BRA BRAKE (GENERAL DESCAPTION BR 2 PREPARATION = TROUBLESHOOTING ‘smn ‘CHECK AND ADJUSTMENT MASTER CYLINDER s+ [BRAKE BOOSTER : vACUUM PUMP (BL) on VACUUM PUMP (ez, 1k2—T6) [FRONT BRAKE . REAR BRAKE errr (rum Sate) REAR BRAKE == (Oize Brake) REAR BRAKE (Parking Brake) = [LOAD SENSING FROPORTIONING [AND 8Y~PASS VALVE (LSP & BY) sn A 44 ANTI-LOCK BRAKE SYSTEM [ABS)-=~~ 8R— 47 ‘ABS ACTUATOR, en—47 [FRONT SPEED SENSOR ~~ aR 2 REAR SPEED SENSOR: oR 53 TROUBLESHOOTING nmin OR 5 SERVICE SPECIFICATIONS <= -sonse OR 103| er eR2 GENERAL DESCRIPTION PREPARATION SST (SPECIAL SERVICE TOOLS) must be taken to replace aaa B0T08 KE ~ GENERAL DESCRIPTION. PREPARATION ich part properly as it could affect the performance of the Replace the parts with parts of the same ETT ae ‘one aaTe ‘mre 20010 ore Te (0081-0000) pacar 40BRAKE ~ PREPARATION BR ‘T= T00T0 re at yi i a ‘ino = ‘GIT 05N0 TOWOTA Ervin Tor 2 aE BEEIS Sa Roa Pow EQUIPMENT cuai BRAKE ~ TROUBLESHOOTING, CHEGK AND ADJUSTMENT TROUBLESHOOTING ‘tha table below to help you find the cause of the problem. The numbers indicate the prio (of the likely eauso of the problem. Chack each part in ordar. Sooner CHECK AND ADJUSTMENT Sep gmt sch BRAKE PEDAL CHECK AND ADJUSTMENT 1. CHECK PEDAL HEIGHT from asphalt shoot: 17.0~ 207.0 mm (7.75 If tho podel height is incorrect, adjust it. 2. IF NECESSARY, ADJUST PEDAL HEIGHT (0) Disconnact the connector from the stop light switch (0) Loosen the stop light switch lock nut and remove the stop light switch. {c) Loosen the push rod tock nut. {)_Adjust the pedal height by turning the pedal push rod. {6} Tighten the push rod lock nut. Torque: 25 Nem (260 kgtem, 19 feibf) (Install the stop light switch and turn it unti it ightly contacts the pedal stopper. (o)_ Turn the stop light switch back one turn.Pada! Freplay RAKE ~ CHECK AND ADJUSTMENT BRS {h) Chock the clearance (A) betwoon stoplight switch and pedal Clearancs (05-244 mm (0.020-0.00¢ in) (Tighten the stop light switch lock nut (Connect the connector to the stop light switeh. () Chack that the stop lights come on when the brake pedal is depressed, and go off when the brake pedal is raleasod. (After adjusting the pedal height, check that ped Araoplay. HINT: If clearance (A) hetwaen the stop light switch {and the brake pedal stopper has been adjusted cor- rectly, the pedal freeplay will meet the specificotions. 3. CHECK PEDAL FREEPLAY (a) Stop the engine and dopross the brake pedal sever ‘ies until there is no mora vacuum left in the boost: (b) Push in the pedal by hand until the beginning of the tasistance is felt, then measure the distance mm (0.12024 In) Tha freeplay to tho 1st point of resistance is ‘due to the play betwaen ths clovis and pin. Itis 1-3 mm (0,040.12 in) on the pedal If incorrect, check the stop light switch clearance. It the clearance is OK. then troubleshoot the brake system, 4. CHECK PEDAL RESERVE DISTANCE Release the parking brake. With the engine running, depress the pedal and m ture the podal reserve distance. as shown. Pedal renerve distance from eephalt shoot at 490 M (60 kat, 110.2 tot: ‘Europe: More than 80 mm (2.15 in) Othore: More than 9B mm (3.74 in) It the reserve distance is incorrect, troubleshoot the brake system. ae BRAKE BOOSTER OPERATIONAL TEST 1. OPERATING CHECK (a) Deorass the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. (0) Depeass the brake pedal and start the engine. f the pedal goes down slightly, operation is normal[aR BRAKE — CHECK AND ADJUSTMENT. 2. AIR TIGHTNESS CHECK (a) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. If the ‘padal govt down farthest tho st time, but gradually ‘ses aftor the 2nd or 3rd time, the booster i air tight. (©) Depress the brake pedal while the engine is running. ‘and stop the engine with the pedal depressed. If there is no chango in the pedal roserve travel after holding the padal for 30 econds, the bocstor ie airtight. BRAKE SYSTEM BLEEDING HINT: If any work ig done on the brake eyetem or if air in tha bra Notice: ‘ave, Wath it off immediately. 1. FILL BRAKE RESERVOIR WITH BRAKE FLUID CChack the fluid laval in the rasarvoir after bie ch wheel. Add fluid, if necessary Fluid: SAE J1703 or FAVES No.116 OOT2 2. BLEED MASTER CYLINDER HINT: If the master eylinder has be: it the rasorvoir becomes empty, bs master eylind (@) Disconnect the brake lines from the master cylinder. (6). Slowly depress the brake pedal and hola it. disatsambles or 1 their from the {(€}. Block off the outer holes with your fingers. and re brake pa and (c) 3 oF 4 times. co)BRI BRAKE ~ CHECK AND ADJUSTMENT 3. CONNECT VINYL TUBE TO BRAKE CALIPER OR WHEEL CYLINDER BLEEDER PLUG Insert other end of the tubs in a half—full container of brake fluid HINT: Begin air bleeding from the whes! oylinder with the longest hydraulic li 4. BLEED BRAKE LINE (a) Slowly depress the brake pedal several times, (©) While an assictant dopreszes the pedal, loosen tho blaeder plug until fluid starts to run out. Then tighten the bleedar plug (ec) Repeat this proced bubbles in the fluid, Blonder plug tightening torque: 11. Nam (110 ahem, 8 fbf) 5, REPEAT PROCEDURE FOR EACH WHEEL, 6. BLEED LSP a BV Until there ore no more air PARKING BRAKE CHECK AND ADJUSTMENT 1. CHECK PARKING BRAKE LEVER TRAVEL Pull the parking brake lever all the way up, and count ‘tha number of clicks Parking brake lever travel at 108 N (20 haf, 4 Ib: ios adjust the parking bral It incor 2. IF NECESSARY, ADJUST PARKING BRAKE LEVER TRAVEL HINT: Betore adjusting the parking br that the raar brake shoe clearance has been adjusted For shoe clearance adjustment, see step 3 on page BR =34 or seo step 1 on (@) Remove the (6) Loosen the lock nut and turn the adjusting nut until the lever travel is correct. (6) Tighton the lock nut. Torque: 8:4 Nem (85 kaf.em, 48 in.tbt) (2) Ingzall the roar console boxBRAKE — MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER REMOVAL Lo EG Oniy] ‘BL EIG Oniy wo ABS Level Waring Switch Connector iia RP | Bence master cyindor | Lowi vanly Siier Gannsor! Gasoline B/G Check vane Bracket Brake Booster ees & 3x Wsieeniin 8 (Cet) Level Warning Switch Connector ww! ABS ‘rake Master Cylinder (Gasoline EG f Check Valve [ste 2 — ORS. ie termntile em Gighem 18D]: Spectted torque non ruta patBRAKE ~ MASTER CYLINDER, oe eee Level Warning Switch Connector ar aie pice enc Brake Booster wh ABS Level Warning Switch Connector Bi Bracket Wire Haeness. AC et va an ot Rinigtem, FT: Spected torque Non-rousabe partAKE, MASTER CYLINDER DISCONNECT LEVEL WARNING SWITCH CONNEC- Tor ‘TAKE OUT FLUID WITH SYRINGE NOTICE: Do not it brake fold remain on & pao 1 Wash it off immediatly. DISCONNECT BRAKE LINES w/e ABS: Using SST. disconnect the 6 brake lines trom the rmastar cylinder and 4—way. w/ ABS: Using SST, disconnect the § brake lines from the master eylinder and 3—way. SST 09023-00100 Torque: 15 Nim (185 kaf-om, 11 fib) REMOVE MASTER CYLINDER LHD w/o ABS: Fomove the 2 nuts, 4—way, wire harness bracket, and check valve bracket (Gasoline E/6), and pull out the ‘master cylinder and gasket LHD w/ ABS: Remove the 2 nuts, 2—way. wire harness bracket, and check valve bracket (Gasoline E/G), and pull out the ‘master cylinder and gasket. HD w/o ABS: 0 2 nuts, 4—way gasket HO w/ ABS: Remove the 2 nuts, 3—wa bracket, bolt. and bracket. and pullout the master cylinder and gosket Tora Nut: 13 Nm (130 katiem. 9 ft101) Bolt: 15 Nem (185 kat-em, 11 feb)aa Rat IASTER CYLINDER COMPONENTS LHo — Reservoir Reservoir Set Serow r <, No.t Pi i; Spring No.2 Piston and Spring | Snap ic rons eine | ee Stopper Bolt ana wi ABs Q— Reservoir No.t Piston and Spring Ccrommet Z 2 is — Grommet 4 tinge Boy: } = SSI Cashes Piston topper Bot 8 19.0057 Nin ahem I] Specited torque @ Nor: reusable $ Liviu soap base glyco! greaseert2 a & S— aeHaue a fens cone ay ” gos yy ij asd! oer ES, soa au au oR Ss " ee ei o—Pesoee ase Q—~ pi & Reser St Screw a i Pigton and Sorina al Grommet Z ane goes idhoellttody Pan ep CR Tgh em, IBD]: Species torave el oy ate! greaBRAKE ~ MASTER CYLINDER Bra MASTER CYLINDER DISASSEMBLY 1. REMOVE RESERVOIR (2) Remove the set screw and pull out the reservoir. Torque: 1.7 Nom (18 kgf-em, 48 intB) (©) Remove the cap and strainer from the reservoir. REMOVE 2 GROMMETS PLACE CYLINDER IN VISE REMOVE PISTON STOPPER BOLT Using soft jaws on the vise and a screwdrive the pistons in all the way and remove th stopper bolt and gasket. HINT: Tape the screwdriver tip betore use. ‘Torque: 10 Nem (100 katem, 7 Tb) push piston 5, REMOVE 2 PISTONS AND SPRINGS (@)_ Using soft jaws on the visa, push in the piston with a scrawdriver and remove the snap ring with snap ring pliers. HINT: Tape the screwdriver tip before use. (©) Remove the No.! piston and spring by hand, puling ‘straight out. not at an angle NOTICE: If pulled out and intalld ot an a iby that the eylindar bore could be da ASSEMBLY NOTICE: e careful not t0 bbe tips on the pistons. fag and 2 wooden blocks on the work ta 3d lightly tap the oylinder flange against the block ‘adges until the No.2 piston drops out of the cylinder DISASSEMBLY HINT: Make sure that the distance (A) from the rag to the top of the blocks is at least 100 rim (3.04 ing. here is ® A. famage the (@ Pi MASTER CYLINDER INSPECTION HINT: Clean the disassembled parts with compressed 1. INSPECT CYLINDER BORE FOR RUST OR SCORING 2. INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary. clean or replace the evlinder.R14 (AKE — MASTER CYLINDER, BRAKE BOOSTER. MASTER CYLINDER ASSEMBLY ‘Assombly isin the reverse order of disassembly. | NOTICE: Apply lithium soup bese glycol graase to the rubber parts Indicated by arrows (See poge BR—11 or 19) MASTER CYLINDER INSTALLATION Installation isin the reverse order of removal |EFORE INSTALLATION, ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD (See page BR—15) AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM (Seo page BR 6), CHECK FOR LEAKS, CHECK AND ‘ADJUST BRAKE PEDAL (See pege BR—4) hes BRAKE BOOSTER BRAKE BOOSTER REMOVAL ‘vacuum Hose Level Warning Switch Connector | Brake Master Cylinder Pin @caekat | Wave Washer Diesel E/G fee) e085.) \_ Gonnector [Nim gram, RIT: Species torque © Non-reusabie partBRAS, BRAKE — BRAKE BOOSTER outer 3. @ tb REMOVE MASTER CYLINDER (See page BR-10) REMOVE THESE PART: © Return spring © Clip levis pin and wave washer REMOVE BRAKE BOOSTER Using piss, remove the clip, and disconnect the vacuum hose, Remove the 4 booster instlation nuts and clevs, Remove the booster and gasket. BRAKE BOOSTER INSTALLATION os (a) () @ @ i} Py @ co} @ @ o) ae ee INSTALL BRAKE BOOSTER Install the clevis to the operating rod, Install tha boostar with a new gasket Install ané torque the 4 booster inst Torque: 14 Nim (148 kgem, 10 fib) Inctall the elevis pin into the wave washer, clevie and brake pedal, and install the clip to the clavis pin. Install the padal return spring ADJUST LENGTH OF BOOSTER PUSH ROD Install the gasket on the master cylinder Sot the SST on the gasket, and lower the pin until its tip slightly touches the piston, sr 09737-00010, lation nuts. ‘Turn the SST upside down, and sot it on the booster. SST 09737-00010, Meacure the clearance betwoen the booster push rod and pin head (SST) Clearance: ‘0mm (@ in) ‘Adjust the booster push rod length until the push rod ‘lightly touches the pin head. HINT: When adjusting the push rod, depress the br pedal enough so that the push rod sticks out INSTALL MASTER CYLINDER (See page R14) FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR—€) CHECK FOR FLUID LEAKAGE CHECK AND ADJUST BRAKE PEDAL (See page BR-4) DO OPERATIONAL CHECK (See page BR-5)7 BRAKE — VACUUM PUMP(3L) VACUUM PUMP (3L) COMPONENTS Car] eo-ning ‘Vacuum Hose Union: ‘check valve 740080, 50 Lock Nut 05.075 7 mm (kgtem, W Bt): Specitied torque @ Nen-rousable part VACUUM PUMP REMOVAL 1. DISCONNECT CONNECTORS AND VACUUM Hoses Disconnect the 2 connectors, 2 vacuum hoses and oll inlet union from the alternator and vacuum pump. Torque: 14 Nm (140 kgf em, 10 fbf)KE, Soft Jaws Soft Jaws ) ® VACUUM PUMPI3L) Bee REMOVE ALTERNATOR WIRE Remove the cover nut alternator wire, bolt and wire harness bracket from the alternator. REMOVE ALTERNATOR Loosen the pivet and adjusting bolts, and remove the eve belt 2 bolts and alternator with vacuum pump. REMOVE VACUUM PUMP FROM ALTERNATOR. Remove the 4 bolts and vacuum pump from the alter- nator. Tora 9: 7.8 Nom (80 kaf-em, 68 Init) VACUUM PUMP DISASSEMBLY REMOVE PULLEY Using soft jaws on the vi and pulley. Torque: 105 Mim (1.078 kotem. 78 feb) move the pulley lock nut REMOVE VACUUM HOSE UNION Using soft jaws on the vise, remove the union bolt, Union and 2 gaskets. ‘Torque: 14 Mm (140 ket-em, 10 feb) ‘ASSEMBLY HINT: Align and insert the union pin into ‘tho matching hola of the casing. REMOVE CHECK VALVE Remove the chack valve and gasket. ‘Torque: 74 Nm (760 kgt-om, 54 ftibf) REMOVE END COVER Remove the 4 screws and end cover. ‘Torque: 4.8 Nm (47 kat-em, 41 inBR18 vi /ACUUM PUMP(SL) eR 2s 10. a REMOVE ROTOR SHAFT WITH BEARING Using a plastic hammer, tap out the rotor shaft with beatin REMOVE OIL SEAL STOP RING REMOVE END PLATE Remove the 2 screws and end plate, Torque: 2.0 Nm (20 kgf-em, 17 in bf) REMOVE O-RING REMOVE ROTOR AND 5 BLADES IF NECESSARY, REMOVE BEARING Using a procs, remove the bearing from the rotor shaft. REMOVE OIL SEAL Using 2 screwdriver, remove the oll seal. [ASSEMBLY HINT: Use SST and » hamm oil sea SST 0995060010 (09951 --00400), (09950-70010 (09951-07150)it vacuum Pump Bide -cpe~ Hose Sie ews =e KE vACUUM VACUUM PUMP INSPECTION MP{aL) 1. INSPECT BLADE (a) Chack the blades for waar or damage. (©) Using a microm sure the height. width anc longth of the bl ‘Minirnum height: 12.20 mm (0.4803 in) (Minionum widths £22.88 mm (0.4047 in) It necessary, replace the blade. 2, INSPECT CHECK VALVE OPERATION (a) Chack that air flowes from the hase side to the pump side, (©) Check that air does not flow from the pump side tothe hose side, If necessary, replace the check valve. VACUUM PUMP ASSEMBLY Assombly Is in the roverse order of disassombly. VACUUM PUMP INSTALLATION Installation ie in the reverse ordor of removal. ‘AFTER INSTALLATION, ADJUST BELT TENSIONBR nay BRAKE ~ VACUUM PUMP(1K2—T, 1KZ—TE) VACUUM PUMP (1KZ—T, 1KZ—TE) COMPONENTS, Gasket Sirsight Ne 14088 19) Cree vane (recrs.50] eeeBRAKE ~ VACUUM PUMP(1K2—T, 1k2—TE) VACUUM PUMP REMOVAL REMOVE VACUUM PUMP. (@) Disconnect the 2 hoses from the vacuum pump. (b) Remove the 2 nuts and pump from the engine. Torque: 21 Nim (210 kgt.em. 18 feibt) (6) Remove the 2 O-rings. VACUUM PUMP DISASSEMBLY ~ Ee 1. REMOVE VACUUM HOSE UNION Using soft jaws on the visa, remove the union bolt, union and 2 gaskets. Torque: 14 Nim (140 kgt-em, 10 fib) 2. REMOVE CHECK VALVE Remove the check valve and gasket. “Torque: 74 Nim (750 kgt-om, 64 fe1bf) 3. REMOVE END COVER @8R22 SRE BRAKE = VACUUM PUMPUIKZ=T, IKE) F Soft Jaws CO) cy) @ (®) 6 © Place the vacuum pump on vise, NOTICE: De not tightan the v Using a pin punch and hammar. drive out the 2 strat ‘ht pins. Remove the end cover and 2 O-rings. REMOVE ROTOR AND 5 BLADES ASSEMBLY HINT: Before installation, apply engine ol! to the rotor and bind REMOVE GEAR Using soft jaws on the vise, clamp the gearin the vise, Remove the lock nut ue: 110 Nim (1,125 kaf.em, 81 F1bF) Remove the gear and woodrutt key. REMOVE SNAP RING Using snap ring pliers. eamove the snap ting. REMOVE ROTOR SHAFT Using a plastic harnm ap out the rotor shaft. ASSEMBLY HINT: Use a pre to the rotor shaft, Intell @ new bearing12-11 14k ia \ tna a wo CS YYacuum Pump Hose Side Pa VACUUM PUMP(IKz. 8 REMOVE BEARING Using @ press and 17 mm socket, press out the bear- ‘ASSEMBLY HINT: 6 SST and a press, in the rotor shaft to the casing ST 09608-04031 VACUUM PUMP INSPECTION 1 @ ) © INSPECT BLADES CCheck the blades for wear or damage. Using a micromet Minimum height: r measure the height, width and length of the blades. 16.50 mm (0.6496 in) Minimum width: 5.95 mm (0.2343 in.) Minimum length 44.96 mm (1.7701 in) HW necessary, replace the blades. INSPECT CHECK VALVE OPERATION CCheck that air flows from the hore side to the pump. side. (Check that air does not flow from the pum side to the hose side H necessary. place the check valve. INSPECT INSIDE SURFACE OF CASING Inepact the inside eurtace on the casing for scoring, H necessary. replc ‘the vacuum pump assembly.BR24 aiid /ACUUM PUMP(IKZ—T. 1K: VACUUM PUMP ASSEMBLY Assembly isin the reverse ordor of disassombly. VACUUM PUMP INSTALLATION jon it in the reverse order of remo BRBRAKE — FRONT BRAKE Bes FRONT BRAKE COMPONENTS. ant-Squest Cece Shim’ Set Ring Innor Ant-Squea! Q es, gala Pad, (Oy i Ohio ag Og dy ofa Piston Seat outer Pad Se tip [Bre Nim (igh em, WBA): Specie torque BRAKE PADS REPLACEMENT 1. REMOVE FRONT WHEEL 2. INSPECT PAD LINING THICKNESS ‘Check the pad thickness and raplace pads if not within the specification 1.0 mm (0.039 In) 3. REMOVE THESE PARTS: lip 2oins ‘Anti=rattle spring 2 pat 4 anti~equeal shims NOTICE: The anti-ratte spring can be used egein pro vided that they havo sufficient reboun cracks or wear, and have heBR BR28 BRAKE ~ FRONT BRAKE 4. @ ® @ @ CHECK DISC THICKNESS AND RUNOUT (See page BR-28) INSTALL NEW PADS NOTICE: When replacing worn pads. the anti—squeal shims must be replaced together withthe ped. ‘amount of brake fluid from the Press in the pietone with a monkey wrench hand an equivalent. HINT: ‘+ Tape the monkey wrench handle before use ‘* Always change the pad on one wheel at a time as ‘there is possibilty of the opposite piston fying ‘© the piston is difficult to push in, loosen the blader plug and push in the piston while latting some brake fluid escape, Install the anti~squeal shims to 2 new pads. to both sides of the BR-25) Install the 2 pads. NOTICE: Da not alow oi! or face. INSTALL ANTI-RATTLE SPRING AND 2 PINS INSTALL CLIP yoton the rubbing CALIPER REMOVAL REMOVE FRONT WHEEL DISCONNECT BRAKE LINE Using SST, disconnect the brake line. ‘ssT 09023-00100 Torque: 18 Nim (156 kat-em, 19 Feibf) REMOVE CALIPER Remove the 2 mounting bolts and calip Torque: 123 N-m (1.280 kotem, 00 fbf) REMOVE THESE PART: © Clip © 2pins © Antirattle spring © 2 pads © 4 anti—squeal shims‘eran form RAKE — FRONT BRAKE li CALIPER DISASSEMBLY 1. REMOVE CYLINDER BOOT SET RINGS AND BOOTS Using @ screwdriver, remove the 4 cylinder boot set rings and boots . REMOVE PISTONS FROM CYLINDER {e)_ Prepare the wooden plate to hold the pistons. (©) Place the plate betwoen the pistons and insert a pad at one side, (6) Use compressed air 1o remove the pistons alternately from the eying DISASSEMBLY front of th \UTION: De net place your fingers in tons when using compressed al 3, REMOVE PISTON SEALS. Using a screwdriver, remove the 4 piston seals from the evlind CALIPER ASSEMBLY si ‘Assembly isin the reverse order of disassembly. NOTICE: Apply lithium soap bate glycol gresse to the ports indicated by the arrows (See page BR~25).(BR R28 BRAKE ~ FRONT BRAKE FRONT BRAKE COMPONENTS: INSPECTION AND REPAIR 1 @ o @ (MEASURE PAD LINING THICKNESS Using 8 ruler, measure the pad lining thickness. ‘Standard thicknest: 11.5 mm (0.453 in) Minimum thicknees: Replace the pad if the thickness is less than the minimum (the 1,0 mm ait is no longer visible, or if shows signs of uneven wear (MEASURE DISC THICKNESS Using @ micrometer, measure the Standard thickness: 22.0 mm (0 Minimum thickness: 20.0 mm (0.787 in) tthe dise is scored or worn, ori its thickness is less than the minimum, repair or replace the dis MEASURE DISC RUNOUT Using a dial indicator, measure the dise runout at 3 position 10 mm (0:39 in) from the outside edge. Maximum dise runout: 0.07 mm (0.0028 in) If the runout is greater than the maximum, rapa dice. HINT: Before measuring the runout, confirm that the front hub bearing play is within the specification IF NECESSARY, ADJUST DISC RUNOUT Remove the hub nuts and disc. Reinstall the dise 1/6 fof a turn round from ite original position on the hub, Install and torque the hub nuts Flomeasure the dise runout. Make a note of the runout and the dise’s position on the hub. Repeat (a) until the disc has been installed on the 4 maining hub position. If the minimum runout recorded in (a) and () is less than the maximum dige runout, inetall the dige in that If the minimum runout recorded in (a) and (6) is greater than the maximum dise runout, replace the disc and repeat step 3. ise thickness. ny theBR20 AKE, CALIPER INSTALLATION RONT BRAKE Installation isin the reverse order of removal. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM (See }R—8) AND CHECK FOR LEAKSeR RAKE ~ REAR BRAKE(Drum B REAR BRAKE (Drum Brake) COMPONENTS aia ai Pin—9 7” ransion Spring ‘i ely T pace hes Baring Bate KE /hn Belcrerk Bracket |B, , mel inpecion Ho eA — Webs of Pup z Tee ‘5 Deceleration . W Engine| RY eae cee foom| Bh neg Jaur sano) AL A mn ws 4 [EJeser 2 % \ # CG vam 4 323 oy rund) se duo yen TE MMO) ID URMOY Cornetass) BRAKE INSPECTION PROCEDURE NTLLOCK BRAKE SYSTEM 1 | Check battery voltage Voltage: 10-14 1a ek and p te trig sete 2 | Check voltage between terminals IG1 and GND of ABS ECU connector. PREPARATION: Fomove ABS ECU with connectors stil connected. CHECK: (@)__Turm the igntion switch ON, (©) Moasure voltage between terminals IG1 and GND of ABS ECU connector. ox: Voltage: 10-14. 0k | check and replace ABS ECU. L 3 | Check continuity between terminals GND of ABS ECU connector and body l ground. Too CHECK: © Measure resistence between terminals GND of ABS ECU con nector and body ground, cy Resistance: 1 20 a NG_)|Repair or replace harness or connector.eres RAKE — ANTI-LOCK BRAKE SYSTEM 4 | Check ECULIG fuse. ‘PREPARATION: Driver See 8 tei NG \ [Check for shor in all the harness and compo. Inonts connected to ECU-IG fuse (See attached wiring diagram). OK ‘Check for open in harness and connector between ABS ECU and battery (See page IN-30)..ores BRAKE — ANTI-LOCK BRAKE SYSTEM pTc 43 Malfunction in Deceleration Sensor CIRCUIT DESCRIPTION rene (Te Owing Coston Tot es Thera alae) 2) ad (0 serie te were coe tom Secure se does rales c0 {Ghar han Ohh» Own 5 8 (2) ro mrt pc et ars verte asda Sow armas lowarsand ac {nore man Gh east 9 sears or or wee nares cocseaton sansa sso INSPECTION PROCEDURE 1 | Check doceter ion sensor (See page BR-59). Na |Roplace deceleration sensor. oK age I 2 | Check for pen or short in harness and connector between sensor and ECU (See NG |Repair or replace harness and connector. 0K ‘Check and repiece ABS ECU.RAKE — ANTI-LOCK BRAKE SYSTEM bTc 44 Deceleration Sensor Circuit CIRCUIT DESCRIPTION ‘This sensor detocts deceleration on the vehicle. The sensor signal is used in ABS control. tthe sensor func- tions abnormally, the ABS warning ight comes on but the ABS stil operates. Dro ose Goan l (syanepan oon cane St Se (aye grton red ON te sri oat | ty OSt Siege, Hea eg ocd WIRING DIA GRAM Driver Side 8 Contor Ji = eee = As ECU ECUIG Deceleration Sensor cer ABs ECUBR88 BRAKE INSPECTION PROCEDURE 1 sor and ECU (See page IN- ANTI-LOCK BRAKE SYSTEM 30). | [«] | ne purr ort nme comeco, 2. | Check voltage between terminals GS1, GS2, GST of ABS ECU and body ground. PREPARATION: (a) Remove ABS ECU with connectors sill connected, (©) Disconnect deceleration sensor connector. (6) Turn the igntion switch ON. CHECK: Measure voltage between terminals GS1, GS2, GST of ECU ‘and Body ground, OK: Voltage: G81, G82: About 5 V GST: As shown bolow on iosw | OFF nv st eee eaten ov ——__] (Check and replace ABS ECU.BRAKE ANTI-LOCK BRAKE SYSTEM ares Dre 48 | Rear Differential Lock Circuit (w/Rear Differential Lock) CIRCUIT DESCRIPTION as Die ncig Coat Tene (a | Smretcr nee dieris ecran | Row stootalek rencrawes eur a WIRING DIAGRAM Diverse 8 [SMG yvee Side WB Contr 8 Oe Se EM 7] nw if Fs 5 | pearoire. tock 322 !8r0) tnaee| 2 Indenortgh — Besiet, | ABB.EGU Boom | [gl Jams Frees mu ef te ax Alexa 48 eo Fi m ifr Lock Detection = Switch [Ferrer INSPECTION PROCEDURE HINT: Roar diforontal lock switch is OFF 1 Check the rear differential lock is trae (See page SA-105). OK NG [Repair the rear differential tock system.ene, BRAKE — ANTI.LOCK BRAKE SYSTEM, 2 | Is DTC output? Check DTC on page BF-58. no )|Normat. ves Ne 3. | Check that REAR DIFF. LOCK indicator light does not go off. No }|coto steps. ves 4 | Check that bulb for REAR DIFF. LOCK indicator light is not burnt out. Yes )|Replace indicator light. No 3 | Check for open im harness and connector between batiory and REAR DIFF. LOCK indicator light, REAR DIFF. LOCK indicator light and ABS ECU (See pag IN-30). 1a reir pan ana or comer [*]BRAKE — ANTI-LOCK BRAKE SYSTEM. ee 6 | Check for short in harness and connector botwet light and ABS ECU (See page IN-30). i= Check and replace ABS ECU. REAR DIFF. LOCK indicator NG |Repair or replace harness or connector.aca [BRAKE — ANTI.LOCK BRAKE SYSTEM tc 49 | Stop Light Switch Circuit CIRCUIT DESCRIPTION ‘This sop ight switch senses whether he brake pedal is depressed or released, and sends the signa tothe ECU. WIRING DIAGRAM ai Engine Room FB Stop Light Switch ag 1 cw Aas ecu 319 WH) 23s (0) STOF retin Connector TA ln x | | fe oF aly . | ; oR ce | a : eee 7 oe as ao) tb 4 Is i vi stor & lum stop [@ JAH Sto» [_G ]re sto mt ae [obs "© [eam gh iar é tise (ek z "we st eF ee t ac a 1: LHD bw Tralee Socket and RHO 2 Lio wie Tra Socket 2 ero and Aur ES. Excont Europe mnBRAKE ones INSPECTION PROCEDURE ANTI.LOCK BRAKE SYSTEM 1. | Check operation of stop light. CHECK: ‘Check that stop ight ights up when brake pedal is depressed and turns off when brake pedal is released. NG )|Repair stop ight circuit (See page BE-33), 2. | Check voltage between terminal STP of ABS ECU and body ground. PREPARATION: Flomave ABS ECU with connectors stl connected. CHECK: Hoazue volagebetwoontrminal STP of ABS ECU and body [RE around when brake pedal is depressed. on Voltage: 8 ~ 14 0k \, [Proceed to next circuit inspection shown on pr lem symptoms table (See page BR-67). NA 3. | Check for open in harness and connector between ABS ECU and stop light switch (See page IN-30), NG | Repair or replace harness or connector. OK Le (Check and replace ABS ECU. PE ree eee Eee eee oeer96 BRAKE — ANTLLOCK BRAKE SYSTEM, | DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION Brehe Die Dong Conon Tah ae 51 | mpi rt eng roma ag nance [ABS rw nae WIRING DIAGRAM Fall safe function: Itrouble occurs in the ABS pumo motor, (soloncia rlay and prohibits ABS control the ECU cuts of curent tothe ABS contol ve a Seog Ra ay 2 eo 2 we — fi cual] eCheck oom lass TA Re | a! ] Connector g i di { Engine nt gk [= |ABs gcu we |! - ‘ace? | | 3% as MB remy, y a Hh "ABS Retuator— © \w sw! + tk 5a? 4: UID Al models RO wale a. OND TET ana 142 TE EIS HD All models HD w Creo Control LHD Al models HD w/o Cauise Control =BRAKE — ANTI-LOCK BRAKE SYSTEM ABS Warning Light Circuit CIRCUIT DESCRIPTION Ifthe ECU detects trouble it lights the ABS warning light while atthe same time prohibiting ABS control. At this timo, the ECU records a DTC in memory. [After removing the short pin of the check connector, connect terminals Te and E, ofthe check connec tor to make the ABS warning ight Bink and output the OTC. WIRING DIAGRAM aatery "on De Sie 8 | fees a RIGE cone sre J6 HO) A) “se | Seton | f a Somer Fries Dass | 224 s sre aa ale Be 18 (LHD) ey Ex Tego aps actor S22 nnDI Je w — Sireton. | {aes ecu re Connector NM | LEE ans ecu iia 6 ck | oat aa ee Cot | at: LHD At models Rio Deege EG sia IND ET and 1K2-TE EG fob Al modes 33 RND w Crise Contot 4 LHD At models FD wo Crise Contd = INSPECTION PROCEDURE Troubleshooting in accordance with the chart below fr each toubl symptom. ABS oa coi [aes nang eae coma 1. | Check ABS warning light. ‘See Combination Mat r Troubleshooting on page BE-50 NG )|Repair bulb or combination meter assembly.Ed BRAKE ANTILOCK BRAKE SYSTEM 2. [etek ans cont ey, PREPARATION: ‘isconnect the connectors from control relay. HEC? Check continuity between each terminal of ABS contro relay Ok: OK Tanna Aba ASS Corina eres va Tremont rd A ma CHECK: (a) Apply battery voltage between terminals AB-1 and AQ 3 (b) Chock continuity between each terminal of ABS contro! relay. ok: Tenia AOS ABS oer ae Tein Ae Bana APE Conny (CHECK: Connect the & test leas to terminal @ of AB and the ©: test lead to terminal § of AB. Check continuity between the ter rinals ok: Continuity If there is no continuity, connect the © test lead to ter minal 4 of AB and the 4 lead to terminal 5 of AB, Recheck continuity between terminals. wa repent ‘round {85 Check fo open in harness and connector Detwesn check connector and ABS conlrelay and bodyBRAKE ANTL-LOCK BRAKE SYSTEM. eae 3. | ts DTC output? Check DTC on page BF-58. No Lo ves [Repair circuit indicated by the code output. 4 | Does ABS warning light go off if short pin is removed? ves LJ WO [Check for short in harness and connocior bet warning light and check connector and (See page IN-20). 5. | Check ABS control relay (See step 2) OK SN SP, Replace ABS control relay. Check for page IN-30). hort in harness and connector between check connector and ABS control relay (SeeBRAKE — ANTI-LOCK BRAKE SYSTEM ‘Te Terminal Circuit CIRCUIT DESCRIPTION Connecting terminals Te and E, of the check connector causes the ECU to display the DTC by flashing the ABS warning light. WIRING DIAGRAM Tie Aa) 522 (RHO) aga ec Dunetion Sea ‘annector nav Connector s a 18 20| Te | BR BRIE, Iragy — PL_F| FPL 1 pe Plena ee S13 (LHD) |) ‘28 RHO ZS) 3 Sg OE, LHD (9R2-F and 1K2-7 B/G) RHO (3RZ Fl and 1K2-TE E/G Except IRZ F, TKZT end 1K2TE E/G Others INSPECTION PROCEDURE 1. | Check voltage between terminals Te and E; of check connector. & = CHECK: i (@)__ Turn the ignition switch ON. 0 D {b] Measure voltage botwoon terminals Te and Ey of check O Voltage: 10-14 V eid Check Connect0r jam ‘OK \ [I ABS warning light dows not Blink oven after T and &; are connected, the ECU may be detec- tive.IAKE — ANTILOCK BRAKE SYSTEM, — 2 | Check for open and short in harness and connector between ABS ECU and check connector, check connector and body ground (See page IN-30) [=] (Check and replace ABS ECU. Na )|Repair or replace harness or connector.R100 BRAKE — ANTI-LOCK BRAKE SYSTEM Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the DTC check Connecting terminals Ts and E; of the check connector in the engine compartmant starts the check. WIRING DIAGRAM 485 ECU gv Check Connector of | a ‘ 13H A Lae wHoy TE gl sunetion |_ 15 EL: LHD (QRZ and 142-7 €/6) 222. KD (GRZ-Fl and TKZ-TE 1G YY 23: Excopt GAZ, TKZ-T and TK2-TE E/G A Others INSPECTION PROCEDURE 1. | Check voltage between terminals Ts and E; of check connector. ‘CHECK: {@)__Turm the ignition switch ON, (b) Measure voltage between terminals Ts and E, of check Voltage: 10-14 Check Connector miner ‘OK \ [if ABS warning light does not blink even atter Ts] and Ey are conecied, he ECU may bo detec: ve. NGBRAKE. ANTI-LOCK ORAKE SYSTEM: 5-101 2 | Check for open and short in hamess and connector between ABS ECU and check connector, check connector ind body around (See page IN-30), oK NG Repair or replace harness or connector. ‘Check and replace ABS ECU.prt02 BRAKE — ANTI-LOCK BRAKE SYSTEM Check for Fluid Leakage (Check for fuid leakage from actuator or hydraulic lines.R103 BRAKE ~ SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA [ine seine rom ana sew Moe ten 95 (749 Om in) ‘estan punp Bags begh (SLEPe) Memon” | 1220 rm (04803 WHET and TRE TE 76) Minor | 150 me 8.6496) (SL €/0) Minmwe TF 9nd ETE £76) Minn | 695 rn (02948 np (0849) — TBLE/G) Minmwm | 220 mm (4087 TREAT 968 TKE=TE €/6) Mimn_| 4498 mm (1.7701 Mirimun_| 10mm 0039 ni 570. | 220 mn 8866 n) Wainwn_| 200m (0787 0) ‘wexmum| 967 rm (6026 mt STO_| 2060 mm (11814 wd Terman | 297.9 (1.689) 510 | 80mm 236m) Tao 0890 315 mm 0.008 HI aw take Ge ale ( Fating tae ie ne eee Onn BIST) binum | 10m (0098 n) arting Be vera a 68 WOKS A 3 Wee ae wn 038 wm 6S) Prting tn ating enim ihre 03 mm O12) 28mm 024in) 09mm 00386)| aR BR.104 TORQUE SPECIFICATIONS BRAKE ~ SERVICE SPECIFICATIONS Se Seat E co [Lrteim pone x ont vr [Treaun pan ok at 108 (Reston ou xeon a eae pp ac a 1 Bente co 300 oH Tint] aT 1 a omen | 90 a