 1. Install the wheel speed sensor to the knuckle.

・ Check the wheel speed sensor before Caution：
installation. ・ When installation, be careful for the wheel
・ Before installing the sensor, clean the inside of speed sensor not to hit against anything.
the sensor installation hole and installation
Note：
surface of the sensor bracket, and the
installation surface of the sensor bracket for ・ Tighten the sensor at the specified torque.
the knuckle and confirm that there is no foreign Tightening torque： 8 N・m { 0.8 kgf・m / 71 lb・in }
material such as rust and pieces of the sensor.
2. Connect the harness clip to the harness.
・ Remove any foreign material such as pieces of
the sensor from the inside of the mounting Note：
hole or the installation surface. ・ Install the harness fixing bolt, and tighten it to
・ Remove any rust on it with wire brush or the the specified torque.
like. Tightening torque： 8 N・m { 0.8 kgf・m / 71 lb・in }
Caution： Note：
・ When rust penetrant is used to remove the ・ Install the harness fixing nut, and tighten it to
wheel speed sensor, clean up the part with the specified torque.
part cleaner or the like.
2. Front wheel speed sensor safety information
Note：
Note：
・ The following applies to the 4x2 (high ride
・ When assembling the hub, do not contact and suspension), 4x4.
break the sensor rotor/wheel speed sensor
unit. ・ Connect the harness clip indicated by the
arrow.
・ The wheel speed sensor unit contains a
magnet so that caution should be taken with
metal objects.
・ Remove the wheel speed sensor first before
removing the hub rotor assembly.
・ When hammering is performed to remove the
knuckle, etc., remove the wheel speed sensor
before starting the work.
・ When installing the sensor, use your hand to
push the sensor installation flange until it is
firmly attached to the installation surface, and
then tighten the bolt.
・ When inserting the sensor, do not pry or
hammer it with a tool.
・ Do not tighten the sensor body fixing bolts with
an air tool, but temporarily tighten by hand and
then fully tighten them.
・ After tightening the bolts, confirm that there is
no clearance between the mounting flange and
2. Wheel speed sensor assembly
the mounting surface again.
3. Harness tightening nut
・ Install the sensor harness using the twist 4. Harness tightening bolt
prevention line as a reference to avoid 5. Sensor tightening bolt
twisting.
・ Be careful not to pull the harness forcibly,
which may result in disconnection.
Note：
・ The following applies to 4x2 (except for high
ride suspension).
6. Front wheel speed sensor inspection

Note：
・ Check the following after installation of the
1. Connector position wheel speed sensor.
2. Wheel speed sensor assembly ・ Turn the ignition switch ON, and confirm that
3. Harness tightening nut the ABS warning light turns off after it
4. Harness tightening bolt illuminates for approximately 3 seconds.
・ Start the engine and drive the vehicle straight
Caution： forward from the stopped state. Slowly
accelerate to 15 km/h (9 mph) and then slowly
・ When installing the harness, check the
apply the brake until the vehicle stops. Confirm
harness for a twist.
that no abnormal noise or problem in braking
4. Front wheel speed sensor connect force during this procedure.
1. Connect the harness connector to the wheel speed ・ Confirm whether the following symptom occurs
sensor. during verification actions above.
・ The ABS warning light turns on, or does not
turn off.
1. Install the disc wheel to vehicle. ・ ABS operation noise or motor rotation noise is
Note： caused.
・ Install the wheel nuts in the numbered order. ・ Brake pedal kickbacks are felt.
Tightening torque： 118 N・m { 12.0 kgf・m / 87.0 lb・・ The target braking force is not produced.
ft } ・ When the above symptom occurs, take the
following action.
・ Check the installation status of the wheel
speed sensor and connection status of the
connector.
・ Check the DTCs, and perform inspection and
take remedies for the ABS system in
accordance with the diagnostic procedure for
each DTC.
Caution：
・ Since the ABS rotates the motor for a moment
right immediately after the vehicle is started,
sound of rotating motor may be heard. This is
the operation for initial check task and not at

fault.
Rear wheel speed sensor
removal
1. Rear wheel speed sensor safety information
Note：
the precautions indicated in the procedure for
the work.
2. Rear wheel speed sensor disconnect
1. Disconnect the harness connector from the wheel
speed sensor.
3. Rear wheel speed sensor removal
1. Disconnect the harness clip from the harness.
Note：
・ Remove the harness fixing bolt.
・ Disconnect the harness fixing clip.
2. Remove the wheel speed sensor from the rear axle
case.
Note：
・ Remove the sensor-fixing bolt and wheel
speed sensor.
Caution：
・ When the wheel speed sensor body does not
little by little.
・ Be careful not to bump or step on the removed
sensor.
・ Insert a flat-head screwdriver or the like into
not pull the harness.
inspection ・ Inspect whether any of the following failures

exists in the appearance of the removed wheel
1. Rear wheel speed sensor inspection speed sensor.
1. Inspect the wheel speed sensor. ・ Check for any damage on sensor's resin collar.
Note：・ Check for any deformation of the cylindrical
・ Inspect the voltage. part of the sensor.
・ Check for any clearance between the sensor
resin section and the sensor mounting flange.
・ Check for any deformation of the flange such
as bending.
・ When any abnormality is found, replace the
wheel speed sensor with a new one.
1. Resistance
2. DMM
3. Battery, 12 V
4. Wheel speed sensor RR
5. Wheel speed sensor RL
Note：
1. Sensor's resin collar
・ Turn the ignition switch OFF. 2. Cylindrical part of the sensor
・ Install the wheel speed sensor to the vehicle, 3. Sensor resin section
and remove the harness connector. 4. Sensor mounting flange
・ Connect a resistance of 100 Ω between the
wheel speed sensor connector 2 pin (-) and
GND.
・ Apply a voltage of 9 to 16 V to the wheel
speed sensor connector pin 1 (+).
・ Connect a DMM between the wheel speed
sensor connector 2 pin (-) and GND.
・ Spin the tire at 1/2 rotation per second, and
confirm that the voltage is within the range of
standard values.
・ Standard value: 0.5 - 2.0 V
・ Replace the wheel speed sensor if the voltage
is not within the range of standard values.
Caution：
・ Inspect also the wheel speed sensor RR side
in the same way.
Note：
・ Inspect the sensor.
installation
1. Rear wheel speed sensor preparation
Note：
・ Check the wheel speed sensor before
installation.
・ Before installing the sensor, clean the inside of
surface of the sensor bracket, and the
installation surface of the sensor bracket for
the knuckle and confirm that there is no foreign
the sensor from the inside of the mounting
hole or the installation surface.
・ Remove any rust on it with wire brush or the
like.
2. Connect the harness clip to the harness.
Caution：
Note：
・ When rust penetrant is used to remove the
wheel speed sensor, clean up the part with ・ Install the harness fixing bolt, and tighten it to
part cleaner or the like. the specified torque.
2. Rear wheel speed sensor safety information Tightening torque： 8 N・m { 0.8 kgf・m / 71 lb・in }
Caution： 4. Rear wheel speed sensor connect

・ When installing the sensor, use your hand to 1. Connect the harness connector to the wheel speed
push the sensor installation flange until it is sensor.
firmly attached to the installation surface, and 5. Rear wheel speed sensor inspection
・ When inserting the sensor, do not pry or strike Note：
it with a tool. ・ Check the following after installation of the
・ Do not tighten the fixing bolts for the sensor wheel speed sensor.
body with an air tool, but temporarily tighten by ・ Turn the ignition switch ON, and confirm that
hand and then fully tighten them. the ABS warning light turns off after it
・ After tightening the bolts, confirm that there is illuminates for approximately 3 seconds.
no gap between the installation flange and the ・ Start the engine and drive the vehicle straight
installation surface again. forward from the stopped state. Slowly
・ Install the sensor harness using the twist accelerate to 15 km/h (9 mph) and then slowly
prevention line as a reference to avoid apply the brake until the vehicle stops. Confirm
twisting. that no abnormal noise or problem in braking
force during this procedure.
which may result in disconnection. ・ Confirm whether the following symptom occurs
during verification actions above.
・ Confirm that there is no harness interference.
3. Rear wheel speed sensor installation turn off.
1. Install the wheel speed sensor to the rear axle case. ・ ABS operation noise or motor rotation noise is
caused.
・ Brake pedal kickbacks are felt.
・ The target braking force is not produced.
・ When the above symptom occurs, take the
following action.
connector.

each DTC.
Caution：
sound of rotating motor may be heard.
・ This is the operation for initial check task and
not at fault.
Rear sensor rotor (drum brake)
removal ・ Insert a flat-head screwdriver or the like into

1. Remove the disc wheel from vehicle. not pull the harness.
2. Rear axle differential oil drain
1. Drain the rear axle differential oil from the rear axle
case.
Note：
the precautions indicated in the procedure for 7. Brake pipe removal
the work.
1. Remove the brake pipe from the wheel cylinder
5. Rear wheel speed sensor disconnect assembly.
1. Disconnect the harness connector from the wheel Note：
speed sensor. ・ Except for the 4x2 high ride suspension
6. Rear wheel speed sensor removal
1. Disconnect the harness clip from the harness.
Note：
・ Remove the harness fixing bolt.
・ Disconnect the harness fixing clip.
2. Remove the wheel speed sensor from the rear axle
case.
Note：
・ Remove the sensor-fixing bolt and wheel
speed sensor.
Caution：
・ When the wheel speed sensor body does not
little by little. Note：
・ Be careful not to bump or step on the removed ・ 4x2 (high ride suspension), 4x4
sensor.
1. Remove the spring from the brake shoe.
Note：
・ Remove the lower side spring.
・ Slide the brake shoe and the lower side spring
toward the ground.

lever.
9. Adjust lever removal
1. Lower spring
1. Remove the adjust lever from the brake shoe.
10. Shoe holder pin removal 12. Adjuster assembly removal
1. Remove the shoe holding spring from the shoe 1. Remove the adjuster assembly from the brake shoe.
holder pin. 13. Brake shoe assembly removal
Note： 1. Remove the brake shoe assembly from the back
・ Push the spring toward the brake shoe and plate.
hold it.
14. Parking brake cable removal
holder pin. 1. Remove the parking brake cable from the back plate.
Note：
・ Press the lock protrusion of the cable with a 12
mm hexagonal offset box wrench and remove
the parking brake outer cable.
・ Remove the parking brake inner cable from
the parking lever.
・ Remove the parking brake cable bolt and nut.
Caution：
・ Do not twist or bend the cable.
・ Be careful for damage to the cable, which will
cause insufficient operation.
2. Remove the shoe holder pin from the brake shoe.

11. Spring removal
Note：
・ Use a grinder to grind the retainer or sensor
rotor surface and remove the retainer or
sensor rotor using a chisel.
18. Axle case oil seal removal
1. Remove the axle case oil seal from the rear axle
case.
Note：
・ Do not reuse the oil seal.
1. 12 mm hexagonal offset box wrench
2. Remove the parking brake cable bracket from the

leaf spring.
Note：
・ Remove the nuts that are holding the cable in
place.
15. Rear wheel cylinder assembly removal
1. Remove the wheel cylinder assembly from the back
plate.
16. Rear axle shaft removal
1. Remove the bearing holder from the axle case.
Note：
・ Remove the fixing nut.
2. Remove the rear axle shaft from the axle case.
Note：
・ Remove the axle shaft together with the back
plate.
・ When pulling out the axle shaft, the axle case
oil seal is damaged. Replace with a new one.
17. Rear axle shaft disassembly
1. Remove the snap ring from the rear axle shaft.
Note：
・ Use snap ring pliers for removal.
・ Do not reuse the snap ring.
2. Remove the shim from the rear axle shaft.
Note：
・ Remove it if any shim is attached.
3. Remove the retainer from the rear axle shaft.
inspection
1. Sensor rotor inspection
Note：
・ Check the sensor rotor for damage or
powdered iron sticking to it.
・ Check the play of the sensor rotor.
・ Check the sensor rotor teeth for damage,
dents, etc.
・ If an abnormality is found, conduct adjustment,
repair, or replacement of the parts as
necessary.
・ If replacement is needed, remove the sensor
rotor from the axle shaft.
installation
1. Axle case oil seal installation
1. Install the axle case oil seal to the axle case using
special tool.
Note：
・ Use the oil seal installer and grip to install a
new oil seal.
SST: 5-8840-2202-0 - oil seal installer

2. Rear axle shaft reassembly
1. Install the retainer to the axle shaft using special tool.
Note：
・ Place a new retainer or sensor rotor on the
bearing installer.
・ Firmly fit the bearing so that it is fixed to the
axle shaft using a retainer or sensor rotor, and
SST: 5-8840-0007-0 - grip
then assemble the axle shaft assembly.
1. Oil seal installer

2. Grip
Note：
・ Measure the dimension of A in the diagram.
： 34.5 to 36.1 mm { 1.36 to 1.42 in }
1. Axle shaft
2. Oil seal
3. Back plate Part No. Thickness
4. Bolt 9-4151-9109-∗ ： 0.24 mm { 0.0094 in }
5. Retainer or sensor rotor
6. Bearing installer 3. Rear axle shaft installation
2. Install the snap ring to the axle shaft using a snap 1. Install the rear axle shaft to the axle case.
ring pliers. Note：
Note：・ Clean the aligning surface of the axle case and
・ Securely install a new snap ring. bearing holder.
・ Replace with new one if there is any ・ Apply liquid gasket, ThreeBond TB1215 or
deformation or damage. equivalent to the installation surface of the axle
case.
Caution：
・ Insert the axle shaft into the axle case so as
not to damage the oil seal.
・ When removing the bearing holder mounting
bolt from the brake ASM, make sure to use a
new bolt.
Note：
・ Install the bearing holder fixing nut, and then
tighten at the specified torque.
Tightening torque： 122 N・m { 12.4 kgf・m / 90 lb・
ft }
4. Rear wheel cylinder assembly installation
1. Install the wheel cylinder assembly to the back plate.
10 to 13 lb・ft }
1. Snap ring
2. Shim
3. Retainer or sensor rotor
3. Install the shim to the axle shaft.

Note：
・ Install shims of appropriate thickness to the
rear ends of the snap ring and retainer or
sensor rotor.
Standard： 0.00 to 0.36 mm { 0.000 to 0.014 in } 5. Brake shoe assembly installation
4. Measure the clearance using a feeler gauge. 1. Install the brake shoe assembly to the back plate.
Note： Note：
・ If the clearance is larger than the standard ・ Apply grease to the brake shoe fitting section
value, replace the shims and adjust it to the and the back plate sliding section.
standard value.
1. Back plate sliding section

2. Brake shoe fitting section
Caution：
・ Always use a new shoe holder pin and spring.
・ Be careful not to damage the wheel cylinder
dust cover.
・ Be careful for the wheel cylinder piston not to
bounce off.
6. Adjust lever spring installation
2. Install the adjust lever spring to the adjust lever.
7. Spring installation
1. Install the spring to the brake shoe.
8. Adjuster assembly installation
1. Adjuster rod
Note： 2. Brake shoe installation portion
・ Clean the adjuster bolt and adjuster rod. 3. Brake shoe installation portion
4. Adjuster rod
1. Apply the grease to the adjuster assembly.
5. Adjuster bolt
Note：
2. Install the spring to the adjuster assembly.
・ Apply grease to the threaded portion of the
adjuster bolt. 3. Install the adjuster assembly to the brake shoe.
・ Install the adjuster rod to the adjuster bolt. 9. Adjust lever installation
・ Apply grease on the brake shoe installation
1. Install the adjust lever to the brake shoe.
portion.
Note：
・ Apply grease to the sliding section of the
adjust lever.
・ Install the adjust lever and ring to the brake
shoe on the trailing side.
Caution：
・ Always use a new ring.
Note：
・ 4x2 (high ride suspension), 4x4
11. Parking brake cable installation

1. Install the parking brake cable to the back plate.
Note：
・ Install the inner cable to the back plate hole.
Then install the case cap of the outer cable to
the back plate.
・ The following applies to 4x2 (except for high
ride suspension).
2. Install the parking brake cable to the bracket.
Nut
Note：
・ The following applies to the 4x2 (high ride
suspension), 4x4. 13. Rear wheel speed sensor preparation
3. Install the parking brake cable to the bracket. Note：
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } ・ Check the wheel speed sensor before
Bolt installation.
4. Install the parking brake cable bracket to the frame. ・ Before installing the sensor, clean the inside of
Tightening torque： 6.5 N・m { 0.66 kgf・m / 58 lb・ surface of the sensor bracket, and the
in } Bolt installation surface of the sensor bracket for
12. Brake pipe installation the knuckle and confirm that there is no foreign
1. Install the brake pipe to the wheel cylinder assembly.
Tightening torque： 16 N・m { 1.6 kgf・m / 12 lb・ft } the sensor from the inside of the mounting
Note： hole or the installation surface.
・ Except for the 4x2 high ride suspension ・ Remove any rust on it with wire brush or the
like.
Caution： 16. Rear wheel speed sensor connect
・ When rust penetrant is used to remove the 1. Connect the harness connector to the wheel speed
wheel speed sensor, clean up the part with sensor.
part cleaner or the like.
17. Brake drum installation
Caution：
・ When installing the sensor, use your hand to
push the sensor installation flange until it is Note：
firmly attached to the installation surface, and ・ Filling up the reservoir tank
Caution：
・ When inserting the sensor, do not pry or strike
it with a tool. ・ Use only the specified brake fluid.
・ Do not tighten the fixing bolts for the sensor ・ Do not use any brake fluid that contains
body with an air tool, but temporarily tighten by petroleum components.
hand and then fully tighten them. Note：
・ After tightening the bolts, confirm that there is ・ Doing so may cause expansion or distortion of
no gap between the installation flange and the the rubber parts in the hydraulic brake system.
installation surface again.
Caution：
・ Install the sensor harness using the twist
prevention line as a reference to avoid ・ Do not use any brake fluid container that
twisting. contains petroleum components or that is wet
with water.
which may result in disconnection. Note：
・ Confirm that there is no harness interference. ・ If water mixes in the brake fluid, its boiling
point decreases.
15. Rear wheel speed sensor installation
1. Install the wheel speed sensor to the rear axle case. contaminations.
Tightening torque： 8 N・m { 0.8 kgf・m / 71 lb・in } Caution：
engine is cold.
the paint.
Note：
2. Connect the harness clip to the harness. neutral, and continue depressing the brake
Note： pedal with a constant amount of pressure.
・ Install the harness fixing bolt, and tighten it to ・ If the pedal stroke gradually increases, there
the specified torque. may be fluid leakage in the oil pressure
system.
・ Air removal from the oil pressure system Note：

・ Air entering the brake pipe will cause an ・ The brake fluid tank is shared with the clutch
insufficient brake operation. fluid tank.
・ In the case of using the brake in a condition ・ As the amount of the fluid is different between
where the fluid level in the reservoir tank is the brake compartment and clutch
extremely low, or removing the brake pipe, compartment depending on the partition inside
conduct air removal. the tank, check the amount of brake fluid in the
brake compartment.
between 2 operators. Caution：
・ Be sure to engage the parking brake during ・ During the air removal work, keep filling the
the air removal work. reservoir tank at least half full with the fluid.
Caution：・ Be sure to refill new brake fluid.
・ Conduct the air removal work with the engine ・ When refilling the fluid, be careful for the air
started to protect damage to the push rod seal, not to enter the fluid.
work.
cylinder.
Note：
system.
・ When the brake pipe is removed at 1 brake, air
1. MAX level
removal is needed for the corresponding wheel
2. MIN level
3. Brake fluid compartment
and one of the brakes is removed, air removal Note：
is needed for the brake system operating with ・ When installing/removing or replacing the
the removed pipe. master cylinder, follow the procedures
1. Apply the parking brake. described below. First, remove air from the
Note： every wheel cylinder and caliper.
・ Pull the parking brake lever to a full extent. ・ Air removal from the brake master cylinder
2. Start the engine. 5. Disconnect the brake pipe from the brake master
Caution： cylinder.
the vacuum booster.

Caution：
the paint.
Note：
front brake pipe.
1. Rear brake pipe

2. Front brake pipe
Note：
necessary.
Note：
1. Rear brake pipe
2. Front brake pipe
it down.
・ Use a finger to completely plug the outlet of Note：
the master cylinder that is removed from the ・ Air removal from the caliper
pedal. 8. Drain air from the brake caliper assembly.
・ Remove the finger from the outlet after the Note：
brake pedal has been completely returned. ・ Remove air from each wheel in the following
・ Repeat the process mentioned above until the order.
brake fluid comes out overflowing from the ・ Right rear wheel cylinder
outlet.
Caution：・ Left front caliper
・ Be careful that the fluid level in the reservoir ・ Right front caliper
level indication.
7. Connect the brake pipe to the brake master cylinder. ・ In this case, follow steps 5 to 7 to remove air
Note： from the master cylinder.
・ Connect the rear brake pipe. ・ Apply an appropriate wrench to the bleeder
screw.
it down. 9. Connect the tube to the bleeder screw.
the brake pedal.
Note：・ Repeat the air removal procedures at least 10
・ Connect a transparent tube to the bleeder times for the front wheel and at least 15 times
screw and put the other end of the tube into a for the rear wheel.
Caution：
fluid.
Note：
repeated.
Note：
Note：
10. Operate the brake pedal. ・ Brake pipe and brake hose
Note：・ Inspect all pipes and hoses for worn, bent,
speed of once per second and hold it down. ・ If any abnormality is found, conduct a
Caution：
Note：
Caution：
1. Brake pedal ・ After removing the pipe and hose, cover the
Note： objects from entering.
flows in the tube. 19. Rear axle differential oil filling
・ Loosen the bleeder screw. 1. Replenish the rear axle case with the rear axle
・ Slowly return the brake pedal. differential oil.
removed.
Note： 1. Release the parking brake lever.
・ Install the gasket to the drain plug, and install Note：
to the axle case.
Note：
Note：
・ Pour in the specified amount of differential oil
・ Loosen the adjust nut and lock nut.
GL5.
Capacity： 2.2 L { 0.58 US gal / 0.48 Imp.gal }
Note：
Note：
・ Repeat the depressing and releasing operation
・ The following applies to limited slip differential
of the brake pedal until the click of the auto
models.
adjuster is not heard.
・ Pour in the specified amount of differential oil
・ If the gap between the brake drum inner
GL5LSD.
diameter and brake shoe is adjusted so that
Capacity： 2.2 L { 0.58 US gal / 0.48 Imp.gal } the gap value is unknown, the number of times
of depressing the brake pedal can be reduced.
Note：
Note：
・ Measure the gap between the brake drum and
brake shoe.
Lining clearance： 0.25 to 0.40 mm { 0.0098 to 0.0157
ft }
in }
Note：
・ If the value does not fall in this range, check
the auto adjuster.
Note：
・ Turn the adjust nut so that the parking brake
lever is pulled up 6 to 9 notches when the
lever is pulled up with the force of 294 N {30
kg/66 lb}.
・ Tighten the lock nut.
Caution：
・ Be careful for the brake not to drag.
22. Rear wheel speed sensor inspection
Note：
21. Brake drum adjustment ・ Check the following after installation of the
Note： wheel speed sensor.
・ All brakes are adjusted automatically. ・ Turn the ignition switch ON, and confirm that
the ABS warning light turns off after it
・ The brakes are adjusted automatically by illuminates for approximately 3 seconds.
・ Start the engine and drive the vehicle straight
・ After depressing and then releasing the pedal, forward from the stopped state. Slowly
a click is heard from the auto adjuster of the accelerate to 15 km/h (9 mph) and then slowly
rear brake. apply the brake until the vehicle stops. Confirm
・ After overhauling the rear brake assembly, that no abnormal noise or problem in braking
conduct adjustment by following the force during this procedure.
procedures below.
・ Confirm whether the following symptom occurs

during verification actions above.
turn off.
・ ABS operation noise or motor rotation noise is
caused.
・ Brake pedal kickbacks are felt.
・ The target braking force is not produced.
・ When the above symptom occurs, take the
following action.
connector.
each DTC.
Caution：
sound of rotating motor may be heard.
・ This is the operation for initial check task and
not at fault.
Yaw rate sensor
removal Note：
・ Remove the mounting nut.
1. Console box removal
3. Remove the yaw rate sensor from the floor.
Note：
・ Below is for the center console type manual
transmission.
1. Remove the shift lever knob from the shift lever.
Note：
2. Remove the shift console cover from the console
box.
Note：
3. Remove the 4WD switch from the console box.
Note：
4. Remove the console box from the floor. 1. Yaw rate sensor
Note： 2. Nut
・ Open the console box cover and remove 2
screws.
・ Remove the control box backward.
・ Below except for the center console type.
5. Remove the console cover from the instrument
panel.
Note：
6. Remove the cup holder cover from the floor.
7. Remove the bracket from the floor.
2. Yaw rate sensor safety information
Caution：
・ Do not use an impact wrench when installing
or removing the yaw rate sensor.
・ The yaw rate sensor is sensible to shocks so
carefully handle it with due attention to
dropping.
3. Yaw rate sensor removal
1. Disconnect the connector from the yaw rate sensor.
2. Remove the nut from the yaw rate sensor.
installation 3. Install the shift console cover to the console box.

Note：
1. Yaw rate sensor installation
1. Install the yaw rate sensor to the floor.
・ Below is for the center console type manual
Caution： transmission.
・ Confirm that the installation surface of yaw 4. Install the shift lever knob to the shift lever.
rate sensor has no deformation.
Note：
・ Inspect that any foreign material is not inserted
between the yaw rate sensor and the floor ・ Below except for the center console type.
panel. 5. Install the bracket to the floor.
2. Install the nut to the yaw rate sensor. 6. Install the cup holder cover to the bracket.
Note： 7. Install the console cover to the instrument panel.
・ Install the installation nut and tighten it to the
Note：
specified torque.
1. Yaw rate sensor

2. Nut
3. Connect the connector to the yaw rate sensor.

2. Console box installation
Note：
1. Install the console box to the floor.
Note：
・ Open the console box cover and install 2
screws.
2. Install the 4WD switch to the console box.
Note：
removal ・ Failure to follow the previously mentioned

precautions may make the center position of
1. Air bag assembly safety information the SRS coil assembly uncertain, which may
Note： result in damage on the SRS coil assembly.
・ Handling of a deployed airbag assembly 3. SRS control unit preparation
Warning： 1. Deactivate the SRS function.
・ When handling the airbag, the safety Note：
precautions must be observed.
・ Turn the ignition switch to LOCK and remove
・ A small amount of sodium hydroxide may be the key.
contained on the surface of a deployed airbag.
・ Remove the SRS fuse from the fuse relay box
・ This is a by-product of the deployment reaction or disconnect the battery ground cable from
and may cause irritation when it contacts with the battery.
skin or eye.
Caution：
・ To handle activated airbag, wear gloves and
safety glasses. ・ Leave it for approximately 15 seconds or
longer.
・ After handling, wash your hands with soap.
4. Driver air bag assembly removal
Note：
・ Handling of an undeployed airbag assembly Note：
・ Confirm the holes on the both sides of the
Warning：
steering cover.
・ When carrying an undeployed airbag, make
sure that the trim cover faces the opposite
direction of your body.
・ When carrying the airbag, never hang the
connector or harness on your hand.
・ When putting down an undeployed airbag,
make sure to face the trim cover upward.
・ Do not place any other item on the steering
wheel with the airbag surface facing
downward.
・ Not following this procedure will result in a fire
or injuries.
Caution：
・ After the airbag is deployed, inspect for
burning due to overheating, melting or other
problems.
・ If the SRS coil assembly is damaged, replace
it. Note：
2. Driver air bag assembly preparation ・ Confirm the lever position in the hole in the
following illustration.
Note：
・ Set the steering wheel so the vehicle tires are
pointing straight forward before removing the
steering wheel.
Caution：
・ Rotate the steering wheel so that the vehicle
wheels are straight, then lock the steering
wheel.
Note： 1. Airbag connector

・ Insert a bar of diameter 6 mm {0.24 in} to 2. Horn connector
remove the driver airbag assembly from the
Warning：
lever.
・ Keep the airbag assembly away from your
body when carrying it.
・ When putting down an undeployed airbag
assembly, make sure to face the trim cover
upward.
・ Place the trim cover upward on a flat surface.
・ Failure to follow this procedure may result in
personal injury.
1. Remove the driver air bag assembly from the

steering wheel.
2. Disconnect the connector from the driver air bag
assembly.
Note：
・ Disconnect the airbag connector.
・ Disconnect the horn connector.
5. Steering wheel removal
Note：
・ Reconfirm that the steering wheel is set to the
position for advancing straight forward.
・ Make setting marks on the steering wheel and
shaft.
・ They are used for reassembly of parts. 6. Meter cluster removal

1. Remove the meter cluster from the instrument panel.
Note：
・ Pull out 4 clips from the instrument panel.
・ Disconnect the switch connector.
1. Remove the nut from the steering shaft.

2. Remove the steering wheel from the steering shaft
using special tool.
1. Clip
7. Instrument panel driver-side lower cover removal

1. Remove the instrument panel driver-side lower cover
from the instrument panel.
Note：
SST: 5-8521-0016-0 - steering wheel remover
・ Pull out the instrument panel driver side lower
cover.
・ Disconnect the switch connector.
・ Remove the DLC.
Caution：
・ Never apply an impact to the steering wheel
with a hammer, etc. to remove it.
・ The steering shaft is designed to absorb
shocks. 1. Instrument panel driver side lower cover
2. DLC
8. Steering cowl removal
1. Remove the steering cowl from the steering column.
1. SRS coil assembly

2. Combination switch assembly
1. Steering cowl upper 11. Steering angle sensor removal

2. Steering cowl lower 1. Remove the steering angle sensor from the SRS coil
assembly.
9. Combination switch assembly removal
combination switch assembly.
2. Remove the combination switch assembly from the
steering column.

2. Steering angle sensor
10. SRS coil assembly removal

1. Remove the SRS coil assembly from the
combination switch assembly.
installation ・ Install with the protruding portion of the SRS

coil assembly aligned with the concave portion
1. Steering angle sensor installation of the cancel cam.
1. Install the steering angle sensor to the SRS coil ・ For vehicles with a steering angle sensor,
assembly. install the steering angle sensor and the
protruding portion of SRS coil assembly,
aligning with the concave portion of the cancel
cam.

2. SRS coil assembly installation 1. Positioning projection

1. Install the SRS coil assembly to the combination 2. Protruding portion of SRS coil assembly and
switch assembly. concave portion of cancel cam
Note：
・ Perform neutral positioning.
・ After rotating it clockwise until it stops, turn it
by 3 or 4 rotations counterclockwise.
・ Confirm that the marks inside the illustrations
are aligned.

2. Combination switch assembly
Note：
・ Assemble it aligning with the positioning
projection.
Note： 2. Steering cowl lower
・ When the SRS coil is replaced with new one,
5. Instrument panel driver-side lower cover installation
bend the lock pin and apply grease to the
arrow part. 1. Install the instrument panel driver-side lower cover
to the instrument panel.
Note：
・ Connect the switch connector.
・ Install the DLC.
1. Lock pin
3. Combination switch assembly installation

1. Install the combination switch assembly to the
steering column.
1. Instrument panel driver side lower cover
2. Connect the harness connector to the combination 2. DLC
switch assembly.
6. Meter cluster installation
4. Steering cowl installation
1. Install the meter cluster to the instrument panel.
1. Install the steering cowl to the steering column.
Note：
Caution：
・ Connect the switch connector.
・ When installing the steering cowl, be careful
not to pinch the harness by the cowl.
1. Clip
1. Steering cowl upper 7. Steering wheel installation
1. Install the steering wheel to the steering shaft. 1. Airbag connector
2. Horn connector
Note：
・ Line up the setting applied during removal, and 2. Install the driver air bag assembly to the steering
install the steering wheel. wheel.
9. SRS control unit setting
1. Reactivate the SRS function.
Note：
・ Install the SRS fuse to the fuse relay box or
connect the battery ground cable to the
battery.
・ Turn the ignition switch on, and confirm that
the SRS airbag warning light turns off after
blinking 7 times.
Caution：
・ Never apply an impact to the steering wheel
with a hammer, etc. to install it.
・ The steering shaft is designed to absorb
shocks.
2. Install the nut to the steering shaft.
8. Driver air bag assembly installation
1. Install the connector to the driver air bag assembly.
Note：
・ Connect the airbag connector.
・ Connect the horn connector.
setting
1. Steering angle sensor writing
Caution：
・ It is necessary to carry out a 0 point learning
for the steering angle sensor when it has been
replaced or the battery has been
disconnected.
・ Make sure to perform the 0 point learning on
an even place (gradient ratio of 1 % or less),
and do not shake the vehicle or open/close the
door during the operation. Also, do not start
the engine to avoid the idling vibrations.
5. Select ABS/ESC.
6. Select Special Functions.
7. Select Learning for Steering Central Position.
Note：
・ Learn by following the on-screen instructions.
・ 0 point learning of the steering angle sensor by
self-propelled driving
・ When performing learning by self-propelled
driving without using a scan tool for 0 point
learning of the steering angle sensor, it is
learned by driving at the vehicle speed at or
above 40 km/h (25 mph) for about 10 seconds.
Caution：
・ After completing 0 point learning, be sure to
confirm that DTC is not detected by driving the
vehicle.
・ EHCU, except for models with ABS/EBD/ESC
1. Flare nut to the wheel cylinder on the front right 4. Flare nut from the master cylinder front side
side 5. Bolt
2. Flare nut to the wheel cylinder on the front left 6. Flare nut from the master cylinder rear side
side 7. Flare nut to the rear wheel cylinder
3. EHCU, except for models with ABS/EBD/ESC
Note：
・ EHCU, with ABS/EBD/TCS/ESC
1. EHCU, models with ABS/EBD/TCS/ESC 5. Flare nut to the wheel cylinder on the front left
2. Flare nut to the wheel cylinder on the rear left side
side 6. Bolt
3. Flare nut to the wheel cylinder on the rear right 7. Flare nut from the master cylinder front side
side 8. Flare nut from the master cylinder rear side
4. Flare nut to the wheel cylinder on the front right
side
Note：
・ Front wheel speed sensor, 2WD except for
high ride suspension
1. Connector 4. Bolt, cable to cable

2. Wheel speed sensor 5. Bolt, sensor to knuckle
3. Nut, cable to upper link
Note：
・ Front wheel speed sensor, 2WD high ride
suspension, 4WD
1. Connector 4. Bolt, cable to knuckle

2. Wheel speed sensor 5. Bolt, sensor to knuckle
3. Nut, cable to upper link
Note：
・ Rear wheel speed sensor
1. Wheel speed sensor left side 2. Wheel speed sensor right side
Note：
・ Front sensor rotor (disc brake)
1. Sensor rotor 4. Front hub rotor assembly

2. Hub and disc rotor
3. Disc-rotor-fixing bolt
Note：
・ Rear sensor rotor (drum brake)
1. Axle shaft assembly installed with the brake 2. Sensor rotor
Note：
・ With yaw rate sensor, ABS/EBD/TCS/ESC
1. Yaw rate sensor 2. Nut
Note：
・ With steering angle sensor, ABS/EBD/TCS/
ESC
1. SRS coil assembly 3. Combination switch


・ EHCU, except for models with ABS/EBD/ESC
1： 16 N・m { 1.6 kgf・m / 12 lb・ft } Note：

2： 8 N・m { 0.8 kgf・m / 71 lb・in } ・ EHCU, with ABS/EBD/TCS/ESC
1： 16 N・m { 1.6 kgf・m / 12 lb・ft } Note：

2： 20 N・m { 2.0 kgf・m / 15 lb・ft } ・ Front wheel speed sensor, 2WD except for
high ride suspension
3： 8 N・m { 0.8 kgf・m / 71 lb・in }
1： 20 N・m { 2.0 kgf・m / 15 lb・ft } Note：

2： 8 N・m { 0.8 kgf・m / 71 lb・in } ・ Front wheel speed sensor, 2WD high ride
suspension, 4WD
3： 8 N・m { 0.8 kgf・m / 71 lb・in }
1： 8 N・m { 0.8 kgf・m / 71 lb・in } Note：

2： 20 N・m { 2.0 kgf・m / 15 lb・ft } ・ Rear wheel speed sensor
1： 8 N・m { 0.8 kgf・m / 71 lb・in }

2： 8 N・m { 0.8 kgf・m / 71 lb・in }
3： 8 N・m { 0.8 kgf・m / 71 lb・in }
4： 8 N・m { 0.8 kgf・m / 71 lb・in }
TFBRK-WE-1211TH_67209_奥付 2011.7.22 10:13 AM ページ 1
Published: Jul., 2011 All rights reserved.

First Edition
WORKSHOP MANUAL
BRAKE
Issued by ISUZU MOTORS LIMITED

E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
TFBRK-WE-1211TH_67209_奥付 2011.7.22 10:13 AM ページ 2
2012MY
WORKSHOP MANUAL
BRAKE
No.TFBRK-WE-1211TH

Tfbrk-We-1211th 1st WSMW 120 TF Tis 12tf

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

Tfbrk-We-1211th 1st WSMW 120 TF Tis 12tf

Uploaded by

Copyright:

Available Formats

2012MY

Section Sub Section

Maintenance precautions of brake

while sliding across the seat, sitting down from

Function, structure, operation of brake

Operation of the brake control function

1. EHCU 4. Left front wheel speed sensor

1. Instrument panel cluster 5. Yaw rate sensor (vehicles with ESC)

Component description Electronic control unit

1. Neutral steer 4. In case of the over steer

Wheel speed sensors

1. Wheel speed sensor

Yaw rate sensor (vehicles with ESC)

ESC OFF switch (vehicles with ESC)

Steering angle sensor (vehicles with ESC)

1. TCS OFF indication light

Switch operations (vehicles with ESC)

Control allowed/prohibited Indication light

Model with multi-information display

1. ESC warning light (vehicles with ESC) 3. Brake warning light

1. Inlet valve 8. Reservoir

1. Inlet valve 11. Outlet valve

Excluding vehicles with ESC

No. Pin function No. Pin function

6 Wheel speed sensor front right signal 23 Not used

Vehicles with ESC

No. Pin function No. Pin function

Note： ・ With the blend proportioning valve

Note： 1. Engine side

1. The first brake point

Primary specifications of brake

4x2 LOW RIDE 4x2 HIGH RIDE, 4x4

Introduction to the trouble diagnosis of brake

Brake basic inspection

Diagnostic system check- ABS/EBD/TCS/ESC controls

Lost communication with the EHCU

Check ABS, EBD, ESC warning light inoperative

Check ABS, EBD, ESC warning light always on

Hydraulic unit operation system check

ESC OFF switch circuit system check

Intermittent conditions of brake

Note： Some electrical components and circuits are sensitive to

Wheels lock when braking

Uneven braking occurs while ABS works

Brake pedal feeling is abnormal

One wheel locks

Brake abnormal noise

Bake does not work efficiently

Brake pedal pulsates

Stepping power of the brake pedal is large

Stroke of the brake pedal is abnormal

Defective straight driving

ESC does not work efficiently

DTC C0035 (Flash Code 21, 22, 23, 24)

DTC C0040 (Flash Code 25, 26, 27, 28)

The ignition switch is ON. DTC C004018

DTC C0045 (Flash Code 31, 32, 33, 34)

DTC C0050 (Flash Code 35, 36, 37, 38)

DTC C0110 (Flash Code 62, 68, 69)

DTC C0131 (Flash Code 72)

DTC C0161 (Flash Code 19)

DTC C0186 (Flash Code 76)

DTC C0196 (Flash Code 75)

Note：・ With the blend proportioning valve