Table of Contents 4- i

Section 4

Brakes
CONTENTS

Brake Control System and Diagnosis .. 4A–1 Brake Pedal Position Sensor Replacement ..... 4A–34
General Description ............................................ 4A–1 Brake Pedal Position Sensor Calibration ......... 4A–35
Hydraulic Brake System Stop Lamp Switch Adjustment ......................... 4A–35
Description and Operation ............................... 4A–1 Stop Lamp Switch Replacement ...................... 4A–36
Brake Assist System Front Brake Hose Replacement....................... 4A–36
Description and Operation ............................... 4A–1 Rear Brake Hose Replacement ....................... 4A–38
Brake Warning System Brake Pipe Replacement ................................. 4A–40
Description and Operation ............................... 4A–1 Brake Pipe and Hose Inspection...................... 4A–43
Schematic and Routing Diagram....................... 4A–2 Master Cylinder Fluid Level Sensor
Hydraulic Brake Schematics .............................. 4A–3 Replacement .................................................. 4A–44
Master Cylinder Reservoir Replacement ......... 4A–45

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Hydraulic Brake Connector End Views .............. 4A–4
Hydraulic Brake Pipe Routing - Master Cylinder Replacement.......................... 4A–46
Master Cylinder to ABS.................................... 4A–5 Master Cylinder Bench Bleeding...................... 4A–48
Vacuum Brake Booster Check Valve and/or 4
Component Location .......................................... 4A–6
Hose Replacement......................................... 4A–49
Hydraulic Brake Component Views ................... 4A–6
Vacuum Brake Booster Replacement .............. 4A–50
Diagnostic Information and Procedures........... 4A–8
Specifications.................................................... 4A–52
Diagnostic Starting Point - Hydraulic Brakes ..... 4A–8
Fastener Tightening Specifications -
Scan Tool Data List - Hydraulic Brakes ............. 4A–8
Hydraulic Brakes ............................................ 4A–52
Scan Tool Data Definitions - Hydraulic Brakes .. 4A–8
Fastener Tightening Specifications - Lighting .. 4A–52
DTC C0267 ........................................................ 4A–8
Brake Component Specifications ..................... 4A–53
Symptoms - Hydraulic Brakes............................ 4A–9
Brake System Specifications............................ 4A–53
Brake Warning Indicator Malfunction ............... 4A–10
Brake Pulsation ................................................ 4A–11 Special Tools and Equipment .......................... 4A–53
Brake System Noise ........................................ 4A–11 Special Tools - Hydraulic Brakes ..................... 4A–53
Braking Action Uneven - Pulls to One Side ..... 4A–12
Front Brakes............................................ 4B–1
Braking Action Uneven - Front to Rear ............ 4A–13
Brake Pedal Excessive Travel ......................... 4A–13 Precautions.......................................................... 4B–1
Brake Pedal Excessive Effort........................... 4A–14 Brake Dust Caution ............................................ 4B–1
Brakes Drag ..................................................... 4A–14 Brake Fluid Irritant Caution ................................ 4B–1
Brake System Slow Release............................ 4A–15 General Description ............................................ 4B–1
Brake Fluid Loss .............................................. 4A–16 Disc Brake System Description and Operation .. 4B–1
Hydraulic Brake System Diagnosis .................. 4A–16 Diagnostic Information and Procedures ........... 4B–2
Brake Assist System Diagnosis ....................... 4A–20 Diagnostic Starting Point - Disc Brakes ............. 4B–2
Brake System Vehicle Road Test .................... 4A–22 Disc Brake System Diagnosis ............................ 4B–2
Brake Pedal Travel Measurement and Brake Rotor Thickness Measurement................ 4B–8
Inspection....................................................... 4A–23 Brake Rotor Thickness Variation
Brake System Vacuum Source Test ................ 4A–23 Measurement ................................................... 4B–8
Brake System External Leak Inspection .......... 4A–24 Brake Rotor Assembled Lateral Runout
Brake System Internal Leak Test ..................... 4A–24 Measurement ................................................... 4B–9
Hydraulic Brake Component Operation Visual Repair Instructions ........................................... 4B–11
Inspection....................................................... 4A–25 Front Disc Brake Pads Replacement ............... 4B–11
Repair Instructions ........................................... 4A–26 Brake Pad Inspection ....................................... 4B–13
Master Cylinder Reservoir Filling ..................... 4A–26 Brake Pad and Rotor Burnishing...................... 4B–13
Hydraulic Brake System Bleeding (Pressure) .. 4A–26 Front Brake Caliper Replacement.................... 4B–14
Hydraulic Brake System Bleeding (Manual)..... 4A–28 Brake Caliper Inspection .................................. 4B–16
Hydraulic Brake System Flushing .................... 4A–29 Front Disc Brake Hardware Replacement........ 4B–17
Brake Pedal Assembly Replacement............... 4A–30 Front Disc Brake Mounting and
Brake Pedal Pushrod Inspection...................... 4A–33 Hardware Inspection ...................................... 4B–19
4- ii Table of Contents

Front Brake Caliper Bracket Replacement....... 4B–20 Brake Rotor Refinishing ................................... 4C–28
Front Brake Rotor Replacement ...................... 4B–21 Specifications .................................................... 4C–29
Brake Rotor Surface and Wear Inspection....... 4B–22 Fastener Tightening Specifications -
Brake Rotor/Drum Balance Inspection............. 4B–23 Disc Brakes .................................................... 4C–29
Front Brake Shield Replacement ..................... 4B–24 Disc Brake Component Specifications ............. 4C–29
Brake Rotor Assembled Lateral Runout Special Tools and Equipment .......................... 4C–30
Correction....................................................... 4B–24 Special Tools - Disc Brakes ............................. 4C–30
Brake Rotor Assembled Lateral Runout
Correction - Indexing...................................... 4B–25 Parking Brake ......................................... 4D–1
Brake Rotor Assembled Lateral Runout General Description ............................................ 4D–1
Correction - Correction Plates........................ 4B–26 Park Brake System
Brake Rotor Assembled Lateral Runout Description and Operation ............................... 4D–1
Correction - On Vehicle Lathe........................ 4B–27
Diagnostic Information and Procedures ........... 4D–2
Brake Rotor Refinishing ................................... 4B–28
Diagnostic Starting Point - Park Brake ............... 4D–2
Specifications.................................................... 4B–29 DTC B0005 ........................................................ 4D–2
Fastener Tightening Specifications - Symptoms - Park Brake ..................................... 4D–3
Disc Brakes .................................................... 4B–29 Park Brake Will Not Hold or Release ................. 4D–3
Disc Brake Component Specifications ............. 4B–29 Park Brake System Diagnosis............................ 4D–4
Special Tools and Equipment .......................... 4B–30 Repair Instructions.............................................. 4D–6
Special Tools - Disc Brakes ............................. 4B–30 Park Brake Adjustment ...................................... 4D–6
Park Brake Shoe Replacement .......................... 4D–8
Rear Brakes ............................................. 4C–1

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Park Brake Lever Assembly Replacement......... 4D–9
Precautions.......................................................... 4C–1 Park Brake Warning Lamp Switch
Brake Dust Caution ............................................ 4C–1 Replacement .................................................. 4D–11
Brake Fluid Irritant Caution ................................ 4C–1 Parking Brake Front Cable Replacement......... 4D–11
General Description ............................................ 4C–1 Parking Brake Rear Cable Replacement ......... 4D–12
Disc Brake System Parking Brake Actuator Replacement .............. 4D–16
Description and Operation ............................... 4C–1 Park Brake Hardware Inspection ..................... 4D–17
Diagnostic Information and Procedures ........... 4C–2 Specifications .................................................... 4D–18
Diagnostic Starting Point - Disc Brakes ............. 4C–2 Fastener Tightening Specifications -
Disc Brake System Diagnosis ............................ 4C–2 Park Brake ..................................................... 4D–18
Brake Rotor Thickness Measurement................ 4C–8 Special Tools and Equipment .......................... 4D–18
Brake Rotor Thickness Variation Special Tools - Park Brake............................... 4D–18
Measurement ................................................... 4C–8
Brake Rotor Assembled Lateral Runout ABS........................................................... 4E–1
Measurement ................................................... 4C–9 Precautions.......................................................... 4E–1
Repair Instructions ........................................... 4C–11 ABS Component Handling Caution .................... 4E–1
Brake Pad and Rotor Burnishing...................... 4C–11 General Description ............................................ 4E–1
Rear Disc Brake Pads Replacement................ 4C–11 ABS Description and Operation ......................... 4E–1
Brake Pad Inspection ....................................... 4C–13 Schematic and Routing Diagram ....................... 4E–4
Rear Brake Caliper Replacement .................... 4C–14 Antilock Brake System Schematic Icons ............ 4E–4
Brake Caliper Inspection .................................. 4C–16 Antilock Brake System Schematics.................... 4E–4
Rear Disc Brake Hardware Replacement ........ 4C–17 Antilock Brake System Connector End Views.... 4E–8
Rear Disc Brake Mounting and
Component Location ........................................ 4E–12
Hardware Inspection ...................................... 4C–18
Antilock Brake System Component Views ....... 4E–12
Rear Brake Caliper Bracket Replacement ....... 4C–20
Rear Brake Rotor Replacement ....................... 4C–21 Diagnostic Information and Procedures ......... 4E–17
Brake Rotor Surface and Wear Inspection....... 4C–22 Diagnostic Starting Point -
Brake Rotor/Drum Balance Inspection............. 4C–23 Antilock Brake System ................................... 4E–17
Rear Disc Brake Backing Plate Scan Tool Output Controls -
Replacement .................................................. 4C–24 Antilock Brake System ................................... 4E–17
Brake Rotor Assembled Lateral Runout Scan Tool Data List -
Correction....................................................... 4C–24 Antilock Brake System ................................... 4E–17
Brake Rotor Assembled Lateral Runout Scan Tool Data Definitions -
Correction - Indexing...................................... 4C–25 Antilock Brake System ................................... 4E–18
Brake Rotor Assembled Lateral Runout Diagnostic Test Drive ....................................... 4E–19
Correction - Correction Plates........................ 4C–26 Initialization Sequence ..................................... 4E–19
Brake Rotor Assembled Lateral Runout DTC C0035-C0050 .......................................... 4E–20
Correction - On Vehicle Lathe........................ 4C–27 DTC C0110 ...................................................... 4E–22
DTC C0131 ...................................................... 4E–24
 Table of Contents 4- iii

DTC C0161 ...................................................... 4E–25 Antilock Brake System

DTC C0186 ...................................................... 4E–26 Automated Bleed Procedure .......................... 4E–46
DTC C0196 ...................................................... 4E–28 Steering Angle Sensor Centering..................... 4E–47
DTC C0201 ...................................................... 4E–30 Electronic Brake Control Module
DTC C0252 ...................................................... 4E–31 Replacement .................................................. 4E–47
DTC C0280 ...................................................... 4E–32 Electronic Brake Control Module
DTC C0292 ...................................................... 4E–33 Programming and Setup ................................ 4E–48
DTC C0460 ...................................................... 4E–34 Brake Pressure Modulator Valve
DTC C0550 ...................................................... 4E–35 Replacement .................................................. 4E–49
DTC C0551 ...................................................... 4E–36 Brake Pressure Modulator Valve Bracket
DTC C0561 ...................................................... 4E–36 Replacement .................................................. 4E–51
DTC C0899 ...................................................... 4E–37 Front Wheel Speed Sensor Replacement........ 4E–52
DTC C0900 ...................................................... 4E–38 Rear Wheel Speed Sensor Replacement ........ 4E–53
Symptoms - Antilock Brake System ................. 4E–38 Electronic Traction Control Switch
ABS Active Indicator Always On ...................... 4E–39 Replacement .................................................. 4E–54
ABS Active Indicator Inoperative ..................... 4E–40 Vehicle Yaw Sensor Replacement................... 4E–55
Traction Control Indicator Always On .............. 4E–42 Specifications.................................................... 4E–55
Traction Control Indicator Inoperative .............. 4E–44 Fastener Tightening Specifications -
Repair Instructions ........................................... 4E–46 Antilock Brake System ................................... 4E–55

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4A-1 Brake Control System and Diagnosis:

Brake Control System and Diagnosis

General Description
Hydraulic Brake System Description and Brake Assist System Description and
Operation Operation
System Component Description System Component Description
The hydraulic brake system consists of the following: The brake assist system consists of the following:
Hydraulic Brake Master Cylinder Fluid Reservoir: Brake Pedal: Receives, multiplies and transfers brake
Contains supply of brake fluid for the hydraulic brake system input force from driver.
system. Brake Pedal Pushrod: Transfers multiplied input force
Hydraulic Brake Master Cylinder: Converts received from brake pedal to brake booster.
mechanical input force into hydraulic output Vacuum Brake Booster: Uses source vacuum to
pressure. decrease effort required by driver when applying
Hydraulic output pressure is distributed from the brake system input force.
master cylinder through two hydraulic circuits, When brake system input force is applied, air at
supplying diagonally-opposed wheel apply circuits. atmospheric pressure is admitted to the rear of both
Hydraulic Brake Pressure Balance Control System: vacuum diaphragms, providing a decrease in brake
Regulates brake fluid pressure delivered to hydraulic pedal effort required. When input force is removed,
brake wheel circuits, in order to control the vacuum replaces atmospheric pressure within the

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distribution of braking force. booster.
Pressure balance control on non-ABS equipped Vacuum Source: Supplies force used by vacuum brake
vehicles, is achieved through a proportioning valve booster to decrease brake pedal effort.
assembly. Vacuum Source Delivery System: Enables delivery
Pressure balance control on ABS equipped vehicles, and retention of source vacuum for vacuum brake
is achieved through dynamic rear proportioning booster.
(DRP), which is a function of the ABS modulator.
Refer to “ABS Description and Operation: ” in System Operation
Antilock Brake System for specific information on the Brake system input force is multiplied by the brake pedal
operation of DRP. and transferred by the pedal pushrod to the hydraulic
Hydraulic Brake Pipes and Flexible Brake Hoses: brake master cylinder. Effort required to apply the brake
Carries brake fluid to and from hydraulic brake system is reduced by the vacuum brake booster.
system components.
Hydraulic Brake Wheel Apply Components:
Converts hydraulic input pressure into mechanical
Brake Warning System Description and
output force. Operation
Brake Warning Indicator
System Operation The instrument panel cluster (IPC) illuminates the Red
Mechanical force is converted into hydraulic pressure by Brake Warning indicator when one or more of the
the master cylinder, regulated to meet braking system following occurs.
demands by the pressure balance control system, and • The body control module (BCM) detects that the park
delivered to the hydraulic brake wheel circuits by the brake is engaged.
pipes and flexible hoses. The wheel apply components • The IPC detects a low brake fluid condition. The IPC
then convert the hydraulic pressure back into receives a low brake fluid signal from the low brake
mechanical force which presses linings against rotating fluid switch in the master cylinder reservoir requesting
brake system components. illumination.
• The electronic brake control module (EBCM) detects
an ABS malfunction which disables dynamic rear
proportioning (DRP). The IPC receives a GMLAN
message from the EBCM requesting illumination.
• The IPC performs the bulb check at the start of each
ignition cycle. The Red Brake Warning indicator
illuminates for approximately 3 seconds before turning
OFF.
• The IPC detects a loss of GMLAN communications
with the EBCM.
 Brake Control System and Diagnosis: 4A-2

Schematic and Routing Diagram

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4A-3 Brake Control System and Diagnosis:

Hydraulic Brake Schematics

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 Brake Control System and Diagnosis: 4A-4

Hydraulic Brake Connector End Views Park Brake Switch

Brake Fluid Level Switch

Connector Part Information

Connector Part Information OEM: 12047682
OEM: 12162195 Service: 12101850
Service: 88987993 Description: 1-Way F Metri-Pack 150 Series (BK)
Description: 2-Way F Metri-Pack 150.2 Series, Terminal Part Information
Sealed, Pull To Seat (BK) Terminal/Tray: 12064971/5
Terminal Part Information Core/Insulation Crimp: E/C

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Terminal/Tray: 12124075/5 Release Tool/Test Probe: 12094429/J-35616-2A
Core/Insulation Crimp: E/C (GY)
Release Tool/Test Probe: 12180559-1/J-35616-2A
(GY) Park Brake Switch
Circuit
Pin Wire Color Function
Brake Fluid Level Switch No.
Circuit Park Brake Switch
Pin Wire Color Function A OG/BK 233
No. Signal
A BK/WH 651 Ground
Brake Warning
B TN/WH 33
Indicator Control
4A-5 Brake Control System and Diagnosis:

Hydraulic Brake Pipe Routing - Master Cylinder to ABS

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1. Master Cylinder Primary Brake Pipe 4. BPMV Brake Pipe to RR Brake Corner
2. Master Cylinder Secondary Brake Pipe 5. BPMV Brake Pipe to LF Brake Corner
3. BPMV Brake Pipe to LR Brake Corner 6. BPMV Brake Pipe to RF Brake Corner
 Brake Control System and Diagnosis: 4A-6

Component Location
Hydraulic Brake Component Views

Near the Brake Booster

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1. Brake Fluid Level Switch 3. Electronic Brake Control Module (EBCM)
2. LF Strut Tower
4A-7 Brake Control System and Diagnosis:

Park Brake Assembly

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1. Park Brake Switch 3. Floor Panel
2. Park Brake Handle
 Brake Control System and Diagnosis: 4A-8

Diagnostic Information and Procedures

Diagnostic Starting Point - Hydraulic Brakes
Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and
Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists.
Reviewing the Description and Operation information will also help you determine if the condition described by the
customer is normal operation. Refer to “Symptoms - Hydraulic Brakes: ” in order to identify the correct procedure for
diagnosing the system and where the procedure is located.

Scan Tool Data List - Hydraulic Brakes

Body Control Module (BCM)

Scan Tool Parameter Data List Units Displayed Typical Data Value
Operating Conditions: Ignition ON, engine OFF, brake fluid level normal, and park brake released.
Park Brake Switch Inputs Released/Applied Released

Electronic Brake Control Module (EBCM)

Scan Tool Parameter Data List Units Displayed Typical Data Value
Operating Conditions: Ignition ON, engine OFF, brake fluid level normal, and park brake released.
Brake Fluid Level Sensor — Low/OK OK

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Scan Tool Data Definitions - Hydraulic Brakes
Park Brake Switch: The scan tool displays the current state of the parking brake switch as seen by the BCM. With
the parking brake applied, the scan tool displays Applied.
Brake Fluid Level Sensor: The scan tool displays the current state of the brake fluid level sensor as reported to the
EBCM by the IPC. When brake fluid is below the minimum level, the scan tool displays Low.

DTC C0267
Diagnostic Instructions
• Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure.
• Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach.
• “Diagnostic Procedure Instructions - Vehicle Diagnostic Information: ” provides an overview of each diagnostic
category.

DTC Descriptor
DTC C0267: Low Brake Fluid Indicated

Diagnostic Fault Information

Short to Open/High Signal
Circuit Short to Voltage
Ground Resistance Performance
Brake Fluid Level Sensor Signal C0267 — — —

Circuit/System Description Action Taken When the DTC Sets

The brake fluid level switch monitors the level of brake • The EBCM disables the antilock brake system (ABS),
fluid in the master cylinder. When the instrument panel traction control system (TCS), dynamic rear
cluster (IPC) sees the brake fluid level switch input proportion (DRP), and vehicle stability enhancement
grounded, it turns ON the Red Brake Warning indicator system (VSES).
and sends a serial data message to the electronic brake
• The ABS indicator is illuminated.
control module (EBCM) indicating the brake fluid level is
low. • The Traction Control indicator is illuminated.
• The Red Brake Warning indicator is illuminated.
Conditions for Running the DTC
The ignition is ON.

Conditions for Setting the DTC

Low brake fluid is detected.
4A-9 Brake Control System and Diagnosis:

Conditions for Clearing the DTC Repair Instructions

• A current DTC will clear when the fault is no longer Perform the “Diagnostic Repair Verification - Vehicle
present. Diagnostic Information: ” after completing the diagnostic
procedure.
• A history DTC will clear after 100 consecutive fault-
free drive cycles. • “Master Cylinder Fluid Level Sensor Replacement”
• “Control Module References: ” for IPC replacement,
Reference Information setup, and programming
Schematic Reference
“Hydraulic Brake Schematics” Symptoms - Hydraulic Brakes
Connector End View Reference
“Hydraulic Brake Connector End Views” NOTE
Description and Operation The following steps must be completed
“Brake Warning System Description and Operation” before using the symptom tables.
Electrical Information Reference
1. Perform the “Brake System Vehicle Road
• “Circuit Testing: ” Test” before using the hydraulic brake
• “Connector Repairs: ” symptom tables in order to duplicate the
• “Testing for Intermittent Conditions and Poor customer concern.
Connections: ” 2. Review the system operation in order to
• “Wiring Repairs: ” familiarize yourself with the system
Scan Tool Reference functions. Refer to the following:

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• “Scan Tool Data List - Hydraulic Brakes” – “Brake Warning System Description
and Operation”
• “Scan Tool Data Definitions - Hydraulic Brakes”
– “Hydraulic Brake System Description
Circuit/System Verification and Operation”
Ignition ON, verify brake fluid in the master cylinder – “Brake Assist System Description and
reservoir is above the minimum level. Operation”
➢ If fluid level is below the minimum, refer to “Brake – “Disc Brake System Description and
Fluid Loss”. Operation: ” in Disc Brakes

Circuit/System Testing Visual/Physical Inspection

• Inspect for aftermarket devices which could affect the
NOTE operation of the hydraulic brake system. Refer to
This test should only be performed if brake “Checking Aftermarket Accessories: ”.
fluid is above the minimum level. • Inspect the easily accessible or visible system
components for obvious damage or conditions which
1. Ignition OFF, disconnect the harness connector at could cause the symptom.
the brake fluid level switch.
2. Ignition OFF, Test for less than 1 ohm of resistance Intermittent
between the ground circuit terminal A and ground. Faulty electrical connections or wiring may be the cause
➢ If greater than the specified range, test the ground of intermittent conditions. Refer to “Testing for
circuit for an open/high resistance. Intermittent Conditions and Poor Connections: ”.
3. Ignition ON, verify the scan tool EBCM Brake Fluid
Level Sensor parameter is OK. Symptom List
➢ If not the specified value, test the signal circuit Refer to a symptom diagnostic procedure from the
terminal B for a short to ground. If the circuit tests following list in order to diagnose the symptom:
normal, replace the IPC. • “Brake Warning Indicator Malfunction”
4. Install a 3A fused jumper wire between the signal • “Brake Pulsation”
circuit terminal B and the ground circuit terminal A. • “Braking Action Uneven - Pulls to One Side”
Verify the scan tool EBCM Brake Fluid Level Sensor • “Braking Action Uneven - Front to Rear”
parameter is Low.
• “Brake Pedal Excessive Travel”
➢ If not the specified value, test the signal circuit for a
• “Brake Pedal Excessive Effort”
short to voltage or an open/high resistance. If the
circuit tests normal, replace the IPC. • “Brake System Slow Release”
5. If all circuits test normal, test or replace the brake • “Brake Fluid Loss”
fluid level switch.
 Brake Control System and Diagnosis: 4A-10

Brake Warning Indicator Malfunction ➢ If the parameter does not cycle between the
Diagnostic Instructions specified values, refer to Park Brake Switch Circuit
Malfunction.
• Perform the “Diagnostic System Check - Vehicle
Diagnostic Information: ” prior to using this diagnostic 4. Verify the scan tool EBCM Brake Fluid Level Sensor
procedure. parameter is OK.
• Review “Strategy Based Diagnosis: ” for an overview ➢ If not the specified value, refer to Brake Fluid Level
of the diagnostic approach. Switch Circuit Malfunction.
• “Diagnostic Procedure Instructions - Vehicle
Diagnostic Information: ” provides an overview of
Circuit/System Testing
each diagnostic category. Park Brake Switch Circuit Malfunction
1. Ignition OFF, disconnect the harness connector at
Circuit/System Description the park brake switch.
The instrument panel cluster (IPC) monitors the brake 2. Ignition ON, verify the scan tool BCM Park Brake
fluid level switch via the brake fluid level sensor signal Switch parameter is Released.
circuit. With the switch closed, the signal circuit is pulled ➢ If not the specified value, test the signal circuit
to ground indicating low fluid level. When low fluid level terminal A for a short to ground. If the circuit tests
is seen, the IPC will illuminate the red brake warning normal, replace the BCM.
indicator. The body control module (BCM) monitors the
park brake switch via the park brake switch signal circuit. 3. Install a 3A fused jumper wire between the signal
With the park brake applied, the switch is closed and the circuit terminal A and ground. Verify the scan tool
BCM Park Brake Switch parameter is Applied.

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signal circuit is grounded. The BCM will then send a
serial data message to the IPC requesting the red brake ➢ If not the specified value, test the signal circuit for a
warning indicator be illuminated. short to voltage or an open/high resistance.
4. If all circuits test normal, test or replace the park
Reference Information brake switch.
Schematic Reference Brake Fluid Level Switch Circuit Malfunction
“Hydraulic Brake Schematics” 1. Ignition OFF, disconnect the harness connector at
Connector End View Reference the brake fluid level switch.
“Hydraulic Brake Connector End Views”
Description and Operation 2. Ignition OFF, test for less than 1.0 ohm of resistance
“Brake Warning System Description and Operation” between the ground circuit terminal A and ground.
Electrical Information Reference ➢ If greater than the specified range, test the ground
• “Circuit Testing: ” circuit for an open/high resistance.
• “Connector Repairs: ” 3. Ignition ON, verify the scan tool EBCM Brake Fluid
Level Sensor parameter is OK.
• “Testing for Intermittent Conditions and Poor
Connections: ” ➢ If not the specified value, test the signal circuit
terminal B for a short to ground. If the circuit tests
• “Wiring Repairs: ” normal, replace the IPC.
Scan Tool Reference
4. Install a 3A fused jumper wire between the signal
• “Scan Tool Data List - Hydraulic Brakes” circuit terminal B and the ground circuit terminal A.
• “Scan Tool Data Definitions - Hydraulic Brakes” Verify the scan tool EBCM Brake Fluid Level Sensor
parameter is Low.
Circuit/System Verification ➢ If not the specified value, test the signal circuit for a
1. Verify the park brake is released and the brake fluid short to voltage or an open/high resistance. If the
is at the proper level. circuit tests normal, replace the IPC.
➢ If the brake fluid is not at the proper level, refer to 5. If all the circuits test normal, test or replace the brake
“Brake Fluid Loss”. fluid level switch.
2. Ignition ON, perform the scan tool IPC Display Test.
The red brake warning indicator should illuminate. Repair Instructions
➢ If the red brake warning indicator does not Perform the “Diagnostic Repair Verification - Vehicle
illuminate, replace the IPC. Diagnostic Information: ” after completing the diagnostic
procedure.
3. Observe the scan tool BCM Park Brake Switch
parameter while applying and releasing the park • “Master Cylinder Fluid Level Sensor Replacement”
brake. The parameter should cycle between Applied • “Park Brake Warning Lamp Switch Replacement: ”
and Release. • “Control Module References: ” for BCM and IPC
replacement, setup, and programming
4A-11 Brake Control System and Diagnosis:

Brake Pulsation
Test Description
The numbers below refers to the step numbers on the diagnostic table:
2.
Suspension components that are not operating properly may cause a disturbance to the vehicle during application of
the brake system.
3.
Antilock brake system operation could produce feedback through the brake pedal during application of the brake
system.
Step Action Yes No
Were you sent here from the Hydraulic Brake Symptom table? Go to “Diagnostic
1 Go to Step 2 Starting Point -
Hydraulic Brakes”
Inspect the suspension system for proper operation. Refer to
2 “Diagnostic Starting Point - Suspension General Diagnosis: ”. Go to Step 6 Go to Step 3
Did you find and correct a condition?
Inspect the antilock brake system, if equipped, for proper
operation. Refer to “Diagnostic Starting Point - Antilock Brake
3 Go to Step 6 Go to Step 4
System: ”.
Did you find and correct a condition?
Inspect the disc brake system for proper operation. Refer to

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4 “Disc Brake System Diagnosis: ”. Go to Step 6 Go to Step 5
Did you find and correct a condition?
Inspect the hydraulic brake system for proper operation. Refer Go to “Diagnostic
5 to “Hydraulic Brake System Diagnosis”. Go to Step 6 Starting Point -
Did you find and correct a condition? Hydraulic Brakes”
Road test the vehicle in order to confirm proper operation.
6 Refer to “Brake System Vehicle Road Test”. Go to Step 2 System OK
Is the condition still present?

Brake System Noise

Step Action Yes No
Were you sent here from the Hydraulic Brake Symptom table? Go to “Diagnostic
1 Go to Step 2 Starting Point -
Hydraulic Brakes”
Inspect the disc brake system for proper operation. Refer to
2 “Disc Brake System Diagnosis: ”. Go to Step 9 Go to Step 3
Did you find and correct a condition?
Inspect the brake assist system for proper operation. Refer to
3 “Brake Assist System Diagnosis: ”. Go to Step 9 Go to Step 4
Did you find and correct a condition?
Inspect the hydraulic brake system for proper operation. Refer
4 to “Hydraulic Brake System Diagnosis”. Go to Step 9 Go to Step 5
Did you find and correct a condition?
Is the vehicle equipped with a drum-in-rotor type of park brake
5 Go to Step 6 Go to Step 8
system?
Ensure the park brake shoes are not adjusted too tightly,
6 possibly causing a noise under certain conditions. Go to Step 7 Go to Step 8
Are the park brake shoes adjusted too tightly?
1. Clean and inspect the park brake shoes for excessive
wear and/or damage.
2. Inspect the drum portion of the rotors for excessive wear,
blueing discoloration, heat spots, and excessive radial
7 runout. Go to Step 9 Go to Step 8
3. If any of these conditions are present, replace the affected
components.
4. Adjust the park brake system.
Did you find and correct a condition?
 Brake Control System and Diagnosis: 4A-12

Step Action Yes No

Inspect the park brake system for proper operation. Refer to Go to “Diagnostic
8 “Park Brake System Diagnosis: ”. Go to Step 9 Starting Point -
Did you find and correct a condition? Hydraulic Brakes”
Road test the vehicle in order to confirm proper operation.
9 Refer to “Brake System Vehicle Road Test”. Go to Step 2 System OK
Is the condition still present?

Braking Action Uneven - Pulls to One Side

Test Description
The numbers below refer to the step numbers on the diagnostic table:
2.
Suspension components that are not operating properly may cause a disturbance to the vehicle during application of
the brake system.
3.
Steering components that are not operating properly may cause a disturbance to the vehicle during application of the
brake system.
Step Action Yes No
Were you sent here from the Hydraulic Brake Symptom table? Go to “Diagnostic
1 Go to Step 2 Starting Point -
Hydraulic Brakes”

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Inspect the suspension system for proper operation. Refer to
2 “Diagnostic Starting Point - Suspension General Diagnosis: ”. Go to Step 6 Go to Step 3
Did you find and correct a condition?
Inspect the steering system for proper operation. Refer to
3 “Diagnostic Starting Point - Power Steering System: ”. Go to Step 6 Go to Step 4
Did you find and correct a condition?
Inspect the hydraulic brake system for proper operation. Refer
4 to “Hydraulic Brake System Diagnosis”. Go to Step 6 Go to Step 5
Did you find and correct a condition?
Inspect the disc brake system for proper operation. Refer to Go to “Diagnostic
5 “Disc Brake System Diagnosis: ”. Go to Step 6 Starting Point -
Did you find and correct a condition? Hydraulic Brakes”
Road test the vehicle in order to confirm proper operation.
6 Refer to “Brake System Vehicle Road Test”. Go to Step 2 System OK
Is the condition still present?
4A-13 Brake Control System and Diagnosis:

Braking Action Uneven - Front to Rear

Test Description
The number below refers to the step number on the diagnostic table.
2.
Suspension components that are not operating properly may cause a disturbance to the vehicle during application of
the brake system.
Step Action Yes No
Were you sent here from the Hydraulic Brake Symptom table? Go to “Diagnostic
1 Go to Step 2 Starting Point -
Hydraulic Brakes”
Inspect the suspension system for proper operation. Refer to
2 “Diagnostic Starting Point - Suspension General Diagnosis: ”. Go to Step 6 Go to Step 3
Did you find and correct a condition?
Inspect the hydraulic brake system for proper operation. Refer
3 to “Hydraulic Brake System Diagnosis”. Go to Step 6 Go to Step 4
Did you find and correct a condition?
Inspect the disc brake system for proper operation. Refer to
4 “Disc Brake System Diagnosis: ”. Go to Step 6 Go to Step 5
Did you find and correct a condition?
Inspect the brake assist system for proper operation. Refer to Go to “Diagnostic
5 “Brake Assist System Diagnosis: ”. Go to Step 6 Starting Point -

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Did you find and correct a condition? Hydraulic Brakes”
Road test the vehicle in order to confirm proper operation.
6 Refer to “Brake System Vehicle Road Test”. Go to Step 2 System OK
Is the condition still present?

Brake Pedal Excessive Travel

Step Action Yes No
Were you sent here from the Hydraulic Brake Symptom table? Go to “Diagnostic
1 Go to Step 2 Starting Point -
Hydraulic Brakes”
Inspect for proper brake pedal travel. Refer to “Brake Pedal
2 Travel Measurement and Inspection”. Go to Step 5 Go to Step 3
Is the brake pedal travel distance within the acceptable limits?
1. Inspect for worn, missing, misaligned, bent or damaged
brake pedal system components.
– For the brake pedal pushrod component inspection,
refer to “Brake Pedal Pushrod Inspection”.
– Inspect the brake pedal bushings for excessive wear
and/or damage and inspect the brake pedal for a
misaligned, bent, and/or damaged condition.
3 2. Replace the brake pedal system components that are Go to Step 4 Go to Step 5
worn, missing, misaligned, bent or damaged. Refer to the
following procedures as necessary:
– “Brake Pedal Assembly Replacement”
– “Vacuum Brake Booster Replacement” - for pedal
pushrod replacement
Did you find and replace any worn, missing, misaligned, bent
or damaged brake pedal system components?
Inspect for proper brake pedal travel. Refer to “Brake Pedal
4 Travel Measurement and Inspection”. Go to Step 8 Go to Step 5
Is the brake pedal travel distance within the acceptable limits?
Inspect the hydraulic brake system for proper operation. Refer
5 to “Hydraulic Brake System Diagnosis”. Go to Step 8 Go to Step 6
Did you find and correct a condition?
Inspect the disc brake system for proper operation. Refer to
6 “Disc Brake System Diagnosis: ”. Go to Step 8 Go to Step 7
Did you find and correct a condition?
 Brake Control System and Diagnosis: 4A-14

Step Action Yes No

Inspect the brake assist system for proper operation. Refer to Go to “Diagnostic
7 “Brake Assist System Diagnosis: ”. Go to Step 8 Starting Point -
Did you find and correct a condition? Hydraulic Brakes”
Road test the vehicle to confirm proper operation. Refer to
8 “Brake System Vehicle Road Test”. Go to Step 2 System OK
Is the condition still present?

Brake Pedal Excessive Effort

Step Action Yes No
Were you sent here from the Hydraulic Brake Symptom table? Go to “Diagnostic
1 Go to Step 2 Starting Point -
Hydraulic Brakes”
Inspect the brake assist system for proper operation. Refer to
2 “Brake Assist System Diagnosis: ”. Go to Step 5 Go to Step 3
Did you find and correct a condition?
Inspect the hydraulic brake system for proper operation. Refer
3 to “Hydraulic Brake System Diagnosis”. Go to Step 5 Go to Step 4
Did you find and correct a condition?
Inspect the disc brake system for proper operation. Refer to Go to “Diagnostic
4 “Disc Brake System Diagnosis: ”. Go to Step 5 Starting Point -

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Did you find and correct a condition? Hydraulic Brakes”
Road test the vehicle to confirm proper operation. Refer to
5 “Brake System Vehicle Road Test”. Go to Step 2 System OK
Is the condition still present?

Brakes Drag
Step Action Yes No
Were you sent here from the Hydraulic Brake Symptom table? Go to “Diagnostic
1 Go to Step 2 Starting Point -
Hydraulic Brakes”
Is the vehicle equipped with an adjustable stop lamp switch
2 Go to Step 3 Go to Step 4
and/or an adjustable cruise control release switch?
1. Inspect the stop lamp switch for proper adjustment to
ensure that the brake pedal is fully releasing.
3 2. Inspect the cruise control release switch, if equipped, for Go to Step 14 Go to Step 4
proper adjustment to ensure that the brake pedal is fully
releasing.
Did you find and correct a condition?
Is the vehicle equipped with a drum-in-rotor type of park brake
4 Go to Step 5 Go to Step 7
system?
Ensure the park brake shoes are not adjusted too tightly,
5 possibly causing drag under certain conditions. Go to Step 6 Go to Step 7
Are the park brake shoes adjusted too tightly?
1. Clean and inspect the park brake shoes for excessive
wear and/or damage.
2. Inspect the drum portion of the rotors for excessive wear,
blueing discoloration, heat spots, and excessive radial
6 runout. Go to Step 14 Go to Step 7
3. If any of these conditions are present, replace the affected
components.
4. Adjust the park brake system.
Did you find and correct a condition?
Inspect the park brake system for proper operation. Refer to
7 “Park Brake System Diagnosis: ”. Go to Step 14 Go to Step 8
Did you find and correct a condition?
4A-15 Brake Control System and Diagnosis:

Step Action Yes No

Inspect the disc brake system for proper operation. Refer to
8 “Disc Brake System Diagnosis: ”. Go to Step 14 Go to Step 9
Did you find and correct a condition?
1. Separate the brake booster pushrod from the brake pedal.
9 2. Inspect the brake corners to determine if the brake drag Go to Step 11 Go to Step 10
condition is still present.
Do the brake corners still exhibit the brake drag condition?
Replace the brake pedal assembly.
10 Go to Step 14 —
Did you complete the replacement?
1. Separate the master cylinder from the brake booster. Do
not disconnect any brake pipes.
11 2. Inspect the brake corners to determine if the brake drag Go to Step 13 Go to Step 12
condition is still present.
Do the brake corners still exhibit the brake drag condition?
Replace the brake booster assembly.
12 Go to Step 14 —
Did you complete the replacement?
Inspect the hydraulic brake system for proper operation. Refer Go to “Diagnostic
13 to “Hydraulic Brake System Diagnosis”. Go to Step 14 Starting Point -
Did you find and correct a condition? Hydraulic Brakes”
1. Install or connect components that were removed or

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disconnected during diagnosis.
14 2. Road test the vehicle in order to confirm proper operation. Go to Step 2 System OK
Refer to “Brake System Vehicle Road Test”.
Is the condition still present?

Brake System Slow Release

Step Action Yes No
Were you sent here from the Hydraulic Brake Symptom table? Go to “Diagnostic
1 Go to Step 2 Starting Point -
Hydraulic Brakes”
Inspect the hydraulic brake system for proper operation. Refer
2 to “Hydraulic Brake System Diagnosis”. Go to Step 5 Go to Step 3
Did you find and correct a condition?
Inspect the brake assist system for proper operation. Refer to
3 “Brake Assist System Diagnosis: ”. Go to Step 5 Go to Step 4
Did you find and correct a condition?
Inspect the disc brake system for proper operation. Refer to Go to “Diagnostic
4 “Disc Brake System Diagnosis: ”. Go to Step 5 Starting Point -
Did you find and correct a condition? Hydraulic Brakes”
Road test the vehicle to confirm proper operation. Refer to
5 “Brake System Vehicle Road Test”. Go to Step 2 System OK
Is the condition still present?
 Brake Control System and Diagnosis: 4A-16

Brake Fluid Loss

Step Action Yes No
Were you sent here from the Hydraulic Brake Symptom table? Go to “Diagnostic
1 Go to Step 2 Starting Point -
Hydraulic Brakes”
Inspect the hydraulic brake system for proper operation. Refer
2 to “Hydraulic Brake System Diagnosis”. Go to Step 6 Go to Step 3
Did you find and correct a condition?
Inspect the disc brake system for proper operation. Refer to
3 “Disc Brake System Diagnosis: ”. Go to Step 6 Go to Step 4
Did you find and correct a condition?
1. Separate the master cylinder from the vacuum brake
booster. Do not disconnect any brake pipes. Refer to
“Master Cylinder Replacement”. Go to “Diagnostic
4 2. Inspect the rear of the master cylinder for a brake fluid Go to Step 5 Starting Point -
leak. Hydraulic Brakes”
3. Inspect for brake fluid in the vacuum brake booster.
Did you find a brake fluid leak?
Replace the brake master cylinder and the vacuum brake
booster. Refer to “Master Cylinder Replacement” and “Vacuum
5 Go to Step 6 —
Brake Booster Replacement”.

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Did you complete the replacement?
1. Install or connect components that were removed or
disconnected during diagnosis.
6 2. Road test the vehicle to confirm proper operation. Refer to Go to Step 2 System OK
“Brake System Vehicle Road Test”.
Is the condition still present?

Hydraulic Brake System Diagnosis

Step Action Yes No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the HYDRAULIC brake system
in order to determine if the HYDRAULIC brake system is operating properly. You will be directed by the appropriate
Symptom table to go to other brake system diagnostic tables as appropriate.
Were you sent here from a Brake Symptom table? Go to “Diagnostic
1 Go to Step 2 Starting Point -
Hydraulic Brakes”
Inspect and adjust the brake fluid level in the brake master
2 cylinder. Refer to “Master Cylinder Reservoir Filling”. Go to Step 3 Go to Step 4
Was the brake fluid level low?
1. Inspect the brake fluid for the following conditions,
indicating brake fluid contamination:
– Fluid separation, indicating two types of fluid are
present
– Swirled appearance - oil-based substance
– Layered appearance - silicone-based substance
3 – Fluid discoloration Go to Step 5 Go to Step 6
– Cloudy appearance - moisture
– Dark appearance/ suspended particles in fluid - dirt,
rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and
the reservoir-to-master cylinder grommets for swelling,
indicating fluid contamination.
Do any of the above conditions exist?
4A-17 Brake Control System and Diagnosis:

Step Action Yes No

1. Inspect the brake fluid for the following conditions,
indicating brake fluid contamination:
– Fluid separation, indicating two types of fluid are
present
– Swirled appearance - oil-based substance
– Layered appearance - silicone-based substance
4 – Fluid discoloration Go to Step 5 Go to Step 12
– Cloudy appearance - moisture
– Dark appearance/ suspended particles in fluid - dirt,
rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and
the reservoir-to-master cylinder grommets for swelling,
indicating fluid contamination.
Do any of the above conditions exist?
1. Flush the hydraulic brake system. Refer to “Hydraulic
Brake System Flushing”.
2. If the brake fluid WAS contaminated with an oil-based or a
silicone-based fluid, indicated by fluid separation and/or a

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swollen master cylinder reservoir cap diaphragm and/or
swollen reservoir-to-master cylinder grommets, perform
the following steps. Refer to the procedures indicated.
a. Remove ALL of the following components listed. Each
component contains internal rubber seals/linings which
have been contaminated.
b. Clean out the hydraulic brake pipes using denatured
alcohol, or equivalent.
c. Dry the brake pipes using non-lubricated, filtered air.
d. Replace ALL of the following components listed. Each
component contains internal rubber seals/linings which
have been contaminated.
– “Master Cylinder Replacement”
– Brake master cylinder reservoir: Clean the brake
master cylinder reservoir using denatured alcohol,
5 or equivalent, then dry the reservoir using non- Go to Step 9 —
lubricated, filtered air, or if necessary, replace the
brake master cylinder reservoir.
– Replace the brake master cylinder reservoir cap
diaphragm.
– “Front Brake Hose Replacement”
– “Rear Brake Hose Replacement”
– “Front Brake Caliper Replacement: ”
– “Rear Brake Caliper Replacement: ”
– “Brake Pressure Modulator Valve Replacement: ”
3. If the brake fluid was NOT contaminated with an oil-based
fluid, but WAS contaminated with water or dirt, rust,
corrosion, and/or brake dust, replace the brake master
cylinder reservoir cap diaphragm which may have allowed
moisture or dirt to enter the system.
4. Refill and bleed the hydraulic brake system. Refer to
“Hydraulic Brake System Bleeding (Pressure)” “Hydraulic
Brake System Bleeding (Manual)”.
Did you complete the operation and any required repairs and/
or replacements?
 Brake Control System and Diagnosis: 4A-18

Step Action Yes No

1. Inspect the following hydraulic brake system components
for external fluid leaks. Replace any of the components
found to be leaking brake fluid. Refer to the appropriate
procedures:
– “Master Cylinder Replacement”
Brake master cylinder reservoir cap diaphragm
– “Front Brake Hose Replacement”
– “Rear Brake Hose Replacement”
– “Brake Pipe Replacement”
– “Front Brake Caliper Replacement: ”
– “Rear Brake Caliper Replacement: ”
6 – “Brake Pressure Modulator Valve Replacement: ” Go to Step 7 Go to Step 12
2. If you repaired or replaced any of the brake system
components listed, bleed the hydraulic brake system.
Refer to “Hydraulic Brake System Bleeding (Pressure)”
“Hydraulic Brake System Bleeding (Manual)”. While
bleeding the hydraulic brake system, observe for the
following conditions:

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– The presence of air in the system at a bleeder valve
location other than at the repair location, except if the
brake master cylinder was replaced
– An unrestricted and even flow of brake fluid per axle
during the bleeding procedure
Did you find and correct a condition?
Was there air in the system at a bleeder valve location other
7 than at the repair location, except if the brake master cylinder Go to Step 19 Go to Step 8
was replaced?
Was the flow of brake fluid unrestricted and even per axle
8 Go to Step 9 Go to Step 10
during the bleeding procedure?
Inspect the hydraulic function of the brake calipers/wheel
cylinders for proper operation. Refer to “Hydraulic Brake
9 Component Operation Visual Inspection: ”. Go to Step 21 Go to Step 14
Was the hydraulic function of the brake calipers/wheel
cylinders operating properly?
Was the flow of brake fluid restricted or uneven through front
10 Go to Step 13 Go to Step 11
axle hydraulic components during the bleeding procedure?
Was the flow of brake fluid restricted or uneven through rear
11 Go to Step 17 —
axle hydraulic components during the bleeding procedure?
Inspect the hydraulic function of the brake calipers/wheel
cylinders for proper operation. Refer to “Hydraulic Brake
12 Component Operation Visual Inspection: ”. Go to Step 15 Go to Step 13
Was the hydraulic function of the brake calipers/wheel
cylinders operating properly?
4A-19 Brake Control System and Diagnosis:

Step Action Yes No

Determine if the brake caliper is restricting the flow of brake
fluid and/or not operating properly:
1. Raise and support the vehicle. Refer to “Lifting and
Jacking the Vehicle: ”.
2. Remove the tire and wheel assemblies. Refer to “Tire and
Wheel Removal and Installation: ”.
13 3. Open the suspected caliper bleeder valve. Go to Step 17 Go to Step 14
4. Using a large C-clamp, compress the caliper piston and
observe for an unrestricted flow of brake fluid and for free
movement of the caliper piston.
5. Close the caliper bleeder valve.
Was the flow of brake fluid unrestricted and did the caliper
piston move freely?
Repair or replace any brake caliper/wheel cylinder that was
not operating properly. Refer to the appropriate procedure.
14 • “Front Brake Caliper Replacement: ” Go to Step 21 —
• “Rear Brake Caliper Replacement: ”
Did you complete the repair and/or replacement?
Bleed the hydraulic brake system to observe for the presence

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of air in the system and to observe for an unrestricted and
even flow of brake fluid per axle during the bleeding
15 Go to Step 19 Go to Step 16
procedure. Refer to “Hydraulic Brake System Bleeding
(Pressure)” “Hydraulic Brake System Bleeding (Manual)”.
Was there air in the system?
Was the flow of brake fluid unrestricted and even per axle
16 Go to Step 21 Go to Step 17
during the bleeding procedure?
1. Inspect the hydraulic brake pipes and flexible brake hoses
for signs of a fluid restriction; such as being bent, kinked,
pinched or damaged. Refer to “Brake Pipe and Hose
Inspection”.
2. Replace any of the hydraulic brake pipes and/or flexible
brake hoses found to be bent, kinked, pinched, or
damaged. Refer to the following procedures as necessary:
17 – “Front Brake Hose Replacement” Go to Step 21 Go to Step 18
– “Rear Brake Hose Replacement”
– “Brake Pipe Replacement”
3. If none of the hydraulic brake pipes or flexible brake hoses
were visibly bent, kinked, pinched, or damaged, replace
the hydraulic brake flex hose at the restricted location.
Did you find and correct a condition?
Replace the brake pressure modulator valve (BPMV), in order
to correct the hydraulic brake dynamic rear proportioning
18 mechanical operation. Refer to “Brake Pressure Modulator Go to Step 21 —
Valve Replacement: ”.
Did you complete the replacement?
1. Inspect the hydraulic brake system components for brake
fluid seepage at a seal and/or fitting location, which may
have drawn air into the system.
2. Inspect the hydraulic brake system components for
19 evidence of a recent repair, which may have introduced air Go to Step 21 Go to Step 20
into the system.
3. Repair or replace any of the components found to be
installed incorrectly or seeping brake fluid.
Did you find and correct a condition?
 Brake Control System and Diagnosis: 4A-20

Step Action Yes No

1. Inspect the brake master cylinder for internal fluid leaks.
Refer to “Brake System Internal Leak Test”.
2. Replace the brake master cylinder if it is found to be Return to Symptom
20 Go to Step 21
leaking brake fluid internally. Refer to “Master Cylinder Table
Replacement”.
Did you find and correct a condition?
Install or connect components that were removed or Hydraulic Brake
disconnected during diagnosis. System OK
21 —
Did you complete the operation? Return to Symptom
Table

Brake Assist System Diagnosis

Step Action Yes No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the brake ASSIST system in
order to determine if the brake ASSIST system is operating properly. You will be directed by the appropriate
Symptom table to go to other brake system diagnostic tables as appropriate.
1 Were you sent here from a Brake Symptom table? Go to Step 3 Go to Step 2
Were you sent here directly from an electrical diagnostic to Go to “Diagnostic
2 investigate vacuum as a possible concern? Go to Step 5 Starting Point -
Hydraulic Brakes”

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Inspect for proper brake pedal travel. Refer to “Brake Pedal
3 Travel Measurement and Inspection”. Go to Step 5 Go to Step 4
Is the brake pedal travel distance within the acceptable limits?
1. Inspect for worn, missing, misaligned, bent, or damaged
brake pedal system components.
– For the brake pedal pushrod component inspection, Inspect for internal
refer to “Brake Pedal Pushrod Inspection”. and external fluid
leaks and air in the
– Inspect the brake pedal bushings for excessive wear hydraulic brake
4 and/or damage and inspect the brake pedal for a Go to Step 5
system
misaligned, bent, and/or damaged condition. Go to “Hydraulic
2. Replace the brake pedal system components that are Brake System
worn, missing, misaligned, bent, or damaged. Diagnosis”
Did you find and replace any worn, missing, misaligned, bent,
or damaged brake pedal system components?
Check the engine vacuum source that supplies vacuum to the
Go to Engine Controls
vacuum brake booster. Refer to “Brake System Vacuum
5 Go to Step 6 Diagnostics
Source Test”.
Information
Is the vacuum reading within the acceptable limits?
6 Does the condition occur during cold start-up conditions? Go to Step 7 Go to Step 8
Check engine vacuum under the same cold start-up
7 conditions. Refer to Engine Controls Diagnostics. Go to Step 18 Go to Step 9
Did you find and correct a condition?
During the vacuum source test, did the vacuum booster check
8 Go to Step 10 Go to Step 9
valve operate properly?
Replace the vacuum booster check valve. Refer to “Vacuum
9 Brake Booster Check Valve and/or Hose Replacement”. Go to Step 10 —
Did you complete the replacement?
If equipped with a booster mounted separate vacuum sensor,
inspect the vacuum sensor grommet for cracks, cuts, dry-rot,
10 or damage. Go to Step 11 Go to Step 12
Does the vacuum sensor grommet exhibit any of the
conditions listed?
Replace the vacuum sensor grommet.
11 Go to Step 12 —
Did you complete the replacement?
4A-21 Brake Control System and Diagnosis:

Step Action Yes No

1. Separate the master cylinder from the vacuum brake
booster. Do not disconnect any brake pipes. Before
removing the master cylinder, first deplete the vacuum by
removing the check valve or applying the brake pedal
several times. Refer to “Master Cylinder Replacement”.
2. If equipped with a vacuum seal on the rear of the master
cylinder, inspect the seal for damage and correct
12 positioning on the master cylinder. Go to Step 13 Go to Step 14
3. If equipped with a vacuum seal that is part of the booster,
inspect the seal for damage.
4. Inspect the master cylinder mating surface of the booster
form deformation and or damage.
Does the vacuum seal and/or the master cylinder mating
surface of the of the booster exhibit any of the conditions
listed?
1. If equipped with a vacuum seal on the rear of the master
cylinder, replace the vacuum seal as necessary.
2. If equipped with a vacuum seal that requires replacement
and which is part of the booster, the booster assembly
13 Go to Step 14 —

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must be replaced.
3. If the master cylinder mating surface of the booster was
deformed and/or damaged, replace the booster.
Did you complete the replacement?
Perform the vacuum boost functional test:
1. Reinstall the master cylinder to the booster.
2. If the engine was started after reinstalling the master
cylinder to the booster, perform the following:
With the engine OFF, depress the brake pedal several
times to deplete the vacuum reserve.
3. Depress and maintain moderate foot pressure on the
14 Go to Step 17 Go to Step 15
brake pedal.

NOTE
The brake pedal should fall slightly, then hold.

4. Start the engine and observe pedal operation.

Is there an audible vacuum leak coming from the brake pedal
area?
Did the brake pedal fall slightly after the engine was started,
15 Go to Step 16 Go to Step 17
then hold?
Perform the vacuum booster leak-down test:
1. Release the brake pedal.
2. Accelerate the engine to approximately 3,000 RPM, then
release the throttle. Wait 2-3 seconds and repeat once.
3. Turn the ignition OFF.
4. Wait 60 seconds.

16 NOTE Go to Step 18 Go to Step 17

• Both pedal applies should be assisted.
• The amount of assist could diminish slightly
with the second apply.

5. Depress the brake pedal 2 times to check for vacuum

booster available vacuum reserve. Observe pedal effort.
Were both pedal applies power assisted?
 Brake Control System and Diagnosis: 4A-22

Step Action Yes No

Replace the vacuum brake booster. Refer to “Vacuum Brake
17 Booster Replacement”. Go to Step 18 —
Did you complete the replacement?
Install or connect any components that were removed or Brake Assist System
disconnected during diagnosis. OK
18 —
Did you complete the operation? Return to Symptom
Table

Brake System Vehicle Road Test 9. While continuing to apply the brakes, shift the
Preliminary Inspections transmission into DRIVE, release the brakes and
allow the engine to idle the vehicle away from the
1. Visually inspect easily accessible brake system
stopped position. Observe for a slow release of the
components for obvious damage and/or leaks which
brake system.
may indicate that the vehicle should not be driven
until further inspections have been completed. 10. With the aid of an assistant to observe the vehicle's
performance from outside of the vehicle, drive the
2. Inspect the brake master cylinder reservoir fluid level
vehicle at a low speed and lightly apply the brakes
and adjust only if necessary for brake system road
while driving past the assistant. Have the assistant
testing. Refer to “Master Cylinder Reservoir Filling”.
observe for brake system noise from the side of the
3. Inspect the tire inflation pressures and adjust as vehicle closest to them, while you observe both the
necessary. pedal effort and the pedal travel.

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4. Inspect the tire tread patterns to ensure that they are 11. If the brake pedal apply effort was excessive, or the
the same or very similar, especially per axle. pedal travel was excessive, DO NOT continue to test
5. Ensure that the vehicle is not loaded unevenly prior drive the vehicle until it is repaired.
to brake system road testing. 12. If the brake pedal apply effort was not excessive and
the pedal travel was not excessive, proceed to step
Road Testing Procedure 13.
13. Drive the vehicle in the opposite direction, at the
! WARNING
same low speed and lightly apply the brakes while
Road test a vehicle under safe conditions driving past the assistant. Have the assistant
and while obeying all traffic laws. Do not observe for brake system noise from the side of the
attempt any maneuvers that could jeopardize vehicle closest to him.
vehicle control. Failure to adhere to these 14. Drive the vehicle at a low speed and shift the
precautions could lead to serious personal transmission into NEUTRAL without applying the
injury and vehicle damage. brakes. Observe for a rapid deceleration in vehicle
speed, indicating possible brake drag.
1. Start the engine and allow it to idle. 15. Select a smooth, dry, clean and level road that is as
2. Check to see if the brake system warning lamp free of heavy traffic as possible for brake system
remains illuminated. moderate speed road testing.
3. If the brake system warning lamp remains 16. Drive the vehicle at a moderate speed. Observe for a
illuminated, DO NOT proceed to test drive the pull and/or incorrect tracking of the vehicle without
vehicle until it is diagnosed and repaired. Refer to the brakes applied.
“Symptoms - Hydraulic Brakes: ”. 17. While continuing to drive the vehicle at a moderate
4. Select a smooth, dry, clean and level road or large speed, perform several light applies of the brakes.
lot that is as free of traffic and obstacles as possible Observe the pedal effort and the pedal travel,
for brake system low speed road testing. observe for brake system noise, pulsation and/or
5. With the transmission in PARK, lightly apply the brake drag.
brake pedal. Observe both the pedal feel and the 18. If the brake pedal apply effort was excessive, or the
pedal travel. pedal travel was excessive, DO NOT continue to test
6. If the brake pedal apply felt spongy, or the pedal drive the vehicle until it is repaired.
travel was excessive, DO NOT drive the vehicle until 19. If the brake pedal apply effort was not excessive and
it is repaired. the pedal travel was not excessive, proceed to step
7. If the brake pedal apply did not feel spongy and the 20.
pedal travel was not excessive, proceed to step 8.
8. Release and apply the brakes.
4A-23 Brake Control System and Diagnosis:

20. While continuing to drive the vehicle at a moderate 8. Subtract the initial measurement, unapplied (1), from
speed, perform several moderate applies of the the averaged, applied measurement (2) to obtain the
brakes. Observe the pedal effort and the pedal brake pedal travel distance.
travel, observe for brake system pulsation and/or
Specification
uneven braking action - either side to side, or front to
Maximum brake pedal travel—Measured with the
rear.
ignition OFF, brake booster power assist
A small amount of vehicle front end dip is expected
depleted, and the brakes cool: 57 mm (2.25 in).
during a moderate apply of the brakes.
21. If the brake pedal apply effort was excessive, or the
pedal travel was excessive, DO NOT continue to test Brake System Vacuum Source Test
drive the vehicle until it is repaired. NOTE
• Engine temperature, accessory load, and
Brake Pedal Travel Measurement and
elevation level will affect engine vacuum.
Inspection
• Vacuum readings will decrease by
Special tool approximately 2.7 kPA (0.8 in HG) for every
J 28662 Brake Pedal Effort Gage, or equivalent 305 m (1000 ft) of elevation above sea
1. With the ignition OFF and the brakes cool, apply the level.
brakes 3-5 times, or until the brake pedal becomes
1. Disconnect the engine vacuum hose from the
firm, in order to deplete the brake booster power
vacuum brake booster check valve.
reserve.

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2. Install a vacuum gage to the engine vacuum hose.
2. Install the J 28662, or equivalent to the brake pedal.
3. Start the engine and allow the engine to idle until
normal operating temperatures are reached.
4. With the vehicle in PARK, the engine idling, and the
air conditioning (A/C) system OFF, check to see if
the engine vacuum reading is within the specified
normal engine vacuum range.
Specification
47-68 kPa (14-20 in Hg)
5. Turn the ignition OFF.
6. If the engine vacuum reading is within the specified
normal range, proceed to step 10.
7. If the engine vacuum reading is NOT within the
specified normal range, inspect the engine vacuum
hose for the following conditions:
– Loose connection to the engine
– Collapse, deformation or contamination
3. Measure and record the distance (1) from the brake – Cracks, cuts, dry-rot
pedal to the rim of the steering wheel. Note the 8. If any of these conditions were found with the engine
points of measurement. vacuum hose, replace the hose, then repeat steps 2-
4. Apply and maintain the brakes with 445 N (100 lb) of 4.
force to the brake pedal, as indicated on the J 9. If none of these conditions were found with the
28662, or equivalent. engine vacuum hose, then there is an engine
5. While maintaining 445 N (100 lb) of force to the vacuum source problem, check the engine vacuum
brake pedal, measure and record the distance (2) system.
from the same point on the brake pedal to the same 10. Remove the vacuum brake booster check valve from
point on the rim of the steering wheel. the booster.
6. Release the brakes and repeat steps 4 and 5 to 11. Install the check valve to the engine vacuum hose.
obtain a second measurement. After obtaining a 12. Install the vacuum gage to the check valve.
second measurement, proceed to step 7.
7. Average the first and second measurements
recorded during the two applies of the brakes.
 Brake Control System and Diagnosis: 4A-24

13. Start the engine and allow the engine to idle in PARK 6. Visually inspect the following brake system
with the A/C system OFF, until normal operating components for brake fluid leaks, excessive
temperatures are reached. corrosion, and damage. Give particular attention to
14. Turn the ignition OFF. all brake pipe and flexible hose connections to
ensure that there are not any slight brake fluid leaks
15. Check to see if the engine vacuum reading is
- even though the brake pedal may feel firm and hold
maintained within the specified normal engine
steady:
vacuum range.
– Master cylinder brake pipe fittings
Specification
– All brake pipe connections
47-68 kPa (14-20 in Hg)
– Brake pipes
16. If the engine vacuum reading is maintained within
– Brake hoses and connections
the specified normal range, proceed to step 18.
– Brake calipers and/or wheel cylinders, if equipped
17. If the engine vacuum reading is NOT maintained
within the specified normal range, replace the brake 7. While slight dampness around the master cylinder
booster check valve, then repeat steps 11-15. reservoir can be considered acceptable, brake fluid
leaking from any of the brake system components
18. Inspect the brake booster check valve grommet for
requires immediate attention. If any of these
the following conditions:
components exhibit signs of brake fluid leakage,
– Loose connection to the vacuum brake booster repair or replace those components. After the repair
– Deformation or contamination or replacement, reinspect the hydraulic brake
– Cracks, cuts, dry-rot system to assure proper function.

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19. If any of these conditions were found with the check
valve grommet, replace the grommet. Brake System Internal Leak Test
! WARNING
Brake System External Leak Inspection
Refer to “Brake Fluid Irritant Caution: ”.
! WARNING
Refer to “Brake Fluid Irritant Caution: ”. ! CAUTION
Refer to “Brake Fluid Effects on Paint and
! CAUTION Electrical Components Notice: ”.
Refer to “Brake Fluid Effects on Paint and
1. Start the engine and allow it to idle.
Electrical Components Notice: ”.
2. Apply light, steady pressure to the brake pedal.
1. In order to inspect for external brake fluid leaks, first Observe both the brake pedal feel and travel.
check the fluid level in the master cylinder. 3. Release the brakes and turn OFF the ignition.
While a slight brake fluid level drop can be 4. If the brake pedal apply felt spongy, but the brake
considered a normal condition due to brake lining pedal travel was not excessive, perform the following
wear, a very low level may indicate a brake fluid leak steps:
in the hydraulic system.
a. Inspect the brake system for external leaks.
2. If the fluid level is abnormally low, adjust the brake Refer to “Brake System External Leak
fluid level. Refer to “Master Cylinder Reservoir Inspection”.
Filling”.
b. Pressure bleed the brake system in order to
3. Start the engine and allow it to idle. purge any air that may be trapped in the system.
4. Apply constant, moderate foot pressure to the brake Refer to “Hydraulic Brake System Bleeding
pedal. (Pressure)” “Hydraulic Brake System Bleeding
If the brake pedal gradually falls away while under (Manual)”.
foot pressure, there may be a brake fluid leak.
5. Turn OFF the ignition.
4A-25 Brake Control System and Diagnosis:

Hydraulic Brake Component Operation

Visual Inspection

5. If the brake pedal apply did not feel spongy, but the
brake pedal travel was excessive, perform the
following steps:

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a. Loosen the master cylinder-to-brake power
booster mounting nuts.
b. Carefully pull the master cylinder away from the
brake power booster just enough to inspect the
mounting surface of the master cylinder.
c. Inspect the master cylinder mounting surface at
the primary piston (2) for brake fluid leaks.
6. If the master cylinder exhibits any leakage around
the primary piston (2), then the primary piston
primary seal (4) and/or secondary seal (3) is leaking ! WARNING
and the master cylinder requires overhaul or
Refer to “Brake Fluid Irritant Caution: ”.
replacement.
7. If the master cylinder primary piston (2) does not
! CAUTION
exhibit any leakage, pressure bleed the brake
system. Refer to “Hydraulic Brake System Bleeding Refer to “Brake Fluid Effects on Paint and
(Pressure)” “Hydraulic Brake System Bleeding Electrical Components Notice: ”.
(Manual)”.
8. If the brake pedal apply did not feel spongy, and the 1. With the tire and wheel assemblies removed and the
brake pedal travel was initially steady and not brake rotors retained by wheel lug nuts, visually
excessive, but then gradually fell, then the master inspect the caliper piston dust boot (2) sealing area
cylinder requires overhaul or replacement due to an to ensure that there are no brake fluid leaks.
internal leak past the secondary piston (1) from the 2. If any evidence of a brake fluid leak is present, the
secondary piston primary seal (6) or secondary seal brake caliper requires overhaul or replacement.
(5). 3. While the brake system is at rest (4), observe the
9. If the brake pedal apply did not feel spongy, and the position of the caliper piston (1) in relation to the
brake pedal travel was initially steady and not caliper housing.
excessive, then fell slightly, then became steady 4. Have an assistant apply and release the brake pedal
again, then the brake pressure modulator valve several times while you observe the operation of the
(BPMV) may be leaking internally, and may require hydraulic brake caliper.
replacement.
a. Observe the caliper piston (1) for unrestricted
and even movement during each apply of the
brake system (5).
b. Observe the caliper piston (1) for an unrestricted
and even return motion during each release of
the brake system (6).
 Brake Control System and Diagnosis: 4A-26

5. If the caliper piston (1) did not exhibit unrestricted

and even movement during brake system apply and/
or release, the piston square seal (3) may be worn or
damaged and the caliper may require overhaul or
replacement.

Repair Instructions
Master Cylinder Reservoir Filling Hydraulic Brake System Bleeding
(Pressure)
! WARNING
Special tool
Refer to “Brake Fluid Irritant Caution: ”. J 29532 Diaphragm Type Brake Pressure Bleeder, or
equivalent
! CAUTION J 44894-A Brake Pressure Bleeder Adapter
When adding fluid to the brake master ! WARNING
cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean, Refer to “Brake Fluid Irritant Caution: ”.
sealed brake fluid container. The use of any

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type of fluid other than the recommended ! CAUTION
type of brake fluid may cause contamination
which could result in damage to the internal When adding fluid to the brake master
rubber seals and/or rubber linings of cylinder reservoir, use only GM approved or
hydraulic brake system components. equivalent DOT-3 brake fluid from a clean,
sealed brake fluid container. The use of any
type of fluid other than the recommended
! CAUTION
type of brake fluid may cause contamination
Refer to “Brake Fluid Effects on Paint and which could result in damage to the internal
Electrical Components Notice: ”. rubber seals and/or rubber linings of
hydraulic brake system components.
1. Visually inspect the brake fluid level through the
brake master cylinder auxiliary reservoir. ! CAUTION
2. If the brake fluid level is at or below the half-full point
Refer to Brake Fluid Effects on Paint and
during routine fluid checks, the brake system should
Electrical Components Notice.
be inspected for wear and possible brake fluid leaks.
3. If the brake fluid level is at or below the half-full point 1. Place a clean shop cloth beneath the brake master
during routine fluid checks, and an inspection of the cylinder to catch brake fluid spills.
brake system did not reveal wear or brake fluid
2. With the ignition OFF and the brakes cool, apply the
leaks, the brake fluid may be topped-off up to the
brakes 3-5 times, or until the brake pedal becomes
maximum-fill level.
firm, in order to deplete the brake booster power
4. If brake system service was just completed, the reserve.
brake fluid may be topped-off up to the maximum-fill
3. If you have performed a brake master cylinder bench
level.
bleeding on this vehicle, or if you disconnected the
5. If the brake fluid level is above the half-full point, brake pipes from the master cylinder, or if you have
adding brake fluid is not recommended under normal disconnected the brake pipes from the proportioning
conditions. valve assembly or the brake modulator assembly,
6. If brake fluid is to be added to the master cylinder you must perform the following steps to bleed air at
auxiliary reservoir, clean the outside of the reservoir the ports of the hydraulic component:
on and around the reservoir cap prior to removing a. If removal of the reservoir cap and diaphragm is
the cap and diaphragm. necessary, clean the outside of the reservoir on
and around the cap prior to removal.
b. With the brake pipes installed securely to the
master cylinder, proportioning valve assembly, or
brake modulator assembly, loosen and separate
one of the brake pipes from the port of the
component.
4A-27 Brake Control System and Diagnosis:

For the proportioning valve assembly or the 13. With the right rear wheel hydraulic circuit bleeder
brake modulator assembly, perform these steps valve tightened securely, and after all air has been
in the sequence of system flow; begin with the purged from the right rear hydraulic circuit, install a
fluid feed pipes from the master cylinder. proper box-end wrench onto the LEFT FRONT
c. Allow a small amount of brake fluid to gravity wheel hydraulic circuit bleeder valve.
bleed from the open port of the component. 14. Install a transparent hose over the end of the bleeder
d. Reconnect the brake pipe to the component and valve, then repeat steps 13-14.
tighten securely. 15. With the left front wheel hydraulic circuit bleeder
e. Have an assistant slowly depress the brake valve tightened securely, and after all air has been
pedal fully and maintain steady pressure on the purged from the left front hydraulic circuit, install a
pedal. proper box-end wrench onto the LEFT REAR wheel
hydraulic circuit bleeder valve.
f. Loosen the same brake pipe to purge air from
the open port of the component. 16. Install a transparent hose over the end of the bleeder
valve, then repeat steps 13-14.
g. Tighten the brake pipe, then have the assistant
slowly release the brake pedal. 17. With the left rear wheel hydraulic circuit bleeder
valve tightened securely, and after all air has been
h. Wait 15 seconds, then repeat steps 3.3-3.7 until
purged from the left rear hydraulic circuit, install a
all air is purged from the same port of the
proper box-end wrench onto the RIGHT FRONT
component.
wheel hydraulic circuit bleeder valve.
i. With the brake pipe installed securely to the
18. Install a transparent hose over the end of the bleeder
master cylinder, proportioning valve assembly, or

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valve, then repeat steps 13-14.
brake modulator assembly, and after all air has
been purged from the first port of the component 19. After completing the final wheel hydraulic circuit
that was bled, loosen and separate the next bleeding procedure, ensure that each of the 4 wheel
brake pipe from the component, then repeat hydraulic circuit bleeder valves is properly tightened.
steps 3.3-3.8 until each of the ports on the 20. Close the J 29532, or equivalent, fluid tank valve,
component has been bled. then disconnect the J 29532, or equivalent, from the
j. After completing the final component port J 44894-A.
bleeding procedure, ensure that each of the 21. Remove the J 44894-A from the brake master
brake pipe-to-component fittings is properly cylinder reservoir.
tightened. 22. Slowly depress and release the brake pedal.
4. Clean the outside of the reservoir on and around the Observe the feel of the brake pedal.
reservoir cap prior to removing the cap and 23. If the brake pedal feels spongy perform the following
diaphragm. steps:
5. Install the J 44894-A to the brake master cylinder a. Inspect the brake system for external leaks.
reservoir. Refer to “Brake System External Leak
6. Connect the J 29532, or equivalent, to the J 44894- Inspection”.
A. b. If equipped with antilock brakes, using a scan
7. Charge the J 29532, or equivalent, air tank to 175- tool, perform the antilock brake system
205 kPa (25-30 psi). automated bleeding procedure to remove any air
8. Open the J 29532, or equivalent, fluid tank valve to that may have been trapped in the brake
allow pressurized brake fluid to enter the brake pressure modulator valve (BPMV). Refer to
system. “Antilock Brake System Automated Bleed
Procedure: ”.
9. Wait approximately 30 seconds, then inspect the
entire hydraulic brake system in order to ensure that 24. Turn the ignition key ON, with the engine OFF.
there are no existing external brake fluid leaks. Check to see if the brake system warning lamp
Any brake fluid leaks identified require repair prior to remains illuminated.
completing this procedure.
NOTE
10. Install a proper box-end wrench onto the RIGHT
DO NOT allow the vehicle to be driven until it
REAR wheel hydraulic circuit bleeder valve.
is diagnosed and repaired.
11. Install a transparent hose over the end of the bleeder
valve. 25. If the brake system warning lamp remains
12. Loosen the bleeder valve to purge air from the wheel illuminated. Refer to “Symptoms - Hydraulic Brakes:
hydraulic circuit. Allow fluid to flow until air bubbles ”.
stop flowing from the bleeder, then tighten the
bleeder valve.
 Brake Control System and Diagnosis: 4A-28

Hydraulic Brake System Bleeding (Manual) h. Wait 15 seconds, then repeat steps 3.3-3.7 until
all air is purged from the same port of the
! WARNING component.
Refer to “Brake Fluid Irritant Caution: ”. i. With the brake pipe installed securely to the
master cylinder, proportioning valve assembly, or
brake modulator assembly, and after all air has
! CAUTION been purged from the first port of the component
When adding fluid to the brake master that was bled, loosen and separate the next
cylinder reservoir, use only GM approved or brake pipe from the component, then repeat
equivalent DOT-3 brake fluid from a clean, steps 3.3-3.8 until each of the ports on the
sealed brake fluid container. The use of any component has been bled.
type of fluid other than the recommended j. After completing the final component port
type of brake fluid may cause contamination bleeding procedure, ensure that each of the
which could result in damage to the internal brake pipe-to-component fittings is properly
rubber seals and/or rubber linings of tightened.
hydraulic brake system components. 4. Ensure the brake master cylinder reservoir remains
at least half-full during this bleeding procedure. Add
! CAUTION fluid as needed to maintain the proper level.
Refer to Brake Fluid Effects on Paint and Clean the outside of the reservoir on and around the
Electrical Components Notice. reservoir cap prior to removing the cap and
diaphragm.

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1. Place a clean shop cloth beneath the brake master 5. Install a proper box-end wrench onto the RIGHT
cylinder to catch brake fluid spills. REAR wheel hydraulic circuit bleeder valve.
2. With the ignition OFF and the brakes cool, apply the 6. Install a transparent hose over the end of the bleeder
brakes 3-5 times, or until the brake pedal effort valve.
increases significantly, in order to deplete the brake 7. Have an assistant slowly depress the brake pedal
booster power reserve. fully and maintain steady pressure on the pedal.
3. If you have performed a brake master cylinder bench 8. Loosen the bleeder valve to purge air from the wheel
bleeding on this vehicle, or if you disconnected the hydraulic circuit.
brake pipes from the master cylinder, or if you have 9. Tighten the bleeder valve, then have the assistant
disconnected the brake pipes from the proportioning slowly release the brake pedal.
valve assembly or the brake modulator assembly,
10. Wait 15 seconds, then repeat steps 8-10 until all air
you must perform the following steps to bleed air at
is purged from the same wheel hydraulic circuit.
the ports of the hydraulic component:
11. With the right rear wheel hydraulic circuit bleeder
a. If removal of the reservoir cap and diaphragm is
valve tightened securely, and after all air has been
necessary, clean the outside of the reservoir on
purged from the right rear hydraulic circuit, install a
and around the cap prior to removal.
proper box-end wrench onto the LEFT FRONT
b. With the brake pipes installed securely to the wheel hydraulic circuit bleeder valve.
master cylinder, proportioning valve assembly, or
12. Install a transparent hose over the end of the bleeder
brake modulator assembly, loosen and separate
valve, then repeat steps 7-11.
one of the brake pipes from the port of the
component. 13. With the left front wheel hydraulic circuit bleeder
For the proportioning valve assembly or the valve tightened securely, and after all air has been
brake modulator assembly, perform these steps purged from the left front hydraulic circuit, install a
in the sequence of system flow; begin with the proper box-end wrench onto the LEFT REAR wheel
fluid feed pipes from the master cylinder. hydraulic circuit bleeder valve.
c. Allow a small amount of brake fluid to gravity 14. Install a transparent hose over the end of the bleeder
bleed from the open port of the component. valve, then repeat steps 7-11.
d. Reconnect the brake pipe to the component and 15. With the left rear wheel hydraulic circuit bleeder
tighten securely. valve tightened securely, and after all air has been
purged from the left rear hydraulic circuit, install a
e. Have an assistant slowly depress the brake
proper box-end wrench onto the RIGHT FRONT
pedal fully and maintain steady pressure on the
wheel hydraulic circuit bleeder valve.
pedal.
16. Install a transparent hose over the end of the bleeder
f. Loosen the same brake pipe to purge air from
valve, then repeat steps 7-11.
the open port of the component.
g. Tighten the brake pipe, then have the assistant
slowly release the brake pedal.
4A-29 Brake Control System and Diagnosis:

17. After completing the final wheel hydraulic circuit 1. Inspect the brake fluid for the following conditions,
bleeding procedure, ensure that each of the 4 wheel indicating brake fluid contamination:
hydraulic circuit bleeder valves is properly tightened.
– Fluid separation, indicating two types of fluid are
18. Slowly depress and release the brake pedal. present; a substance other than the
Observe the feel of the brake pedal. recommended brake fluid has been introduced
19. If the brake pedal feels spongy, repeat the bleeding into the brake hydraulic system
procedure again. If the brake pedal still feels spongy – Swirled appearance—Oil-based substance
after repeating the bleeding procedure, perform the
– Layered appearance—Silicone-based
following steps:
substance
a. Inspect the brake system for external leaks.
– Fluid discoloration, indicating the presence of
Refer to “Brake System External Leak
moisture or particles that have been introduced
Inspection”.
into the brake hydraulic system
b. Pressure bleed the hydraulic brake system in
– Cloudy appearance—Moisture
order to purge any air that may still be trapped in
the system. – Dark appearance/suspended particles in fluid—
Dirt, rust, corrosion, brake dust
20. Turn the ignition key ON, with the engine OFF.
Check to see if the brake system warning lamp 2. Inspect the master cylinder reservoir cap diaphragm
remains illuminated. and the reservoir-to-master cylinder grommets for
swelling, indicating brake fluid contamination.
NOTE 3. If the brake fluid WAS contaminated with an oil-

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DO NOT allow the vehicle to be driven until it based or a silicone-based substance, indicated by
is diagnosed and repaired. fluid separation and/or a swollen master cylinder
reservoir cap diaphragm and/or swollen reservoir-to-
21. If the brake system warning lamp remains master cylinder grommets, perform the following:
illuminated. Refer to “Symptoms - Hydraulic Brakes: a. Remove ALL of the following components listed
”. from the vehicle. Each component contains
internal rubber seals/linings which have been
Hydraulic Brake System Flushing contaminated by the contaminated brake fluid in
the brake hydraulic system.
! WARNING Refer to the procedures indicated:
Refer to “Brake Fluid Irritant Caution: ”. – “Master Cylinder Reservoir Replacement”
– “Master Cylinder Replacement”
! CAUTION – “Front Brake Hose Replacement”
When adding fluid to the brake master – “Rear Brake Hose Replacement”
cylinder reservoir, use only GM approved or – “Front Brake Caliper Replacement: ”
equivalent DOT-3 brake fluid from a clean, – “Rear Brake Caliper Replacement: ”
sealed brake fluid container. The use of any – “Brake Pressure Modulator Valve
type of fluid other than the recommended Replacement: ”
type of brake fluid may cause contamination
b. Clean out all the hydraulic brake pipes using
which could result in damage to the internal
denatured alcohol, or equivalent.
rubber seals and/or rubber linings of
hydraulic brake system components. c. Dry the brake pipes using non-lubricated, filtered
air.
! CAUTION
Refer to Brake Fluid Effects on Paint and
Electrical Components Notice.
 Brake Control System and Diagnosis: 4A-30

d. Repair or replace ALL of the following Brake Pedal Assembly Replacement

components listed and install them to the Removal Procedure
vehicle. Each component contains internal
rubber seals/linings which have been
contaminated by the contaminated brake fluid in
the brake hydraulic system.
Refer to the procedures indicated:
– Clean the brake master cylinder reservoir
using denatured alcohol, or equivalent, then
dry the reservoir using non-lubricated, filtered
air. Inspect the reservoir for cracks and/or
damage and replace if necessary. Refer to
“Master Cylinder Reservoir Replacement”.
Replace the brake master cylinder reservoir
cap diaphragm.
– “Master Cylinder Replacement”
– “Front Brake Hose Replacement”
– “Rear Brake Hose Replacement”
– “Front Brake Caliper Replacement: ”
– “Rear Brake Caliper Replacement: ” 1. Disconnect the accelerator pedal assembly electrical

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– “Brake Pressure Modulator Valve connector.
Replacement: ”
4. If the brake fluid was NOT contaminated with an oil-
based or a silicone-based substance, but WAS
contaminated with water or dirt, rust, corrosion, and/
or brake dust, replace the brake master cylinder
reservoir cap diaphragm which may have allowed
the moisture or particles to enter the hydraulic
system.
5. Pressure bleed the hydraulic brake system; begin
the procedure with the pressure bleeder reservoir
filled to the maximum-fill level with the correct brake
fluid as indicated. Refer to “Hydraulic Brake System
Bleeding (Pressure)” “Hydraulic Brake System
Bleeding (Manual)”.

2. Remove the retaining clip and washer from the brake

pedal.
3. Release the brake booster pushrod from the brake
pedal.
4. Disconnect the brake pedal position sensor electrical
connector.
4A-31 Brake Control System and Diagnosis:

5. Remove the brake pedal bracket-to-steering column 8. Loosen, but do not remove, the steering column
bracket bolt. bracket to cowl nut.
9. While simultaneously disengaging the brake pedal

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bracket pilot bushings from the foam insulation
panel, pull the brake pedal assembly back and
toward the center of the vehicle.
10. Remove the brake pedal assembly from the vehicle.

6. Remove the brake booster mounting nuts.

7. Position the brake booster forward to clear the studs
from the front of the dash.

11. Remove the accelerator pedal assembly from the

brake pedal bracket. Refer to “Accelerator Pedal
Position Sensor Replacement: ”.
 Brake Control System and Diagnosis: 4A-32

Installation Procedure

4. Install the brake pedal bracket-to-steering column

1. Install the accelerator pedal assembly to the brake bracket bolt.
pedal bracket. Refer to “Accelerator Pedal Position Tightening torque

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Sensor Replacement: ”. Tighten the bolt to 25 N⋅m (18 lb ft).
5. Loosely install the brake booster mounting nuts.
6. Apply a thin coating of lithium grease to the pushrod
pin on the brake pedal.

2. Install the brake pedal assembly into the vehicle,

while guiding the brake pedal bracket pilot bushings
into the foam insulator panel.
3. Position the booster studs through dash panel.
7. Connect the brake booster pushrod to the brake
! CAUTION pedal.
Refer to “Fastener Notice: ”. 8. Install the washer and retaining clip to the brake
pedal.
4A-33 Brake Control System and Diagnosis:

9. Tighten the vacuum brake booster mounting nuts. 12. Connect the accelerator pedal assembly electrical
connector.
Tightening torque
Tighten the nuts to 25 N⋅m (18 lb ft).

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Brake Pedal Pushrod Inspection

10. Install the steering column bracket to cowl nut.

1. Disconnect the brake pedal pushrod (1) from the
Tightening torque
brake pedal.
Tighten the nuts to 25 N⋅m (18 lb ft).
2. Inspect the brake pedal pushrod eyelet bushing (2),
11. Connect the brake pedal position sensor electrical if equipped, for cracks and/or excessive wear.
connector. 3. Reposition the pedal pushrod boot (3) toward the
front of the vehicle to expose as much of the pedal
pushrod (1) as possible.
4. Inspect the brake pedal pushrod (1) for straightness.
5. If the brake pedal pushrod eyelet bushing (2)
exhibited cracks and/or excessive wear, then the
bushing requires replacement.
6. If the brake pedal pushrod (1) is not straight, then the
pushrod requires replacement.
7. Return the pedal pushrod boot (3) to its original
position on the pedal pushrod (1).
8. Connect the brake pedal pushrod (1) to the brake
pedal.
 Brake Control System and Diagnosis: 4A-34

Brake Pedal Position Sensor Replacement

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Callout Component Name
Preliminary Procedures
1. Remove the left side instrument panel sound insulator. Refer to “Instrument Panel Insulator Panel Replacement -
Left Side: ”.
2. Remove the left side knee bolster. Refer to “Knee Bolster Replacement: ”.
Brake Pedal Position Sensor Bolt
Tip:
1
• Calibrate the position sensor. Refer to “Brake Pedal Position Sensor Calibration”.
• Do not reuse the position sensor or bolt. Always use a new sensor and bolt.
Brake Pedal Position Sensor Assembly

! CAUTION
Refer to “Fastener Notice: ”.
2
Tip: Disconnect the electrical connector.
Tightening torque
2.5 N⋅m (22 lb in)
4A-35 Brake Control System and Diagnosis:

Brake Pedal Position Sensor Calibration 2. Disconnect the electrical connector from the stop
Calibration Criteria lamp switch.
The brake pedal position sensor (BPPS) receives a low
reference signal and a 5-volt reference signal from the
BCM. Whenever the brake pedal is applied, the BPPS
applies a variable voltage signal to the BCM through the
stop lamp switch signal circuit. The BPPS calibration
must be performed after the BPPS or body control
module (BCM) have been serviced. The calibration
procedure will set BPPS home value. This value is used
by the BCM to determine the action of the driver applying
the brake system and to provide this information to the
vehicle subsystems via the communication bus.

Calibration Procedure
• Install a scan tool.
• Turn ON the ignition, with the engine OFF.
• Select Diagnostics.
• Select the year.
• Select the vehicle type. 3. Rotate the switch counterclockwise and remove the

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switch from the switch retainer.
• Select BCM.
• Select Module Setup. NOTE
• Select the BPPS calibration procedure and follow the Do NOT depress the brake pedal assembly
directions displayed on the screen. during the stop lamp switch installation. This
will cause a drag condition on the brake.
Stop Lamp Switch Adjustment
4. Install the switch to the bracket by turning and
Adjustment Procedure pushing the switch until the switch bottoms on the
1. Remove the left instrument panel (I/P) insulator brake pedal.
panel. Refer to “Instrument Panel Insulator Panel 5. Connect the electrical connector to the stop lamp
Replacement - Left Side: ”. switch.
6. Inspect the stop lamps for proper operation
7. Install the left I/P insulator panel. Refer to
“Instrument Panel Insulator Panel Replacement -
Left Side: ”.

! CAUTION
Proper stoplamp switch adjustment is
essential. Improper stoplamp switch
adjustment may cause brake drag, heat
buildup and excessive brake lining wear.
 Brake Control System and Diagnosis: 4A-36

Stop Lamp Switch Replacement 4. Install the switch to the bracket by turning and
Adjustment Procedure pushing the switch until the switch bottoms on the
brake pedal.
1. Remove the left instrument panel (I/P) insulator
panel. Refer to “Instrument Panel Insulator Panel 5. Connect the electrical connector to the stop lamp
Replacement - Left Side: ”. switch.
6. Inspect the stop lamps for proper operation
7. Install the left I/P insulator panel. Refer to
“Instrument Panel Insulator Panel Replacement -
Left Side: ”.

Front Brake Hose Replacement

! WARNING
Refer to “Brake Fluid Irritant Caution: ”.

! CAUTION
Refer to “Brake Fluid Effects on Paint and
Electrical Components Notice: ”.

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Removal Procedure

! CAUTION
Proper stoplamp switch adjustment is
essential. Improper stoplamp switch
adjustment may cause brake drag, heat
buildup and excessive brake lining wear.

2. Disconnect the electrical connector from the stop

lamp switch.

1. Raise and support the vehicle. Refer to “Lifting and

Jacking the Vehicle: ”.
2. Remove the tire and wheel assembly. Refer to “Tire
and Wheel Removal and Installation: ”.
3. Release the wheel speed sensor wire harness
retainers and harness from the front brake hose.

3. Rotate the switch counterclockwise and remove the

switch from the switch retainer.

NOTE
Do NOT depress the brake pedal assembly
during the stop lamp switch installation. This
will cause a drag condition on the brake.
4A-37 Brake Control System and Diagnosis:

Installation Procedure

4. Clean all dirt and foreign material from the brake

hose ends and the brake pipe fitting. 1. Remove the caps or plugs from the opening in the
5. Using a backup wrench on the hose fitting, brake caliper and the brake hose.

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disconnect the brake pipe fitting from the brake
NOTE
hose. Cap or plug the brake pipe fitting end and the
brake hose end to prevent fluid loss and Install NEW copper brake hose gaskets.
contamination.
2. Assemble the NEW copper brake hose gaskets, and
6. Release the retaining clip from the brake hose
the brake hose bolt, to the brake hose.
mounting bracket and the brake hose.
! CAUTION
Refer to “Fastener Notice: ”.

3. Install the brake hose fitting bolt to the brake caliper.

Tightening torque
Tighten the bolt to 52 N⋅m (38 lb ft).
4. Install the front brake hose bracket retaining bolt.
Tightening torque
Tighten the bolt to 12 N⋅m (106 lb in).

7. Remove the brake hose fitting bolt from the brake

caliper.
8. Remove the brake hose bracket retaining bolt.
9. Remove the brake hose from the brake caliper.
10. Remove and discard the copper brake hose gaskets.
These gaskets may be stuck to the brake caliper
and/or the brake hose end.
11. Cap or plug the opening in the brake caliper and the
brake hose to prevent fluid loss and contamination.
 Brake Control System and Diagnosis: 4A-38

6. Using a backup wrench on the hose fitting, connect

the brake pipe fitting at the front brake hose.
Tightening torque
Tighten the fitting to 18 N⋅m (13 lb ft).
7. Install the brake hose retaining clip to the brake hose
and the brake hose mounting bracket.
8. Connect the wheel speed sensor wire harness and
harness retainers to the front brake hose.
9. Install the tire and wheel assembly. Refer to “Tire
and Wheel Removal and Installation: ”.
10. Ensure that the hose does not make contact with any
part of the suspension. Check the hose in extreme
right and extreme left turn conditions. If the hose
makes contact, remove the hose and correct the
condition.
11. Bleed the hydraulic brake system. Refer to
“Hydraulic Brake System Bleeding (Pressure)”
5. Remove the caps or plugs from the brake pipe fitting
“Hydraulic Brake System Bleeding (Manual)”.
end and the brake hose end.
12. Lower the vehicle.

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Rear Brake Hose Replacement
4A-39 Brake Control System and Diagnosis:

Callout Component Name

! WARNING
Refer to “Brake Fluid Irritant Caution: ”.

Preliminary Procedures
1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
Brake Hose Fitting Bolt

! CAUTION
1 Refer to “Fastener Notice: ”.

Tightening torque
52 N⋅m (38 lb ft)
Brake Hose Fitting Gasket (Qty: 2)
2
Tip: DO NOT reuse the brake hose fitting gaskets. Install NEW gaskets.
Brake Hose Bolt
3 Tightening torque

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12 N⋅m (106 lb in)
Brake Hose Bracket Bolt
4 Tightening torque
12 N⋅m (106 lb in)
Brake Pipe Fitting
Tip:
• Use a backup wrench when removing or installing brake pipe fittings.
5
• Cap or plug the brake pipe fitting to prevent brake fluid leaks and contamination.
Tightening torque
18 N⋅m (13 lb ft)
Brake Hose
6 Tip: Bleed the hydraulic brake system. Refer to “Hydraulic Brake System Bleeding (Pressure)”
“Hydraulic Brake System Bleeding (Manual)”.
 Brake Control System and Diagnosis: 4A-40

Brake Pipe Replacement

Special tool
J 45405 Brake Pipe Flaring Kit

! WARNING
Refer to “Brake Fluid Irritant Caution: ”.

! WARNING
Always use double walled steel brake pipe
when replacing brake pipes. The use of any
other pipe is not recommended and may
cause brake system failure. Carefully route
and retain replacement brake pipes. Always
use the correct fasteners and the original
location for replacement brake pipes. Failure
to properly route and retain brake pipes may
cause damage to the brake pipes and cause 1. Inspect the area of brake pipe to be repaired or
brake system failure. replaced.
2. Release the brake pipe to be replaced from the

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! CAUTION retainers, as required.
Refer to “Brake Fluid Effects on Paint and 3. Select an appropriate location to section the brake
Electrical Components Notice: ”. pipe, if necessary.
– Allow adequate clearance in order to maneuver
NOTE the J 45405.
When servicing the brake pipes, note the – Avoid sectioning the brake pipe at bends or
following: mounting points.
• If sectioning the brake pipe, use 4. Using a string or wire, measure the length of the pipe
replacement pipe of the same type and to be replaced including all pipe bends.
outside diameter. 5. Add to the measurement taken the appropriate
• Use fittings of the appropriate size and additional length required for each flare to be
type. created.
• Only create flares of the same type or Specification
design as originally equipped on the
• 6.35 mm (0.250 in) for 4.76 mm (3/16 in)
vehicle.
diameter pipe
• 9.50 mm (0.374 in) for 6.35 mm (1/4 in)
diameter pipe

NOTE
Ensure that the brake pipe end to be flared is
cut at a square, 90 degree angle to the pipe
length.

6. Using the pipe cutter included in the J 45405,

carefully cut the brake pipe squarely to the
measured length.
7. Remove the sectioned brake pipe from the vehicle.
8. Select the appropriate size of brake pipe and tube
nuts, as necessary. The brake pipe outside diameter
determines brake pipe size.
4A-41 Brake Control System and Diagnosis:

NOTE
Ensure that all loose remnants of the nylon
coating have been removed from the brake
pipe.

– Inspect the stripped end of the brake pipe to

ensure that the proper amount of coating has
been removed.
Specification
• 6.35 mm (0.250 in) for 4.76 mm (3/16 in)
diameter pipe
• 9.50 mm (0.374 in) for 6.35 mm (1/4 in)
diameter pipe

9. Strip the nylon coating from the brake pipe end to be

flared, if necessary.
– Select the appropriate blade on the coating

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stripping tool included in the J 45405, by
unthreading the blade block from the stripping tool
and installing the block with the desired blade
facing the tool rollers.
Specification
• 6.35 mm (0.250 in) blade for 4.76 mm (3/16
in) diameter pipe
• 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in)
diameter pipe
– Insert the brake pipe end to be flared into the
10. Chamfer the inside and outside diameter of the pipe
stripping tool to the depth of the ledge on the tool
with the de-burring tool included in the J 45405.
rollers.
11. Install the tube nuts on the brake pipe, noting their
– While holding the brake pipe firmly against the
orientation.
stripping tool roller ledges, rotate the thumbwheel
of the tool until the blade contacts the brake pipe 12. Clean the brake pipe and the J 45405 of lubricant,
coated surface. contaminants, and debris.

NOTE
Do not gouge the metal surface of the brake
pipe.

– Rotate the stripping tool in a clockwise direction,

ensuring that the brake pipe end remains against
the tool roller ledges.
– After each successive revolution of the stripping
tool, carefully rotate the thumbwheel of the tool
clockwise, in order to continue stripping the
coating from the brake pipe until the metal pipe
surface is exposed.
– Loosen the thumbwheel of the tool and remove
the brake pipe.

13. Loosen the die clamping screw of the J 45405.

 Brake Control System and Diagnosis: 4A-42

14. Select the corresponding die set and install the die
halves into the die cage with the full, flat face of one
die facing the clamping screw, and the counterbores
of both dies facing the forming ram.

23. While guiding the forming mandrel into the exposed

end of pipe to be flared, operate the lever of the J
45405 until the forming mandrel bottoms against the

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clamping dies.
15. Place the flat face of an unused die (1) against the 24. Rotate the hydraulic fluid control valve
die halves in the clamping cage and hold firmly counterclockwise to the open position to allow the
against the counterbored face of the dies. hydraulic forming ram to retract.
16. Insert the prepared end of the pipe to be flared
through the back of the dies until the pipe is seated
against the flat surface of the unused die (1).
17. Remove the unused die (1).
18. Ensure that the rear of both dies are seated firmly
against the enclosed end of the die cage.
19. Firmly hand tighten the clamping screw (2) against
the dies.

25. Insert the finishing cone into the forming ram.

26. Rotate the hydraulic fluid control valve clockwise to
the closed position.
27. Rotate the body of the J 45405 until it bottoms
against the die cage.
28. While guiding the finishing cone into the exposed
end of pipe to be flared, operate the lever of the J
45405 until the finishing cone bottoms against the
20. Select the appropriate forming mandrel and place dies.
into the forming ram. 29. Rotate the hydraulic fluid control valve
21. Rotate the hydraulic fluid control valve clockwise to counterclockwise to the open position to allow the
the closed position. hydraulic forming ram to retract.
22. Rotate the body of the J 45405 until it bottoms 30. Loosen the die clamping screw and remove the dies
against the die cage. and pipe.
4A-43 Brake Control System and Diagnosis:

31. If necessary, lightly tap the dies until the die halves Brake Pipe and Hose Inspection
separate.
! WARNING
Refer to “Brake Fluid Irritant Caution: ”.

! CAUTION
Refer to “Brake Fluid Effects on Paint and
Electrical Components Notice: ”.

1. Visually inspect all of the brake pipes for the

following conditions:
– Kinks, improper routing, missing or damaged
retainers
– Leaking fittings, excessive corrosion
2. If any of the brake pipes exhibited any of the
conditions listed, then the identified pipe, or pipes,
require replacement.
3. Ensure that the vehicle axles are properly supported
32. Inspect the brake pipe flare for correct shape and at ride height in order to maintain the proper

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diameter (a). relationship of the flexible brake hoses to the
chassis.
Specification
• 6.74-7.10 mm (0.265-0.279 in) flare diameter for
4.76 mm (3/16 in) diameter pipe
• 8.57-9.27 mm (0.344-0.358 in) flare diameter for
6.35 mm (1/4 in) diameter pipe
33. If necessary, using the removed section of brake
pipe as a template, shape the new pipe with a
suitable brake pipe bending tool.

NOTE
When installing the pipe, maintain a
clearance of 19 mm (3/4 in) from all moving or
vibrating components.

34. Install the pipe to the vehicle with the appropriate

brake pipe unions, as required.
35. If previously released, secure the brake pipe to the
retainers.
4. Visually inspect all of the flexible brake hoses for the
36. Bleed the hydraulic brake system. Refer to
following conditions:
“Hydraulic Brake System Bleeding (Pressure)”
“Hydraulic Brake System Bleeding (Manual)”. – Kinks (1), improper routing, twists, chafing,
missing or damaged retainers
37. With the aid of an assistant, inspect the brake pipe
flares for leaks by starting the engine and applying – Leaking connections, cracking, dry-rot, blisters,
the brakes. bulges
5. If any of the flexible brake hoses exhibited any of the
conditions listed, then the identified flexible brake
hose, or hoses require replacement.
6. Squeeze the flexible brake hoses with firm finger
pressure to check for soft spots (2), indicating an
internal restriction. Check the entire length of each
flexible brake hose.
7. If any of the flexible brake hoses were found to have
soft spots (2), then the identified flexible brake hose,
or hoses require replacement.
 Brake Control System and Diagnosis: 4A-44

Master Cylinder Fluid Level Sensor Installation Procedure

Replacement
Removal Procedure

1. While noting the proper orientation, install the brake

fluid level sensor to the master cylinder.

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1. Remove the underhood electrical center. Refer to 2. Press the brake fluid level sensor firmly into the
“Underhood Electrical Center or Junction Block master cylinder reservoir, ensuring that the retaining
Replacement: ”. tabs are fully engaged.
2. Disconnect the brake fluid level sensor electrical
connector.

3. Connect the brake fluid level sensor electrical

connector.
3. While simultaneously depressing the retaining tabs 4. Install the underhood electrical center. Refer to
on the opposite side of the sensor electrical “Underhood Electrical Center or Junction Block
connection, carefully pull the sensor from the master Replacement: ”.
cylinder reservoir.
4. Remove the low brake fluid level sensor.
4A-45 Brake Control System and Diagnosis:

Master Cylinder Reservoir Replacement

Removal Procedure
! WARNING
Refer to “Brake Fluid Irritant Caution: ”.

! CAUTION
When adding fluid to the brake master
cylinder reservoir, use only GM approved or
equivalent DOT-3 brake fluid from a clean,
sealed brake fluid container. The use of any
type of fluid other than the recommended
type of brake fluid may cause contamination
which could result in damage to the internal
rubber seals and/or rubber linings of
hydraulic brake system components.

! CAUTION 4. Remove the brake fluid level sensor. Refer to

“Master Cylinder Fluid Level Sensor Replacement”.
Refer to “Brake Fluid Effects on Paint and

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Electrical Components Notice: ”.

5. Remove the master cylinder reservoir attachment

pins and discard the pins.
6. Release the reservoir from the master cylinder by
1. Remove the underhood electrical center. Refer to
carefully pulling reservoir straight up.
“Underhood Electrical Center or Junction Block
Replacement: ”. 7. Remove the reservoir seals from the master cylinder
body.
2. Remove the brake fluid from the reservoir. Discard
the fluid into an approved container.
3. Disconnect the brake fluid level sensor electrical
connector.
 Brake Control System and Diagnosis: 4A-46

Installation Procedure

5. Connect the brake fluid level sensor electrical

1. Install the reservoir seals to the master cylinder connector.
body. 6. Install the underhood electrical center. Refer to

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2. Install the reservoir to the master cylinder body by “Underhood Electrical Center or Junction Block
pushing the reservoir bayonets straight down into the Replacement: ”.
seals in the master cylinder body. 7. Fill the master cylinder reservoir. Refer to “Master
3. Install NEW reservoir attachment pins. Ensure that Cylinder Reservoir Filling”.
the attachment pins are fully and firmly seated. 8. Bleed the brake system. Refer to “Hydraulic Brake
System Bleeding (Pressure)” “Hydraulic Brake
System Bleeding (Manual)”.

Master Cylinder Replacement

Removal Procedure
! WARNING
Refer to “Brake Fluid Irritant Caution: ”.

! CAUTION
Refer to “Brake Fluid Effects on Paint and
Electrical Components Notice: ”.

4. Install the brake fluid level sensor. Refer to “Master

Cylinder Fluid Level Sensor Replacement”.
4A-47 Brake Control System and Diagnosis:

1. Remove the underhood electrical center. Refer to Installation Procedure

“Underhood Electrical Center or Junction Block
Replacement: ”.
2. Disconnect the electrical connector from the brake
fluid level sensor.

1. Bench bleed the master cylinder. Refer to “Master

Cylinder Bench Bleeding”.

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2. Install the master cylinder to the brake booster.

3. Disconnect the brake pipes from the master cylinder. ! CAUTION

NOTE Refer to “Fastener Notice: ”.

Install a rubber cap or plug to the exposed 3. Install the master cylinder mounting nuts.
brake pipe fitting ends in order to prevent
brake fluid loss and contamination. Tightening torque
Tighten the master cylinder mounting nuts to 25
4. Plug the open brake pipe ends. N⋅m (18 lb ft).

5. Remove master cylinder mounting nuts. 4. Remove the plugs from the brake pipes.
6. Remove the master cylinder from the vehicle. 5. Connect the brake pipes to the master cylinder.
7. Drain the master cylinder reservoir of all brake fluid. Tightening torque
Tighten the brake pipe fittings at the master
cylinder to 18 N⋅m (13 lb ft).
 Brake Control System and Diagnosis: 4A-48

6. Connect the electrical connector to the brake fluid 1. Secure the mounting flange of the brake master
level sensor. cylinder in a bench vise so that the rear of the
7. Install the underhood electrical center. Refer to primary piston is accessible.

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“Underhood Electrical Center or Junction Block 2. Remove the cap from the hose nipple on the master
Replacement: ”. cylinder reservoir.
8. Bleed the hydraulic brake system. Refer to 3. Install suitable fittings to the master cylinder ports
“Hydraulic Brake System Bleeding (Pressure)” that match the type of flare seat required and also
“Hydraulic Brake System Bleeding (Manual)”. provide for hose attachment.
4. Install transparent hoses to the fittings, then route
Master Cylinder Bench Bleeding the hoses into the master cylinder reservoir.
5. Ensure that the ends of the transparent hoses
! WARNING running into the reservoir are fully submerged in the
Refer to “Brake Fluid Irritant Caution: ”. brake fluid.
6. Using a smooth, round-ended tool, depress and
release the primary piston as far as it will travel, a
! CAUTION
depth of about 25 mm (1 in), several times. Observe
When adding fluid to the brake master the flow of fluid coming from the ports.
cylinder reservoir, use only GM approved or As air is bled from the primary and secondary
equivalent DOT-3 brake fluid from a clean, pistons, the effort required to depress the primary
sealed brake fluid container. The use of any piston will increase and the amount of travel will
type of fluid other than the recommended decrease.
type of brake fluid may cause contamination 7. Continue to depress and release the primary piston
which could result in damage to the internal until fluid flows freely from the ports with no evidence
rubber seals and/or rubber linings of of air bubbles.
hydraulic brake system components.
8. Remove the transparent hoses from the reservoir.
9. Install the cap to the hose nipple on the reservoir, to
! CAUTION
prevent fluid loss and contamination.
Refer to “Brake Fluid Effects on Paint and 10. Remove the fittings with the transparent hoses from
Electrical Components Notice: ”. the master cylinder ports. Wrap the master cylinder
with a clean shop cloth to prevent brake fluid spills.
11. Remove the master cylinder from the vise.
4A-49 Brake Control System and Diagnosis:

Vacuum Brake Booster Check Valve and/or Installation Procedure

Hose Replacement
Removal Procedure

1. Install the vacuum hose to the check valve.

2. Install the brake booster check valve and hose

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1. Release the retaining clamp (1) and remove the assembly to the booster.
vacuum hose (2) from the vacuum port on the
engine.

3. Install the vacuum hose (2) to the engine vacuum

port.
2. Remove the check valve and hose from the brake 4. Install the vacuum hose clamp (1).
booster by gently turning the check valve right then
left while pulling straight out from the grommet.
3. Remove the vacuum hose from the check valve.
 Brake Control System and Diagnosis: 4A-50

Vacuum Brake Booster Replacement 7. Remove the brake pressure modulator valve
Removal Procedure assembly. Refer to “Brake Pressure Modulator Valve
Replacement: ”.

1. Remove and position aside the underhood electrical

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center. Refer to “Underhood Electrical Center or 8. Remove the brake pressure modulator valve
Junction Block Replacement: ”. bracket. Refer to “Brake Pressure Modulator Valve
Bracket Replacement: ”.
2. Disconnect the coolant surge hose from the surge
tank and position aside.
3. Remove the master cylinder mounting nuts. Do not
disconnect the brake pipes from the master cylinder.
4. Carefully pull the master cylinder away from the
vacuum booster and position aside.
5. Disconnect the vacuum booster check valve and
hose assembly from the booster. Refer to “Vacuum
Brake Booster Check Valve and/or Hose
Replacement”.

9. Remove the brake booster push rod-to-brake pedal

retaining clip.
10. Remove the foam washer from the brake pedal
assembly.

6. Without disconnecting the electrical connectors,

remove the transaxle control module (TCM) with the
bracket from the bracket on the strut tower and
position aside on top of the engine. Refer to
“Transmission Control Module Replacement: ”.
4A-51 Brake Control System and Diagnosis:

11. Remove the brake booster mounting nuts. 8. Fully seat the brake booster to the front of dash and
the brake pedal assembly.
NOTE

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Ensure that the foam insulator on the ! CAUTION
mounting surface of the brake booster Refer to “Fastener Notice: ”.
withdraws with the booster.
9. Tighten the vacuum brake booster mounting nuts.
12. Disengage the brake booster from the front of dash
and the brake pedal bracket. Maneuver the booster Tightening torque
toward the center of the vehicle in order to ease Tighten the nuts to 25 N⋅m (18 lb ft).
removal.

Installation Procedure

10. Install the brake pressure modulator valve bracket.

Refer to “Brake Pressure Modulator Valve Bracket
Replacement: ”.
1. Install the foam insulator the vacuum brake booster. 11. Install the brake pressure modulator valve assembly.
2. Install the brake booster to the vehicle. Refer to “Brake Pressure Modulator Valve
Replacement: ”.
3. Install, but do not tighten, the booster mounting nuts.
4. Lightly lubricate the booster push rod pivot pin on the
brake pedal with silicone lubricant.
5. Install the booster push rod to the pivot pin on the
brake pedal.
6. Install the foam washer to the pivot pin.
7. Install the brake booster push rod retaining clip.
 Brake Control System and Diagnosis: 4A-52

12. Install the vacuum booster check valve and hose 14. Install the coolant surge hose and clamp to the surge
assembly to the booster. tank.
13. Reposition and install the master cylinder to the 15. Install the underhood electrical center. Refer to

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booster. Refer to “Master Cylinder Replacement”. “Underhood Electrical Center or Junction Block
Replacement: ”.
16. If necessary, bleed the brake system. Refer to
“Hydraulic Brake System Bleeding (Pressure)”
“Hydraulic Brake System Bleeding (Manual)”.

Specifications
Fastener Tightening Specifications - Hydraulic Brakes
Specification
Application
Metric English
Brake Hose Bolt 12 N⋅m 106 lb in
Brake Hose Bracket Bolt 12 N⋅m 106 lb in
Brake Hose Fitting Bolt - Front 40 N⋅m 30 lb ft
Brake Hose Fitting Bolt - Rear 52 N⋅m 38 lb ft
Brake Pedal Bracket Bolt 25 N⋅m 18 lb ft
Brake Pipe Fittings 18 N⋅m 13 lb ft
Brake Pipe Fitting - Rear Brake Crossover Pipe 25 N⋅m 18 lb ft
Master Cylinder Mounting Nuts 25 N⋅m 18 lb ft
Steering Column Bracket Nut 25 N⋅m 18 lb ft
Vacuum Brake Booster Mounting Nuts 25 N⋅m 18 lb ft

Fastener Tightening Specifications - Lighting

Specification
Application
Metric English
CHMSL to Liftgate Screws 2 N⋅m 18 lb in
Fog Lamp Screws 2 N⋅m 18 lb in
Fog Lamp to Fascia Screws 4 N⋅m 35 lb in
Headlamp bolts 2.5 N⋅m 22 lb in
License Plate Bulb Assembly Screws 4 N⋅m 35 lb in
Tail Lamp Screws 2.5 N⋅m 22 lb in
4A-53 Brake Control System and Diagnosis:

Brake Component Specifications

Specification
Application
Metric English
Brake Caliper Bleeder Valve - Front 13 N⋅m 115 lb in
Brake Caliper Bleeder Valve - Rear 13 N⋅m 115 lb in

Brake System Specifications

Specification
Application
Metric English
Brake Pedal Travel
Maximum specification with 445 N (100 lbs) of force applied to
57 mm 2.25 in
the brake pedal with the ignition OFF and the booster power
reserve depleted.

Special Tools and Equipment

Special Tools - Hydraulic Brakes Tool Number/
Illustration
Tool Number/ Description
Illustration
Description

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J 45405
J 28662 Brake Pipe Flaring Kit
Brake Pedal Effort Gage

J 29532
Diaphragm Pressure
Bleeder

J 44894-A
Brake Pressure Bleeder
Adapter
 Front Brakes: 4B-1

Front Brakes
Precautions
Brake Dust Caution
! WARNING
Avoid taking the following actions when you service wheel brake parts:
• Do not grind brake linings.
• Do not sand brake linings.
• Do not clean wheel brake parts with a dry brush or with compressed air.
Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in
dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened
cloth in order to remove any dust on brake parts. Equipment is available commercially in order to
perform this washing function. These wet methods prevent fibers from becoming airborne.

Brake Fluid Irritant Caution

! WARNING

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Brake fluid may irritate eyes and skin. In case of contact, take the following actions:
• Eye contact—rinse thoroughly with water.
• Skin contact—wash with soap and water.
• If ingested—consult a physician immediately.

General Description
Disc Brake System Description and Operation
System Component Description
The disc brake system consists of the following components:
Disc Brake Pads: Applies mechanical output force from the hydraulic brake calipers to friction surfaces of brake
rotors.
Disc Brake Rotors: Uses mechanical output force applied to friction surfaces from the disc brake pads to slow speed
of tire and wheel assembly rotation.
Disc Brake Pad Hardware: Secures disc brake pads firmly in proper relationship to the hydraulic brake calipers.
Enables a sliding motion of brake pads when mechanical output force is applied.
Disc Brake Caliper Hardware: Provides mounting for hydraulic brake caliper and secures the caliper firmly in proper
relationship to caliper bracket. Enables a sliding motion of the brake caliper to the brake pads when mechanical
output force is applied.

System Operation
Mechanical output force is applied from the hydraulic brake caliper pistons to the inner brake pads. As the pistons
press the inner brake pads outward, the caliper housings draw the outer brake pads inward. This allows the output
force to be equally distributed. The brake pads apply the output force to the friction surfaces on both sides of the brake
rotors, which slows the rotation of the tire and wheel assemblies. The correct function of both the brake pad and brake
caliper hardware is essential for even distribution of braking force.
4B-2 Front Brakes:

Diagnostic Information and Procedures

Diagnostic Starting Point - Disc Brakes
Begin the disc brake system diagnosis with “Diagnostic Starting Point - Hydraulic Brakes: ”. The use of the Diagnostic
Starting Point will lead to the identification of the correct procedure for diagnosing the system and where the procedure
is located.

Disc Brake System Diagnosis

Test Description
The numbers below refer to the step numbers on the diagnostic table:
9.
Lubricant leaks from non-brake system components may come in contact with and contaminate brake system
components.
10.
Lubricant leaks from non-brake system components may come in contact with and contaminate brake system
components.
13.
Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake pulsation.
17.
Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake pulsation.
20.

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Disc brake rotor assembled lateral runout (LRO) that exceeds the maximum acceptable level can lead to thickness
variation.
Step Action Yes No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the DISC brake system in order
to determine if the DISC brake system is operating properly. You will be directed by the appropriate Symptom table to
go to other brake system diagnostic tables as appropriate.
Were you sent here from a Brake Symptom table? Go to “Diagnostic
1 Go to Step 2 Starting Point -
Hydraulic Brakes: ”
Visually inspect the disc brake pads for the following
conditions:
Refer to “Brake Pad Inspection: ”.
• Lining thickness below specifications
• Uneven and/or abnormal wear - edge-to-edge and/or side-
2 Go to Step 3 Go to Step 12
to-side
• Looseness or damage - including pad hardware
• Evidence of contamination from an external substance
Did you find any conditions to indicate a concern with any of
the front and/or rear disc brake pads?
3 Are any of the front and/or rear disc brake pads contaminated? Go to Step 8 Go to Step 4
Are any of the front and/or rear disc brake pads worn
4 Go to Step 7 Go to Step 5
unevenly?
Are any of the front and/or rear disc brake pads and/or pad
5 Go to Step 7 Go to Step 6
hardware loose or damaged?
1. Remove and inspect the worn disc brake pads for glazing,
looseness, heat spots or damage.
6 2. Replace the worn disc brake pads as a complete axle set. Go to Step 12 —
Refer to “Front Disc Brake Pads Replacement” and/or
“Rear Disc Brake Pads Replacement: ”.
Did you complete the inspection and replacement?
 Front Brakes: 4B-3

Step Action Yes No

! CAUTION
Support the brake caliper with heavy mechanic
wire, or equivalent, whenever it is separated from
its mount and the hydraulic flexible brake hose is
still connected. Failure to support the caliper in
this manner will cause the flexible brake hose to
bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a
brake fluid leak.

NOTE
Do NOT disconnect the hydraulic brake flex hoses
from the calipers.

1. Remove the front and/or rear disc brake calipers, as

appropriate, from the mounting brackets and support the
calipers. Refer to “Front Brake Caliper Replacement” and/
or “Rear Brake Caliper Replacement: ”.
2. Inspect the disc brake caliper mounting bracket and the

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7 mounting/sliding hardware for the following conditions: Go to Step 12 —
Refer to “Front Disc Brake Mounting and Hardware
Inspection” and/or “Rear Disc Brake Mounting and
Hardware Inspection: ”.
– Binding or seized hardware
– Worn, damaged or missing hardware components
– Loose, bent, cracked, or damaged caliper mounting
bracket
3. Replace components as required. Refer to the following
procedures in Disc Brakes, as required:
– “Front Brake Caliper Bracket Replacement”
– “Rear Brake Caliper Bracket Replacement: ”
– “Front Disc Brake Hardware Replacement”
– “Rear Disc Brake Hardware Replacement: ”
4. Replace the unevenly-worn, loose or damaged disc brake
pads as a complete axle set. Refer to “Front Disc Brake
Pads Replacement” and/or “Rear Disc Brake Pads
Replacement: ”.
Did you complete the inspection and replacement?
1. Inspect the disc brake calipers, brake hoses and brake
pipes for evidence of an external brake fluid leak.
2. Replace any components found to be leaking brake fluid.
Refer to the following procedures as required:
– “Front Brake Caliper Replacement”
8 – “Rear Brake Caliper Replacement: ” Go to Step 11 Go to Step 9
– “Front Brake Hose Replacement: ”
– “Rear Brake Hose Replacement: ”
– “Brake Pipe Replacement: ”
Did you find and correct the source of the leak causing
contamination of the pads?
4B-4 Front Brakes:

Step Action Yes No

1. Inspect the wheel drive shaft outer seals for damage and
evidence of a grease leak.
2. Replace any wheel drive shaft seal that is found to be
leaking grease which may be the source of the
9 contamination to the pads. Refer to “Front Wheel Drive Go to Step 11 Go to Step 10
Shaft Outer Joint and Seal Replacement: ” and/or “Rear
Wheel Drive Shaft Outer Joint and Seal Replacement: ”.
Did you find and correct the source of the leak causing
contamination of the pads?
1. Inspect the automatic transmission cooling system lines, if
equipped, for damage and evidence of an external fluid
leak which may be the source of the contamination to the
pads.
2. Inspect the power steering system hoses for damage and
10 evidence of an external fluid leak which may be the source Go to Step 11 —
of the contamination to the pads.
3. Replace any components found to be leaking fluid which
may be the source of the contamination to the pads.
Did you find and correct the source of the leak causing
contamination of the pads?

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 Front Brakes: 4B-5

Step Action Yes No

1. Clean the remaining disc brake system components to
remove any traces of the contaminant.

! CAUTION
Support the brake caliper with heavy mechanic
wire, or equivalent, whenever it is separated from
its mount and the hydraulic flexible brake hose is
still connected. Failure to support the caliper in
this manner will cause the flexible brake hose to
bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a
brake fluid leak.

NOTE
Do NOT disconnect the hydraulic brake flex hoses
from the calipers.

2. Remove the front and/or rear disc brake calipers, as

11 appropriate, from the mounting brackets and support the Go to Step 12 —
calipers. Refer to “Front Brake Caliper Replacement” and/

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or “Rear Brake Caliper Replacement: ”.
3. Inspect the disc brake caliper mounting/sliding hardware
for the following conditions:
Refer to “Front Disc Brake Mounting and Hardware
Inspection” and/or “Rear Disc Brake Mounting and
Hardware Inspection: ”.
– Binding or seized hardware
– Distorted, worn, damaged or missing hardware
components
4. Replace the caliper mounting/sliding hardware
components as required. Refer to “Front Disc Brake
Hardware Replacement” and/or “Rear Disc Brake
Hardware Replacement: ”.
5. Replace the contaminated disc brake pads as a complete
axle set. Refer to “Front Disc Brake Pads Replacement”
and/or “Rear Disc Brake Pads Replacement: ”.
Did you complete the cleaning, inspection and replacement?
1. Check the thickness of each of the disc brake rotors.

NOTE
Make the following determination AND ANSWER
the question INDIVIDUALLY for EACH rotor.
12 Go to Step 13 Go to Step 16
2. Make a determination for each brake rotor if the rotor can
be REFINISHED and REMAIN ABOVE the minimum
requirements.
Refer to “Brake Rotor Thickness Measurement: ”.
Does the disc brake rotor meet the minimum requirements for
REFINISHING?
4B-6 Front Brakes:

Step Action Yes No

NOTE
Perform the following inspection AND ANSWER
the question INDIVIDUALLY for EACH rotor.

13 Inspect each of the disc brake rotors for thickness variation Go to Step 15 Go to Step 14
that exceeds the maximum acceptable level. Refer to “Brake
Rotor Thickness Variation Measurement: ”.
Does the brake rotor exhibit thickness variation that exceeds
the maximum acceptable level?
1. Inspect each of the disc brake rotors for the following
surface and wear conditions:
Refer to “Brake Rotor Surface and Wear Inspection: ”.
– Heavy rust and/or pitting
– Cracks and/or heat spots
– Excessive blueing discoloration
– Deep or excessive scoring beyond maximum
acceptable level
14 NOTE Go to Step 15 Go to Step 20

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Make the following determination AND ANSWER
the question INDIVIDUALLY for EACH rotor.

2. Make a determination for each brake rotor if the rotor

requires refinishing based upon the results of the
inspection.
If the brake rotor exhibits any of the conditions listed
previously, it requires refinishing.
Does the brake rotor require REFINISHING?
1. Refinish the brake rotor. Refer to “Brake Rotor Refinishing:
”.
15 2. Inspect the brake rotor thickness. Refer to “Brake Rotor Go to Step 20 Go to Step 19
Thickness Measurement: ”.
Were you able to REFINISH the brake rotor within the
minimum requirements?
16 Is the brake rotor at or below the DISCARD requirements? Go to Step 19 Go to Step 17
NOTE
Perform the following inspection AND ANSWER
the question INDIVIDUALLY for EACH rotor.

17 Inspect each of the disc brake rotors for thickness variation Go to Step 19 Go to Step 18
that exceeds the maximum acceptable level. Refer to “Brake
Rotor Thickness Variation Measurement: ”.
Does the brake rotor exhibit thickness variation that exceeds
the maximum acceptable level?
 Front Brakes: 4B-7

Step Action Yes No

1. Inspect each of the disc brake rotors for the following
surface and wear conditions:
Refer to “Brake Rotor Surface and Wear Inspection: ”.
– Heavy rust and/or pitting
– Cracks and/or heat spots
– Excessive blueing discoloration
– Deep or excessive scoring beyond maximum
acceptable level
18 NOTE Go to Step 19 Go to Step 20
Make the following determination AND ANSWER
the question INDIVIDUALLY for EACH rotor.

2. Make a determination for each brake rotor if the rotor

requires replacement based upon the results of the
inspection.
If the brake rotor exhibits any of the conditions listed
previously, it requires replacement.
Does the brake rotor require REPLACEMENT?
NOTE

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Whenever a brake rotor is replaced, the assembled
lateral runout (LRO) of the rotor must be measured
to ensure optimum performance of the disc
19 brakes. Go to Step 22 —

Replace the brake rotor. Refer to “Front Brake Rotor

Replacement” or “Rear Brake Rotor Replacement: ”.
Did you complete the replacement?
NOTE
Perform the following inspection AND ANSWER
the question INDIVIDUALLY for EACH rotor.

Inspect each of the disc brake rotors for assembled lateral

20 runout (LRO) that exceeds the maximum acceptable level. Go to Step 21 Go to Step 22
Refer to “Brake Rotor Assembled Lateral Runout
Measurement: ”.
Does the brake rotor exhibit assembled LRO that exceeds the
maximum acceptable level?
Correct the LRO for each brake rotor that was determined to
have LRO exceeding the maximum acceptable level. Refer to
21 Go to Step 22 —
“Brake Rotor Assembled Lateral Runout Correction: ”.
Did you complete the operation?
Install or connect components that were removed or Disc Brake System
disconnected during diagnosis. OK
22 —
Did you complete the operation? Return to Symptom
Table
4B-8 Front Brakes:

Brake Rotor Thickness Measurement 6. If the lowest thickness measurement of the brake
rotor is at or below the minimum allowable thickness
! WARNING after refinishing specification, the rotor may not be
refinished.
Refer to “Brake Dust Caution: ”.
7. If the lowest thickness measurement of the brake
rotor is at or below the discard thickness
specification, the rotor requires replacement.

Brake Rotor Thickness Variation

Measurement
! WARNING
Refer to “Brake Dust Caution: ”.

NOTE
Any disc brake rotor that exhibits thickness
variation exceeding the maximum acceptable
level must be refinished or replaced.
Thickness variation exceeding the maximum
acceptable level can cause brake pulsation.

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1. If the inboard friction surface of the brake rotor is not
1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with
accessible, reposition and support the caliper with the brake pads. Refer to “Front Disc Brake Pads
the brake pads. Refer to “Front Disc Brake Pads Replacement” and/or “Rear Disc Brake Pads
Replacement” and/or “Rear Disc Brake Pads Replacement: ”.
Replacement: ”. 2. Clean the friction surfaces of the brake rotor with
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake
denatured alcohol, or an equivalent approved brake cleaner.
cleaner.
3. Using a micrometer calibrated in thousanths-of-a-
milimeter, or ten-thousanths-of-an-inch, measure
and record the lowest thickness of the brake rotor at
4 or more points, equally spaced around the rotor.
Ensure that the measurements are only taken within
the friction surfaces and that the micrometer is
positioned the same distance from the outside edge
of the rotor, about 13 mm (½ in), for each
measurement.
4. Compare the lowest thickness measurement
recorded to the following specifications:
Specification - Front
Brake rotor discard thickness: 27.4 mm (1.079 in)
Specification - Rear
Brake rotor discard thickness: 18.4 mm (0.724 in)
5. If the lowest thickness measurement of the brake 3. Using a micrometer calibrated in thousanths-of-a-
rotor is above the minimum allowable thickness after millimeter, or ten-thousanths-of-an-inch, measure
refinishing specification, the rotor may be able to be and record the thickness of the brake rotor at four or
refinished, depending upon surface and wear more points, evenly spaced around the rotor.
conditions which may be present. Ensure that the measurements are only taken within
the friction surfaces and that the micrometer is
positioned the same distance from the outer edge of
the rotor, about 13 mm (0.5 in), for each
measurement.
 Front Brakes: 4B-9

4. Calculate the difference between the highest and 1. Matchmark the position of the brake rotor to the
lowest thickness measurements recorded to obtain wheel studs if this has not been done already.
the amount of thickness variation.
5. Compare the thickness variation measurement to NOTE
the following specification: Whenever the brake rotor has been separated
from the hub/axle flange, any rust or
Specification
contaminants should be cleaned from the
Brake rotor maximum allowable thickness
hub/axle flange and the brake rotor mating
variation: 0.025 mm (0.001 in)
surfaces. Failure to do this may result in
NOTE excessive assembled lateral runout (LRO) of
the brake rotor, which could lead to brake
Whenever a brake rotor is refinished or
pulsation.
replaced, the assembled lateral runout (LRO)
of the rotor must be measured to ensure 2. Inspect the mating surface of the hub/axle flange
optimum performance of the disc brakes. and the brake rotor to ensure that there are no
foreign particles, corrosion, rust, or debris remaining.
6. If the brake rotor thickness variation measurement
If the wheel hub/axle flange and/or if the brake rotor
exceeds the specification, the rotor requires
mating surfaces exhibit these conditions, perform the
refinishing or replacement.
following steps:
a. Remove the brake rotor from the vehicle. Refer
Brake Rotor Assembled Lateral Runout to “Front Brake Rotor Replacement” and/or

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Measurement “Rear Brake Rotor Replacement: ”.
Special tool b. Using the J 42450-A, thoroughly clean any rust
J 39544-KIT Torque-Limiting Socket Set, or or corrosion from the mating surface of the hub/
equivalent axle flange.
J 41013 Rotor Resurfacing Kit c. Using the J 41013, thoroughly clean any rust or
J 42450-A Wheel Hub Resurfacing Kit corrosion from the mating surface of the brake
J 45101 Hub and Wheel Runout Gage rotor.
J 45101-100 Conical Brake Rotor Washers d. Clean the friction surfaces of the brake rotor with
denatured alcohol, or an equivalent approved
! WARNING
brake cleaner.
Refer to “Brake Dust Caution: ”Brake Dust 3. Install the rotor to the hub/axle flange using the
Caution. matchmark made prior to removal.

NOTE
• Brake rotor assembled lateral runout
(LRO) exceeding the maximum allowable
specification can cause thickness
variation to develop in the brake rotor over
time, usually between 4 800-11 300 km
(3,000-7,000 mi).
• Brake rotor thickness variation MUST be
checked BEFORE checking for assembled
lateral runout (LRO). Thickness variation
exceeding the maximum acceptable level
can cause brake pulsation. Refer to “Brake
Rotor Thickness Variation Measurement: ”.

4. Hold the rotor firmly in place against the hub/axle

flange and install one of the J 45101-100 (1), and
one lug nut (2) onto the upper-most wheel stud.
5. Continue to hold the rotor secure and tighten the lug
nut firmly by hand.
4B-10 Front Brakes:

11. Measure and record the assembled LRO of the

brake rotor.
a. Rotate the rotor until the lowest reading is
displayed on the indicator dial, then set the dial
to zero.
b. Rotate the rotor until the highest reading is
displayed on the dial.
c. Mark the location of the high spot relative to the
nearest wheel stud, or studs.
d. Measure and record the amount of LRO.
12. Compare the brake rotor assembled LRO to the
following specification:
Specification
• Front brake rotor maximum allowable
assembled lateral runout: 0.05 mm (0.002 in)
• Rear brake rotor maximum allowable
6. Install the remaining J 45101-100 and lug nuts onto assembled lateral runout: 0.05 mm (0.002 in)
the wheel studs and tighten the nuts firmly by hand 13. If the brake rotor assembled LRO is within
in a star-pattern. specifications, proceed to step 18.

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7. Using the J 39544-KIT, or equivalent, tighten the lug If the brake rotor assembled LRO exceeds the
nuts in a star-pattern to specification, in order to specification, refinish the rotor to ensure true
properly secure the rotor. Refer to “Tire and Wheel parallelism. Refer to “Brake Rotor Refinishing: ”.
Removal and Installation: ”. After refinishing the rotor, proceed to step 14.
8. If the brake rotor has been REFINISHED or 14. Mount a dial indicator, J 45101, or equivalent, to the
REPLACED with a new rotor, proceed to step 14. steering knuckle and position the indicator button so
9. If the brake rotor meets the following criteria, it contacts the brake rotor friction surface at a 90
proceed to step 10. degree angle, approximately 13 mm (0.5 in) from the
outer edge of the rotor.
– The rotor is within specifications and is being
REUSED. 15. Measure and record the assembled LRO of the
brake rotor.
– The rotor has NOT been refinished.
a. Rotate the rotor until the lowest reading is
– The rotor does NOT exhibit thickness variation
displayed on the indicator dial, then set the dial
exceeding the maximum allowable level.
to zero.
b. Rotate the rotor until the highest reading is
displayed on the dial.
c. Mark the location of the high spot relative to the
nearest wheel stud, or studs.
d. Measure and record the amount of LRO.
16. Compare the brake rotor assembled LRO to the
following specification:
Specification
• Front brake rotor maximum allowable
assembled lateral runout: 0.05 mm (0.002 in)
• Rear brake rotor maximum allowable
assembled lateral runout: 0.05 mm (0.002 in)
17. If the brake rotor assembled LRO measurement
exceeds the specification, bring the LRO to within
specifications. Refer to “Brake Rotor Assembled
Lateral Runout Correction: ”.
10. Mount a dial indicator, J 45101, or equivalent, to the
steering knuckle and position the indicator button so 18. If the brake rotor assembled LRO measurement is
it contacts the brake rotor friction surface at a 90 within specification, install the brake caliper and
degree angle, approximately 13 mm (0.5 in) from the depress the brake pedal several times to secure the
outer edge of the rotor. rotor in place before removing the J 45101-100 and
the lug nuts.
 Front Brakes: 4B-11

Repair Instructions
Front Disc Brake Pads Replacement

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Callout Component Name
! WARNING
Refer to “Brake Dust Caution: ”Brake Dust Caution.

! CAUTION
Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its
mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this
manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage
to the brake hose and in turn may cause a brake fluid leak.

Preliminary Procedures
1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid
needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level,
remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
5. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
4B-12 Front Brakes:

Callout Component Name

Guide Pin Bolt

! CAUTION
Refer to “Fastener Notice: ”.

NOTE
Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
1 applied.

Tip:
• Hold the brake caliper guide pin stationary when removing the guide pin bolt.
• Rotate the caliper up and to the rear until it rests on the mounting bracket and support with heavy
mechanics wire or equivalent.
• Place a block of wood or an old brake pad against the brake caliper pistons.
• Using a brake pad spreader tool or equivalent, fully seat the caliper pistons in the caliper bores.

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Tightening torque
44 N⋅m (32 lb ft)
Brake Pad (Qty: 2)
Tip:
2
1. If installing the original brake pads, mark the position of the brake pads and springs.
2. Position the brake pad with the wear indicator facing the inboard surface of the brake rotor.
Spring (Qty: 2)
Tip:
1. If replacing the brake pads, DO NOT reuse the springs. Install NEW springs.
2. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
3 3. Slowly release the brake pedal.
4. Wait 15 seconds, then repeat steps 2-3 until a firm brake pedal is obtained. This will properly seat
the brake caliper pistons and brake pads.
5. Fill the master cylinder reservoir to the proper level. Refer to “Master Cylinder Reservoir Filling: ”.
6. Burnish the pads and rotors. Refer to “Brake Pad and Rotor Burnishing: ”.
 Front Brakes: 4B-13

Brake Pad Inspection • Verify that any disc brake pad shims that may be
required are in place and not damaged or excessively
corroded. Replace any missing or damaged shims in
order to preserve proper disc brake performance.
• Replace the disc brake pads if any have separated
from the mounting plates.
• Inspect the disc brake pads friction surfaces for
cracks, fractures, or damage which may cause noise
or otherwise impair disc brake performance.
• Inspect the noise insulators on the brake pad
mounting plate. Replace the brake pads if the noise
insulators have separated from the brake pad
mounting plate.

Brake Pad and Rotor Burnishing

! WARNING
Road test a vehicle under safe conditions
and while obeying all traffic laws. Do not
! WARNING attempt any maneuvers that could jeopardize

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Refer to “Brake Dust Caution: ”. vehicle control. Failure to adhere to these
precautions could lead to serious personal
• Inspect the disc brake pads at regular intervals, or injury and vehicle damage.
whenever the tire and wheel assemblies are removed
from the vehicle. ! WARNING
• If replacement is necessary, always replace disc
Refer to “Brake Dust Caution: ”.
brake pads in axle sets.
• Inspect both edges of the disc brake pad friction Burnishing the brake pads and brake rotors is necessary
surfaces (3). The highest rate of wear normally occurs in order to ensure that the braking surfaces are properly
at the trailing edge of the disc brake pads. prepared after service has been performed on the disc
• Inspect the thickness of the disc brake pads (3) in brake system.
order to ensure that they have not worn excessively. This procedure should be performed whenever the disc
The disc brake pad wear should be approximately brake rotors have been refinished or replaced, and/or
even per axle set. whenever the disc brake pads have been replaced.
• Both front and rear disc brake pads have integral, 1. Select a smooth road with little or no traffic.
audible wear sensors (1). When the disc brake pad 2. Accelerate the vehicle to 48 km/h (30 mph).
wear reaches the minimum allowable thickness, the
wear sensor contacts the disc brake rotor (2). The NOTE
wear indicator will then produce an audible, high- Use care to avoid overheating the brakes
pitched warning noise during wheel rotation. while performing this step.
• Replace the disc brake pads when the friction surface
(3) is worn to within 2 mm (0.080 in) of the mounting 3. Using moderate to firm pressure, apply the brakes to
plates. bring the vehicle to a stop. Do not allow the brakes to
• Remove the brake calipers and inspect the friction lock.
surfaces of the inner and outer disc brake pads to 4. Repeat steps 2 and 3 until approximately 20 stops
ensure that they are level. Place the disc brake pad have been completed. Allow sufficient cooling
friction surfaces together and measure the gap periods between stops in order to properly burnish
between the surfaces. If more than 0.5 mm (0.020 in) the brake pads and rotors.
gap exists midway between the length of the disc
brake pads, replace the disc brake pads.
4B-14 Front Brakes:

Front Brake Caliper Replacement

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 Front Brakes: 4B-15

Callout Component Name

! WARNING
Refer to “Brake Fluid Irritant Caution”.

! WARNING
Refer to “Brake Dust Caution: ”.

Preliminary Procedures
1. Raise the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
Brake Hose Fitting Bolt

! CAUTION
Refer to “Fastener Notice: ”.
1
Tip: Cap or plug the brake hose to prevent brake fluid loss and contamination.
Tightening torque
52 N⋅m (38 lb ft)

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Brake Hose Fitting Gasket (Qty: 2)
2
Tip: DO NOT reuse the gaskets. Install NEW gaskets.
Brake Caliper Guide Pin Bolt (Qty: 2)

NOTE
Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
3 come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

Tip: Hold the brake caliper guide pin stationary while removing and installing the guide pin bolt.
Tightening torque
44 N⋅m (32 lb ft)
Disc Brake Caliper
Tip:
1. Bleed the brake system. Refer to “Hydraulic Brake System Bleeding (Pressure): ” “Hydraulic Brake
System Bleeding (Manual): ”.
4 2. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
3. Slowly release the brake pedal.
4. Wait 15 seconds, then repeat steps 2-3 until a firm brake pedal is obtained. This will properly seat
the brake caliper pistons and brake pads.
5. Fill the master cylinder reservoir to the proper level. Refer to “Master Cylinder Reservoir Filling: ”.
4B-16 Front Brakes:

Brake Caliper Inspection

4. Inspect for smooth and complete travel of the caliper

piston, or pistons, into the caliper bore, or bores:
! WARNING The movement of a caliper piston into a caliper bore

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Refer to “Brake Dust Caution: ”. should be smooth and even. If a caliper piston is
frozen or difficult to bottom, the caliper requires
overhaul or replacement.
! WARNING
– For single piston caliper applications, insert a
Refer to “Brake Fluid Irritant Caution”. discarded inner brake pad (2) or block of wood in
front of the piston. Using a large C-clamp (1)
1. Inspect the brake caliper housing (1) for cracks, installed over the body of the caliper (3) and
excess wear, and/or damage. If any of these against the brake pad or block of wood, slowly
conditions are present, the brake caliper requires bottom the piston in the bore.
replacement. – For dual piston caliper applications, insert a
2. Inspect the caliper piston dust boot seal (2) for discarded inner brake pad (2) or block of wood in
cracks, tears, cuts, deterioration and/or improper front of the pistons. Using 2 large C-clamps (1)
seating in the caliper body. If any of these conditions installed over the body of the caliper (3) and
are present, the brake caliper requires overhaul or against the brake pad or block of wood, slowly
replacement. bottom the pistons evenly into the bores.
3. Inspect for brake fluid leakage around the caliper
piston dust boot seal (2) and on the disc brake pads.
If there is any evidence of brake fluid leakage, the
brake caliper requires overhaul or replacement.
 Front Brakes: 4B-17

Front Disc Brake Hardware Replacement

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4B-18 Front Brakes:

Callout Component Name

! WARNING
Refer to “Brake Dust Caution: ”.

! CAUTION
Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its
mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this
manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage
to the brake hose and in turn may cause a brake fluid leak.

Preliminary Procedures
1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
Brake Caliper Guide Pin Bolt (Qty: 2)

! CAUTION
Refer to “Fastener Notice: ”.

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NOTE
1 Install an open end wrench to hold the brake caliper guide pin in line with the brake
caliper while removing or installing the caliper guide pin bolt. DO NOT allow the open
end wrench to come in contact with the brake caliper.

Tip: Hold the brake caliper guide pin stationary when removing the guide pin bolt.
Tightening torque
44 N⋅m (32 lb ft)
Front Brake Caliper
Tip:
2
• Do not disconnect the brake caliper hose.
• Support the brake caliper with heavy mechanics wire or equivalent.
Brake Caliper Upper Guide Pin
Tip:
3
• The guide pins are not interchangeable. Note the location of the guide pins.
• Apply a small amount of high-temperature silicone grease to the guide pins.
Brake Caliper Lower Guide Pin
Tip:
4
• The guide pins are not interchangeable. Note the location of the guide pins.
• Apply a small amount of high-temperature silicone grease to the guide pins.
Brake Caliper Guide Pin Seal (Qty: 2)
5
Tip: Ensure the lip of the seals are fully seated in the grooves of the guide pins.
 Front Brakes: 4B-19

Front Disc Brake Mounting and Hardware

Inspection
! WARNING
Refer to “Brake Dust Caution: ”.

! WARNING
Refer to “Brake Fluid Irritant Caution”.

1. Inspect the fluid level in the brake master cylinder

auxiliary reservoir.
2. If the brake fluid level is midway between the
maximum-full point and the minimum allowable level,
no brake fluid needs to be removed from the
reservoir before proceeding.
3. If the brake fluid level is higher than midway between
the maximum-full point and the minimum allowable 9. Ensure the disc brake pads are held firmly in place
level, remove brake fluid to the midway point before on the brake caliper mounting bracket (5), yet slide
proceeding. easily on the mounting hardware without binding.

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10. Inspect the disc brake pad mounting hardware, pad
retainers (7), for the following:
– Bent mounting tabs
– Excessive corrosion
– Looseness at the brake caliper mounting bracket
– Excessive wear and/or looseness at the disc
brake pads
– Missing mounting hardware
11. If any of the conditions listed are found, the disc
brake pad mounting hardware requires replacement.
12. Inspect the brake caliper guide pins (2) by gently
pushing inward, without disengaging the slides from
the boots, then pull outward, and observe for the
following:
– Bent or damaged brake caliper bolts (1)
– Restricted caliper guide pin movement
4. Install a large C-clamp (1), over the body of the – Corrosion
brake caliper (2) with the C-clamp ends against the
– Split or torn boots (4)
rear of the caliper body and against the outer brake
pad. – Missing boots
5. Tighten the C-clamp (1) until the caliper piston is – Looseness in the brake caliper mounting bracket
compressed into the caliper bore leaving a gap of – Seized or binding caliper guide pins
approximately 10 mm (0.38 in) between the disc 13. If any of the conditions listed are found, the brake
brake pads and the brake rotor. caliper mounting hardware requires replacement.
6. Remove the C-clamp (1) from the caliper (2). 14. Inspect the brake caliper mounting bracket (5) for
7. Grasp the brake caliper and attempt to move the being bent, cracked, or damaged.
brake caliper vertically. The brake caliper should not 15. If any of the conditions listed are found, the brake
exhibit excessive looseness. caliper mounting bracket requires replacement.
8. Grasp the brake caliper and move the brake caliper
inboard and outboard. The brake caliper should slide
smoothly with minimal force.
4B-20 Front Brakes:

Front Brake Caliper Bracket Replacement

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Callout Component Name
! WARNING
Refer to “Brake Dust Caution: ”.

! CAUTION
Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its
mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this
manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage
to the brake hose and in turn may cause a brake fluid leak.

Preliminary Procedures
1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
3. Without disconnecting the brake caliper flexible hose, remove the brake caliper and support with heavy
mechanics wire or equivalent. Refer to “Front Brake Caliper Replacement”.
4. Remove the brake pads.
Brake Caliper Bracket Bolt (Qty: 2)

! CAUTION
1 Refer to “Fastener Notice: ”.

Tightening torque
111 N⋅m (82 lb ft)
2 Brake Caliper Bracket
 Front Brakes: 4B-21

Front Brake Rotor Replacement

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Callout Component Name
! WARNING
Refer to “Brake Dust Caution: ”.

! CAUTION
Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its
mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this
manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage
to the brake hose and in turn may cause a brake fluid leak.

Preliminary Procedures
1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
3. Remove the brake caliper and bracket as an assembly and support with heavy mechanics wire or equivalent.
Refer to “Front Brake Caliper Bracket Replacement”.
Brake Rotor Retaining Screw (Qty: 2)

! CAUTION
1 Refer to “Fastener Notice: ”.

Tightening torque
10 N⋅m (89 lb in)
4B-22 Front Brakes:

Callout Component Name

Disc Brake Rotor
Tip:
1. If installing a new brake rotor, clean the friction surfaces of the brake rotor with denatured alcohol.
2. If reinstalling the original brake rotor, mark the relationship of the rotor to the wheel hub.
3. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/
axle flange.
4. Using the J 41013, thoroughly clean any rust or corrosion from the mating surface of the rotor to
2 the hub/axle flange.
5. If the brake rotor is to be machined, check the thickness variation measurement. Refer to “Brake
Rotor Thickness Variation Measurement: ”.
6. After installing the brake rotor, measure the assembled lateral runout (LRO) of the brake rotor.
Refer to “Brake Rotor Assembled Lateral Runout Correction: ”.
7. If the brake rotor assembled LRO measurement exceeds specification, bring the LRO to within
specification. Refer to “Brake Rotor Assembled Lateral Runout Correction: ” - Indexing.
8. If the brake rotor was refinished or replaced, burnish the pads and rotors. Refer to “Brake Pad and
Rotor Burnishing: ”.

Brake Rotor Surface and Wear Inspection

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! WARNING
Refer to “Brake Dust Caution: ”.

1. If the inboard friction surface of the brake rotor is not

accessible, reposition and support the caliper with
the brake pads. Refer to “Front Disc Brake Pads
Replacement” and/or “Rear Disc Brake Pads
Replacement: ”.
2. Clean the friction surfaces of the brake rotor with
denatured alcohol, or an equivalent approved brake
cleaner.
3. Inspect the friction surfaces of the brake rotor for the
following Braking Surface Conditions:
– Heavy rust and/or pitting
Light surface rust can be removed with an
abrasive disc. Heavy surface rust and/or pitting 5. Using a micrometer calibrated in thousandths-of-a-
must be removed by refinishing the rotor. millimeter, or ten-thousandths-of-an-inch, measure
– Cracks and/or heat spots and record the scoring depth of any grooves present
– Excessive blueing discoloration on the rotor friction surfaces.
4. If the friction surfaces of the brake rotor exhibit one 6. Compare the groove scoring depth recorded to the
or more of the Braking Surface Conditions, the rotor following specification:
requires refinishing or replacement. Specification
Brake rotor maximum allowable scoring: 1.50
mm (0.059 in)
7. If the brake rotor scoring depth exceeds the
specification, or if an excessive amount of scoring is
present, the rotor requires refinishing or
replacement.
 Front Brakes: 4B-23

Brake Rotor/Drum Balance Inspection

1. Support the vehicle drive axle on a suitable hoist.
Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel assemblies from the
drive axle. Refer to “Tire and Wheel Removal and
Installation: ”.

! WARNING
Refer to Work Stall Test Caution.

3. Reinstall the wheel nuts in order to retain the brake

rotors.
4. Run the vehicle at the concern speed while
inspecting for the presence of the vibration.

! CAUTION
Do not depress the brake pedal with the
brake rotors and/or the brake drums 7. If a brake rotor was replaced as a result of following
removed, or with the brake calipers the previous steps, or if necessary to confirm the
repositioned away from the brake rotors, or results obtained during the previous steps, and/or to

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damage to the brake system may result. check the non-drive axle components, perform the
following:
5. If the vibration is still present, remove the rotors from a. Mount the brake rotor/drum on a balancer in the
the drive axle, then run the vehicle back to the same manner as a tire and wheel assembly.
concern speed.
NOTE
6. If the vibration is eliminated when the brake rotors
are removed from the drive axle, repeat the test with Check brake rotors/drums for static
one rotor installed at a time. Replace the rotor that is imbalance only; ignore the dynamic
causing or contributing to the vibration concern. imbalance readings.

b. Inspect the rotor/drum for static imbalance.

There is not a set tolerance for brake rotor/drum static
imbalance. However, any brake rotor/drum measured in
this same manner which is over 21 g (¾ oz) may have
the potential to cause or contribute to a vibration. Rotors/
drums suspected of causing or contributing to a vibration
should be replaced. Any rotor/drum that is replaced
should be checked for imbalance in the same manner.
4B-24 Front Brakes:

Front Brake Shield Replacement

Callout Component Name

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! WARNING
Refer to “Brake Dust Caution: ”.

Preliminary Procedures
1. Raise the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
3. Without disconnecting the brake caliper hose, remove the brake caliper and bracket as an assembly and support
with heavy mechanics wire or equivalent. Refer to “Front Brake Caliper Bracket Replacement”.
4. Remove the front brake rotor. Refer to “Front Brake Rotor Replacement”.
5. Remove the wheel bearing/hub. Refer to “Front Wheel Bearing and Hub Replacement: ”.
1 Disc Brake Splash Shield

Brake Rotor Assembled Lateral Runout • The indexing method of correcting assembled LRO is
Correction most effective when the LRO specification is only
exceeded by a relatively small amount: 0.025-0.127
NOTE mm (0.001-0.005 in). Indexing is used to achieve the
best possible match of high spots to low spots
• Brake rotor thickness variation MUST be between related components. Refer to “Brake Rotor
checked BEFORE checking for assembled Assembled Lateral Runout Correction - Indexing: ”.
lateral runout (LRO). Thickness variation
exceeding the maximum acceptable level • The correction plate method of correcting assembled
can cause brake pulsation. Refer to “Brake LRO involves the addition of a tapered plate between
Rotor Thickness Variation Measurement: ”. the brake rotor and the hub/axle flange. The
correction plate method can be used to correct LRO
• Brake rotor assembled lateral runout that exceeds the specification by up to 0.23 mm
(LRO) exceeding the maximum allowable (0.009 in). Refer to “Brake Rotor Assembled Lateral
specification can cause thickness Runout Correction - Correction Plates: ”.
variation to develop in the brake rotor over
time, usually between 4 800-11 300 km • The on-vehicle brake lathe method is used to bring
(3,000-7,000 mi). Refer to “Brake Rotor the LRO to within specifications through
Assembled Lateral Runout Measurement: compensating for LRO while refinishing the brake
”. rotor. Refer to “Brake Rotor Assembled Lateral
Runout Correction - On Vehicle Lathe: ”.
Review the following acceptable methods for bringing If the assembled LRO cannot be corrected using these
the brake rotor assembled LRO to within specifications. methods, then other components must be suspected as
Determine which method to use for the specific vehicle causing and/or contributing to the LRO concern.
being repaired.
 Front Brakes: 4B-25

Brake Rotor Assembled Lateral Runout

Correction - Indexing
Special tool
J 39544-KIT Torque-Limiting Socket Set, or
equivalent
J 45101-100 Conical Brake Rotor Washers

! WARNING
Refer to “Brake Dust Caution: ”.

NOTE
• Brake rotor thickness variation MUST be
checked BEFORE checking for assembled
lateral runout (LRO). Thickness variation
exceeding the maximum acceptable level
can cause brake pulsation. Refer to “Brake
Rotor Thickness Variation Measurement: ”. 6. Install the remaining J 45101-100 and lug nuts onto
• Brake rotor assembled LRO exceeding the the wheel studs and tighten the nuts firmly by hand
maximum allowable specification can in a star-pattern.

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cause thickness variation to develop in the 7. Using the J 39544-KIT, or equivalent, tighten the lug
brake rotor over time, usually between 4 nuts in a star-pattern to specification, in order to
800-11 300 km (3,000-7,000 mi). Refer to properly secure the rotor. Refer to “Tire and Wheel
“Brake Rotor Assembled Lateral Runout Removal and Installation: ”.
Measurement: ”.
8. Measure the assembled LRO of the brake rotor.
Refer to “Brake Rotor Assembled Lateral Runout
Measurement: ”.
9. Compare the amount of change between this
measurement and the original measurement.
10. If this measurement is within specifications, proceed
to step 14.
11. If this measurement still exceeds specifications,
repeat steps 1-9 until the best assembled LRO
measurement is obtained.
12. Matchmark the final location of the rotor to the wheel
studs if the orientation is different than it was
originally.
13. If the brake rotor assembled LRO measurement still
exceeds the maximum allowable specification, refer
to “Brake Rotor Assembled Lateral Runout
Correction: ”.
14. If the brake rotor assembled LRO is within
1. Remove the J 45101-100 and the lug nuts that were specification, install the brake caliper and depress
installed during the assembled LRO measurement the brake pedal several times to secure the rotor in
procedure. place before removing the J 45101-100 and the lug
nuts.
2. Inspect the mating surface of the hub/axle flange
and the brake rotor to ensure that there are no
foreign particles or debris remaining.
3. Index the brake rotor in a different orientation to the
hub/axle flange.
4. Hold the rotor firmly in place against the hub/axle
flange and install one of the J 45101-100 (1) and
one lug nut (2) onto the upper-most wheel stud.
5. Continue to hold the rotor secure and tighten the lug
nut firmly by hand.
4B-26 Front Brakes:

Brake Rotor Assembled Lateral Runout 2. Remove the J 45101-100 and the lug nuts that were
Correction - Correction Plates installed during the assembled LRO measurement
procedure and/or the indexing correction procedure.
Special tool 3. Inspect the mounting surface of the hub/axle flange
J 39544-KIT Complete Torque Socket Set-10 Pieces, and the brake rotor to ensure that there are no
or equivalent foreign particles or debris remaining.
J 45101-100 Conical Brake Rotor Washers
4. Select the correction plate, following the
! WARNING manufacturer's instructions, which has a
specification closest to the assembled LRO
Refer to “Brake Dust Caution: ”. measurement.
For example: If the assembled LRO measurement
NOTE was 0.076 mm (0.003 in), the 0.076 mm (0.003 in)
correction plate would be used. If the measurement
• Brake rotor thickness variation MUST be was 0.127 mm (0.005 in), the 0.152 mm (0.006 in)
checked BEFORE checking for assembled correction plate would be used.
lateral runout (LRO). Thickness variation
exceeding the maximum acceptable level 5. Determine the positioning for the correction plate (1)
can cause brake pulsation. Refer to “Brake using the high spot mark (3) made during the brake
Rotor Thickness Variation Measurement: ”. rotor assembled LRO measurement procedure.
• Brake rotor assembled LRO exceeding the NOTE
maximum allowable specification can
• Do NOT install used correction plates in an

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cause thickness variation to develop in the
brake rotor over time, usually between 4 attempt to correct brake rotor assembled
800-11 300 km (3,000-7,000 mi). Refer to LRO.
“Brake Rotor Assembled Lateral Runout • Do NOT stack up, or install more than one
Measurement: ”. correction plate onto one hub/axle flange
location, in an attempt to correct brake
rotor assembled LRO.

6. Install the correction plate (1) onto the hub/axle

flange, with the V-shaped notch (2) orientated to
align with the high spot mark (3), that was positioned
to face upward.

7. Install the brake rotor to the hub/axle flange. Use the

matchmark made prior to removal for proper
orientation to the flange.
8. Hold the rotor firmly in place against the hub/axle
1. Rotate the brake rotor to position the high spot, flange and install one of the J 45101-100 (1) and
identified and marked during the brake rotor one lug nut (2) onto the upper-most wheel stud.
assembled LRO measurement procedure, to face
9. Continue to hold the rotor secure and tighten the lug
upward.
nut firmly by hand.
 Front Brakes: 4B-27

Brake Rotor Assembled Lateral Runout

Correction - On Vehicle Lathe
Special tool
J 45101-100 Conical Brake Rotor Washers

! WARNING
Refer to “Brake Dust Caution: ”.

NOTE
• Brake rotor thickness variation MUST be
checked BEFORE checking for assembled
lateral runout (LRO). Thickness variation
exceeding the maximum acceptable level
can cause brake pulsation. Refer to “Brake
Rotor Thickness Variation Measurement: ”.
• Brake rotor assembled LRO exceeding the
10. Install the remaining J 45101-100 and lug nuts onto maximum allowable specification can
the wheel studs and tighten the nuts firmly by hand cause thickness variation to develop in the
in a star-pattern. brake rotor over time, usually between 4

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11. Using the J 39544-KIT, or equivalent, tighten the lug 800-11 300 km (3,000-7,000 mi). Refer to
nuts in a star-pattern to specification, in order to “Brake Rotor Assembled Lateral Runout
properly secure the rotor. Refer to “Tire and Wheel Measurement: ”.
Removal and Installation: ”.
1. Ensure that the caliper and caliper bracket that are
12. Measure the assembled LRO of the brake rotor. already being supported, are clear from contacting
Refer to “Brake Rotor Assembled Lateral Runout any rotating components, such as the brake rotor.
Measurement: ”.
2. Remove the J 45101-100 and the lug nuts that were
13. If the brake rotor assembled LRO measurement still installed during the assembled LRO measurement
exceeds the maximum allowable specification, refer procedure and/or the indexing correction procedure.
to “Brake Rotor Assembled Lateral Runout
3. Inspect the mounting surface of the hub/axle flange
Correction: ”.
and the brake rotor to ensure that there are no
14. If the brake rotor assembled LRO measurement is foreign particles or debris remaining.
within specification, install the brake caliper and
4. Set up the lathe, following the manufacturer's
depress the brake pedal several times to secure the
instructions.
rotor in place before removing the J 45101-100 and
the lug nuts. 5. Refinish the brake rotor, following the brake lathe
manufacturer's instructions.
6. After each successive cut, inspect the brake rotor
thickness. Refer to “Brake Rotor Thickness
Measurement: ”.
7. If at any time the brake rotor exceeds the minimum
allowable thickness after refinish specification, the
brake rotor must be replaced. After replacing the
rotor, proceed to step 10.
4B-28 Front Brakes:

8. After refinishing the brake rotor, use the following – Scoring of the disc brake rotor friction
procedure in order to obtain the desired non- surface less than the maximum
directional finish: allowable specification
a. Follow the brake lathe manufacturer's • Before refinishing a brake rotor, the rotor
recommended speed setting for applying a non- MUST first be checked for adequate
directional finish. thickness to allow the rotor to be
b. Using moderate pressure, apply the non- refinished and remain above the minimum
directional finish: allowable thickness after refinish
specification. Refer to “Brake Rotor
– If the lathe is equipped with a non-directional
Thickness Measurement: ”.
finishing tool, apply the finish with 120-grit
Disc brake rotors should only be
aluminum oxide sandpaper.
refinished if they have adequate thickness
– If the lathe is not equipped with a non- to be refinished and if one or more of the
directional finishing tool, apply the finish with a following conditions exist:
sanding block and 150-grit aluminum oxide
– Thickness variation in excess of the
sandpaper.
maximum allowable specification
c. After applying a non-directional finish, clean
– Excessive corrosion/rust and/or pitting
each friction surface of the brake rotor with
denatured alcohol, or an equivalent approved – Cracks and/or heat spots
brake cleaner. – Excessive blueing discoloration
9. Remove the lathe from the vehicle. – Scoring of the disc brake rotor surface

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10. Measure the assembled LRO of the brake rotor. in excess of the maximum allowable
Refer to “Brake Rotor Assembled Lateral Runout specification
Measurement: ”. • Disc brake rotors may need to be
11. If the brake rotor assembled LRO measurement still refinished as part of the process for
exceeds the maximum allowable specification, refer correcting brake rotor assembled lateral
to “Brake Rotor Assembled Lateral Runout runout (LRO) that exceeds the maximum
Correction: ”. allowable specification.
12. If the brake rotor assembled LRO is within
NOTE
specification, install the brake caliper and depress
the brake pedal several times to secure the rotor in If the vehicle is equipped with cross-drilled
place before removing the J 45101-100 and the lug rotors, use a lathe with positive rake tooling.
nuts. This setup requires less cutting pressure,
which will result in less vibration, and a
better surface finish. Also, use a vibration
Brake Rotor Refinishing
dampener when cutting. Otherwise, refinish
Special tool according to the following instructions.
J 41013 Rotor Resurfacing Kit
J 42450-A Wheel Hub Resurfacing Kit NOTE
Whenever the brake rotor has been separated
! WARNING
from the hub/axle flange, clean any rust or
Refer to “Brake Dust Caution: ”. contaminants from the hub/axle flange and
the brake rotor mating surfaces. Failure to do
NOTE this may result in increased assembled
lateral runout (LRO) of the brake rotor, which
• The disc brake rotors do not require could lead to brake pulsation.
refinishing as part of routine brake system
service. New disc brake rotors do not 1. Using the J 42450-A, thoroughly clean any rust or
require refinishing. corrosion from the mating surface of the hub/axle
Do not refinish disc brake rotors in an flange.
attempt to correct the following 2. Using the J 41013, thoroughly clean any rust or
conditions: corrosion from the mating surface and mounting
– Brake system noise - squeal, growl, surface of the brake rotor.
groan 3. Inspect the mating surfaces of the hub/axle flange
– Uneven and/or premature disc brake pad and the rotor to ensure that there are no foreign
wear particles or debris remaining.
– Superficial or cosmetic corrosion/rust of
the disc brake rotor friction surface
 Front Brakes: 4B-29

4. Mount the brake rotor to the brake lathe according to 12. After refinishing the brake rotor, use the following
the lathe manufacturer's instructions, ensuring that procedure in order to obtain the desired non-
all mounting attachments and adapters are clean directional finish:
and free of debris. a. Follow the brake lathe manufacturer's
5. Ensure that any vibration dampening attachments recommended speed setting for applying a non-
are securely in place. directional finish.
6. With the brake lathe running, slowly bring in the b. Using moderate pressure, apply the non-
cutting tools until they just contact the brake rotor directional finish:
friction surfaces. – If the lathe is equipped with a non-directional
7. Observe the witness mark on the brake rotor. If the finishing tool, apply the finish with 120-grit
witness mark extends approximately three-quarters aluminum oxide sandpaper.
or more of the way around the brake rotor friction – If the lathe is not equipped with a non-
surface on each side, the brake rotor is properly directional finishing tool, apply the finish with a
mounted to the lathe. sanding block and 150-grit aluminum oxide
8. If the witness mark does not extend three-quarters or sandpaper.
more of the way around the brake rotor, re-mount the c. After applying a non-directional finish, clean
rotor to the lathe. each friction surface of the brake rotor with
9. Following the brake lathe manufacturer's denatured alcohol, or an equivalent approved
instructions, refinish the brake rotor. brake cleaner.
10. After each successive cut, inspect the brake rotor 13. Remove the brake rotor from the brake lathe.

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thickness. Refer to “Brake Rotor Thickness 14. Measure the assembled LRO of the brake rotor to
Measurement: ”. ensure optimum performance of the disc brakes.
11. If at any time the brake rotor exceeds the minimum Refer to “Brake Rotor Assembled Lateral Runout
allowable thickness after refinish specification, the Measurement: ”.
brake rotor must be replaced. 15. If the brake rotor assembled LRO measurement
exceeds the specification, bring the LRO to within
specifications. Refer to “Brake Rotor Assembled
Lateral Runout Correction: ”.

Specifications
Fastener Tightening Specifications - Disc Brakes
Specification
Application
Metric English
Brake Caliper Bleeder Valve 10 N⋅m 89 lb in
Brake Caliper Bracket Bolt - Front 185 N⋅m 137 lb ft
Brake Caliper Guide Pin Bolt - Front 27 N⋅m 20 lb ft
Brake Hose Fitting Bolt - Front 52 N⋅m 38 lb ft
Brake Rotor Screw 10 N⋅m 89 lb in

Disc Brake Component Specifications

Specification
Application
Metric English
Front Brakes
Brake Pad Lining Minimum Thickness 2.0 mm 0.080 in
Brake Rotor Diameter 296.00 mm 11.654 in
Brake Rotor Discard Thickness* 27.4 mm 1.079 in
Maximum Allowable Lateral Runout 0.06 mm 0.002 in
Maximum Allowable Scoring 1.50 mm 0.059 in
Maximum Allowable Thickness Variation 0.025 mm 0.001 in
* All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification.
After refinishing the rotor, replace any rotor that does not meet the minimum thickness specifications.
4B-30 Front Brakes:

Special Tools and Equipment

Special Tools - Disc Brakes Tool Number/
Illustration
Tool Number/ Description
Illustration
Description

J 45101-100
J 39544-KIT Conical Brake Rotor
Complete Torque Socket Washers
Set - 10 Pieces

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J 41013
Rotor Resurfacing Kit

J 42450-A
Wheel Hub Resurfacing Kit

J 45101
Hub and Wheel Runout
Gage
 Rear Brakes: 4C-1

Rear Brakes
Precautions
Brake Dust Caution
! WARNING
Avoid taking the following actions when you service wheel brake parts:
• Do not grind brake linings.
• Do not sand brake linings.
• Do not clean wheel brake parts with a dry brush or with compressed air.
Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in
dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened
cloth in order to remove any dust on brake parts. Equipment is available commercially in order to
perform this washing function. These wet methods prevent fibers from becoming airborne.

Brake Fluid Irritant Caution

! WARNING

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Brake fluid may irritate eyes and skin. In case of contact, take the following actions:
• Eye contact—rinse thoroughly with water.
• Skin contact—wash with soap and water.
• If ingested—consult a physician immediately.

General Description
Disc Brake System Description and Operation
System Component Description
The disc brake system consists of the following components:
Disc Brake Pads: Applies mechanical output force from the hydraulic brake calipers to friction surfaces of brake
rotors.
Disc Brake Rotors: Uses mechanical output force applied to friction surfaces from the disc brake pads to slow speed
of tire and wheel assembly rotation.
Disc Brake Pad Hardware: Secures disc brake pads firmly in proper relationship to the hydraulic brake calipers.
Enables a sliding motion of brake pads when mechanical output force is applied.
Disc Brake Caliper Hardware: Provides mounting for hydraulic brake caliper and secures the caliper firmly in proper
relationship to caliper bracket. Enables a sliding motion of the brake caliper to the brake pads when mechanical
output force is applied.

System Operation
Mechanical output force is applied from the hydraulic brake caliper pistons to the inner brake pads. As the pistons
press the inner brake pads outward, the caliper housings draw the outer brake pads inward. This allows the output
force to be equally distributed. The brake pads apply the output force to the friction surfaces on both sides of the brake
rotors, which slows the rotation of the tire and wheel assemblies. The correct function of both the brake pad and brake
caliper hardware is essential for even distribution of braking force.
4C-2 Rear Brakes:

Diagnostic Information and Procedures

Diagnostic Starting Point - Disc Brakes
Begin the disc brake system diagnosis with “Diagnostic Starting Point - Hydraulic Brakes: ”. The use of the Diagnostic
Starting Point will lead to the identification of the correct procedure for diagnosing the system and where the procedure
is located.

Disc Brake System Diagnosis

Test Description
The numbers below refer to the step numbers on the diagnostic table:
9.
Lubricant leaks from non-brake system components may come in contact with and contaminate brake system
components.
10.
Lubricant leaks from non-brake system components may come in contact with and contaminate brake system
components.
13.
Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake pulsation.
17.
Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake pulsation.
20.

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Disc brake rotor assembled lateral runout (LRO) that exceeds the maximum acceptable level can lead to thickness
variation.
Step Action Yes No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the DISC brake system in order
to determine if the DISC brake system is operating properly. You will be directed by the appropriate Symptom table to
go to other brake system diagnostic tables as appropriate.
Were you sent here from a Brake Symptom table? Go to “Diagnostic
1 Go to Step 2 Starting Point -
Hydraulic Brakes: ”
Visually inspect the disc brake pads for the following
conditions:
Refer to “Brake Pad Inspection: ”
• Lining thickness below specifications
• Uneven and/or abnormal wear - edge-to-edge and/or side-
2 Go to Step 3 Go to Step 12
to-side
• Looseness or damage - including pad hardware
• Evidence of contamination from an external substance
Did you find any conditions to indicate a concern with any of
the front and/or rear disc brake pads?
3 Are any of the front and/or rear disc brake pads contaminated? Go to Step 8 Go to Step 4
Are any of the front and/or rear disc brake pads worn
4 Go to Step 7 Go to Step 5
unevenly?
Are any of the front and/or rear disc brake pads and/or pad
5 Go to Step 7 Go to Step 6
hardware loose or damaged?
1. Remove and inspect the worn disc brake pads for glazing,
looseness, heat spots or damage.
6 2. Replace the worn disc brake pads as a complete axle set. Go to Step 12 —
Refer to “Front Disc Brake Pads Replacement: ” and/or
“Rear Disc Brake Pads Replacement”.
Did you complete the inspection and replacement?
 Rear Brakes: 4C-3

Step Action Yes No

! CAUTION
Support the brake caliper with heavy mechanic
wire, or equivalent, whenever it is separated from
its mount and the hydraulic flexible brake hose is
still connected. Failure to support the caliper in
this manner will cause the flexible brake hose to
bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a
brake fluid leak.

NOTE
Do NOT disconnect the hydraulic brake flex hoses
from the calipers.

1. Remove the front and/or rear disc brake calipers, as

appropriate, from the mounting brackets and support the
calipers. Refer to “Front Brake Caliper Replacement: ”
and/or “Rear Brake Caliper Replacement”.
2. Inspect the disc brake caliper mounting bracket and the

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7 mounting/sliding hardware for the following conditions: Go to Step 12 —
Refer to “Front Disc Brake Mounting and Hardware
Inspection: ” and/or “Rear Disc Brake Mounting and
Hardware Inspection”.
– Binding or seized hardware
– Worn, damaged or missing hardware components
– Loose, bent, cracked, or damaged caliper mounting
bracket
3. Replace components as required. Refer to the following
procedures in Disc Brakes, as required:
– “Front Brake Caliper Bracket Replacement: ”
– “Rear Brake Caliper Bracket Replacement”
– “Front Disc Brake Hardware Replacement: ”
– “Rear Disc Brake Hardware Replacement”
4. Replace the unevenly-worn, loose or damaged disc brake
pads as a complete axle set. Refer to “Front Disc Brake
Pads Replacement: ” and/or “Rear Disc Brake Pads
Replacement”.
Did you complete the inspection and replacement?
1. Inspect the disc brake calipers, brake hoses and brake
pipes for evidence of an external brake fluid leak.
2. Replace any components found to be leaking brake fluid.
Refer to the following procedures as required:
– “Front Brake Caliper Replacement: ”
8 – “Rear Brake Caliper Replacement” Go to Step 11 Go to Step 9
– “Front Brake Hose Replacement: ”
– “Rear Brake Hose Replacement: ”
– “Brake Pipe Replacement: ”
Did you find and correct the source of the leak causing
contamination of the pads?
4C-4 Rear Brakes:

Step Action Yes No

1. Inspect the wheel drive shaft outer seals for damage and
evidence of a grease leak.
2. Replace any wheel drive shaft seal that is found to be
leaking grease which may be the source of the
9 contamination to the pads. Refer to “Front Wheel Drive Go to Step 11 Go to Step 10
Shaft Outer Joint and Seal Replacement: ” and/or “Rear
Wheel Drive Shaft Outer Joint and Seal Replacement: ”.
Did you find and correct the source of the leak causing
contamination of the pads?
1. Inspect the automatic transmission cooling system lines, if
equipped, for damage and evidence of an external fluid
leak which may be the source of the contamination to the
pads.
2. Inspect the power steering system hoses for damage and
10 evidence of an external fluid leak which may be the source Go to Step 11 —
of the contamination to the pads.
3. Replace any components found to be leaking fluid which
may be the source of the contamination to the pads.
Did you find and correct the source of the leak causing
contamination of the pads?

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 Rear Brakes: 4C-5

Step Action Yes No

1. Clean the remaining disc brake system components to
remove any traces of the contaminant.

! CAUTION
Support the brake caliper with heavy mechanic
wire, or equivalent, whenever it is separated from
its mount and the hydraulic flexible brake hose is
still connected. Failure to support the caliper in
this manner will cause the flexible brake hose to
bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a
brake fluid leak.

NOTE
Do NOT disconnect the hydraulic brake flex hoses
from the calipers.

2. Remove the front and/or rear disc brake calipers, as

11 appropriate, from the mounting brackets and support the Go to Step 12 —
calipers. Refer to “Front Brake Caliper Replacement: ”

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and/or “Rear Brake Caliper Replacement”.
3. Inspect the disc brake caliper mounting/sliding hardware
for the following conditions:
Refer to “Front Disc Brake Mounting and Hardware
Inspection: ” and/or “Rear Disc Brake Mounting and
Hardware Inspection”.
– Binding or seized hardware
– Distorted, worn, damaged or missing hardware
components
4. Replace the caliper mounting/sliding hardware
components as required. Refer to “Front Disc Brake
Hardware Replacement: ” and/or “Rear Disc Brake
Hardware Replacement”.
5. Replace the contaminated disc brake pads as a complete
axle set. Refer to “Front Disc Brake Pads Replacement: ”
and/or “Rear Disc Brake Pads Replacement”.
Did you complete the cleaning, inspection and replacement?
1. Check the thickness of each of the disc brake rotors.

NOTE
Make the following determination AND ANSWER
the question INDIVIDUALLY for EACH rotor.
12 Go to Step 13 Go to Step 16
2. Make a determination for each brake rotor if the rotor can
be REFINISHED and REMAIN ABOVE the minimum
requirements.
Refer to “Brake Rotor Thickness Measurement: ”.
Does the disc brake rotor meet the minimum requirements for
REFINISHING?
4C-6 Rear Brakes:

Step Action Yes No

NOTE
Perform the following inspection AND ANSWER
the question INDIVIDUALLY for EACH rotor.

13 Inspect each of the disc brake rotors for thickness variation Go to Step 15 Go to Step 14
that exceeds the maximum acceptable level. Refer to “Brake
Rotor Thickness Variation Measurement: ”.
Does the brake rotor exhibit thickness variation that exceeds
the maximum acceptable level?
1. Inspect each of the disc brake rotors for the following
surface and wear conditions:
Refer to “Brake Rotor Surface and Wear Inspection: ”.
– Heavy rust and/or pitting
– Cracks and/or heat spots
– Excessive blueing discoloration
– Deep or excessive scoring beyond maximum
acceptable level
14 NOTE Go to Step 15 Go to Step 20

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Make the following determination AND ANSWER
the question INDIVIDUALLY for EACH rotor.

2. Make a determination for each brake rotor if the rotor

requires refinishing based upon the results of the
inspection.
If the brake rotor exhibits any of the conditions listed
previously, it requires refinishing.
Does the brake rotor require REFINISHING?
1. Refinish the brake rotor. Refer to “Brake Rotor Refinishing:
”.
15 2. Inspect the brake rotor thickness. Refer to “Brake Rotor Go to Step 20 Go to Step 19
Thickness Measurement: ”.
Were you able to REFINISH the brake rotor within the
minimum requirements?
16 Is the brake rotor at or below the DISCARD requirements? Go to Step 19 Go to Step 17
NOTE
Perform the following inspection AND ANSWER
the question INDIVIDUALLY for EACH rotor.

17 Inspect each of the disc brake rotors for thickness variation Go to Step 19 Go to Step 18
that exceeds the maximum acceptable level. Refer to “Brake
Rotor Thickness Variation Measurement: ”.
Does the brake rotor exhibit thickness variation that exceeds
the maximum acceptable level?
 Rear Brakes: 4C-7

Step Action Yes No

1. Inspect each of the disc brake rotors for the following
surface and wear conditions:
Refer to “Brake Rotor Surface and Wear Inspection: ”.
– Heavy rust and/or pitting
– Cracks and/or heat spots
– Excessive blueing discoloration
– Deep or excessive scoring beyond maximum
acceptable level
18 NOTE Go to Step 19 Go to Step 20
Make the following determination AND ANSWER
the question INDIVIDUALLY for EACH rotor.

2. Make a determination for each brake rotor if the rotor

requires replacement based upon the results of the
inspection.
If the brake rotor exhibits any of the conditions listed
previously, it requires replacement.
Does the brake rotor require REPLACEMENT?
NOTE

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Whenever a brake rotor is replaced, the assembled
lateral runout (LRO) of the rotor must be measured
to ensure optimum performance of the disc
19 brakes. Go to Step 22 —

Replace the brake rotor. Refer to “Front Brake Rotor

Replacement: ” or “Rear Brake Rotor Replacement”.
Did you complete the replacement?
NOTE
Perform the following inspection AND ANSWER
the question INDIVIDUALLY for EACH rotor.

Inspect each of the disc brake rotors for assembled lateral

20 runout (LRO) that exceeds the maximum acceptable level. Go to Step 21 Go to Step 22
Refer to “Brake Rotor Assembled Lateral Runout
Measurement: ”.
Does the brake rotor exhibit assembled LRO that exceeds the
maximum acceptable level?
Correct the LRO for each brake rotor that was determined to
have LRO exceeding the maximum acceptable level. Refer to
21 Go to Step 22 —
“Brake Rotor Assembled Lateral Runout Correction: ”.
Did you complete the operation?
Install or connect components that were removed or Disc Brake System
disconnected during diagnosis. OK
22 —
Did you complete the operation? Return to Symptom
Table
4C-8 Rear Brakes:

Brake Rotor Thickness Measurement 6. If the lowest thickness measurement of the brake
rotor is at or below the minimum allowable thickness
! WARNING after refinishing specification, the rotor may not be
refinished.
Refer to “Brake Dust Caution: ”.
7. If the lowest thickness measurement of the brake
rotor is at or below the discard thickness
specification, the rotor requires replacement.

Brake Rotor Thickness Variation

Measurement
! WARNING
Refer to “Brake Dust Caution: ”.

NOTE
Any disc brake rotor that exhibits thickness
variation exceeding the maximum acceptable
level must be refinished or replaced.
Thickness variation exceeding the maximum
acceptable level can cause brake pulsation.

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1. If the inboard friction surface of the brake rotor is not
1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with
accessible, reposition and support the caliper with the brake pads. Refer to “Front Disc Brake Pads
the brake pads. Refer to “Front Disc Brake Pads Replacement: ” and/or “Rear Disc Brake Pads
Replacement: ” and/or “Rear Disc Brake Pads Replacement”.
Replacement”. 2. Clean the friction surfaces of the brake rotor with
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake
denatured alcohol, or an equivalent approved brake cleaner.
cleaner.
3. Using a micrometer calibrated in thousanths-of-a-
milimeter, or ten-thousanths-of-an-inch, measure
and record the lowest thickness of the brake rotor at
4 or more points, equally spaced around the rotor.
Ensure that the measurements are only taken within
the friction surfaces and that the micrometer is
positioned the same distance from the outside edge
of the rotor, about 13 mm (½ in), for each
measurement.
4. Compare the lowest thickness measurement
recorded to the following specifications:
Specification - Front
Brake rotor discard thickness: 27.4 mm (1.079 in)
Specification - Rear
Brake rotor discard thickness: 18.4 mm (0.724 in)
5. If the lowest thickness measurement of the brake 3. Using a micrometer calibrated in thousanths-of-a-
rotor is above the minimum allowable thickness after millimeter, or ten-thousanths-of-an-inch, measure
refinishing specification, the rotor may be able to be and record the thickness of the brake rotor at four or
refinished, depending upon surface and wear more points, evenly spaced around the rotor.
conditions which may be present. Ensure that the measurements are only taken within
the friction surfaces and that the micrometer is
positioned the same distance from the outer edge of
the rotor, about 13 mm (0.5 in), for each
measurement.
 Rear Brakes: 4C-9

4. Calculate the difference between the highest and 1. Matchmark the position of the brake rotor to the
lowest thickness measurements recorded to obtain wheel studs if this has not been done already.
the amount of thickness variation.
5. Compare the thickness variation measurement to NOTE
the following specification: Whenever the brake rotor has been separated
from the hub/axle flange, any rust or
Specification
contaminants should be cleaned from the
Brake rotor maximum allowable thickness
hub/axle flange and the brake rotor mating
variation: 0.025 mm (0.001 in)
surfaces. Failure to do this may result in
NOTE excessive assembled lateral runout (LRO) of
the brake rotor, which could lead to brake
Whenever a brake rotor is refinished or
pulsation.
replaced, the assembled lateral runout (LRO)
of the rotor must be measured to ensure 2. Inspect the mating surface of the hub/axle flange
optimum performance of the disc brakes. and the brake rotor to ensure that there are no
foreign particles, corrosion, rust, or debris remaining.
6. If the brake rotor thickness variation measurement
If the wheel hub/axle flange and/or if the brake rotor
exceeds the specification, the rotor requires
mating surfaces exhibit these conditions, perform the
refinishing or replacement.
following steps:
a. Remove the brake rotor from the vehicle. Refer
Brake Rotor Assembled Lateral Runout to “Front Brake Rotor Replacement: ” and/or

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Measurement “Rear Brake Rotor Replacement”.
Special tool b. Using the J 42450-A, thoroughly clean any rust
J 39544-KIT Torque-Limiting Socket Set, or or corrosion from the mating surface of the hub/
equivalent axle flange.
J 41013 Rotor Resurfacing Kit c. Using the J 41013, thoroughly clean any rust or
J 42450-A Wheel Hub Resurfacing Kit corrosion from the mating surface of the brake
J 45101 Hub and Wheel Runout Gage rotor.
J 45101-100 Conical Brake Rotor Washers d. Clean the friction surfaces of the brake rotor with
denatured alcohol, or an equivalent approved
! WARNING
brake cleaner.
Refer to “Brake Dust Caution: ”. 3. Install the rotor to the hub/axle flange using the
matchmark made prior to removal.
NOTE
• Brake rotor assembled lateral runout
(LRO) exceeding the maximum allowable
specification can cause thickness
variation to develop in the brake rotor over
time, usually between 4 800-11 300 km
(3,000-7,000 mi).
• Brake rotor thickness variation MUST be
checked BEFORE checking for assembled
lateral runout (LRO). Thickness variation
exceeding the maximum acceptable level
can cause brake pulsation. Refer to “Brake
Rotor Thickness Variation Measurement: ”.

4. Hold the rotor firmly in place against the hub/axle

flange and install one of the J 45101-100 (1), and
one lug nut (2) onto the upper-most wheel stud.
5. Continue to hold the rotor secure and tighten the lug
nut firmly by hand.
4C-10 Rear Brakes:

11. Measure and record the assembled LRO of the

brake rotor.
a. Rotate the rotor until the lowest reading is
displayed on the indicator dial, then set the dial
to zero.
b. Rotate the rotor until the highest reading is
displayed on the dial.
c. Mark the location of the high spot relative to the
nearest wheel stud, or studs.
d. Measure and record the amount of LRO.
12. Compare the brake rotor assembled LRO to the
following specification:
Specification
• Front brake rotor maximum allowable
assembled lateral runout: 0.05 mm (0.002 in)
• Rear brake rotor maximum allowable
6. Install the remaining J 45101-100 and lug nuts onto assembled lateral runout: 0.05 mm (0.002 in)
the wheel studs and tighten the nuts firmly by hand 13. If the brake rotor assembled LRO is within
in a star-pattern. specifications, proceed to step 18.

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7. Using the J 39544-KIT, or equivalent, tighten the lug If the brake rotor assembled LRO exceeds the
nuts in a star-pattern to specification, in order to specification, refinish the rotor to ensure true
properly secure the rotor. Refer to “Tire and Wheel parallelism. Refer to “Brake Rotor Refinishing: ”.
Removal and Installation: ”. After refinishing the rotor, proceed to step 14.
8. If the brake rotor has been REFINISHED or 14. Mount a dial indicator, J 45101, or equivalent, to the
REPLACED with a new rotor, proceed to step 14. steering knuckle and position the indicator button so
9. If the brake rotor meets the following criteria, it contacts the brake rotor friction surface at a 90
proceed to step 10. degree angle, approximately 13 mm (0.5 in) from the
outer edge of the rotor.
– The rotor is within specifications and is being
REUSED. 15. Measure and record the assembled LRO of the
brake rotor.
– The rotor has NOT been refinished.
a. Rotate the rotor until the lowest reading is
– The rotor does NOT exhibit thickness variation
displayed on the indicator dial, then set the dial
exceeding the maximum allowable level.
to zero.
b. Rotate the rotor until the highest reading is
displayed on the dial.
c. Mark the location of the high spot relative to the
nearest wheel stud, or studs.
d. Measure and record the amount of LRO.
16. Compare the brake rotor assembled LRO to the
following specification:
Specification
• Front brake rotor maximum allowable
assembled lateral runout: 0.05 mm (0.002 in)
• Rear brake rotor maximum allowable
assembled lateral runout: 0.05 mm (0.002 in)
17. If the brake rotor assembled LRO measurement
exceeds the specification, bring the LRO to within
specifications. Refer to “Brake Rotor Assembled
Lateral Runout Correction: ”.
10. Mount a dial indicator, J 45101, or equivalent, to the
steering knuckle and position the indicator button so 18. If the brake rotor assembled LRO measurement is
it contacts the brake rotor friction surface at a 90 within specification, install the brake caliper and
degree angle, approximately 13 mm (0.5 in) from the depress the brake pedal several times to secure the
outer edge of the rotor. rotor in place before removing the J 45101-100 and
the lug nuts.
 Rear Brakes: 4C-11

Repair Instructions
Brake Pad and Rotor Burnishing
! WARNING
Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any
maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to
serious personal injury and vehicle damage.

! WARNING
Refer to “Brake Dust Caution: ”.

Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly
prepared after service has been performed on the disc brake system.
This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or
whenever the disc brake pads have been replaced.
1. Select a smooth road with little or no traffic.
2. Accelerate the vehicle to 48 km/h (30 mph).

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NOTE
Use care to avoid overheating the brakes while performing this step.

3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock.
4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between
stops in order to properly burnish the brake pads and rotors.

Rear Disc Brake Pads Replacement

4C-12 Rear Brakes:

Callout Component Name

! WARNING
Refer to “Brake Dust Caution: ”.

! CAUTION
Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its
mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this
manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage
to the brake hose and in turn may cause a brake fluid leak.

Preliminary Procedures
1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid
needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level,
remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
5. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.

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Guide Pin Bolt

! CAUTION
Refer to “Fastener Notice: ”.

NOTE
Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
come in contact with the brake caliper will cause a pulsation when the brakes are
1 applied.

Tip:
• Hold the brake caliper guide pin stationary when removing the guide pin bolt.
• Rotate the caliper up and to the rear until it rests on the mounting bracket and support with heavy
mechanics wire or equivalent.
• Place a block of wood or an old brake pad against the brake caliper piston.
• Using a brake pad spreader tool or equivalent, fully seat the caliper piston in the caliper bore.
Tightening torque
35 N⋅m (26 lb ft)
Brake Pad (Qty: 2)
Tip:
2
1. If installing the original brake pads, mark the position of the brake pads and springs.
2. Position the brake pad with the wear indicator facing the inboard surface of the brake rotor.
Spring (Qty: 2)
Tip:
1. If replacing the brake pads, DO NOT reuse the springs. Install NEW springs.
2. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
3 3. Slowly release the brake pedal.
4. Wait 15 seconds, then repeat steps 2-3 until a firm brake pedal is obtained. This will properly seat
the brake caliper pistons and brake pads.
5. Fill the master cylinder reservoir to the proper level. Refer to “Master Cylinder Reservoir Filling: ”.
6. Burnish the pads and rotors. Refer to “Brake Pad and Rotor Burnishing: ”.
 Rear Brakes: 4C-13

Brake Pad Inspection

! WARNING

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Refer to “Brake Dust Caution: ”.

• Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are removed from the
vehicle.
• If replacement is necessary, always replace disc brake pads in axle sets.
• Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally occurs at the
trailing edge of the disc brake pads.
• Inspect the thickness of the disc brake pads (3) in order to ensure that they have not worn excessively. The disc
brake pad wear should be approximately even per axle set.
• Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake pad wear reaches
the minimum allowable thickness, the wear sensor contacts the disc brake rotor (2). The wear indicator will then
produce an audible, high-pitched warning noise during wheel rotation.
• Replace the disc brake pads when the friction surface (3) is worn to within 2 mm (0.080 in) of the mounting plates.
• Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to ensure that
they are level. Place the disc brake pad friction surfaces together and measure the gap between the surfaces. If
more than 0.5 mm (0.020 in) gap exists midway between the length of the disc brake pads, replace the disc brake
pads.
• Verify that any disc brake pad shims that may be required are in place and not damaged or excessively corroded.
Replace any missing or damaged shims in order to preserve proper disc brake performance.
• Replace the disc brake pads if any have separated from the mounting plates.
• Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause noise or otherwise
impair disc brake performance.
• Inspect the noise insulators on the brake pad mounting plate. Replace the brake pads if the noise insulators have
separated from the brake pad mounting plate.
4C-14 Rear Brakes:

Rear Brake Caliper Replacement

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 Rear Brakes: 4C-15

Callout Component Name

! WARNING
Refer to “Brake Dust Caution: ”.

! WARNING
Refer to “Brake Fluid Irritant Caution: ”.

Preliminary Procedures
1. Raise and support vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
Brake Hose Fitting Bolt

! CAUTION
1 Refer to “Fastener Notice: ”.

Tightening torque
52 N⋅m (38 lb ft)
Brake Hose Fitting Gasket (Qty: 2)

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2
Tip: DO NOT reuse the gaskets. Install NEW gaskets.
Brake Hose
3
Tip: Cap or plug the brake hose to prevent brake fluid leaks and contamination.
Brake Caliper Guide Pin Bolt (Qty: 2)

NOTE
Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper. Allowing the open end wrench to
4 come in contact with the brake caliper will cause a pulsation when the brakes are
applied.

Tip: Hold the brake caliper guide pin stationary while removing and installing the guide pin bolt.
Tightening torque
Tighten the bolts to 35 N⋅m (26 lb ft)
Disc Brake Caliper
Tip:
1. Bleed the brake system. Refer to “Hydraulic Brake System Bleeding (Pressure): ” “Hydraulic Brake
System Bleeding (Manual): ”.
5 2. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
3. Slowly release the brake pedal.
4. Wait 15 seconds, then repeat steps 2-3 until a firm brake pedal is obtained. This will properly seat
the brake caliper pistons and brake pads.
5. Fill the master cylinder reservoir to the proper level. Refer to “Master Cylinder Reservoir Filling: ”.
4C-16 Rear Brakes:

Brake Caliper Inspection

4. Inspect for smooth and complete travel of the caliper

piston, or pistons, into the caliper bore, or bores:
! WARNING The movement of a caliper piston into a caliper bore

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Refer to “Brake Dust Caution: ”. should be smooth and even. If a caliper piston is
frozen or difficult to bottom, the caliper requires
overhaul or replacement.
! WARNING
– For single piston caliper applications, insert a
Refer to “Brake Fluid Irritant Caution: ”. discarded inner brake pad (2) or block of wood in
front of the piston. Using a large C-clamp (1)
1. Inspect the brake caliper housing (1) for cracks, installed over the body of the caliper (3) and
excess wear, and/or damage. If any of these against the brake pad or block of wood, slowly
conditions are present, the brake caliper requires bottom the piston in the bore.
replacement. – For dual piston caliper applications, insert a
2. Inspect the caliper piston dust boot seal (2) for discarded inner brake pad (2) or block of wood in
cracks, tears, cuts, deterioration and/or improper front of the pistons. Using 2 large C-clamps (1)
seating in the caliper body. If any of these conditions installed over the body of the caliper (3) and
are present, the brake caliper requires overhaul or against the brake pad or block of wood, slowly
replacement. bottom the pistons evenly into the bores.
3. Inspect for brake fluid leakage around the caliper
piston dust boot seal (2) and on the disc brake pads.
If there is any evidence of brake fluid leakage, the
brake caliper requires overhaul or replacement.
 Rear Brakes: 4C-17

Rear Disc Brake Hardware Replacement

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Callout Component Name
! WARNING
Refer to “Brake Dust Caution: ”.

! CAUTION
Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its
mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this
manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage
to the brake hose and in turn may cause a brake fluid leak.

Preliminary Procedures
1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
Brake Caliper Guide Pin Bolt (Qty: 2)

! CAUTION
Refer to “Fastener Notice: ”.

NOTE
1 Install an open end wrench to hold the caliper guide pin in line with the brake caliper
while removing or installing the caliper guide pin bolt. DO NOT allow the open end
wrench to come in contact with the brake caliper.

Tip: Hold the brake caliper guide pin stationary when removing the guide pin bolt.
Tightening torque
35 N⋅m (26 lb ft)
4C-18 Rear Brakes:

Callout Component Name

Rear Brake Caliper
Tip:
2
• Do not disconnect the brake caliper hose.
• Support the brake caliper with heavy mechanics wire or equivalent.
Upper Guide Pin
Tip:
3
• The guide pins are not interchangeable. Note the location of the guide pins.
• Apply a small amount of high-temperature silicone grease to the guide pin.
Lower Guide Pin
Tip:
4
• The guide pins are not interchangeable. Note the location of the guide pins.
• Apply a small amount of high-temperature silicone grease to the guide pin.
Guide Pin Seal (Qty: 2)
5
Tip: Ensure the lip of the seal is fully seated in the groove of the guide pin.

Rear Disc Brake Mounting and Hardware 1. Install a large C-clamp, over the body of the brake
Inspection caliper with the C-clamp ends against the rear of the

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caliper body and against the outer brake pad.
! WARNING
! CAUTION
Refer to “Brake Dust Caution: ”.
When using a large C-clamp to compress a
caliper piston into a caliper bore of a caliper
! WARNING equipped with an integral park brake
Refer to “Brake Fluid Irritant Caution: ”. mechanism, do not exceed more than 1 mm
(0.039 in) of piston travel. Exceeding this
amount of piston travel will cause damage to
the internal adjusting mechanism and/or the
integral park brake mechanism.

2. Tighten the C-clamp just enough to compress the

caliper piston 1 mm (0.039 in) of travel only.
3. Remove the C-clamp from the caliper.
4. Grasp the brake caliper and attempt to move the
brake caliper vertically. The brake caliper should not
exhibit excessive looseness.
5. Without disconnecting the hydraulic brake flex hose,
remove the caliper from the caliper bracket, and
support the caliper. Refer to “Rear Brake Caliper
Replacement”.
6. Inspect the caliper bolts to ensure that they are not
bent or damaged. If the bolts are bent or damaged,
the bolts require replacement.
 Rear Brakes: 4C-19

7. Ensure the disc brake pads are held firmly in place

on the brake caliper mounting bracket, yet slide
easily on the mounting hardware (3) without binding.

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8. Inspect the disc brake pad mounting hardware, pad
retainers (3), for the following:
– Bent mounting tabs
– Excessive corrosion
– Looseness at the brake caliper mounting bracket
– Excessive wear and/or looseness at the disc
brake pads
– Missing mounting hardware
9. If any of the conditions listed are found, the disc
brake pad mounting hardware requires replacement.
10. Inspect the brake caliper guide pins (1, 4) by gently
pushing inward, without disengaging the slides from
the boots, then pull outward, and observe for the
following:
– Restricted caliper guide pin movement
– Corrosion
– Split or torn boots (2)
– Missing boots
– Looseness in the brake caliper mounting bracket
– Seized or binding caliper guide pins
11. If any of the conditions listed are found, the brake
caliper mounting hardware requires replacement.
12. Inspect the brake caliper mounting bracket for being
bent, cracked, or damaged.
13. If any of the conditions listed are found, the brake
caliper mounting bracket requires replacement.
4C-20 Rear Brakes:

Rear Brake Caliper Bracket Replacement

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Callout Component Name
! WARNING
Refer to “Brake Dust Caution: ”.

! CAUTION
Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its
mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this
manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage
to the brake hose and in turn may cause a brake fluid leak.

Preliminary Procedures
1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
Brake Caliper Guide Pin Bolt (Qty: 2)

! CAUTION
1 Refer to “Fastener Notice: ”.

Tightening torque
35 N⋅m (26 lb ft).
Rear Brake Caliper
Tip:
2
• Do not disconnect the brake caliper hose.
• Support the brake caliper with heavy mechanics wire or equivalent.
 Rear Brakes: 4C-21

Callout Component Name

Disc Brake Pad
3 Tip: Install the brake pads in their original positions. The brake pad with the wear sensor is mounted
facing the inboard surface of the disc brake rotor.
Disc Brake Pad Shims (Qty: 2)
4
Tip: If installing new brake pads, discard the disc brake pad shims. Install NEW shims.
Brake Caliper Bracket Bolt (Qty: 2)
5 Tightening torque
105 N⋅m (77 lb ft)
6 Brake Caliper Bracket

Rear Brake Rotor Replacement

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Callout Component Name
! WARNING
Refer to “Brake Dust Caution: ”.

! CAUTION
Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its
mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this
manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage
to the brake hose and in turn may cause a brake fluid leak.

Preliminary Procedures
1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
3. Remove the brake caliper and bracket as an assembly and support with heavy mechanics wire or equivalent.
Refer to “Rear Brake Caliper Bracket Replacement”.
Brake Rotor Screw

! CAUTION
1 Refer to “Fastener Notice: ”.

Tightening torque
10 N⋅m (89 lb in)
4C-22 Rear Brakes:

Callout Component Name

Disc Brake Rotor
Tip:
1. If installing a new brake rotor, clean the friction surfaces of the brake rotor with denatured alcohol.
2. If reinstalling the original brake rotor, mark the relationship or the rotor to the wheel hub.
3. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/
axle flange.
4. Using the J 41013, thoroughly clean any rust or corrosion from the mating surface of the rotor to
2 the hub/axle flange.
5. If the brake rotor is to be machined, check the thickness variation measurement. Refer to “Brake
Rotor Thickness Variation Measurement: ”.
6. After installing the brake rotor, measure the assembled lateral runout (LRO) of the brake rotor.
Refer to “Brake Rotor Assembled Lateral Runout Correction: ”.
7. If the brake rotor assembled LRO measurement exceeds specification, bring the LRO to within
specification. Refer to “Brake Rotor Assembled Lateral Runout Correction - Indexing: ”.
8. If the brake rotor was refinished or replaced, burnish the pads and rotors. Refer to “Brake Pad and
Rotor Burnishing: ”.

Brake Rotor Surface and Wear Inspection

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! WARNING
Refer to “Brake Dust Caution: ”.

1. If the inboard friction surface of the brake rotor is not

accessible, reposition and support the caliper with
the brake pads. Refer to “Front Disc Brake Pads
Replacement: ” and/or “Rear Disc Brake Pads
Replacement”.
2. Clean the friction surfaces of the brake rotor with
denatured alcohol, or an equivalent approved brake
cleaner.
3. Inspect the friction surfaces of the brake rotor for the
following Braking Surface Conditions:
– Heavy rust and/or pitting
Light surface rust can be removed with an
abrasive disc. Heavy surface rust and/or pitting 5. Using a micrometer calibrated in thousandths-of-a-
must be removed by refinishing the rotor. millimeter, or ten-thousandths-of-an-inch, measure
– Cracks and/or heat spots and record the scoring depth of any grooves present
– Excessive blueing discoloration on the rotor friction surfaces.
4. If the friction surfaces of the brake rotor exhibit one 6. Compare the groove scoring depth recorded to the
or more of the Braking Surface Conditions, the rotor following specification:
requires refinishing or replacement. Specification
Brake rotor maximum allowable scoring: 1.50
mm (0.059 in)
7. If the brake rotor scoring depth exceeds the
specification, or if an excessive amount of scoring is
present, the rotor requires refinishing or
replacement.
 Rear Brakes: 4C-23

Brake Rotor/Drum Balance Inspection

1. Support the vehicle drive axle on a suitable hoist.
Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel assemblies from the
drive axle. Refer to “Tire and Wheel Removal and
Installation: ”.

! WARNING
Refer to Work Stall Test Caution.

3. Reinstall the wheel nuts in order to retain the brake

rotors.
4. Run the vehicle at the concern speed while
inspecting for the presence of the vibration.

! CAUTION
Do not depress the brake pedal with the
brake rotors and/or the brake drums 7. If a brake rotor was replaced as a result of following
removed, or with the brake calipers the previous steps, or if necessary to confirm the
repositioned away from the brake rotors, or results obtained during the previous steps, and/or to

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damage to the brake system may result. check the non-drive axle components, perform the
following:
5. If the vibration is still present, remove the rotors from a. Mount the brake rotor/drum on a balancer in the
the drive axle, then run the vehicle back to the same manner as a tire and wheel assembly.
concern speed.
NOTE
6. If the vibration is eliminated when the brake rotors
are removed from the drive axle, repeat the test with Check brake rotors/drums for static
one rotor installed at a time. Replace the rotor that is imbalance only; ignore the dynamic
causing or contributing to the vibration concern. imbalance readings.

b. Inspect the rotor/drum for static imbalance.

There is not a set tolerance for brake rotor/drum static
imbalance. However, any brake rotor/drum measured in
this same manner which is over 21 g (¾ oz) may have
the potential to cause or contribute to a vibration. Rotors/
drums suspected of causing or contributing to a vibration
should be replaced. Any rotor/drum that is replaced
should be checked for imbalance in the same manner.
4C-24 Rear Brakes:

Rear Disc Brake Backing Plate Replacement

Callout Component Name

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! WARNING
Refer to “Brake Dust Caution: ”.

Preliminary Procedures
1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
3. Remove the park brake shoes. Refer to “Park Brake Shoe Replacement: ”.
4. Remove the wheel speed sensor. Refer to “Rear Wheel Speed Sensor Replacement: ”.
5. Disconnect the park brake cable from the actuator and mounting bracket. Refer to “Parking Brake Rear Cable
Replacement: ”.
6. Remove the wheel bearing/hub assembly. Refer to “Rear Wheel Bearing and Hub Replacement: ”.
1 Disc Brake Backing Plate

Brake Rotor Assembled Lateral Runout Review the following acceptable methods for bringing
Correction the brake rotor assembled LRO to within specifications.
Determine which method to use for the specific vehicle
NOTE being repaired.
• Brake rotor thickness variation MUST be • The indexing method of correcting assembled LRO is
checked BEFORE checking for assembled most effective when the LRO specification is only
lateral runout (LRO). Thickness variation exceeded by a relatively small amount: 0.025-0.127
exceeding the maximum acceptable level mm (0.001-0.005 in). Indexing is used to achieve the
can cause brake pulsation. Refer to “Brake best possible match of high spots to low spots
Rotor Thickness Variation Measurement: ”. between related components. Refer to “Brake Rotor
Assembled Lateral Runout Correction - Indexing: ”.
• Brake rotor assembled lateral runout
(LRO) exceeding the maximum allowable • The correction plate method of correcting assembled
specification can cause thickness LRO involves the addition of a tapered plate between
variation to develop in the brake rotor over the brake rotor and the hub/axle flange. The
time, usually between 4 800-11 300 km correction plate method can be used to correct LRO
(3,000-7,000 mi). Refer to “Brake Rotor that exceeds the specification by up to 0.23 mm
Assembled Lateral Runout Measurement: (0.009 in). Refer to “Brake Rotor Assembled Lateral
”. Runout Correction - Correction Plates: ”.
 Rear Brakes: 4C-25

• The on-vehicle brake lathe method is used to bring 2. Inspect the mating surface of the hub/axle flange
the LRO to within specifications through and the brake rotor to ensure that there are no
compensating for LRO while refinishing the brake foreign particles or debris remaining.
rotor. Refer to “Brake Rotor Assembled Lateral 3. Index the brake rotor in a different orientation to the
Runout Correction - On Vehicle Lathe: ”. hub/axle flange.
If the assembled LRO cannot be corrected using these
4. Hold the rotor firmly in place against the hub/axle
methods, then other components must be suspected as
flange and install one of the J 45101-100 (1) and
causing and/or contributing to the LRO concern.
one lug nut (2) onto the upper-most wheel stud.
5. Continue to hold the rotor secure and tighten the lug
Brake Rotor Assembled Lateral Runout nut firmly by hand.
Correction - Indexing
Special tool
J 39544-KIT Torque-Limiting Socket Set, or
equivalent
J 45101-100 Conical Brake Rotor Washers

! WARNING
Refer to “Brake Dust Caution: ”.

NOTE

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• Brake rotor thickness variation MUST be
checked BEFORE checking for assembled
lateral runout (LRO). Thickness variation
exceeding the maximum acceptable level
can cause brake pulsation. Refer to “Brake
Rotor Thickness Variation Measurement: ”.
• Brake rotor assembled LRO exceeding the
maximum allowable specification can 6. Install the remaining J 45101-100 and lug nuts onto
cause thickness variation to develop in the the wheel studs and tighten the nuts firmly by hand
brake rotor over time, usually between 4 in a star-pattern.
800-11 300 km (3,000-7,000 mi). Refer to 7. Using the J 39544-KIT, or equivalent, tighten the lug
“Brake Rotor Assembled Lateral Runout nuts in a star-pattern to specification, in order to
Measurement: ”. properly secure the rotor. Refer to “Tire and Wheel
Removal and Installation: ”.
8. Measure the assembled LRO of the brake rotor.
Refer to “Brake Rotor Assembled Lateral Runout
Measurement: ”.
9. Compare the amount of change between this
measurement and the original measurement.
10. If this measurement is within specifications, proceed
to step 14.
11. If this measurement still exceeds specifications,
repeat steps 1-9 until the best assembled LRO
measurement is obtained.
12. Matchmark the final location of the rotor to the wheel
studs if the orientation is different than it was
originally.
13. If the brake rotor assembled LRO measurement still
exceeds the maximum allowable specification, refer
to “Brake Rotor Assembled Lateral Runout
Correction: ”.
1. Remove the J 45101-100 and the lug nuts that were 14. If the brake rotor assembled LRO is within
installed during the assembled LRO measurement specification, install the brake caliper and depress
procedure. the brake pedal several times to secure the rotor in
place before removing the J 45101-100 and the lug
nuts.
4C-26 Rear Brakes:

Brake Rotor Assembled Lateral Runout 2. Remove the J 45101-100 and the lug nuts that were
Correction - Correction Plates installed during the assembled LRO measurement
procedure and/or the indexing correction procedure.
Special tool 3. Inspect the mounting surface of the hub/axle flange
J 39544-KIT Complete Torque Socket Set-10 Pieces, and the brake rotor to ensure that there are no
or equivalent foreign particles or debris remaining.
J 45101-100 Conical Brake Rotor Washers
4. Select the correction plate, following the
! WARNING manufacturer's instructions, which has a
specification closest to the assembled LRO
Refer to “Brake Dust Caution: ”. measurement.
For example: If the assembled LRO measurement
NOTE was 0.076 mm (0.003 in), the 0.076 mm (0.003 in)
correction plate would be used. If the measurement
• Brake rotor thickness variation MUST be was 0.127 mm (0.005 in), the 0.152 mm (0.006 in)
checked BEFORE checking for assembled correction plate would be used.
lateral runout (LRO). Thickness variation
exceeding the maximum acceptable level 5. Determine the positioning for the correction plate (1)
can cause brake pulsation. Refer to “Brake using the high spot mark (3) made during the brake
Rotor Thickness Variation Measurement: ”. rotor assembled LRO measurement procedure.
• Brake rotor assembled LRO exceeding the NOTE
maximum allowable specification can
• Do NOT install used correction plates in an

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cause thickness variation to develop in the
brake rotor over time, usually between 4 attempt to correct brake rotor assembled
800-11 300 km (3,000-7,000 mi). Refer to LRO.
“Brake Rotor Assembled Lateral Runout • Do NOT stack up, or install more than one
Measurement: ”. correction plate onto one hub/axle flange
location, in an attempt to correct brake
rotor assembled LRO.

6. Install the correction plate (1) onto the hub/axle

flange, with the V-shaped notch (2) orientated to
align with the high spot mark (3), that was positioned
to face upward.

7. Install the brake rotor to the hub/axle flange. Use the

matchmark made prior to removal for proper
orientation to the flange.
8. Hold the rotor firmly in place against the hub/axle
1. Rotate the brake rotor to position the high spot, flange and install one of the J 45101-100 (1) and
identified and marked during the brake rotor one lug nut (2) onto the upper-most wheel stud.
assembled LRO measurement procedure, to face
9. Continue to hold the rotor secure and tighten the lug
upward.
nut firmly by hand.
 Rear Brakes: 4C-27

Brake Rotor Assembled Lateral Runout

Correction - On Vehicle Lathe
Special tool
J 45101-100 Conical Brake Rotor Washers

! WARNING
Refer to “Brake Dust Caution: ”.

NOTE
• Brake rotor thickness variation MUST be
checked BEFORE checking for assembled
lateral runout (LRO). Thickness variation
exceeding the maximum acceptable level
can cause brake pulsation. Refer to “Brake
Rotor Thickness Variation Measurement: ”.
• Brake rotor assembled LRO exceeding the
10. Install the remaining J 45101-100 and lug nuts onto maximum allowable specification can
the wheel studs and tighten the nuts firmly by hand cause thickness variation to develop in the
in a star-pattern. brake rotor over time, usually between 4

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11. Using the J 39544-KIT, or equivalent, tighten the lug 800-11 300 km (3,000-7,000 mi). Refer to
nuts in a star-pattern to specification, in order to “Brake Rotor Assembled Lateral Runout
properly secure the rotor. Refer to “Tire and Wheel Measurement: ”.
Removal and Installation: ”.
1. Ensure that the caliper and caliper bracket that are
12. Measure the assembled LRO of the brake rotor. already being supported, are clear from contacting
Refer to “Brake Rotor Assembled Lateral Runout any rotating components, such as the brake rotor.
Measurement: ”.
2. Remove the J 45101-100 and the lug nuts that were
13. If the brake rotor assembled LRO measurement still installed during the assembled LRO measurement
exceeds the maximum allowable specification, refer procedure and/or the indexing correction procedure.
to “Brake Rotor Assembled Lateral Runout
3. Inspect the mounting surface of the hub/axle flange
Correction: ”.
and the brake rotor to ensure that there are no
14. If the brake rotor assembled LRO measurement is foreign particles or debris remaining.
within specification, install the brake caliper and
4. Set up the lathe, following the manufacturer's
depress the brake pedal several times to secure the
instructions.
rotor in place before removing the J 45101-100 and
the lug nuts. 5. Refinish the brake rotor, following the brake lathe
manufacturer's instructions.
6. After each successive cut, inspect the brake rotor
thickness. Refer to “Brake Rotor Thickness
Measurement: ”.
7. If at any time the brake rotor exceeds the minimum
allowable thickness after refinish specification, the
brake rotor must be replaced. After replacing the
rotor, proceed to step 10.
4C-28 Rear Brakes:

8. After refinishing the brake rotor, use the following – Brake system noise - squeal, growl,
procedure in order to obtain the desired non- groan
directional finish:
– Uneven and/or premature disc brake pad
a. Follow the brake lathe manufacturer's wear
recommended speed setting for applying a non-
– Superficial or cosmetic corrosion/rust of
directional finish.
the disc brake rotor friction surface
b. Using moderate pressure, apply the non-
– Scoring of the disc brake rotor friction
directional finish:
surface less than the maximum
– If the lathe is equipped with a non-directional allowable specification
finishing tool, apply the finish with 120-grit
• Before refinishing a brake rotor, the rotor
aluminum oxide sandpaper.
MUST first be checked for adequate
– If the lathe is not equipped with a non- thickness to allow the rotor to be
directional finishing tool, apply the finish with a refinished and remain above the minimum
sanding block and 150-grit aluminum oxide allowable thickness after refinish
sandpaper. specification. Refer to “Brake Rotor
c. After applying a non-directional finish, clean Thickness Measurement: ”.
each friction surface of the brake rotor with Disc brake rotors should only be
denatured alcohol, or an equivalent approved refinished if they have adequate thickness
brake cleaner. to be refinished and if one or more of the
9. Remove the lathe from the vehicle. following conditions exist:

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10. Measure the assembled LRO of the brake rotor. – Thickness variation in excess of the
Refer to “Brake Rotor Assembled Lateral Runout maximum allowable specification
Measurement: ”. – Excessive corrosion/rust and/or pitting
11. If the brake rotor assembled LRO measurement still – Cracks and/or heat spots
exceeds the maximum allowable specification, refer – Excessive blueing discoloration
to “Brake Rotor Assembled Lateral Runout
– Scoring of the disc brake rotor surface
Correction: ”.
in excess of the maximum allowable
12. If the brake rotor assembled LRO is within specification
specification, install the brake caliper and depress
• Disc brake rotors may need to be
the brake pedal several times to secure the rotor in
refinished as part of the process for
place before removing the J 45101-100 and the lug
correcting brake rotor assembled lateral
nuts.
runout (LRO) that exceeds the maximum
allowable specification.
Brake Rotor Refinishing
NOTE
Special tool
J 41013 Rotor Resurfacing Kit If the vehicle is equipped with cross-drilled
J 42450-A Wheel Hub Resurfacing Kit rotors, use a lathe with positive rake tooling.
This setup requires less cutting pressure,
! WARNING which will result in less vibration, and a
better surface finish. Also, use a vibration
Refer to “Brake Dust Caution: ”.
dampener when cutting. Otherwise, refinish
according to the following instructions.
NOTE
• The disc brake rotors do not require NOTE
refinishing as part of routine brake system Whenever the brake rotor has been separated
service. New disc brake rotors do not from the hub/axle flange, clean any rust or
require refinishing. contaminants from the hub/axle flange and
Do not refinish disc brake rotors in an the brake rotor mating surfaces. Failure to do
attempt to correct the following this may result in increased assembled
conditions: lateral runout (LRO) of the brake rotor, which
could lead to brake pulsation.
 Rear Brakes: 4C-29

1. Using the J 42450-A, thoroughly clean any rust or 11. If at any time the brake rotor exceeds the minimum
corrosion from the mating surface of the hub/axle allowable thickness after refinish specification, the
flange. brake rotor must be replaced.
2. Using the J 41013, thoroughly clean any rust or 12. After refinishing the brake rotor, use the following
corrosion from the mating surface and mounting procedure in order to obtain the desired non-
surface of the brake rotor. directional finish:
3. Inspect the mating surfaces of the hub/axle flange a. Follow the brake lathe manufacturer's
and the rotor to ensure that there are no foreign recommended speed setting for applying a non-
particles or debris remaining. directional finish.
4. Mount the brake rotor to the brake lathe according to b. Using moderate pressure, apply the non-
the lathe manufacturer's instructions, ensuring that directional finish:
all mounting attachments and adapters are clean – If the lathe is equipped with a non-directional
and free of debris. finishing tool, apply the finish with 120-grit
5. Ensure that any vibration dampening attachments aluminum oxide sandpaper.
are securely in place. – If the lathe is not equipped with a non-
6. With the brake lathe running, slowly bring in the directional finishing tool, apply the finish with a
cutting tools until they just contact the brake rotor sanding block and 150-grit aluminum oxide
friction surfaces. sandpaper.
7. Observe the witness mark on the brake rotor. If the c. After applying a non-directional finish, clean
witness mark extends approximately three-quarters each friction surface of the brake rotor with

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or more of the way around the brake rotor friction denatured alcohol, or an equivalent approved
surface on each side, the brake rotor is properly brake cleaner.
mounted to the lathe. 13. Remove the brake rotor from the brake lathe.
8. If the witness mark does not extend three-quarters or 14. Measure the assembled LRO of the brake rotor to
more of the way around the brake rotor, re-mount the ensure optimum performance of the disc brakes.
rotor to the lathe. Refer to “Brake Rotor Assembled Lateral Runout
9. Following the brake lathe manufacturer's Measurement: ”.
instructions, refinish the brake rotor. 15. If the brake rotor assembled LRO measurement
10. After each successive cut, inspect the brake rotor exceeds the specification, bring the LRO to within
thickness. Refer to “Brake Rotor Thickness specifications. Refer to “Brake Rotor Assembled
Measurement: ”. Lateral Runout Correction: ”.

Specifications
Fastener Tightening Specifications - Disc Brakes
Specification
Application
Metric English
Brake Caliper Bleeder Valve 10 N⋅m 89 lb in
Brake Caliper Bracket Bolt - Rear 120 N⋅m 89 lb ft
Brake Caliper Guide Pin Bolt - Rear 27 N⋅m 20 lb ft
Brake Hose Fitting Bolt - Rear 52 N⋅m 38 lb ft
Brake Rotor Screw 10 N⋅m 89 lb in

Disc Brake Component Specifications

Specification
Application
Metric English
Rear Brakes
Brake Pad Lining Minimum Thickness 2.0 mm 0.080 in
Brake Rotor Diameter 191 mm 7.520 in
Rotor Discard Thickness * 18.4 mm 0.724 in
Maximum Allowable Lateral Runout 0.06 mm 0.002 in
Maximum Allowable Scoring 1.50 mm 0.059 in
Maximum Allowable Thickness Variation 0.025 mm 0.001 in
* All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification.
After refinishing the rotor, replace any rotor that does not meet the minimum thickness specifications.
4C-30 Rear Brakes:

Special Tools and Equipment

Special Tools - Disc Brakes Tool Number/
Illustration
Tool Number/ Description
Illustration
Description

J 45101-100
J 39544-KIT Conical Brake Rotor
Complete Torque Socket Washers
Set - 10 Pieces

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J 41013
Rotor Resurfacing Kit

J 42450-A
Wheel Hub Resurfacing Kit

J 45101
Hub and Wheel Runout
Gage
 Parking Brake: 4D-1

Parking Brake
General Description
Park Brake System Description and Operation
System Component Description
The park brake system consists of the following:
Park Brake Lever Assembly: Receives, multiplies, and transfers park brake system apply input force from driver to
park brake cable system.
Releases applied park brake system when lever release button is depressed and lever is returned to the at rest
position.
Park Brake Cables: Transfers input force received from park brake lever, through park brake cable equalizer, to park
brake apply lever.
Park Brake Cable Equalizer: Evenly distributes input force to both the left and right park brake units.
Threaded front park brake cable adjuster is also used to remove slack in park brake cables.
Park Brake Apply Lever: Multiplies and transfers input force to park brake actuator/adjuster.
Park Brake Actuator/Adjuster: Uses multiplied input force from apply lever to expand drum brake shoes toward the
friction surface of the brake drum.
Threaded park brake actuators/adjusters are also used to control clearance between the drum brake shoes and
the friction surface of the brake drum.

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System Operation
Park brake apply input force is received by the park brake lever assembly being applied. The input force is multiplied
by the lever assembly, transferred and evenly distributed, through the park brake cables and the park brake cable
equalizer, to the left and right park brake apply levers. The park brake apply levers multiply and transfer the apply input
force to the park brake actuators/adjusters which expand the drum brake shoes toward the friction surface of the brake
drum in order to prevent the rotation of the rear tire and wheel assemblies. The park brake lever assembly releases an
applied park brake system when it is released and returned to the at rest position.
4D-2 Parking Brake:

Diagnostic Information and Procedures

Diagnostic Starting Point - Park Brake
Begin the system diagnosis by reviewing the system description and operation. Reviewing the description and
operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists.
Reviewing the description and operation information will also help you determine if the condition described by the
customer is normal operation. Refer to “Symptoms - Park Brake” in order to identify the correct procedure for
diagnosing the system and where the procedure is located.

DTC B0005
Diagnostic Instructions
• Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure.
• Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach
• “Diagnostic Procedure Instructions - Vehicle Diagnostic Information: ” provides an overview of each diagnostic
category

DTC Descriptor
DTC B0005: In Park Switch Signal Circuit

Diagnostic Fault Information

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Short to Open/High Signal
Circuit Short to Voltage
Ground Resistance Performance
Park Brake Switch Signal B0005 — — —

Circuit/System Description Reference Information

The body control module (BCM) monitors the park brake Schematic Reference
switch via the park brake switch signal circuit. With the “Hydraulic Brake Schematics: ”
park brake applied, the switch is closed and the signal Connector End View Reference
circuit is grounded. The BCM will then send a serial data “Hydraulic Brake Connector End Views: ”
message to the IPC requesting the red brake warning Description and Operation
indicator be illuminated. “Brake Warning System Description and Operation: ”
Electrical Information Reference
Conditions for Running the DTC • “Circuit Testing: ”
Ignition is ON • “Connector Repairs: ”
• “Testing for Intermittent Conditions and Poor
Conditions for Setting the DTC Connections: ”
• Vehicle speed is greater than 5 mph (8 km/h) • “Wiring Repairs: ”
• The BCM detects the park brake switch signal is
grounded Circuit/System Verification
Observe the scan tool BCM Park Brake Switch
Action Taken When the DTC Sets parameter while applying and releasing the park brake.
The red brake warning indicator is illuminated The parameter should cycle between Applied and
Release.
Conditions for Clearing the DTC
• A current DTC will clear when the condition for setting
the DTC is no longer present
• A history DTC will clear after 100 malfunction free
ignition cycles
 Parking Brake: 4D-3

Circuit/System Testing Repair Instructions

1. Ignition OFF, disconnect the harness connector at Perform the “Diagnostic Repair Verification - Vehicle
the park brake switch. Diagnostic Information: ” after completing the diagnostic
procedure.
2. Ignition ON, verify the scan tool BCM Park Brake
Switch parameter is Released. • “Park Brake Warning Lamp Switch Replacement”
➢ If not the specified value, test the signal circuit • “Control Module References: ” for BCM replacement,
terminal A for a short to ground. If the circuit tests setup, and programming
normal, replace the BCM.
3. Install a 3A fused jumper wire between the signal Symptoms - Park Brake
circuit terminal A and ground. Verify the scan tool
BCM Park Brake Switch parameter is Applied. NOTE
➢ If not the specified value, test the signal circuit for a Review the system operation in order to
short to voltage or an open/high resistance. If the familiarize yourself with the system
circuit tests normal, replace the BCM. functions.
4. If all circuits test normal, test or replace the park Refer to “Park Brake System Description and
brake switch. Operation”.

Visual/Physical Inspection
• Inspect for aftermarket devices which could affect the

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operation of the park brake system.
• Inspect the easily accessible or visible system
components for obvious damage or conditions which
could cause the symptom.

Symptom List
Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
“Park Brake Will Not Hold or Release”

Park Brake Will Not Hold or Release

Step Action Yes No
Were you sent here from the Park Brake Symptom table? Go to “Diagnostic
1 Go to Step 2 Starting Point - Park
Brake”
Inspect the disc brake system for proper operation. Refer to
2 “Disc Brake System Diagnosis: ”. Go to Step 5 Go to Step 3
Did you find and correct a condition?
Inspect the park brake system for proper operation. Refer to
3 “Park Brake System Diagnosis”. Go to Step 5 Go to Step 4
Did you find and correct a condition?
Inspect the hydraulic brake system for proper operation. Refer Go to “Diagnostic
4 to “Hydraulic Brake System Diagnosis: ”. Go to Step 5 Starting Point - Park
Did you find and correct a condition? Brake”
Road test the vehicle in order to confirm proper operation.
5 Refer to “Brake System Vehicle Road Test: ”. Go to Step 2 System OK
Is the condition still present?
4D-4 Parking Brake:

Park Brake System Diagnosis

Step Action Yes No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the PARK brake system in
order to determine if the PARK brake system is operating properly. You will be directed by the appropriate Symptom
table to go to other brake system diagnostic tables as appropriate.
1 Were you sent here from a Hydraulic Brake Symptom table? Go to Step 4 Go to Step 2
2 Were you sent here from a Park Brake Symptom table? Go to Step 4 Go to Step 3
Is the symptom related to the ability of the park brake system Go to “Diagnostic Go to “Diagnostic
3 to hold and/or release? Starting Point - Park Starting Point -
Brake” Hydraulic Brakes: ”
1. Raise and support the vehicle with the rear axle supported
by jack stands. Refer to “Lifting and Jacking the Vehicle: ”.
2. Shift the transmission into NEUTRAL.
4 3. With the park brake RELEASED, attempt to rotate the rear Go to Step 9 Go to Step 5
wheels to check the rear brakes for a significant amount of
drag.
Do the rear brakes have a significant amount of drag?
1. Apply the park brake.
5 2. Attempt to rotate the rear wheels to check the rear brakes Go to Step 19 Go to Step 6
for a significant amount of drag.

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Do the rear brakes have a significant amount of drag?
Visually inspect the park brake cable connections and the
cables that are accessible on the UNDERSIDE of the vehicle
6 for disconnections and/or damage. Go to Step 7 Go to Step 8
Were any of the park brake cables disconnected and/or
damaged?
Reconnect or replace the park brake cables as necessary.
Refer to the following procedures as necessary:
7 • “Parking Brake Front Cable Replacement” Go to Step 19 —
• “Parking Brake Rear Cable Replacement”
Did you complete the repair and/or replacement?
Check the adjustment of the park brake. Refer to “Park Brake
8 Adjustment”. Go to Step 19 Go to Step 9
Did you find and correct the condition?
! CAUTION
Do not depress the brake pedal with the brake
rotors and/or the brake drums removed, or with
the brake calipers repositioned away from the
brake rotors, or damage to the brake system may
result.
9 1. Remove the rear brake rotors. Refer to “Rear Brake Rotor Go to Step 10 Go to Step 11
Replacement: ”.
2. Inspect the park brake shoe hardware for looseness,
damaged, broken or missing components.
3. Check the park brake actuators for a seized condition.
Does the park brake hardware and/or the park brake actuators
require replacement?
1. Replace park brake hardware components as necessary.
Refer to“Park Brake Shoe Replacement”.
10 2. Replace the park brake actuators as necessary. Refer to Go to Step 19 Go to Step 18
“Parking Brake Actuator Replacement”.
Did you find and correct the condition?
Have an assistant apply and release the park brake, while you
11 observe the park brake cables for free movement. Go to Step 12 Go to Step 14
Did the park brake cables move freely?
 Parking Brake: 4D-5

Step Action Yes No

Check the adjustment of the park brake. Refer to “Park Brake
12 Adjustment”. Go to Step 19 Go to Step 13
Did you find and correct the condition?
1. With the transmission still in NEUTRAL, apply the park
brake.
2. Attempt to rotate the rear wheels to check the rear brakes
for a significant amount of drag. Go to “Symptoms -
13 Go to Step 19
3. Release the park brake. Park Brake”
4. Rotate the rear wheels to check the rear brakes for a
significant reduction of drag.
Did the park brake apply and release properly?
Disconnect the park brake cable connections that are
accessible on the UNDERSIDE of the vehicle one at a time
14 and check each cable for free movement. Go to Step 15 Go to Step 16
Do any of the park brake cables accessible on the underside
of the vehicle require replacement?
Replace any of the park brake cables that do not have free
movement - not releasing properly. Refer to the following
procedures as necessary:
15 Go to Step 19 —

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• “Parking Brake Front Cable Replacement”
• “Parking Brake Rear Cable Replacement”
Did you complete the replacement?
Disconnect the front park brake cable connection accessible
INSIDE the vehicle at the park brake lever assembly and
check for free movement.
16 Replace the front park brake cable if it does not have free Go to Step 19 Go to Step 17
movement. Refer to “Parking Brake Front Cable
Replacement”.
Did you find and correct a condition?
Inspect the park brake lever assembly for proper operation
and replace if necessary. Refer to “Park Brake Lever
17 Go to Step 19 Go to Step 18
Assembly Replacement”.
Did you find and correct the condition?
1. Replace the component that is used to adjust the park
brake system. Refer to “Park Brake Lever Assembly
Replacement”. Go to “Symptoms -
18 Go to Step 19
Park Brake”
2. Adjust the park brake. Refer to “Park Brake Adjustment”.
Did you complete the replacement and adjustment?
1. Install or connect any components that were removed or
disconnected during diagnosis. Go to “Symptoms -
19 System OK
2. Verify the operation of the park brake system. Park Brake”
Does the park brake operate correctly?
4D-6 Parking Brake:

Repair Instructions
Park Brake Adjustment
Special tool
J 21177-A Drum to Brake Shoe Clearance Gauge

Park Brake Shoe Adjustment

! WARNING
Refer to “Brake Dust Caution: ”.

1. Apply and fully release the park brake lever.

2. Verify that the park brake lever releases completely.
3. Turn ON the ignition. Verify that the red BRAKE
warning indicator lamp is off.
4. Turn OFF the ignition.
5. Raise and support the vehicle. Refer to “Lifting and
Jacking the Vehicle: ”.
6. Remove the rear tire and wheel assemblies. Refer to 10. Position the outside measurement contacts of the J

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“Tire and Wheel Removal and Installation: ”. 21177-A over the park brake shoe (1) at the widest
point.
NOTE
Do not operate the park brake lever with the NOTE
rear disc brake rotors removed. If the gap between the adjuster nut and the
adjuster screw exceeds 5 mm (0.25 in) during
7. Remove the rear disc brake rotors. Refer to “Rear the adjustment procedure, the park brake
Brake Rotor Replacement: ”. shoe must be replaced.

11. Adjust the park brake shoe-to-drum clearance by

rotating the adjustment nut on the park brake
actuator.
Specification
0.38 mm (0.015 in)
12. Install the rear brake rotors. Refer to “Rear Brake
Rotor Replacement: ”.
13. Install the rear tire and wheel assemblies. Refer to
“Tire and Wheel Removal and Installation: ”.
14. Apply the park brake lever. Inspect the rotation of the
rear wheels:
– The wheels should not rotate forward.
– The wheels should drag or not rotate rearward.
15. If the rear tire and wheel assemblies rotate forward
or do not exhibit drag rearward, proceed to the park
8. Place the inside measurement contacts of the J brake cable adjustment.
21177-A at the widest point of the drum portion of the 16. Release the park brake lever. Verify that the wheels
brake rotor (1). rotate freely.
9. Tighten the set screw on the tool in order to ensure
the proper measurement when removing the tool
from the drum.
 Parking Brake: 4D-7

Park Brake Cable Adjustment

4. Using ONLY hand tools, tighten the park brake cable

1. Remove the front floor console. Refer to “Console adjusting nut (1) until light to moderate drag is
Replacement: ”. exhibited while rotating the rear wheels.

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2. With the park brake lever in the fully released 5. Attempt to rotate the rear wheels. There should be
position, using ONLY hand tools, loosen the no rotation forward or rearward.
adjusting nut completely to the end of the front cable 6. Fully release the park brake lever.
threaded rod. 7. Verify the park brake is released by rotating the rear
3. Raise the park brake lever 1 detent position. wheels. The wheels should rotate freely and exhibit
no park brake shoe drag.
! CAUTION
8. If the wheels do not rotate freely, repeat the park
Refer to “Fastener Notice: ”. brake cable adjustment procedure.
9. Raise the park brake lever 3 detent positions and
attempt to rotate the rear wheels:
– One of the wheels should not rotate forward or
rearward.
– The other wheel should not rotate forward or
rearward, or should require substantial effort to
rotate.
10. Install the front floor console. Refer to “Console
Replacement: ”.
11. Release the park brake lever.
4D-8 Parking Brake:

Park Brake Shoe Replacement

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Callout Component Name
! WARNING
Refer to “Brake Dust Caution: ”.

Preliminary Procedures
1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the rear tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
3. Remove the rear brake rotor. Refer to “Rear Brake Rotor Replacement: ”.
Park Brake Shoe Hold Down Spring (Qty: 2)
1 Procedure
Compress the spring and rotate ¼ turn to release.
2 Park Brake Shoe Hold Down Spring Pin (Qty: 2)
Park Brake Shoe Adjuster Spring
Procedure
3 Using the J 38400, remove the adjuster spring.
Special tool
J 38400 Brake Shoe Spanner and Spring Remover
Park Brake Shoe Adjuster Screw
4 Procedure
Clean the threads and apply high temperature grease to the adjuster screw.
Park Brake Shoe Return Spring
Procedure
5 Using the J 38400, remove the return spring.
Special tool
J 38400 Brake Shoe Spanner and Spring Remover
 Parking Brake: 4D-9

Callout Component Name

Park Brake Shoe (Qty: 2)
Procedure
1. Use denatured alcohol to clean brake dust or grease from the park brake shoes and hardware.
6 2. If reinstalling the park brake shoes, note the location of the park brake shoes for installation.
3. Apply a small amount of high temperature silicone grease to the brake shoe and backing plate
contact points.
4. Adjust the park brake. Refer to “Park Brake Adjustment”.

Park Brake Lever Assembly Replacement

Removal Procedure
1. Disable the supplemental inflatable restraint (SIR)
system. Refer to “SIR Disabling and Enabling: ”.
2. Remove the front floor console. Refer to “Console
Replacement: ”.
3. Ensure that the park brake lever is in the fully
released position.

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6. Disconnect the electrical connector from the park
brake warning lamp switch.

4. Release the tension from the park brake cable

system at the front cable adjusting nut (1).
5. Using ONLY hand tools, loosen the adjusting nut (1)
completely to the end of the front cable threaded rod.

7. With the park brake lever (1) in the released position,

release the rear park brake cable (2) ends from the
cable equalizer.
8. Release the rear cable fittings from the park brake
lever bracket.
4D-10 Parking Brake:

9. Remove the park brake lever mounting nuts. 3. Secure the rear cable fittings to the park brake lever
10. Remove the park brake lever assembly from the bracket. Attempt to pull the park brake cables free of
vehicle. the lever bracket, to ensure that the retaining tabs on

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the fittings are properly secured.
Installation Procedure 4. Install the cable ends to the cable equalizer.

1. Install the park brake lever assembly to the vehicle. 5. Connect the electrical connector to the park brake
warning lamp switch.
! CAUTION 6. Adjust the park brake cable tension. Refer to “Park
Refer to “Fastener Notice: ”. Brake Adjustment”.
7. Install the front floor console. Refer to “Console
2. Install the park brake lever assembly mounting nuts. Replacement: ”.
Tightening torque 8. Enable the SIR system. Refer to “SIR Disabling and
Tighten the nuts to 25 N⋅m (18 lb ft). Enabling: ”.
 Parking Brake: 4D-11

Park Brake Warning Lamp Switch ! CAUTION

Replacement Refer to “Fastener Notice: ”.
Removal Procedure
3. Install the park brake warning lamp switch mounting
screw (1).
Tightening torque
Tighten the screw to 4 N⋅m (35 lb in).
4. Connect the park brake warning lamp switch
electrical connector (2).
5. Install the front floor console. Refer to “Console
Replacement: ”.
6. Enable the SIR system. Refer to “SIR Disabling and
Enabling: ”.
7. Verify correct park brake warning lamp operation.

Parking Brake Front Cable Replacement

Removal Procedure
1. Disable the supplemental inflatable restraint (SIR)

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system. Refer to “SIR Disabling and Enabling: ”.
1. Disable the supplemental inflatable restraint (SIR)
2. Remove the front floor console. Refer to “Console
system. Refer to “SIR Disabling and Enabling: ”.
Replacement: ”.
2. Remove the front floor console. Refer to “Console
Replacement: ”.
3. Disconnect the warning lamp switch electrical
connector (2).
4. Remove the warning lamp switch mounting screw
(1).
5. Remove the switch from the park brake lever
assembly.

Installation Procedure

3. With park brake lever in the released position, using

ONLY hand tools, remove the park brake cable
adjusting nut and washer.
4. Release the rear park brake cable ends from the
cable equalizer on the front cable.
5. Remove the front park brake cable from the park
brake lever by pulling the cable rearward.

1. Align the park brake warning lamp switch locating

tab to the locating hole on the park brake lever
assembly.
2. Install the switch to the park brake lever.
4D-12 Parking Brake:

Installation Procedure Parking Brake Rear Cable Replacement

Removal Procedure
Special tool
J 37043 Park Brake Cable Release Tool
1. Remove the front floor console. Refer to “Console
Replacement: ”.
2. Ensure the park brake lever is in the fully released
position.

1. Install the front park brake cable to the park brake

lever.

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2. Install the rear cable ends to the cable equalizer.

3. Release the tension from the park brake cable

system at the front cable adjusting nut (1).
Using only hand tools, loosen the adjusting nut (1)
completely to the end of the front cable threaded rod.

3. Using ONLY hand tools, install the washer and NEW

adjusting nut (1) to the front park brake cable.
4. Adjust the park brake cable tension. Refer to “Park
Brake Adjustment”.
5. Install the front floor console. Refer to “Console
Replacement: ”.
6. Enable the SIR system. Refer to “SIR Disabling and
Enabling: ”.
4. Remove the rear carpet retainers. Refer to “Rear
Carpet Retainer Replacement: ”.
5. Position the carpet forward in order to access the
rear park brake cables and body pass-through
grommets.
 Parking Brake: 4D-13

6. With the park brake lever (1) in the released position,

release the appropriate rear park brake cable (2)
from the cable equalizer.
7. Release the rear cable fitting from the park brake
lever bracket and remove the cable from the lever
assembly.

13. Remove the bolt (1) from the park brake cable
retainer at the lower suspension trailing arm.
14. Remove the cable (2) from the opening in the vehicle

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underbody.

8. Fold back the park brake cable routing tabs on the

vehicle interior floor.
9. Release the rear park brake cable body pass-
through grommet.

15. Slide the inner cable (1) forward and remove from
the actuator.
16. Slide the spring (2) forward
17. Using the J 37043, remove the park brake cable
from the mounting bracket

10. Raise and support the vehicle. Refer to “Lifting and

Jacking the Vehicle: ”.
11. Remove the rear tire and wheel assembly. Refer to
“Tire and Wheel Removal and Installation: ”.
12. Remove the bolt (1) from the park brake cable-to-
underbody retainer.
4D-14 Parking Brake:

Installation Procedure 7. Install the bolt (1) to the park brake cable retainer
and lower trailing arm.
NOTE
Tightening torque
After installing the park brake cable in the Tighten the bolt and nut to 12 N⋅m (106 lb in).
mounting bracket, ensure that the locking
tabs on the cable are open and seated
correctly against the mounting bracket.

1. Install the park brake cable in the mounting bracket.

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8. Install and secure park brake cable pass-through
grommet to the opening in the vehicle underbody.
9. Install the park brake cable (2) to the underbody
retainer.
2. Slide the inner cable forward (1) and install on the 10. Install the bolt to the park brake cable retainer and
park brake actuator. the vehicle underbody (3).
3. Position the spring (2) against the mounting bracket. Tightening torque
4. Install the rear tire and wheel assembly. Refer to Tighten the bolt to 25 N⋅m (18 lb ft).
“Tire and Wheel Removal and Installation: ”.
11. Lower the vehicle.

5. Insert the cable (2) through the opening in the

vehicle underbody.
6. Install the park brake cable retaining bracket to the
rear suspension lower trailing arm.

! CAUTION
Refer to “Fastener Notice: ”.
 Parking Brake: 4D-15

12. Secure the cable fitting to the park brake lever

bracket. Attempt to pull the park brake cable free of
the lever bracket, to ensure that the retaining tabs on

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the fitting are properly secured.
13. Install the cable end (2) to the cable equalizer.

14. Position park brake cable to routing tabs on vehicle

interior floor.
15. Secure park brake cable to floor by folding routing
tabs over park brake cable.
16. Reposition the carpet to the installed position.
17. Install the rear carpet retainers. Refer to “Rear
Carpet Retainer Replacement: ”.
18. Adjust the park brake cable tension. Refer to “Park
Brake Adjustment”.
19. Install the front floor console. Refer to “Console
Replacement: ”.
4D-16 Parking Brake:

Parking Brake Actuator Replacement

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Callout Component Name
! WARNING
Refer to “Brake Dust Caution: ”.

Preliminary Procedures
1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
3. Remove the disc brake backing plate. Refer to “Rear Disc Brake Backing Plate Replacement: ”.
Park Brake Cable Eye
Procedure
1. Using the J 37043, release the locking fingers on the park brake cable.
1
2. Remove the park brake cable from the actuator lever.
Special tool
J 37043 Parking Brake Cable Release Tool
Parking Brake Actuator
2 Procedure
Adjust the park brake. Refer to “Park Brake Adjustment”.
 Parking Brake: 4D-17

Park Brake Hardware Inspection 6. If any of the conditions listed were found, which
could lead to improper park brake apply and/or
! WARNING release, the park brake lever requires repair or
replacement.
Refer to “Brake Dust Caution: ”.
7. Visually inspect the park brake cable for the
1. With the brake rotors removed, visually inspect the following:
upper return/adjuster actuator spring and the lower – Improper mounting to the backing plate
return spring for the following: – Improper mounting at the park brake lever
– Excessive corrosion – Broken or missing cable end lug
– Excessive stretching 8. If any of the conditions listed were found, which
– Broken hook ends could lead to improper park brake apply and/or
– Twisting or binding release, the park brake cable requires repair or
replacement.
2. If any of the conditions listed were found, which
could lead to improper park brake apply and/or 9. Apply the park brake lever/pedal three clicks.
release, the adjuster hardware and/or return springs 10. Visually inspect the park brake cable for the
require replacement. following:
3. Visually inspect the adjuster and the adjuster – Unequal travel between the left and the right park
actuator lever for the following: brake systems
– Misalignment with the park brake lever – No travel on one or both of the park brake

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– Misalignment with the park brake shoes systems
11. If any of the conditions listed were found, which
– Broken or bent adjuster actuator lever
could lead to improper park brake apply and/or
– Bent adjuster actuator lever pivot pin release, the park brake cable requires replacement
4. If any of the conditions listed were found, which and/or adjustment.
could lead to improper park brake apply and/or 12. Release the park brake lever/pedal.
release, the adjuster hardware requires repair or
replacement. 13. Visually inspect the park brake cable for the
following:
5. Inspect the park brake lever for the following:
– Unequal release between the left and the right
– Bent park brake systems
– Broken pivot pin – No release at one or both of the park brake
– Seized at the pivot pin systems
– Broken at park brake cable attachment 14. If any of the conditions listed were found, which
– Improper contact with the adjuster could lead to improper park brake apply and/or
release, the park brake cable requires replacement
and/or adjustment.
4D-18 Parking Brake:

Specifications
Fastener Tightening Specifications - Park Brake
Specification
Application
Metric English
Park Brake Cable Bracket-to-Trailing Arm Bolt and Nut 12 N⋅m 106 lb in
Park Brake Cable Bracket-to-Underbody Bolt 25 N⋅m 18 lb ft
Park Brake Lever Assembly Mounting Nuts 25 N⋅m 18 lb ft
Park Brake Warning Lamp Switch Mounting Screw 4 N⋅m 35 lb in

Special Tools and Equipment

Special Tools - Park Brake
Tool Number/
Illustration
Description

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J 21177-A
Drum-to-Brake Shoe
Clearance Gage

J 37043
Parking Brake Cable
Release Tool

J 38400
Brake Shoe Spanner and
Spring Remover
 ABS: 4E-1

ABS
Precautions
ABS Component Handling Caution
! WARNING
Certain components in the Antilock Brake System (ABS) are not intended to be serviced individually.
Attempting to remove or disconnect certain system components may result in personal injury and/or
improper system operation. Only those components with approved removal and installation
procedures should be serviced.

General Description
ABS Description and Operation The BPMV contains the following components:
This vehicle is equipped with the Continental Teves MK – ABS pump Motor and pump
25E antilock braking system. – Inlet Valves (one per wheel)
The vehicle is equipped with the following braking

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– Outlet Valves (one per wheel)
systems:
– Master Cylinder Isolation Valves (one per drive
• Antilock Brake System (ABS)
wheel)
• Electronic Brake Force Distribution (EBD)
– Prime Valves (one per drive wheel)
• Traction Control System (TCS)
– A master cylinder pressure sensor
• Vehicle Stability Enhancement System (VSES) (w/
• The wheel speed sensor receives a 12-volt power
JL4)
supply voltage from the electronic brake control
The following components are involved in the operation
module (EBCM) and provides an output signal to the
of the above systems:
EBCM. As the wheel spins, the wheel speed sensor
• Electronic Brake Control Module (EBCM) - The EBCM sends the EBCM a DC square wave signal. The
controls the system functions and detects failures. EBCM uses the frequency of the square wave signal
The EBCM contains the following components: to calculate the wheel speed.
– Motor Relay - The motor relay is energized when • Traction Control Switch - The TCS is manually
the ignition is ON and no ABS DTCs are present. It disabled or enabled using the traction control switch.
supplies battery positive voltage to the pump motor.
• Stoplamp Switch - The EBCM uses the stoplamp
– Valve Relay - The valve relay is energized when the switch as an indication that the brake pedal is applied.
ignition is ON and no ABS DTCs are present. It
• Lateral Accelerometer Sensor (w/JL4) - The EBCM
supplies battery positive voltage to the solenoid
uses the lateral accelerometer sensor as an indication
valves.
of the lateral acceleration of the vehicle.
• Brake Pressure Modulator Valve (BPMV) - The BPMV
• Yaw Rate Sensor (w/JL4) - The EBCM uses the yaw
contains the hydraulic valves and pump motor that are
rate sensor as an indication of the yaw rate of the
controlled electrically by the EBCM. The BPMV uses
vehicle.
a 4 circuit configuration with a diagonal split. The
BPMV directs fluid from the reservoir of the master • Steering Wheel Position Sensor (SWPS) (w/JL4) -
cylinder to the left front and right rear wheels and fluid The EBCM uses the SWPS as an indication of the
from the other reservoir to the right front and left rear position and rotation of the steering wheel.
wheels. The diagonal circuits are hydraulically
isolated so that a leak or malfunction in one circuit will
allow continued braking ability on the other.

NOTE
There is a rubber isolator located under the
BPMV and on the mounting studs. The
rubber isolators protect the BPMV and the
EBCM from vehicle vibrations.
4E-2 ABS:

Initialization Sequence Pressure Hold

The EBCM performs 1 initialization test each ignition The EBCM closes the inlet valve and keeps the outlet
cycle. The initialization of the EBCM occurs when 1 set valve closed in order to isolate the system when wheel
of the following conditions occur: slip occurs. This holds the pressure steady on the brake
Both of the following conditions occur: so that the hydraulic pressure does not increase or
• The EBCM detects that there is a minimum of 500 decrease.
RPM from the ECM via a serial data message.
• The stop lamp switch is not applied. Pressure Decrease
OR The EBCM decreases the pressure to individual wheels
Both of the following conditions occur: during a deceleration when wheel slip occurs. The inlet
valve is closed and the outlet valve is opened. The
• The vehicle speed is greater than 16 km/h (10 mph).
excess fluid is stored in the accumulator until the return
• The stop lamp switch is applied. pump can return the fluid to the master cylinder.
The initialization sequence may also be commanded
with a scan tool. Pressure Increase
The initialization sequence cycles each solenoid valve The EBCM increases the pressure to individual wheels
and the pump motor, as well as the necessary relays, for during a deceleration in order to reduce the speed of the
approximately 1.5 seconds to check component wheel. The inlet valve is opened and the outlet valve is
operation. The EBCM sets a DTC if any error is closed. The increased pressure is delivered from the
detected. The initialization sequence may be heard and master cylinder.
felt while it is taking place, and is considered part of

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normal system operation.
Electronic Brake Force Distribution (EBD)
The EBCM defines a drive cycle as the completion of the
The electronic brake force distribution (EBD) is a control
initialization sequence.
system that replaces the hydraulic proportioning function
of the mechanical proportioning valve in the base brake
Antilock Brake System (ABS) system. The EBC control system is part of the operation
When wheel slip is detected during a brake application, software in the EBCM. The EBC uses active control with
the ABS enters antilock mode. During antilock braking, existing ABS in order to regulate the vehicle's rear brake
hydraulic pressure in the individual wheel circuits is pressure.
controlled to prevent any wheel from slipping. A separate The red brake warning indicator is illuminated when the
hydraulic line and specific solenoid valves are provided dynamic rear proportioning function is disabled.
for each wheel. The ABS can decrease, hold, or
increase hydraulic pressure to each wheel brake. The
Traction Control System (TCS)
ABS cannot, however, increase hydraulic pressure
When drive wheel slip is noted while the brake is not
above the amount which is transmitted by the master
applied, the electronic brake control module (EBCM) will
cylinder during braking.
enter traction control mode.
During antilock braking, a series of rapid pulsations is
First, the EBCM requests the engine control module
felt in the brake pedal. These pulsations are caused by
(ECM) to reduce the amount of torque to the drive
the rapid changes in position of the individual solenoid
wheels via the serial data. The ECM reduces torque to
valves as the EBCM responds to wheel speed sensor
the drive wheels by retarding spark timing and turning off
inputs and attempts to prevent wheel slip. These pedal
fuel injectors. The ECM reports the amount torque
pulsations are present only during antilock braking and
delivered to the drive wheels via the serial data circuit.
stop when normal braking is resumed or when the
If the engine torque reduction does not eliminate drive
vehicle comes to a stop. A ticking or popping noise may
wheel slip, the EBCM will actively apply the drive wheel
also be heard as the solenoid valves cycle rapidly.
brakes. During traction control braking, hydraulic
During antilock braking on dry pavement, intermittent
pressure in each drive wheel circuit is controlled to
chirping noises may be heard as the tires approach
prevent the drive wheels from slipping. The master
slipping. These noises and pedal pulsations are
cylinder isolation valve closes in order to isolate the
considered normal during antilock operation.
master cylinder from the rest of the hydraulic system.
Vehicles equipped with ABS may be stopped by
The prime valve then opens in order to allow the pump to
applying normal force to the brake pedal. Brake pedal
accumulate brake fluid in order to build hydraulic
operation during normal braking is no different than that
pressure for braking. The drive wheel inlet and outlet
of previous non-ABS systems. Maintaining a constant
solenoid valves then open and close in order to perform
force on the brake pedal provides the shortest stopping
the following functions:
distance while maintaining vehicle stability.
• Pressure hold
• Pressure increase
• Pressure decrease
 ABS: 4E-3

Vehicle Stability Enhancement System (VSES) Driver Information Indicators and Messages
The vehicle stability enhancement system (VSES) adds The following indicators are used to inform the driver of
an additional level of vehicle control to the EBCM. several different factors.
Yaw rate is the rate of rotation about the vehicle's vertical Brake Warning Indicator
axis. The VSES is activated when the EBCM determines The instrument panel cluster (IPC) illuminates the brake
that the desired yaw rate does not match the actual yaw warning indicator when the following occurs.
rate as measured by the yaw rate sensor. • The electronic brake control module (EBCM) detects
The desired yaw rate is calculated from the following that the park brake is engaged. The IPC receives a
parameters: serial data message from the EBCM requesting
• The position of the steering wheel illumination.
• The speed of the vehicle • The instrument panel cluster (IPC) detects a low
• The lateral, or sideways acceleration of the vehicle brake fluid condition and the IPC will illumination the
The difference between the desired yaw rate and the brake warning indicator.
actual yaw rate is the yaw rate error, which is a • The IPC performs the bulb check.
measurement of oversteer or understeer. If the yaw rate • The EBCM detects an ABS-disabling malfunction
error becomes too large, the EBCM attempts to correct which also disables electronic brake force distribution
the vehicle's yaw motion by applying differential braking (EBD) and sends a serial data message to the IPC
to the appropriate wheel. The amount of differential requesting illumination.
braking applied to the left or right front wheel is based on Stability System Indicator
both the yaw rate error and side slip rate error. The IPC illuminates the stability system caution indicator
The VSES activations generally occur during aggressive

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when one or more of the following conditions exists. The
driving, in turns or on bumpy roads without much use of EBCM sets any one of many VSES-disabling DTCs. The
the accelerator pedal. When braking during VSES EBCM sends a serial data message to the IPC
activation, the pedal pulsations feel different than the requesting illumination.
ABS pedal pulsations. The brake pedal pulsates at a
higher frequency during VSES activation. ABS Indicator
The instrument panel cluster (IPC) illuminates the
ECE 13 Response Antilock Brake System (ABS) indicator when the
The electronic brake control module (EBCM) illuminates following occurs:
the ABS indicator when a malfunction which disables
• The electronic brake control module (EBCM) detects
ABS is detected. Usually, the ABS indicator is turned
a malfunction with the antilock brake system. The IPC
OFF during the following ignition cycle unless the fault is
receives a serial data message from the EBCM
detected during that ignition cycle. However, the setting
requesting illumination.
of a wheel speed sensor related DTC causes the ABS
indicator to remain illuminated during the following • The IPC performs the displays test at the start of each
ignition cycle until the vehicle is operated at a speed ignition cycle. The indicator illuminates for
greater than 13 km/h (8 mph). This allows the EBCM to approximately 5 seconds.
verify that no malfunction exists, before turning OFF the • The IPC detects a loss of serial data communications
ABS indicator. This reaction occurs even if the ABS with the EBCM.
indicator turns OFF when the scan tool is used to clear
the DTCs. When repairing these vehicles, it is important Traction Control System Indicator
to ensure that the ECE 13 response has occurred and TRAC OFF
that the ABS indicator does not illuminate after returning The instrument panel cluster (IPC) illuminates the TRAC
the vehicle to the customer. It is also important to verify OFF indicator when the following occurs:
that ECE 13 is not the cause of an ABS indicator which • The electronic brake control module (EBCM) inhibits
is illuminated when no DTCs are set, before attempting the traction control system due to a malfunction in the
to diagnose other possible causes. traction control system. The IPC receives a serial data
message from the EBCM requesting illumination.
• The Body Control module (BCM) detects that the
traction control switch has been pressed (signal circuit
is low). The Body Control module (BCM) sends a
serial data message to the EBCM in order to disable
traction control. The IPC receives a serial data
message from the EBCM requesting illumination. The
BCM sends a serial data message to the radio in
order to activate an audible warning.
4E-4 ABS:

Schematic and Routing Diagram

Antilock Brake System Schematic Icons
Icon Icon Definition
NOTE
Twisted-pair wires provide an effective shield that helps protect
sensitive electronic components from electrical interference. If the
wires were covered with shielding, install new shielding.
In order to prevent electrical interference from degrading the
performance of the connected components, you must maintain the
proper specification when making any repairs to the twisted-pair wires
shown:
• The wires must be twisted a minimum of 10 turns per 31 cm (12 in)
as measured anywhere along the length of the wires
• The outside diameter of the twisted wires must not exceed 6.0 mm
(0.25 in)

Antilock Brake System Schematics

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 ABS: 4E-5

Serial Data, Traction Switch, and Instrument Panel

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4E-6 ABS:

Wheel Speed Sensor

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 ABS: 4E-7

Yaw Rate and Lateral Accelerator Sensor, and Steering Angle Sensor

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4E-8 ABS:

Antilock Brake System Connector End Electronic Brake Control Module (EBCM)
Views
Brake Pedal Position Sensor

Connector Part Information

OEM: 7-1355628-6
Connector Part Information Service: —
OEM: 15332132 Description: 47-Way F MK25/60 Series (BK)
Service: 88953364 Terminal Part Information
Description: 3-Way F GT 150 Series (BK) Pins: 32
Terminal Part Information Terminal/Tray: 7116-4141-02/10

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Terminal/Tray: 12191812/19 Core/Insulation Crimp: 4/3
Core/Insulation Crimp: E/C Release Tool/Test Probe: 12094430/J-35616-42
Release Tool/Test Probe: 15315247/J-35616-2A (RD)
(GY) Pins: 1, 16
Terminal/Tray: 7116-4142-02/10
Brake Pedal Position Sensor Core/Insulation Crimp: Pins 1 - A/3
Circuit Core/Insulation Crimp: Pins 16 - D/3
Pin Wire Color Function Release Tool/Test Probe: 12094430/J-35616-42
No.
Brake Pedal (RD)
A OG/BK 6035 Displacement Sensor Pins: 3, 11, 12, 13, 14, 18, 19, 22, 29, 33, 34, 36, 37,
Low Reference 42, 43, 45, 46, 8
Brake Pedal Terminal/Tray: 638551-1/16
B D-BU 6037 Displacement Sensor Core/Insulation Crimp: Pins 3, 11, 12, 13, 14, 18, 19,
Signal 22, 29, 33, 34, 36, 37, 42, 43, 45, 46 - K/K
Brake Pedal Core/Insulation Crimp: Pins 8 - J/J
C GY 6036 Displacement Sensor 5 Release Tool/Test Probe: 15315247/J-35616-64B
Volt Reference (L-BU)

Electronic Brake Control Module (EBCM)

Circuit
Pin Wire Color Function
No.
1 RD/BK 142 Battery Positive Voltage
2 — — Not Used
3 D-GN/WH 817 Vehicle Speed Signal
4-7 — — Not Used
Serial Data
8 L-BU 5986
Communication Enable
9-10 — — Not Used
High Speed GMLAN
11 TN/BK 2500
Serial Data Bus+
High Speed GMLAN
12 TN/BK 2500
Serial Data Bus+
High Speed GMLAN
13 TN 2501
Serial Data Bus-
High Speed GMLAN
14 TN 2501
Serial Data Bus-
15 — — Not Used
16 BK 250 Ground
17 — — Not Used
 ABS: 4E-9

Circuit Steering Angle Sensor

Pin Wire Color Function
No.
CAN Bus High Serial
18 TN/WH 6433
Data
CAN Bus Low Serial
19 L-GN/BK 6432
Data
20-21 — — Not Used
Steering Angle Sensor
22 GY 6044
5 Volt Reference
23-28 — — Not Used
Steering Angle Sensor
29 OG/BK 6045
Low Reference
30-31 — — Not Used
32 RD/WH 140 Battery Positive Voltage
Right Front Wheel Connector Part Information
33 TN 833 Speed Sensor Low OEM: 1488752-1
Reference Service: 88988374
Right Front Wheel Description: 6-Way F Receptacle 0.64 Unsealed
34 D-GN 872 (BK)
Speed Sensor Signal
35 — — Not Used Terminal Part Information
Left Rear Wheel Speed Terminal/Tray: 1393365-2/7
36 TN 884

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Sensor Signal Core/Insulation Crimp: K/K
Left Rear Wheel Speed Release Tool/Test Probe: 15315247/J-35616-64B
37 OG 885 (L-BU)
Sensor Low Reference
38-41 — — Not Used
Right Rear Wheel Steering Angle Sensor
42 WH 883 Speed Sensor Low Circuit
Pin Wire Color Function
Reference No.
Right Rear Wheel Steering Angle Sensor
43 BN 882 1 GY 6044
Speed Sensor Signal 5 Volt Reference
44 — — Not Used CAN Bus High
2 BN/WH 6437
Left Front Wheel Speed Terminated Serial Data
45 L-BU 830 CAN Bus High Serial
Sensor Signal 3 TN/WH 6433
Left Front Wheel Speed Data
46 YE 873 CAN Bus Low Serial
Sensor Low Reference 4 L-GN/BK 6432
47 — — Not Used Data
CAN Bus Low
5 WH/BK 6436
Terminated Serial Data
Steering Angle Sensor
6 OG/BK 6045
Low Reference
4E-10 ABS:

Traction Control Switch (TCS) Wheel Speed Sensor (WSS) - LF

Circuit
Pin Wire Color Function
No.
Left Front Wheel Speed
A YE 873
Sensor Low Reference
Left Front Wheel Speed
B L-BU 830
Sensor Signal

Wheel Speed Sensor (WSS) - LR

Connector Part Information

OEM: 50-57-9403
Service: —
Description: 3-Way F Receptacle 0.64 Unsealed
(BK)
Terminal Part Information
Terminal/Tray: 16-02-1110/20

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Core/Insulation Crimp: H/H
Release Tool/Test Probe: J-38125-213/J-35616-64B Connector Part Information
(L-BU) OEM: 12162343
Service: —
Traction Control Switch (TCS) Description: 2-Way M Metri-Pack 150 (GY)
Circuit Terminal Part Information
Pin Wire Color Function
No. Terminal/Tray: 12045773/2
Traction Control Switch Core/Insulation Crimp: E/1
1 L-BU 1788
Signal Release Tool/Test Probe: 12094429/J-35616-3 (GY)
2 BK/WH 1551 Ground
3 PU/WH 1382 LED Dimming Signal Wheel Speed Sensor (WSS) - LR
Circuit
Pin Wire Color Function
Wheel Speed Sensor (WSS) - LF No.
Left Rear Wheel Speed
A OG 885
Sensor Low Reference
Left Rear Wheel Speed
B TN 884
Sensor Signal

Connector Part Information

OEM: 12052644
Service: —
Description: 2-Way F Metri-Pack 150 Series, Sealed
(GY)
Terminal Part Information
Terminal/Tray: 12048074/2
Core/Insulation Crimp: E/1
Release Tool/Test Probe: 12094429/J-35616-2A
(GY)
 ABS: 4E-11

Wheel Speed Sensor (WSS) - RF Wheel Speed Sensor (WSS) - RR

Circuit
Pin Wire Color Function
No.
Right Rear Wheel
A WH 883 Speed Sensor Low
Reference
Right Rear Wheel
B BN 882
Speed Sensor Signal

Yaw Rate and Lateral Acceleration Sensor

Connector Part Information

OEM: 12052644
Service: —
Description: 2-Way F Metri-Pack 150 Series, Sealed
(GY)
Terminal Part Information
Terminal/Tray: 12048074/2

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Core/Insulation Crimp: E/1
Release Tool/Test Probe: 12094429/J-35616-2A
(GY) Connector Part Information
OEM: 2-967616-1
Wheel Speed Sensor (WSS) - RF Service: 88953345
Circuit Description: 6-Way F Micro Series (BK)
Pin Wire Color Function
No. Terminal Part Information
Right Front Wheel Terminal/Tray: 962885-5/15
A TN 833 Speed Sensor Low Core/Insulation Crimp: 6/6
Reference Release Tool/Test Probe: 12094429/J-35616-64B
Right Front Wheel (L-BU)
B D-GN 872
Speed Sensor Signal
Yaw Rate and Lateral Acceleration Sensor
Wheel Speed Sensor (WSS) - RR Circuit
Pin Wire Color Function
No.
CAN Bus Low
1 WH/BK 6436
Terminated Serial Data
CAN Bus High
2 BN/WH 6437
Terminated Serial Data
Steering Angle Sensor
3 GY 6044
5 Volt Reference
4 — — Not Used
Steering Angle Sensor
5 OG/BK 6045
Low Reference
6 — — Not Used

Connector Part Information

OEM: 12162343
Service: —
Description: 2-Way M Metri-Pack 150 (GY)
Terminal Part Information
Terminal/Tray: 12045773/2
Core/Insulation Crimp: E/1
Release Tool/Test Probe: 12094429/J-35616-3 (GY)
4E-12 ABS:

Component Location
Antilock Brake System Component Views

LF Suspension

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1. C103 Left Shown, C104 Right Similar 2. Wheel Speed Sensor (WSS) - LF, RF Similar
 ABS: 4E-13

Near the Brake Booster

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1. Brake Fluid Level Switch 3. Electronic Brake Control Module (EBCM)
2. LF Strut Tower
4E-14 ABS:

Instrument Panel

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1. Ambient Light Sensor 8. HVAC Control Module
2. Instrument Panel Cluster (IPC) 9. Heated Seat Switch - Driver, Heated Seat Switch - Front Passenger
3. Driver Information Center (DIC) Switch 10. Power Window Switch - Main
4. Hazard Switch 11. Traction Control Switch (TCS)
5. Inflatable Restraint Passenger Air Bag ON/OFF Indicator 12. Dimmer Switch
6. Rear Wiper/Washer Switch/Fog Lamp Switch (T96) 13. Outside Rear View Mirror Switch
7. Radio
 ABS: 4E-15

Center of the Floor

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1. Floor Panel 6. Rollover Sensor (ASF)
2. Console 7. Inflatable Restraint Sensing and Diagnostic Module (SDM)
3. Yaw Rate and Lateral Acceleration Sensor 8. Seat Belt Pretensioner - Left
4. Seat Belt Pretensioner - Right 9. Inflatable Restraint Side Impact Sensor (SIS) - Left (ASF)
5. Inflatable Restraint Side Impact Sensor (SIS) - Right (ASF)
4E-16 ABS:

Rear ABS Sensors

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1. Rear Cradle 3. Wheel Speed Sensor (WSS) - RR
2. Wheel Speed Sensor (WSS) - LR
 ABS: 4E-17

Diagnostic Information and Procedures

Diagnostic Starting Point - Antilock Brake System
Begin the system diagnosis with “Diagnostic System Check - Vehicle Diagnostic Information: ”. The Diagnostic System
Check will provide the following information:
• The identification of the control modules which command the system
• The ability of the control modules to communicate through the serial data circuit
• The identification of any stored diagnostic trouble codes (DTCs) and their status
The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the
procedure is located.

Scan Tool Output Controls - Antilock Brake System

Scan Tool Output Additional Menu
Description
Control Selection(s)
Automated Bleed Used in order to bleed ABS hydraulics. Refer to “Antilock Brake
—
Procedure System Automated Bleed Procedure”
Pump Motor Test — Commands the pump motor ON and OFF.
Solenoid Tests — Commands the solenoid ON and OFF.
Steering Pos. Sensor
— Calibration procedure to center the steering angle sensor
Calibration

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Scan Tool Data List - Antilock Brake System
The electronic brake control module (EBCM) Scan Tool Data Lists contain all the antilock brake system related
parameters that are available on the scan tool. The parameters in the list are arranged in alphabetical order. The
column, “Data List,” indicates the location of the parameter within the scan tool menu selections.
Use the EBCM Scan Tool Data Lists as directed by a diagnostic table or in order to supplement the diagnostic
procedures. Begin all the diagnostic procedures with the antilock brake system (ABS) Diagnostic Starting Point. Use
the EBCM Scan Tool Data Lists only after the following is determined:
• There is no published DTC procedure nor published symptom procedure for the customer concern.
OR
• The DTC or symptom diagnostic procedure indicated by the diagnostic system check does not resolve the customer
concern.
The Typical Data Values are obtained from a properly operating vehicle under the conditions specified in the first row
of the Scan Tool Data List table. Comparison of the parameter values from the suspect vehicle with the Typical Data
Values may reveal the source of the customer concern.
The ID Information menu is located on the EBCM main screen.
4E-18 ABS:

EBCM Scan Tool Data List

Scan Tool Parameter Data List Units Displayed Typical Data Value
Operating Conditions: Ignition is ON, engine OFF, and vehicle is stationary
ABS Active ABS Yes/No No
ABS Failed ABS On/Off Off
Brake Fluid Level Sensor ABS OK/Low OK
BPP Signal ABS Released/Applied Released
Battery Voltage Signal ABS Volts B+
Delivered Torque TCS % 0-100%
DRP Active ABS Yes/No No
DRP Disabled ABS Yes/No No
Lateral Accelerometer Input VSES Data m/s Acceleration
LF Inlet Solenoid Command ABS Active/Inactive Inactive
LF Outlet Solenoid
ABS Active/Inactive Inactive
Command
LF Wheel Speed Sensor ABS/TCS km/h or mph 0
LR Wheel Speed Sensor ABS/TCS km/h or mph 0
LR Inlet Solenoid Command ABS Active/Inactive Inactive
LR Outlet Solenoid
ABS Active/Inactive Inactive
Command
Low Tire Press. Lamp TPM ON/OFF OFF

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Panic Brake Assist Failed ABS No/Yes No
Pump Motor Command
ABS B+/0 B+
Voltage
Requested Torque TCS % 0-100%
RF Inlet Solenoid Command ABS Active/Inactive Inactive
RF Outlet Solenoid
ABS Active/Inactive Inactive
Command
RF Wheel Speed Sensor ABS/TCS km/h or mph 0
RR Inlet Solenoid Command ABS Active/Inactive Inactive
RR Outlet Solenoid
ABS Active/Inactive Inactive
Command
RR Wheel Speed Sensor ABS/TCS km/h or mph 0
Steering Wheel Position VSES Data Degrees Varies 0-720+ or −
Steering Sensor VSES Data Centered/Uncentered Centered
TCS Active TCS No/Yes No
TCS Failed TCS No/Yes No
TCS Switch Status TCS On/Off Off
VSES Active VSES Data Yes/No Yes
VSES Failed VSES Data Yes/No No
Yaw Rate Sensor Input VSES Data m/s Acceleration

Scan Tool Data Definitions - Antilock Brake BPP Signal:: The scan tool will display Released/
System Applied depending on the state of the brake pedal
The ABS scan tool data definitions contain a brief position.
description of all ABS related parameters available on Delivered Torque: The scan tool displays 25-95%. The
the scan tool. The parameters available on the scan tool scan tool displays 25% when the powertrain control
are listed below in alphanumeric order. module (PCM) is providing the minimum percentage
ABS Active: The scan tool displays Yes/No. The scan of available torque in an attempt to eliminate wheel
tool displays No when a when not active. slip.
ABS Failed: The scan tool displays On/Off. The scan DRP Active: The scan tool will display Yes/No
tool displays On when a when the ABS Failed. depending on the state of the DRP.
Battery Voltage Signal:: The scan tool will display DRP Disabled: The scan tool will display Yes/No
Voltage depending on the state of the battery and depending on the state of the DRP.
charging system. Lateral Accelerometer Input: The scan tool displays
Brake Fluid Level Sensor: The scan tool displays OK/ m/s^2. The lateral accelerometer signal from the
Low The scan tool indicates Low when the brake lateral accelerometer sensor, roughly 2.5 volts
fluid sensor detects fluid lose. equals 0 g lateral acceleration.
 ABS: 4E-19

LF Inlet Solenoid Command:: The scan tool displays TCS Active: The scan tool displays Yes or No. The
Active/Inactive. The scan tool displays Active when scan tool displays Yes if the TCS indicator is
the left front Outlet solenoid is commanded on. currently being commanded ON.
LF Outlet Solenoid Command:: The scan tool TCS Failed: The scan tool displays Yes/No. The scan
displays Active/Inactive. The scan tool displays tool displays Yes when the TCS will not engage
Active when the left front Outlet solenoid is caused from a malfunction.
commanded on. VSES Active: The scan tool displays Yes or No.
LF Wheel Speed Sensor: The scan tool displays 0-327 Indicates if Vehicle Stability Enhancement System
km/h (0-204 mph). The scan tool displays 0 km/h (0 (VSES) is currently active.
mph) when the vehicle is not moving or is moving at VSES Failed: The scan tool displays Yes or No.
speeds less than or equal to 0 km/h (0 mph). Indicates if the EBCM disabled VSES due to a
Low Tire Press. Lamp: The scan tool displays ON or malfunction.
OFF. Yaw Rate Sensor Input: The scan tool displays m/s^2.
LR Wheel Speed Sensor: The scan tool displays 0- The yaw rate signal from the yaw rate sensor,
327 km/h (0-204 mph). The scan tool displays 0 km/ roughly 2.5 volts equals 0°/second yaw rate.
h (0 mph) when the vehicle is not moving or is
moving at speeds less than or equal to 0 km/h (0 Diagnostic Test Drive
mph).
When servicing vehicles, the vehicle antilock brake
LR Outlet Solenoid Command: The scan tool displays
system (ABS) and traction control system (TCS), test
Active/Inactive. The scan tool displays Active when
drives will be necessary to allow all tests to be run, and
the left front Outlet solenoid is commanded on.
all system functions to be enabled and exercised. A test
Panic Brake Assist Failed: The scan tool displays No/

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drive may also be required to duplicate specific DTCs
Yes. The scan tool displays No when the Panic
covered in this section. The diagnostic system check
brake Assist functions properly.
(including test drive) should be run when vehicle repairs
Pump Motor Command Voltage: The scan tool
are complete in order to verify the repair.
displays battery voltage when the pump motor is
The diagnostic test drive will vary for ABS/TCS
commanded on.
problems.
Requested Torque: The scan tool displays 40-95%.
The scan tool displays 40% when the electronic 1. Read the Diagnostic Aids and the Conditions for
brake control module (EBCM) requests the minimum Setting the DTC.
percentage of available torque in an attempt to 2. Reconnect any previously disconnected
eliminate wheel slip. components.
RF Outlet Solenoid Command: The scan tool displays 3. Start the engine.
Active/Inactive. The scan tool displays Active when 4. Drive the vehicle under the following conditions for at
the right front Outlet solenoid is commanded on. least 10 minutes. At no times should any unlawful or
RF Inlet Solenoid Command: The scan tool displays unsafe maneuvers be performed.
Active/Inactive. The scan tool displays Active when
the right front Inlet solenoid is commanded on. – Highway driving
RF Wheel Speed Sensor: The scan tool displays 0- – Rough roads
327 km/h (0-204 mph). The scan tool displays 0 km/ – Verify the customer's concern and duplicate
h (0 mph) when the vehicle is not moving or is driving conditions.
moving at speeds less than or equal to 0 km/h (0 – With the engine still running, use the scan tool and
mph). check for any DTCs. If any DTCs are set, perform
RR Wheel Speed Sensor: The scan tool displays 0- the appropriate DTC table.
327 km/h (0-204 mph). The scan tool displays 0 km/
h (0 mph) when the vehicle is not moving or is
moving at speeds less than or equal to 0 km/h (0 Initialization Sequence
mph). The electronic brake control module (ECBM) performs
RR Outlet Solenoid Command: The scan tool the initialization test once each ignition cycle, when the
displays Active/Inactive. The scan tool displays vehicle speed reaches 15 km/h (9 mph). The
Active when the right front Inlet solenoid is initialization sequence cycles each valve solenoid and
commanded on. the pump motor, as well as the necessary relays, to
RR Inlet Solenoid Command: The scan tool displays check component operation. If any error is detected, the
Active/Inactive. The scan tool displays Active when EBCM will set a DTC. The initialization sequence may
the right front Inlet solenoid is commanded on. be heard and felt while it is taking place, and is
Steering Wheel Position: The scan tool displays considered part of normal operation.
degrees. The steering wheel position signal varies
from 720°+ to & 720°-.
Steering Sensor: The scan tool displays centered or
uncentered.
4E-20 ABS:

DTC C0035-C0050
DTC Descriptors
DTC C0035 00: Left Front Wheel Speed Sensor Circuit No Additional Information
DTC C0035 0F: Left Front Wheel Speed Sensor Circuit Erratic Signal
DTC C0035 18: Left Front Wheel Speed Sensor Circuit Signal Amplitude Less Than Minimum
DTC C0040 00: Right Front Wheel Speed Sensor Circuit No Additional Information
DTC C0040 0F: Right Front Wheel Speed Sensor Circuit Erratic Signal
DTC C0040 18: Right Front Wheel Speed Sensor Circuit Signal Amplitude Less Than Minimum
DTC C0045 00: Left Rear Wheel Speed Sensor Circuit No Additional Information
DTC C0045 0F: Left Rear Wheel Speed Sensor Circuit Erratic Signal
DTC C0045 18: Left Rear Wheel Speed Sensor Circuit Signal Amplitude Less Than Minimum
DTC C0050 00: Right Rear Wheel Speed Sensor Circuit No Additional Information
DTC C0050 0F: Right Rear Wheel Speed Sensor Circuit Erratic Signal
DTC C0050 18: Right Rear Wheel Speed Sensor Circuit Signal Amplitude Less Than Minimum

Diagnostic Fault Information

Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure.
Short to Open/High Signal
Circuit Short to Voltage
Ground Resistance Performance
Left Front Sensor Signal C0035 00 C0035 00 C0035 00 C0035 0F, 18
Left Front Sensor Low Reference C0035 00 C0035 00 C0035 00 C0035 0F, 18

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Right Front Sensor Signal C0040 00 C0040 00 C0040 00 C0040 0F, 18
Right Front Sensor Low Reference C0040 00 C0040 00 C0040 00 C0040 0F, 18
Left Rear Sensor Signal C0045 00 C0045 00 C0045 00 C0045 0F, 18
Left Rear Sensor Low Reference C0045 00 C0045 00 C0045 00 C0045 0F, 18
Right Rear Sensor Signal C0050 00 C0050 00 C0050 00 C0050 0F, 18
Right Rear Sensor Low Reference C0050 00 C0050 00 C0050 00 C0050 0F, 18

Circuit/System Description Conditions for Setting the DTC

The wheel speed sensor receives a 12-volt power supply C0035 - C0050 00
voltage from the electronic brake control module
• An open is detected on the wheel speed sensor signal
(EBCM) and provides an output signal to the EBCM. As
circuit.
the wheel spins, the wheel speed sensor sends the
EBCM a DC square wave signal. The EBCM uses the • A short to ground is detected on the wheel speed
frequency of the square wave signal to calculate the sensor signal circuit.
wheel speed. • A short to voltage is detected on the wheel speed
sensor signal circuit.
Conditions for Running the DTC C0035 - C0050 0F
The EBCM detects a rapid variation in the wheel speed.
C0035 - C0050 00
The wheel speed changes by 20 km/h (12 mph) or more
• The ignition is ON. in 0.01 second. The change must occur 3 times with no
• Ignition voltage is greater than 9.5 volts. more than 0.2 second between occurrences.
C0035 - C0050 0F C0035 - C0050 18
• The ignition is ON. • One wheel speed is 2km/h (1.2 mph).
• Ignition voltage is greater than 9.5 volts. • The remaining wheel speeds are greater than 10 km/h
• The brake pedal is not pressed. (6.2 mph).
• A DTC is not set for the other wheel speed circuit on • The difference between the remaining wheel speeds
the same axle. is less than 8 km/h (5 mph) from each other for 180
seconds.
C0035 - C0050 18
OR
• The ignition is ON.
• The 2 wheel speed sensor inputs are 0 and DTCs are
• Ignition voltage is greater than 9.5 volts. set.
• The brake pedal is not pressed. • The 2 suspect wheel speeds equal zero for 6
• No other wheel speed circuit DTCs are set. seconds.
• At least 2 other wheel speeds are not 0 km/h. • The other wheel speeds are greater than 15 km/h (10
mph).
 ABS: 4E-21

• The other wheel speeds are within 11 km/h (7 mph) of Electrical Information Reference
each other.
• “Circuit Testing: ”
Action Taken When the DTC Sets • “Testing for Intermittent Conditions and Poor
Connections: ”
• The EBCM disables the Antilock Brake System (ABS)
• “Wiring Repairs: ”
Control System for the duration of the ignition cycle.
• “Connector Repairs: ”
• ABS indicator turns ON.
Scan Tool Reference
• Driver information center (DIC) displays the ABS “Scan Tool Data List - Antilock Brake System”
FAULT message.
• If both rear wheel speed DTCs are set, the dynamic Circuit/System Verification
rear proportioning (DRP) is disabled and the Brake With scan tool installed drive the vehicle in a straight line
Warning indicator turns ON. at a speed greater than 10 km/h (6 mph), all wheel
speed sensors should read the same speed.
Conditions for Clearing the MIL/DTC
• The condition for setting the DTC is no longer present Circuit/System Testing
and the DTC is cleared with a scan tool. Note: It is recommend that Component Testing is
• The EBCM automatically clears the history DTC when performed before Circuit Testing when diagnosing wheel
a current DTC is not detected in 100 consecutive drive speed sensors.
cycles. Note: Performing Circuit Testing with EBCM connector
disconnected and key on will cause U codes to set.
• The ABS telltale will remain on until a vehicle speed of

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Clear DTCs after performing the test.
13 kmp (8 mph) or greater is achieved, unless the
scan tool is used to clear the DTC. 1. With the ignition OFF, disconnect the wheel speed
sensor connector. Ignition ON, Measure for voltage
Diagnostic Aids above 7.5 V on the wheel speed sensor signal
If 2 or more wheel speed sensors are inoperative circuit.
diagnose each wheel speed sensor individually. ➢ If voltage is below 7.5 check for a short to ground,
If the customer comments that the ABS indicator is ON open or replace EBCM.
only during moist environmental conditions: rain, snow, 2. Ignition OFF, disconnect the EBCM connector. With
vehicle wash, etc., inspect the wheel speed sensor the EBCM connector disconnected and the ignition
wiring for signs of water intrusion. If the DTC is not ON, measure for 0 volts between the wheel speed
current, clear all DTCs and simulate the effects of water sensor signal circuit or the wheel speed sensor low
intrusion by using the following procedure: reference circuit and ground at the EBCM connector.
1. Spray the suspected area with a 5 percent saltwater ➢ If over 0 volts, repair short to voltage in the wheel
solution. To create a 5 percent saltwater solution, speed sensor signal circuit or the wheel speed
add 2 teaspoons of salt to 8 fl oz of water (10 g of sensor supply voltage circuit.
salt to 200 ml of water). 3. With the ignition OFF and the wheel speed sensor
2. Test drive the vehicle over various road surfaces, harness disconnected, Measure for infinite ohms of
bumps, turns, etc., above 40 km/h (25 mph) for at resistance between ground and the wheel speed
least 30 seconds. Also rotate steering wheel from sensor signal and the wheel speed sensor low
stop to stop for intermittent condition caused from reference circuit from the EBCM connector.
open or chaffing of the front wheel speed sensor ➢ If less than infinite ohms, repair short to ground in
harness. the sensor signal or the low reference circuit.
3. If the DTC returns, replace the suspected wheel 4. Measure for infinite ohms of resistance between the
speed sensor or repair the wheel speed sensor wheel speed sensor signal circuit and the wheel
wiring. speed low reference circuit at the EBCM connector.
4. Rinse the area thoroughly when completed. ➢ If less than infinite ohms, repair short between the
wheel speed sensor signal circuit and the wheel
Reference Information speed sensor low reference circuit.
Schematic Reference 5. If all circuits test normal replace the suspect wheel
“Antilock Brake System Schematics” speed sensor.
Connector End View Reference
“Antilock Brake System Connector End Views”
Description and Operation Reference
“ABS Description and Operation”
4E-22 ABS:

Component Testing DTC C0110

1. Ignition OFF, disconnect the wheel speed sensor DTC Descriptors
connector. Measure for 12 volts on the wheel speed DTC C0110 04: Pump Motor Circuit Open Circuit
sensor signal circuit. DTC C0110 61: Pump Motor Circuit Actuator Stuck
2. Measure for 12 volts on the wheel speed sensor
signal circuit. Diagnostic Fault Information
➢ If the If voltage is below 7.5 check for a short to NOTE
ground, open or replace EBCM.
Always perform the “Diagnostic System
3. At the wheel speed sensor, connect a 3 Amp fused
Check - Vehicle Diagnostic Information: ”
jumper wire between wheel speed sensor low
prior to using this diagnostic procedure.
reference terminal and the low reference terminal of
the wheel speed harness connector. Set-up a DMM
to measure current flow (mA/A). Connect the Circuit/System Description
positive terminal of the DMM to the wheel speed The pump motor is an integral part of the brake pressure
sensor signal terminal at the wheel speed sensor modulator valve (BPMV), while the pump motor relay is
harness connector and the negative lead to the integral to the electronic brake control module (EBCM).
wheel speed sensor signal terminal of the wheel The pump motor relay is not engaged during normal
speed sensor. Spin the wheel very slowly, the system operation. When Antilock Brake System (ABS)
amperage should fall and rise between 4 mA and 16 operation is required the EBCM activates the pump
mA. Measure the low and the high readings. motor relay and battery power is provided to the pump

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➢ If the low amperage output of the wheel speed motor.
sensor signal circuit is below 4 mA or above 8 mA
replace the wheel speed sensor. Conditions for Running the DTC
➢ If the high amperage output of the wheel speed C0110 04
sensor signal circuit is below 12 mA or above 16 • The ignition switch is in the ON position.
mA replace the wheel speed sensor.
• Initialization is complete.
C0110 61
Repair Instructions
Perform the “Diagnostic System Check - Vehicle • The test is initiated once per ignition cycle, when the
Diagnostic Information: ” after completing the diagnostic vehicle speed is greater than 8 km/h (5 mph), and a
procedure. fault was set on the last ignition cycle.
“Control Module References: ” for EBCM and BPMV • The vehicle speed is greater than 20 km/h (13 mph),
replacement, setup, and programming and the brake is not applied.
• The vehicle speed is greater than 40 km/h (26 mph).
Repair Verification
“Diagnostic Repair Verification - Vehicle Diagnostic Conditions for Setting the DTC
Information: ” C0110 04
The EBCM detects a low voltage in the pump motor
supply circuit when the feedback voltage is less than 6
volts for more than 1.8 seconds, and the pump motor is
not activated. The ground circuit is open, and the
feedback voltage is greater than 0.93 volt for 1.8
seconds, the pump is not activated.
C00110 61
The pump motor continues to rotate briefly after
activation creating a feedback voltage. The EBCM sets
the code if the measured feedback voltage indicates a
binding or stalled pump motor.
 ABS: 4E-23

Action Taken When the DTC Sets Circuit/System Testing

• The EBCM disables the ABS for the duration of the 1. With the ignition OFF, disconnect the EBCM harness
ignition cycle. connector and connect a test lamp between the
• The ABS indicator turns ON. battery positive voltage circuit terminal going to the
ABS pump motor and to ground. It is important that
Conditions for Clearing the DTC the test lamp is connected before the ignition is
turned ON.
• The condition for the DTC is no longer present and
the DTC is cleared with a scan tool. 2. With the ignition ON, verify that the test lamp
illuminates.
• The EBCM automatically clears the history DTC when
a current DTC is not detected in 100 consecutive drive ➢ If the test lamp does not illuminate, repair the open
cycles. or high resistance in the battery positive voltage
circuit.
Diagnostic Aids 3. Connect a test lamp between the battery positive
The pump motor is integral to the BPMV. The pump voltage circuit and pump motor ground circuit at the
motor is not serviceable. Inspect the power and ground EBCM connector, verify that the test lamp
circuits proper connections. illuminates.
➢ If the test lamp does not illuminate, repair the open
Reference Information or high resistance in the pump motor ground circuit.
Schematic Reference 4. With ignition OFF, separate the EBCM from the
“Antilock Brake System Schematics” BPMV

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Connector End View Reference 5. Inspect the EBCM to BPMV connector for conditions
“Antilock Brake System Connector End Views” such as damage, corrosion, or presence of brake
Description and Operation Reference fluid.
“ABS Description and Operation”
➢ If connector corrosion or damage is evident,
Electrical Information Reference replace BPMV and/or EBCM as necessary.
• “Circuit Testing: ” ➢ If brake fluid is present, replace both BPMV and
• “Connector Repairs: ” EBCM.
• “Testing for Intermittent Conditions and Poor 6. Connect the EBCM harness to the EBCM with the
Connections: ” BPMV still separated.
• “Wiring Repairs: ” 7. Connect a test lamp between the pump motor
Scan Tool Reference circuits, the internal EBCM connector.
“Scan Tool Data List - Antilock Brake System” for EBCM 8. With ignition ON, use the scan tool to perform the
Pump Motor Test.
Circuit/System Verification ➢ If test lamp illuminates replace the BPMV.
With scan tool installed, clear the DTCs then drive the
➢ If test lamp does not illuminate replace the EBCM
vehicle in a straight line at a speed greater than 20 km/h
and BPMV.
(13 mph). If the DTC did not set as a current DTC see
diagnostic aids.
Repair Instructions
Perform the “Diagnostic Repair Verification - Vehicle
Diagnostic Information: ” after completing the diagnostic
procedure.
• “Electronic Brake Control Module Replacement”
• “Control Module References: ” for EBCM
replacement, setup, and programming

Repair Verification
“Diagnostic Repair Verification - Vehicle Diagnostic
Information: ”
4E-24 ABS:

DTC C0131
DTC Descriptor
DTC C0131 00: ABS Pressure Circuit No Additional Information
DTC C0131 4B: ABS Pressure Circuit Calibration Not Learned
DTC C0131 5A: ABS Pressure Circuit Calibration Not Learned Plausibility Failure

Diagnostic Fault Information

Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure.
Short to Open/High Signal
Circuit Short to Voltage
Ground Resistance Performance
ABS Pressure Circuit C0131 00 C0131 00 C0131 00 —
Pressure Circuit Calibration Not Learned — — — C0131 4B
Pressure Circuit Calibration Not Learned
— — — C0131 5A
Plausibility Failure

Circuit/System Description Reference Information

The electronic brake control module (EBCM) uses input Schematic Reference
from the brake pressure sensor for more accurate “Antilock Brake System Schematics”
control during a Vehicle Stability Enhancement System Connector End View Reference
(VSES) event. “Antilock Brake System Connector End Views”
Description and Operation Reference

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Conditions for Running the DTC “ABS Description and Operation”
• The ignition is ON. Electrical Information Reference
• Ignition voltage is greater than 9.5 volts • “Circuit Testing: ”
• “Connector Repairs: ”
Conditions for Setting the DTC • “Testing for Intermittent Conditions and Poor
• Pressure signal does not correlate to estimated Connections: ”
pressure over time. • “Wiring Repairs: ”
• Brake signal does not correlate to pressure signal. Scan Tool Reference
• Signal is erratic and changes faster than physically “Scan Tool Data List - Antilock Brake System” for EBCM
allowed.
Circuit/System Testing
Action Taken When the DTC Sets 1. Apply and release brake pedal. Verify brake lamps
• The EBCM disables the VSES and TCS for the operate properly.
duration of the ignition cycle. ➢ If brake lamps do not operate properly, refer to
• The electronic stability control (ESC) telltale turns ON. Symptoms - Lighting Systems.
2. Replace EBCM/brake pressure modulator valve
Conditions for Clearing the DTC (BPMV) assembly.
• The condition for setting the DTC is no longer present
and the DTC is cleared with a scan tool. Repair Instructions
• The EBCM automatically clears the history DTC when NOTE
a current DTC is not detected in 100 consecutive drive
Always perform the “Diagnostic Repair
cycles.
Verification - Vehicle Diagnostic Information:
” after completing the diagnostic procedure.
Diagnostic Aids
The pressure sensor is integral to the brake pressure • “Electronic Brake Control Module Replacement”
modulator valve (BPMV). The pressure sensor is not • “Control Module References: ” for EBCM
serviceable. replacement, setup, and programming.
Inspect the brake pressure sensor contacts for proper
connections.
Repair Verification
“Diagnostic Repair Verification - Vehicle Diagnostic
Information: ”
 ABS: 4E-25

DTC C0161 Conditions for Clearing the DTC

DTC Descriptor • The condition for the DTC is no longer present and
DTC C0161 00: Antilock Brake System (ABS) Brake the DTC is cleared with a scan tool.
Switch/Sensor Circuit not Plausible. • The EBCM automatically clears the history DTC when
a current DTC is not detected in 100 consecutive drive
Diagnostic Fault Information cycles.
Perform the “Diagnostic System Check - Vehicle
Diagnostic Information: ” prior to using this diagnostic Diagnostic Aids
procedure. The DTC C0161 00 can be set if the vehicle has been
driven with the brake applied during acceleration.
Circuit/System Description
The brake pedal position (BPP) sensor is an input to the Reference Information
body control module (BCM). The BCM then sends a Schematic Reference
serial data message to the electronic brake control “Antilock Brake System Schematics”
module (EBCM) and other electronic control modules. Connector End View Reference
The BPP sensor is a potentiometer type sensor with a 5- “Antilock Brake System Connector End Views”
volt reference circuit and a low reference circuit. Description and Operation Reference
“ABS Description and Operation”
Conditions for Running the DTC Electrical Information Reference
• The ignition is ON. • “Circuit Testing: ”

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• The vehicle speed is greater than 16 km/h (10 mph). • “Connector Repairs: ”
• The ignition voltage is greater than 9.5 volts. • “Testing for Intermittent Conditions and Poor
Connections: ”
Conditions for Setting the DTC • “Wiring Repairs: ”
• The vehicle speed is greater than 40 km/h (25 mph) Scan Tool Reference
and then slow down to less than 3 Km/h (2 mph) 4 “Scan Tool Data List - Antilock Brake System” for EBCM
times and the brake pedal signal does not show any
change in state. Circuit/System Verification
• The vehicles speed is greater than 20 Km/h (12 mph) With the ignition ON, use a scan tool to display DTCs for
and the brake pedal signal indicates an active state the BCM.
for continuously more than 6 minutes. ➢ If DTC C0277 or C0890 and C0297 are present, go
• The brake light switch signal coming from the module to “Diagnostic System Check - Vehicle Diagnostic
sends invalid data to the EBCM in terms of the rolling Information: ”.
count value. ➢ If no DTCs are present, go to Diagnostic Aids.

Action Taken When the DTC Sets Repair Verification

The ABS/TCS remains functional. “Diagnostic Repair Verification - Vehicle Diagnostic
Information: ”
4E-26 ABS:

DTC C0186
Diagnostic Instructions
• Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure.
• Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach.
• “Diagnostic Procedure Instructions - Vehicle Diagnostic Information: ” provides an overview of each diagnostic
category.

DTC Descriptors
DTC C0186 00: Lateral Accelerometer Circuit Electrical Failure
DTC C0186 5A: Lateral Accelerometer Circuit Erratic
DTC C0186 3B: Lateral Accelerometer Self Test Failure
DTC C0186 1A: Lateral Accelerometer Offset Failure

Diagnostic Fault Information

Short to Open/High Signal
Circuit Short to Voltage
Ground Resistance Performance
Lateral Accelerometer Supply Voltage
C0186 00 C0186 00 C0186 00 —
Circuit
C0186 5A, 3B,
Lateral Accelerometer CAN Bus High Circuit C0186 00 C0186 00 C0186 00
1A

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C0186 5A, 3B,
Lateral Accelerometer CAN Bus Low Circuit C0186 00 C0186 00 C0186 00
1A
Lateral Accelerometer Ground Circuit — C0186 00 — —

Circuit/System Description Action Taken When the DTC Sets

The lateral accelerometer and the yaw rate sensors are One or more of the following actions may occur:
combined into one sensor external to the electronic • Vehicle stability enhancement system (VSES) are
brake control module (EBCM). The vehicle stability disabled.
enhancement system (VSES) uses the lateral
• The VSES indicator turns ON
accelerometer input when calculating the desired yaw
rate. The usable output signal is a serial data CAN • The driver information center (DIC) displays the
circuits. Service ESC message.

Conditions for Running the DTC Conditions for Clearing the DTC
The ignition switch is in the ON position. • The condition for the DTC is no longer present.
• The EBCM automatically clears the history DTC when
Conditions for Setting the DTC a current DTC is not detected in 100 consecutive drive
• The yaw/lateral combination sensor reports an cycles.
internal failure.
• The yaw/lateral combination sensor learns a wrong Diagnostic Aids
offset value. • Possible causes of this DTC are as follows:
• Incorrectly mounted yaw/lateral sensor. • Incorrectly mounted yaw/lateral sensor.
• Internal failure in the yaw/lateral sensor
• Intermittent wiring connections.
 ABS: 4E-27

Reference Information 6. Test for 0 volts between the communication circuit

Schematic Reference terminal 2 and ground.
“Antilock Brake System Schematics” ➢ If greater than the specified value, test the
Connector End View Reference communication circuit for a short to voltage.
“Antilock Brake System Connector End Views” 7. Ignition OFF, test for infinite resistance between the
Electrical Information Reference communication circuit terminal 5 and ground.
• “Circuit Testing: ” ➢ If not the specified value, test the communication
• “Connector Repairs: ” circuit for a short to ground.
• “Testing for Intermittent Conditions and Poor 8. Test for infinite resistance between the
Connections: ” communication circuit terminal 2 and ground.
• “Wiring Repairs: ” ➢ If not the specified value, test the communication
Scan Tool Reference circuit for a short to ground.
“Scan Tool Data List - Antilock Brake System” for EBCM 9. Test for less than 1 ohm of resistance between the
communication circuit terminals 1 and terminal 5.
Circuit/System Verification
➢ If greater than the specified range, test the
With scan tool installed, clear the DTCs then drive the
communication circuit for an open/high resistance.
vehicle in a straight line at a speed greater than 20 km/h
(13 mph). If the DTC did not set as a current DTC see 10. Test for less than 1 ohm of resistance between the
Diagnostic Aids. communication circuit terminals 2 and terminal 2.
➢ If greater than the specified range, test the

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Circuit/System Testing communication circuit for an open/high resistance.
1. Ignition OFF, disconnect the harness connector at 11. Test for infinite resistance between the
the Yaw Rate/Lateral Accelerometer. communication circuit 5 and the communication
circuit 2.
2. Test for less than 1 ohm of resistance between the
low reference circuit terminal 5 and ground. ➢ If not the specified value, test the communication
circuits for a short together.
➢ If greater than the specified range, test for an open/
high resistance in the low reference circuit. If the 12. If all circuits test normal, replace the Yaw Rate/
circuit tests normal, replace the EBCM. Lateral sensor.
3. Ignition ON, test for 11.8 — 12.2 volts between the
12-volt reference circuit terminal 3 and ground. Repair Instructions
➢ If less than the specified range, test the 12-volt NOTE
reference circuit for a short to ground or an open/
Perform the “Diagnostic Repair Verification -
high resistance. If the circuit tests normal, replace
Vehicle Diagnostic Information: ” after
the EBCM.
completing the diagnostic procedure.
➢ If greater than the specified range, test the 12-volt
reference circuit for a short to voltage. If the circuit • “Steering Angle Sensor Centering”
tests normal, replace the EBCM. • “Diagnostic Test Drive”
4. Ignition OFF, disconnect the harness connector at • “Control Module References: ” for EBCM
the Steering Angle sensor. replacement, setup, and programming
5. Ignition ON, test for 0 volts between the
communication circuit terminal 5 and ground.
➢ If greater than the specified value, test the
communication circuit for a short to voltage.
4E-28 ABS:

DTC C0196
Diagnostic Instructions
• Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure.
• Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach.
• “Diagnostic Procedure Instructions - Vehicle Diagnostic Information: ” provides an overview of each diagnostic
category.

DTC Descriptors
DTC C0196 00: Yaw Rate Circuit Electrical failure
DTC C0196 5A: Yaw Rate Circuit Erratic
DTC C0196 3B: Yaw Rate Circuit Self Test Failure
DTC C0196 1A: Yaw Rate Circuit Offset Failure

Diagnostic Fault Information

Short to Open/High Signal
Circuit Short to Voltage
Ground Resistance Performance
Yaw Rate Supply Voltage Circuit C0196 00 C0196 00 C0196 00 —
C0196 5A, 3B,
Yaw Rate CAN Bus High Circuit C0196 00 C0196 00 C0196 00
1A
C0196 5A, 3B,

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Yaw Rate CAN Bus Low Circuit C0196 00 C0196 00 C0196 00
1A
Yaw Rate Ground Circuit — C0196 00 — —

Circuit/System Description Action Taken When the DTC Sets

The vehicle stability enhancement system (VSES) is One or more of the following actions may occur:
activated by the electronic brake control module (EBCM) • Vehicle Stability Enhancement System (VSES) are
calculating the desired yaw rate and comparing it to the disabled.
actual yaw rate input. The Yaw/Lateral sensor
• The VSES indicator turns ON.
communicates to the EBCM on a dedicated CAN bus.
The desired yaw rate is calculated from measured • The driver information center (DIC) displays the
steering wheel position, vehicle speed, and lateral Service ESC message.
acceleration. The difference between the desired yaw
rate and actual yaw rate is the yaw rate error, which is a Conditions for Clearing the DTC
measurement of over-steer or under-steer. If the yaw • The condition for the DTC is no longer present.
rate error becomes too large, the EBCM will attempt to • The EBCM automatically clears the history DTC when
correct the vehicle's yaw motion by applying differential a current DTC is not detected in 100 consecutive drive
braking to the wheels. cycles.

Conditions for Running the DTC Diagnostic Aids

The ignition switch is in the ON position.
The ignition voltage is greater than 9.5 volts. • Possible causes of this DTC are as follows:
• Inspect the mounting of the Yaw sensor to ensure
Conditions for Setting the DTC proper orientation and installation of the sensor.
• The yaw/lateral combination sensor reports an • On a level surface, read the Yaw sensor offset value
internal failure. to ensure a value within the proper range.
• The yaw/lateral combination sensor learns a wrong
offset value
• Incorrectly mounted yaw/lateral sensor.
 ABS: 4E-29

Reference Information 6. Test for 0 volts between the communication circuit

Schematic Reference terminal 2 and ground.
“Antilock Brake System Schematics” ➢ If greater than the specified value, test the
Connector End View Reference communication circuit for a short to voltage.
“Antilock Brake System Connector End Views” 7. Ignition OFF, test for infinite resistance between the
Electrical Information Reference communication circuit terminal 5 and ground.
• “Circuit Testing: ” ➢ If not the specified value, test the communication
• “Connector Repairs: ” circuit for a short to ground.
• “Testing for Intermittent Conditions and Poor 8. Test for infinite resistance between the
Connections: ” communication circuit terminal 2 and ground.
• “Wiring Repairs: ” ➢ If not the specified value, test the communication
Scan Tool Reference circuit for a short to ground.
“Scan Tool Data List - Antilock Brake System” for EBCM 9. Test for less than 1 ohm of resistance between the
communication circuit terminals 1 and terminal 5.
Circuit/System Verification
➢ If greater than the specified range, test the
With scan tool installed, clear the DTCs then drive the
communication circuit for an open/high resistance.
vehicle in a straight line at a speed greater than 20 km/h
(13 mph). If the DTC did not set as a current DTC see 10. Test for less than 1 ohm of resistance between the
Diagnostic Aids. communication circuit terminals 2 and terminal 2.
➢ If greater than the specified range, test the

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Circuit/System Testing communication circuit for an open/high resistance.
1. Ignition OFF, disconnect the harness connector at 11. Test for infinite resistance between the
the Yaw Rate/Lateral Accelerometer. communication circuit 5 and the communication
circuit 2.
2. Test for less than 1 ohm of resistance between the
low reference circuit terminal 5 and ground. ➢ If not the specified value, test the communication
circuits for a short together.
➢ If greater than the specified range, test for an open/
high resistance in the low reference circuit. If the 12. If all circuits test normal, replace the Yaw Rate/
circuit tests normal, replace the EBCM. Lateral sensor.
3. Ignition ON, test for 11.8 — 12.2 volts between the
12-volt reference circuit terminal 3 and ground. Repair Instructions
➢ If less than the specified range, test the 12-volt NOTE
reference circuit for a short to ground or an open/
Perform the “Diagnostic Repair Verification -
high resistance. If the circuit tests normal, replace
Vehicle Diagnostic Information: ” after
the EBCM.
completing the diagnostic procedure.
➢ If greater than the specified range, test the 12-volt
reference circuit for a short to voltage. If the circuit • “Steering Angle Sensor Centering”
tests normal, replace the EBCM. • “Diagnostic Test Drive”
4. Ignition OFF, disconnect the harness connector at • “Control Module References: ” for EBCM
the Steering Angle sensor. replacement, setup, and programming
5. Ignition ON, test for 0 volts between the
communication circuit terminal 5 and ground.
➢ If greater than the specified value, test the
communication circuit for a short to voltage.
4E-30 ABS:

DTC C0201 Conditions for Clearing the DTC

DTC Descriptor • The condition for setting the DTC is no longer present.
DTC C0201 04: Antilock Brake System (ABS) Enable • The EBCM automatically clears the history DTC when
Relay Contact Circuit a current DTC is not detected in 100 consecutive drive
cycles.
Diagnostic Fault Information
Reference Information
NOTE
Schematic Reference
Always perform the “Diagnostic System “Antilock Brake System Schematics”
Check - Vehicle Diagnostic Information: ” Connector End View Reference
prior to using this diagnostic procedure. “Antilock Brake System Connector End Views”
Electrical Information Reference
Circuit/System Description • “Circuit Testing: ”
The solenoid relay, located within the electronic brake • “Connector Repairs: ”
control module (EBCM), supplies battery voltage to all of
the valve solenoids. • “Testing for Intermittent Conditions and Poor
Connections: ”
Conditions for Running the DTC • “Wiring Repairs: ”
Scan Tool Reference
• Ignition voltage is greater than 9.5 volts.
“Scan Tool Data List - Antilock Brake System”
• The solenoid relay is commanded ON.

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Circuit/System Verification
Conditions for Setting the DTC With the scan tool, access the ABS special functions
One or more of the following conditions exists: menu and perform the ABS Motor test. The pump motor
• The EBCM detects an open in the battery positive should function and no DTCs should be set.
voltage circuit to the solenoid valve relay.
• The EBCM detects a stuck open solenoid valve relay Circuit/System Testing
or an open circuit between the solenoid valve relay Test for an open or a short to ground in the solenoid
and solenoid valves. valve battery positive voltage circuit.
➢ If battery positive voltage circuit tests normal,
Action Taken When the DTC Sets replace the EBCM/BPMV assembly.
• The EBCM disables the ABS/EBD for the duration of
the ignition cycle. Repair Instructions
• The ABS indicator turns ON. NOTE
• The red brake warning indicator turns ON.
Always perform the “Diagnostic Repair
Verification - Vehicle Diagnostic Information:
” after completing the diagnostic procedure.

“Control Module References: ” for EBCM replacement,

setup, and programming.
 ABS: 4E-31

DTC C0252
Diagnostic Instructions
• Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure.
• Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach.
• “Diagnostic Procedure Instructions - Vehicle Diagnostic Information: ” provides an overview of each diagnostic
category.

DTC Descriptor
DTC C0252 4A: Dynamic Sensor Offset Checksum Error

Diagnostic Fault Information

Short to Open/High Signal
Circuit Short to Voltage
Ground Resistance Performance
Steering Wheel Position Sensor
— — — C0252 4A
Uncorrelated

Circuit/System Description Action Taken When the DTC Sets

The vehicle stability enhancement system (VSES) is One or more of the following actions may occur:
activated by the electronic brake control module (EBCM) • The Vehicle Stability Enhancement System (VSES) is
and calculates the desired yaw rate and comparing it to disabled.

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the actual yaw rate input. The desired yaw rate is
• The VSES/TCS indicators turn ON.
calculated from measured steering wheel position,
vehicle speed, and lateral acceleration. The difference
between the desired yaw rate and actual yaw rate is the Conditions for Clearing the DTC
yaw rate error, which is a measurement of oversteer or • The condition for the DTC is no longer present.
understeer. If the yaw rate error becomes to large, the • The EBCM automatically clears the history DTC when
EBCM will attempt to correct the vehicle's yaw motion by a current DTC is not detected in 100 consecutive drive
applying differential braking to the left or right front cycles.
wheel.
The amount of differential braking applied to the left or Diagnostic Aids
right front wheel is based on both the yaw rate error and The following conditions can cause this concern:
side slip rate error. The side slip rate error is a function of An EBCM internal failure
the lateral acceleration minus the product of the yaw rate
and vehicle speed. The yaw rate error and side slip rate
Reference Information
error are combined to produce the total delta velocity
Schematic Reference
error. When the delta velocity error becomes too large
“Antilock Brake System Schematics”
and the VSES system activates, the drivers steering
Connector End View Reference
inputs combined with the differential braking will attempt
“Antilock Brake System Connector End Views”
to bring the delta velocity error toward 0. The VSES
Electrical Information Reference
activations generally occur during aggressive driving, in
the turns or bumpy roads with out much use of the • “Circuit Testing: ”
accelerator pedal. When braking during VSES • “Connector Repairs: ”
activation, the brake pedal will feel different than the • “Testing for Intermittent Conditions and Poor
antilock brake system (ABS) pedal pulsation. The brake Connections: ”
pedal pulsates at a higher frequency during VSES • “Wiring Repairs: ”
activation. Scan Tool Reference
“Scan Tool Data List - Antilock Brake System” for EBCM
Conditions for Running the DTC
• Ignition is On. Circuit/System Verification
• The ignition voltage is above 9.5 volts. Clear DTC, test drive vehicle under normal driving
conditions.
Conditions for Setting the DTC ➢ Verify DTC resets.
One of the following conditions exists:
There is an incorrect checksum stored in the EEPROM
area where the dynamic sensor offsets are saved.
4E-32 ABS:

Circuit/System Testing Conditions for Clearing the DTC

1. Clear DTCs, test drive the vehicle under normal • The condition for the DTC is no longer present and
driving conditions. the DTC is cleared with a scan tool.
2. If the DTC did not set as a current DTC see • The EBCM automatically clears the history DTC when
diagnostic aids. a current DTC is not detected in 100 consecutive drive
➢ If the DTC reset as current DTC, replace the cycles.
EBCM.
Diagnostic Aids
Repair Instructions If there are any other DTCs recorded against the
Perform the “Diagnostic Repair Verification - Vehicle dynamic sensor diagnose them first.
Diagnostic Information: ” after completing the diagnostic This DTC may be stored as a history DTC without
procedure. affecting the operation of the module. If stored only as a
“Control Module References: ” for EBCM history DTC and not retrieved as a current DTC, do not
replace the module.
Repair Verification If this DTC is retrieved as both a current and history
“Diagnostic Repair Verification - Vehicle Diagnostic DTC, replace the yaw rate/accelerometer sensor.
Information: ”
Reference Information
Schematic Reference
DTC C0280 “Antilock Brake System Schematics”
Diagnostic Instructions Connector End View Reference

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• Perform the “Diagnostic System Check - Vehicle “Antilock Brake System Connector End Views”
Diagnostic Information: ” prior to using the diagnostic Description and Operation
procedure. “ABS Description and Operation”
• Review “Strategy Based Diagnosis: ” for an overview Electrical Information Reference
of the diagnostic approach. • “Circuit Testing: ”
• “Diagnostic Procedure Instructions - Vehicle • “Connector Repairs: ”
Diagnostic Information: ” provides an overview of
• “Testing for Intermittent Conditions and Poor
each diagnostic category.
Connections: ”
• “Wiring Repairs: ”
DTC Descriptor
Scan Tool Reference
DTC C0280: Stability System Active Too Long
“Scan Tool Data List - Antilock Brake System” for EBCM
Circuit/System Description
Circuit/System Verification
The electronic brake control module (EBCM) detects a
malfunction when VSES brake intervention is active for 1. If the DTC did not set as a current DTC see
more than an excessive amount of time. diagnostic aids.
2. If the DTC is set as a current DTC.
Conditions for Running the DTC ➢ Replace the yaw rate/accelerometer sensor.
The ignition switch is in the ON position.
The ignition voltage is above 9.5 volts. Repair Instructions
Always perform the “Diagnostic System Check - Vehicle
Conditions for Setting the DTC Diagnostic Information: ” after completing the diagnostic
The EBCM detects VSES is active for more than 15 procedure.
seconds. “Control Module References: ” for yaw rate/
accelerometer replacement, setup, and programming
Action Taken When the DTC Sets
One or more of the following actions may occur: Repair Verification
• The VSES functionality is disabled “Diagnostic Repair Verification - Vehicle Diagnostic
Information: ”
• The TCS/VSES indicators turn ON.
 ABS: 4E-33

DTC C0292 Diagnostic Aids

Diagnostic Fault Information If the yaw and lateral accelerometer sensor is
disconnected, DTCs will set and the EBCM will not
• Perform the “Diagnostic System Check - Vehicle
provide 5-volt reference.
Diagnostic Information: ” prior to using this diagnostic
procedure.
Reference Information
• Review “Strategy Based Diagnosis: ” for an overview
Schematic Reference
of the diagnostic approach.
“Antilock Brake System Schematics”
• “Diagnostic Procedure Instructions - Vehicle Connector End View Reference
Diagnostic Information: ” provides an overview of “Antilock Brake System Connector End Views”
each diagnostic category.
Electrical Information Reference
• “Circuit Testing: ”
DTC Descriptor
DTC C0292: VSES Combination Sensor Circuits • “Connector Repairs: ”
• “Testing for Intermittent Conditions and Poor
Circuit/System Description Connections: ”
The electronic brake control module (EBCM) supplies a • “Wiring Repairs: ”
reference voltage of 5 volts to the yaw rate sensor lateral Scan Tool Reference
accelerometer and the steering wheel position sensor. “Scan Tool Data List - Antilock Brake System” for EBCM
The sensor supply voltage is monitored via an internal
feedback circuit to the EBCM microprocessor. Circuit/System Testing

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1. Ignition OFF, disconnect the yaw rate sensor/lateral
Conditions for Running the DTC accelerometer connector.
• The ignition is ON. 2. Ignition OFF, test for less than 1 ohm of resistance
• Ignition voltage is greater than 9.5 volts. between the low reference circuit and ground.
➢ If greater than 1 ohm, test the low reference circuit
Conditions for Setting the DTC and the EBCM ground circuit for an open/high
The yaw/lateral sensor is setting an internal electronic resistance. If the circuits test normal, replace the
failure. EBCM.
3. Test the lateral accelerometer signal circuit, the 5-
Action Taken When the DTC Sets volt reference circuit, and the low reference circuit for
• Vehicle stability enhancement system (VSES) is an open/high resistance or a short to voltage or
disabled ground.
• The VSES indicator turns ON. ➢ If all circuits test normal, replace the yaw rate
• The driver information center (DIC) displays the sensor/lateral accelerometer.
Service ESC message. ➢ If the DTC sets again after replacing the yaw rate
sensor/lateral accelerometer, replace the EBCM.
Conditions for Clearing the DTC
• The condition for setting the DTC is no longer present Repair Instructions
and the DTC is cleared with a scan tool. Perform the “Diagnostic Repair Verification - Vehicle
Diagnostic Information: ” after completing the diagnostic
• The EBCM automatically clears the history DTC when
procedure.
a current DTC is not detected in 100 consecutive drive
“Control Module References: ” for EBCM replacement,
cycles.
setup, and programming
4E-34 ABS:

DTC C0460
Diagnostic Instructions
• Perform the prior to using this diagnostic procedure.
• Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach.
• “Diagnostic Procedure Instructions - Vehicle Diagnostic Information: ” provides an overview of each diagnostic
category.

DTC Descriptors
DTC C0460 00: Steering Position Signal
DTC C0460 39: Steering Position Signal
DTC C0460 42: Steering Position Signal Initialization Not Accomplished
DTC C0460 4B: Steering Position Signal Calibration Not Accomplished
DTC C0460 5A: Steering Position Signal Not Plausible
DTC C0460 71: Steering Position Signal Internal Failure
DTC C0460 72: Steering Position Signal Rolling Count Invalid

Diagnostic Fault Information

Short to Open/High Signal
Circuit Short to Voltage
Ground Resistance Performance
Steering Wheel Position Sensor 12 Volt

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C0292 C0292 C0292 —
Reference Voltage
Low Reference C0460 00 C0460 00 — —
C0460 42, 4B,
Steering Wheel Position Signal Can HI C0460 00 C0460 00 —
5A, 71, 72
C0460 42, 4B,
Steering Wheel Position Signal Can Lo C0460 00 C0460 00 —
5A, 71, 72

Circuit/System Description Action Taken When the DTC Sets

The steering angle sensor shares a 12-volt ignition • Vehicle stability enhancement system (VSES) are
supply voltage with the electronic brake control module disabled.
(EBCM) and the yaw-rate/lateral sensor. The EBCM
• The VSES indicator turns ON
applies a ground to the steering angle sensor low
reference circuit, which is shared with the yaw-rate/ • The driver indicator turns ON
lateral sensor. If equipped, this vehicle received the
steering wheel position signal from the power steering Conditions for Clearing the DTC
control module (PSCM) over GMLAN. • The condition for the DTC is no longer present and
The steering angle sensor provides a GMLAN signal the DTC is cleared with a scan tool.
output to the EBCM that represents the steering wheel • The EBCM automatically clears the history DTC when
degree of rotation. The EBCM utilizes this signal to a current DTC is not detected in 100 consecutive drive
calculate the driver intended driving direction. cycles.

Conditions for Running the DTC Diagnostic Aids

• The ignition is ON. • If DTC C0292 is set, diagnose that DTC first.
• Ignition voltage is greater than 9.5 volts. • If the steering wheel position sensor is disconnected,
DTCs will set and the EBCM will not provide 12-volt
Conditions for Setting the DTC reference.
• Steering angle sensor is reporting an internal • A poor ground connection for the EBCM may cause
electronic failure. this DTC to set.
• Steering angle sensor has not been initialized.
• Steering angle sensor offset is greater than 15 Reference Information
degrees. Schematic Reference
“Antilock Brake System Schematics”
Connector End View Reference
“Antilock Brake System Connector End Views”
Description and Operation Reference
“ABS Description and Operation”
Electrical Information Reference
 ABS: 4E-35

• “Circuit Testing: ” Diagnostic Fault Information

• “Connector Repairs: ”
NOTE
• “Testing for Intermittent Conditions and Poor
Connections: ” Always perform the “Diagnostic System
Check - Vehicle Diagnostic Information: ”
• “Wiring Repairs: ” prior to using this diagnostic procedure.
Scan Tool Reference
“Scan Tool Data List - Antilock Brake System” for EBCM
“Steering Angle Sensor Centering” Circuit/System Description
The electronic brake control module (EBCM) detects an
Circuit/System Verification internal malfunction.
1. Position the steering wheel to the straight-ahead,
centered, position. Conditions for Running the DTC
The ignition switch is in the ON position.
2. Install a scan tool, ignition ON, engine OFF, and view
steering wheel position, the signal should be
approximately 0° with the steering wheel straight Conditions for Setting the DTC
ahead and should varies approximately 720+ or An internal EBCM malfunction exists.
720−.
Action Taken When the DTC Sets
3. As the steering wheel is turned, signal should travel
One or more of the following actions may occur:
smoothly between 720°+ 720°−.
• The Antilock Brake System (ABS)/dynamic rear

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Circuit/System Testing proportion (DRP) are disabled.
1. Ignition OFF, disconnect the steering wheel position • The ABS/TCS/ESC indicators turn ON.
sensor (SWPS) connector. • The red BRAKE Warning indicator turns ON.
2. Ignition OFF, test for less than 1 ohm of resistance
between the low reference circuit and ground. Conditions for Clearing the DTC
➢ If greater than 1 ohm, test the low reference circuit • The condition for the DTC is no longer present and
and the EBCM ground circuit for a short to voltage the DTC is cleared with a scan tool.
or an open/high resistance. If the circuits test • The EBCM automatically clears the history DTC when
normal, replace the EBCM. a current DTC is not detected in 100 consecutive drive
3. Test the CAN Hi circuit, CAN Lo circuit, 12-volt cycles.
reference circuit, and the low reference circuit for an
open/high resistance or a short to voltage or ground. Reference Information
➢ If all circuits test normal, perform the steering Schematic Reference
positions calibration in EBCM, and Scan Tool “Antilock Brake System Schematics”
Output Control. Connector End View Reference
“Antilock Brake System Connector End Views”
➢ If all circuits test normal, and the steering positions
Description and Operation
calibration failed, replace the SWPS.
“ABS Description and Operation”
➢ If the DTC sets again after replacing the SWPS,
Electrical Information Reference
replace the EBCM.
• “Circuit Testing: ”
Repair Instructions • “Connector Repairs: ”
Perform the “Diagnostic Repair Verification - Vehicle • “Testing for Intermittent Conditions and Poor
Diagnostic Information: ” after completing the diagnostic Connections: ”
procedure. • “Wiring Repairs: ”
• “Electronic Brake Control Module Replacement” Scan Tool Reference
• “Control Module References: ” for EBCM “Scan Tool Data List - Antilock Brake System” for EBCM
replacement, setup, and programming
Circuit/System Verification
DTC C0550 DTC C0550 will set as result of internal (EBCM) circuit
failure.
DTC Descriptor Verify that the DTC will not clear with a scan tool.
DTC C0550: Electronic Control Unit (ECU)
Performance ➢ Replace the EBCM.
4E-36 ABS:

DTC C0551 Circuit/System Verification

DTC Descriptors Verify that the EBCM is the correct module for the
DTC C0551 45: Option Configuration Error/Variant not vehicle.
programmed ➢ If the EBCM is not correct, replace the EBCM.
DTC C0551 47: Option Configuration Error/VIN not ➢ Reprogram the EBCM.
programmed
Repair Instructions
Diagnostic Fault Information “Control Module References: ” for EBCM
Perform the “Diagnostic System Check - Vehicle
Diagnostic Information: ” prior to using this diagnostic Repair Verification
procedure. “Diagnostic Repair Verification - Vehicle Diagnostic
Information: ”
Circuit/System Description
When the electronic brake control module (EBCM) is
replaced, software and calibrations are flash
DTC C0561
programmed into the EBCM. The EBCM receives the Diagnostic Instructions
VIN number from the BCM in order for the EBCM to • Perform the “Diagnostic System Check - Vehicle
automatically calibrate to the vehicle. Diagnostic Information: ” prior to using this diagnostic
procedure.
Conditions for Running the DTC • Review “Strategy Based Diagnosis: ” for an overview
The ignition switch is in the ON position. of the diagnostic approach.

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• “Diagnostic Procedure Instructions - Vehicle
Conditions for Setting the DTC Diagnostic Information: ” provides an overview of
C0551 45 each diagnostic category.
The option configuration has not been programmed.
C0551 47 DTC Descriptor
The incorrect EBCM has been installed in the vehicle. DTC C0561 71: System Disabled Information Stored

Action Taken When the DTC Sets Circuit/System Description

One or more of the following actions may occur: The electronic brake control module (EBCM) disables
• The antilock brake system (ABS) and engine traction the ABS when other electronic control modules set
(ETS) are disabled. DTCs for components that effect the operation of the
• The ABS/TCS indicators turn ON. traction control system.

Conditions for Clearing the DTC Conditions for Running the DTC
• The condition for the DTC is no longer present. • The ignition switch is in the ON position.
• The correct calibration must be programmed into the • Ignition voltage is greater than 8 volts.
EBCM
Conditions for Setting the DTC
Reference Information The power-train control module (PCM) or body control
Schematic Reference module (BCM) diagnosis a condition prevention the
“Antilock Brake System Schematics” engine control portion of the traction control function and
Connector End View Reference sends a serial data message to the EBCM indicating that
“Antilock Brake System Connector End Views” torque reduction is not allowed. The PCM or BCM will
Description and Operation typically set a DTC and the EBCM will set this DTC.
“ABS Description and Operation”
Electrical Information Reference Action Taken When the DTC Sets
One or more of the following actions may occur:
• “Circuit Testing: ”
• The EBCM disables the traction control system (TCS)
• “Connector Repairs: ”
until the DTC becomes a history DTC.
• “Testing for Intermittent Conditions and Poor
• The traction Off Indicator turns ON.
Connections: ”
• The Antilock Brake System (ABS) remains functional.
• “Wiring Repairs: ”
Scan Tool Reference
“Scan Tool Data List - Antilock Brake System” for EBCM
 ABS: 4E-37

Conditions for Clearing the DTC Action Taken When the DTC Sets
• The condition for the DTC is no longer present. The ABS indicator turns ON until the voltage returns to
above 10 volts.
• The EBCM automatically clears the history DTC when
a current DTC is not detected in 100 consecutive drive
cycles. Conditions for Clearing the DTC
• The condition for the DTC is no longer present.
Circuit/System Verification • The EBCM automatically clears the history DTC when
This DTC is for information only. As an aid to the a current DTC is not detected in 100 consecutive drive
technician, this DTC indicates that there are no problems cycles.
in the ABS/TCS system.
Reference Information
Repair Verification Schematic Reference
“Diagnostic Repair Verification - Vehicle Diagnostic “Antilock Brake System Schematics”
Information: ” Connector End View Reference
“Antilock Brake System Connector End Views”
DTC C0899 Description and Operation
“ABS Description and Operation”
Diagnostic Instructions Electrical Information Reference
• Perform the “Diagnostic System Check - Vehicle
• “Circuit Testing: ”
Diagnostic Information: ” prior to using this diagnostic
procedure. • “Connector Repairs: ”

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• Review “Strategy Based Diagnosis: ” for an overview • “Testing for Intermittent Conditions and Poor
of the diagnostic approach. Connections: ”
• “Diagnostic Procedure Instructions - Vehicle • “Wiring Repairs: ”
Diagnostic Information: ” provides an overview of Scan Tool Reference
each diagnostic category. “Scan Tool Data List - Antilock Brake System” for EBCM

DTC Descriptor Circuit/System Testing

DTC C0899: Device Voltage Low 1. Measure the voltage at the battery terminals.
2. With scan tool, read the battery voltage in the EBCM
Circuit/System Description data list.
The electronic brake control module (EBCM) monitors ➢ If less than 10 volts, test the ground circuit of the
the battery voltage level available for system operation. EBCM for high resistance. If the circuit test normal,
A low voltage condition prevents the system from test or replace the EBCM.
operating properly.
3. Go to “Battery Inspection/Test: ” and “Charging
System Test: ”.
Conditions for Running the DTC
The ignition is ON. Repair Instructions
Perform the “Diagnostic System Check - Vehicle
Conditions for Setting the DTC Diagnostic Information: ” After completing the diagnostic
This fault will be set if the battery voltage to EBCM is procedure.
less than 10 volts for 200 msec.
• “Control Module References: ” for EBCM
replacement, setup, and programming
• “Generator Replacement: ”

Repair Verification
“Diagnostic Repair Verification - Vehicle Diagnostic
Information: ”
4E-38 ABS:

DTC C0900 Circuit/System Testing

DTC Descriptor 1. Measure the voltage at the battery terminals.
DTC C0900: Device Voltage High 2. With scan tool, read the battery voltage in the EBCM
data list.
Diagnostic Fault Information ➢ If more than 17 volt, test the check the charging
NOTE system.
3. Go to “Battery Inspection/Test: ” and “Charging
Always perform the “Diagnostic System
System Test: ”.
Check - Vehicle Diagnostic Information: ”
prior to using this diagnostic procedure.
Repair Instructions
Perform the “Diagnostic System Check - Vehicle
Circuit/System Description Diagnostic Information: ” After completing the diagnostic
The electronic brake control module (EBCM) monitors procedure.
the battery voltage. If the voltage level is too high, • “Control Module References: ” for EBCM
damage may result in the system. When a high voltage replacement, setup, and programming
condition is detected the EBCM turns OFF the system
relay which removes battery voltage from the solenoid • “Generator Replacement: ”
valves and pump motor.
Repair Verification
Conditions for Running the DTC “Diagnostic Repair Verification - Vehicle Diagnostic
Information: ”

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Ignition is ON.

Conditions for Setting the DTC Symptoms - Antilock Brake System

The system voltage is greater than 17 volts for 10 msec.
NOTE
Action Taken When the DTC Sets The following steps must be completed
before using the symptom tables.
• ABS disabled if ignition voltage exceeds 17 volts.
1. Perform the “Diagnostic System Check -
• The Antilock Brake System (ABS) indicator and
Vehicle Diagnostic Information: ” in
engine traction (ETS)/ brake warning lamp turns ON if
Vehicle DTC Information before using the
voltage exceeds 17 volts.
symptom tables in order to verify that all
of the following are true:
Conditions for Clearing the DTC
– There are no DTCs set.
• The condition for the DTC is no longer present.
– The control modules can communicate
• The EBCM automatically clears the history DTC when via the serial data link.
a current DTC is not detected in 100 consecutive drive
2. Review the system operation in order to
cycles.
familiarize yourself with the system
functions. Refer to “ABS Description and
Diagnostic Aids Operation”.
Test the charging system. Refer to “Battery Inspection/
Test: ” and “Charging System Test: ”. Visual/Physical Inspection
• Inspect for aftermarket devices which could affect the
Reference Information operation of the antilock brake system (ABS). Refer to
Schematic Reference “Checking Aftermarket Accessories: ” in Wiring
“Antilock Brake System Schematics” Systems.
Connector End View Reference
“Antilock Brake System Connector End Views” • Inspect the easily accessible or visible system
Description and Operation components for obvious damage or conditions which
“ABS Description and Operation” could cause the symptom.
Electrical Information Reference • Inspect the master cylinder reservoir for the proper
fluid level.
• “Circuit Testing: ”
• “Connector Repairs: ”
• “Testing for Intermittent Conditions and Poor
Connections: ”
• “Wiring Repairs: ”
Scan Tool Reference
“Scan Tool Data List - Antilock Brake System” for EBCM
 ABS: 4E-39

Intermittent Symptom List

Faulty electrical connections or wiring may be the cause Refer to a symptom diagnostic procedure from the
of intermittent conditions. Refer to “Testing for following list in order to diagnose the symptom:
Intermittent Conditions and Poor Connections: ” in • “ABS Active Indicator Always On”
Wiring Systems.
• “ABS Active Indicator Inoperative”
• “Traction Control Indicator Always On”
• “Traction Control Indicator Inoperative”

ABS Active Indicator Always On

Circuit Description
The instrument panel cluster (IPC) turns the ABS indicator on during the IPC bulb check for approximately 3 seconds
when the ignition switch is turned to the ON position. If the electronic brake control module (EBCM) sets a diagnostic
trouble code (DTC) the EBCM sends a class 2 message to the body control module (BCM) and the BCM sends a
class 2 message to the IPC to command the antilock brake system (ABS) indicator ON.

Diagnostic Aids
• It is very important that a thorough inspection of the wiring and connectors be performed. Failure to carefully and
fully inspect wiring and connectors may result in misdiagnosis, causing part replacement with reappearance of the
malfunction.

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• Thoroughly inspect any circuitry that may be causing the complaint for the following conditions:
– Backed out terminals
– Improper mating
– Broken locks
– Improperly formed or damaged terminals
– Poor terminal-to-wiring connections
– Physical damage to the wiring harness
• The following conditions may cause an intermittent malfunction:
– A poor connection
– Rubbed-through wire insulation
– A broken wire inside the insulation
• If an intermittent malfunction exists refer to “Inducing Intermittent Fault Conditions: ” in Wiring Systems.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2.
Confirm if the scan tool can turn ON and OFF all indicator lamps on the instrument cluster.
4.
Verify if the circuits going to the instrument cluster or the cluster is at fault.
Step Action Yes No
Schematic Reference: “Antilock Brake System Schematics”
Connector End View Reference: refer to “Antilock Brake System Connector End Views” or “Displays and Gages
Connector End Views: ”
Did you perform the Diagnostic System Check - Vehicle? Go to “Diagnostic
System Check -
Vehicle Diagnostic
1 Go to Step 2
Information: ” in
Vehicle DTC
Information
4E-40 ABS:

Step Action Yes No

1. Using a scan tool, select the brake control module (BCM),
Special Functions mode.
2. Select Output Control, Solenoid Test.
2 3. Select the antilock brake system (ABS) Telltale Indicator. Go to Step 3 Go to Step 4
4. In the ABS Telltale test mode you can turn the instrument
panel indicators ON or OFF.
All indicators will turn ON when commanded on.
Does the ABS indicator turn on then OFF?
Replace the electronic brake control module (EBCM). Refer to Go to “Diagnostic
“Control Module References: ” in Computer/Integrating System Check -
Systems. Vehicle Diagnostic
3 —
Is the replacement complete? Information: ” in
Vehicle DTC
Information
1. Disconnect the instrument cluster and connect a test light
across the appropriate power and ground terminals.
2. With the test light OFF, repair the open in power or ground Go to “Diagnostic
circuit to cluster System Check -
Vehicle Diagnostic
4 3. With the test light ON, check the connector for poor —
Information: ” in

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connection to cluster. Vehicle DTC
4. If OK, replace the instrument cluster. Refer to “Control Information
Module References: ” in Computer/Integrating Systems.
Is the instrument cluster replacement complete?

ABS Active Indicator Inoperative

Circuit Description
The instrument panel cluster (IPC) turns the ABS indicator on during the IPC bulb check for approximately 3 seconds
when the ignition switch is turned to the ON position. If the electronic brake control module (EBCM) sets a diagnostic
trouble code (DTC) the EBCM sends a class 2 message to the body control module (BCM) and the BCM sends a
class 2 message to the IPC to command the ABS indicator on.

Diagnostic Aids
• It is very important that a thorough inspection of the wiring and connectors be performed. Failure to carefully and
fully inspect wiring and connectors may result in misdiagnosis, causing part replacement with reappearance of the
malfunction.
• Thoroughly inspect any circuitry that may be causing the complaint for the following conditions:
– Backed out terminals
– Improper mating
– Broken locks
– Improperly formed or damaged terminals
– Poor terminal-to-wiring connections
– Physical damage to the wiring harness
• The following conditions may cause an intermittent malfunction:
– A poor connection
– Rubbed-through wire insulation
– A broken wire inside the insulation
• If an intermittent malfunction exists refer to “Inducing Intermittent Fault Conditions: ” in Wiring Systems.
 ABS: 4E-41

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2.
Confirm if the scan tool can turn on and off all the indicator lamps in the instrument cluster.
4.
Verify if the circuits going to the instrument cluster or the cluster is at fault.
Step Action Yes No
Schematic Reference: “Antilock Brake System Schematics”
Connector End View Reference: refer to “Antilock Brake System Connector End Views” or “Displays and Gages
Connector End Views: ”
Did you perform the Diagnostic System Check - Vehicle? Go to “Diagnostic
System Check -
Vehicle Diagnostic
1 Go to Step 2
Information: ” in
Vehicle DTC
Information
1. Using a scan tool, select the Brake Control Module,
Special Functions mode, Output Control.
2. Select Solenoid Test.
2 3. Select ABS Telltale Indicator. Go to Step 3 Go to Step 4
4. In the ABS Telltale Test mode you can turn the instrument

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panel indicators ON or OFF. All indicators will turn ON
when commanded on.
Does the ABS indicator turn on then off?
Replace the ABS module. Refer to “Control Module Go to “Diagnostic
References: ” in Computer/Integrating Systems. System Check -
Is the replacement complete? Vehicle Diagnostic
3 —
Information: ” in
Vehicle DTC
Information
1. Disconnect the instrument cluster and connect a test light
across the appropriate power and ground terminals.
2. With the test light OFF, repair the open in power or ground Go to “Diagnostic
circuit to cluster. System Check -
Vehicle Diagnostic
4 3. With the test light ON, check the connector for poor —
Information: ” in
connection to the cluster. Vehicle DTC
4. If OK, replace the instrument cluster. Refer to “Control Information
Module References: ” in Computer/Integrating Systems.
Is the instrument cluster replacement complete?
4E-42 ABS:

Traction Control Indicator Always On

Circuit Description
The TRAC OFF indicator is controlled by the instrument cluster via class 2 serial data messages from the electronic
brake control module (EBCM). When the body control module (BCM) sees the traction control switch input grounded
through the momentary traction control switch, it sends a class 2 message to the EBCM that tells the EBCM that the
traction control switch has been pressed. The EBCM then disables traction control and sends a message to the
instrument cluster to turn the TRAC OFF indicator ON. Each time the ignition is cycled from OFF to ON, the traction
control system (TCS) is enabled.
The following conditions will cause the TRAC OFF indicator to illuminate:
• The EBCM has disabled the TCS due to a DTC.
• The driver manually disabling the TCS via the traction control switch.
• The instrument cluster bulb check. When the ignition switch is turned to ON, the TRAC OFF indicator will turn on for
approximately 3 seconds and then turn OFF.

Diagnostic Aids
• It is very important that a thorough inspection of the wiring and connectors be performed. Failure to carefully and
fully inspect wiring and connectors may result in misdiagnosis, causing part replacement with reappearance of the
malfunction.
• Thoroughly inspect any circuitry that may be causing the complaint for the following conditions:
– Backed out terminals

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– Improper mating
– Broken locks
– Improperly formed or damaged terminals
– Poor terminal-to-wiring connections
– Physical damage to the wiring harness
• The following conditions may cause an intermittent malfunction:
– A poor connection
– Rubbed-through wire insulation
– A broken wire inside the insulation
• If an intermittent malfunction exists refer “Inducing Intermittent Fault Conditions: ” in Wiring Systems for further
diagnosis.
 ABS: 4E-43

Step Action Yes No

Schematic Reference: “Antilock Brake System Schematics”
Connector End View Reference: refer to “Antilock Brake System Connector End Views” or “Displays and Gages
Connector End Views: ”
Did you perform the Diagnostic System Check - Vehicle? Go to “Diagnostic
System Check -
Vehicle Diagnostic
1 Go to Step 2
Information: ” in
Vehicle DTC
Information
1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF. Go to “Testing for
Intermittent
2 3. With a scan tool, observe the Traction Switch parameter in Conditions and Poor Go to Step 3
the EBCM data display. Connections: ” in
4. Activate the traction control switch. Wiring Systems
Does the Traction Switch parameter change state?
1. Turn OFF the ignition.
2. Disconnect the traction control switch connector.
3. Connect a fused jumper from the signal circuit of the
traction control switch harness connector to a good
3 Go to Step 5 Go to Step 4

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ground.
4. Turn ON the ignition, with the engine OFF.
5. With a scan tool, observe the Traction Switch parameter.
Does the scan tool display Applied?
Test the signal circuit of the traction control switch for an open
or high resistance. Refer to “Testing for Intermittent Conditions
4 and Poor Connections: ” and “Connector Repairs: ” in Wiring Go to Step 10 Go to Step 6
Systems.
Did you find and correct the condition?
Test the ground circuit of the traction control switch for an open
or high resistance. Refer to and “Testing for Continuity: ” in
5 Go to Step 10 Go to Step 7
Wiring Systems.
Did you find and correct the condition?
Inspect for poor connections at the harness connector of the
body control module (BCM). Refer to “Testing for Intermittent
6 Conditions and Poor Connections: ” and “Connector Repairs: ” Go to Step 10 Go to Step 8
in Wiring Systems.
Did you find and correct the condition?
Inspect for poor connections at the harness connector of the
traction control switch. Refer to “Testing for Intermittent
7 Conditions and Poor Connections: ” and “Connector Repairs: ” Go to Step 10 Go to Step 9
in Wiring Systems.
Did you find and correct the condition?
Replace the BCM. Refer to “Control Module References: ” in
8 Computer/Integrating Systems. Go to Step 10 —
Did you complete the replacement?
Replace the traction control switch. Refer to “Electronic
9 Traction Control Switch Replacement”. Go to Step 10 —
Did you complete the replacement?
Operate the system in order to verify the repair.
10 System OK Go to Step 2
Did you correct the condition?
4E-44 ABS:

Traction Control Indicator Inoperative

Circuit Description
The TRAC OFF indicator is controlled by the instrument cluster via class 2 serial data messages from the electronic
brake control module (EBCM). When the body control module (BCM) sees the traction control switch input grounded
through the momentary traction control switch, it sends a class 2 message to the EBCM that tells the EBCM that the
traction control switch has been pressed. The EBCM then disables traction control and sends a message to the
instrument cluster to turn the TRAC OFF indicator ON. Each time the ignition is cycled from OFF to ON, the traction
control system (TCS) is enabled.
The following conditions will cause the TRAC OFF indicator to illuminate:
• The EBCM has disabled the TCS due to a DTC.
• The driver manually disabling the TCS via the traction control switch
• The instrument cluster bulb check—When the ignition switch is turned to ON, the TRAC OFF indicator will turn on
for approximately 3 seconds and then turn OFF.

Diagnostic Aids
• It is very important that a thorough inspection of the wiring and connectors be performed. Failure to carefully and
fully inspect wiring and connectors may result in misdiagnosis, causing part replacement with reappearance of the
malfunction.
• Thoroughly inspect any circuitry that may be causing the complaint for the following conditions:
– Backed out terminals

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– Improper mating
– Broken locks
– Improperly formed or damaged terminals
– Poor terminal-to-wiring connections
– Physical damage to the wiring harness
• The following conditions may cause an intermittent malfunction:
– A poor connection
– Rubbed-through wire insulation
– A broken wire inside the insulation
• If an intermittent malfunction exists refer to “Inducing Intermittent Fault Conditions: ” in Wiring Systems for further
diagnosis.
 ABS: 4E-45

Step Action Yes No

Schematic Reference: “Antilock Brake System Schematics”
Connector End View Reference: refer to “Antilock Brake System Connector End Views” or “Displays and Gages
Connector End Views: ”
Did you perform the Diagnostic System Check - Vehicle? Go to “Diagnostic
System Check -
Vehicle Diagnostic
1 Go to Step 2
Information: ” in
Vehicle DTC
Information
1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
2 3. With a scan tool, observe the Traction Switch parameter in Go to Step 3 Go to Step 4
the EBCM data display.
Does the scan tool display Released?
1. Activate the traction control switch. Go to “Testing for
2. With the scan tool, observe the Traction Switch parameter. Intermittent
3 Does the Traction Switch parameter change state? Conditions and Poor Go to Step 4
Connections: ” in
Wiring Systems
1. Turn OFF the ignition.

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2. Disconnect the traction control switch connector.
4 3. Turn ON the ignition, with the engine OFF. Go to Step 7 Go to Step 5
4. With a scan tool, observe the Traction Switch parameter.
Does the scan tool display Inactive?
Test the signal circuit of the traction control switch for a short
to ground. Refer to and “Testing for Short to Ground: ” in
5 Go to Step 10 Go to Step 6
Wiring Systems.
Did you find and correct the condition?
Inspect for poor connections at the harness connector of the
body control module (BCM). Refer to “Testing for Intermittent
6 Conditions and Poor Connections: ” and “Wiring Repairs: ” in Go to Step 10 Go to Step 8
Wiring Systems.
Did you find and correct the condition?
Inspect for poor connections at the harness connector of the
traction control switch. Refer to “Testing for Intermittent
7 Conditions and Poor Connections: ” and “Connector Repairs: ” Go to Step 10 Go to Step 9
in Wiring Systems.
Did you find and correct the condition?
Replace the BCM. Refer to “Control Module References: ” in
8 Computer/Integrating Systems. Go to Step 10 —
Did you complete the replacement?
Replace the traction control switch. Refer to “Electronic
9 Traction Control Switch Replacement”. Go to Step 10 —
Did you complete the replacement?
Operate the system in order to verify the repair.
10 System OK Go to Step 2
Did you correct the condition?
4E-46 ABS:

Repair Instructions
Antilock Brake System Automated Bleed Automated Bleed Procedure
Procedure 1. Raise and support the vehicle. Refer to “Lifting and
Jacking the Vehicle: ”.
! WARNING
2. Remove all 4 tire and wheel assemblies. Refer to
Refer to “Brake Fluid Irritant Caution: ”. “Tire and Wheel Removal and Installation: ”.
3. Inspect the brake system for leaks and visual
! CAUTION damage. Refer to “Symptoms - Hydraulic Brakes: ”.
Repair or replace components as needed.
Refer to “Brake Fluid Effects on Paint and
Electrical Components Notice: ”. 4. Lower the vehicle.
5. Inspect the battery state of charge. Refer to “Battery
NOTE Inspection/Test: ”.
Before performing the antilock brake system 6. Install a scan tool.
(ABS) Automated Bleed Procedure, first 7. Turn the ignition ON, with the engine OFF.
perform a manual or pressure bleed of the 8. With the scan tool, establish communications with
base brake system. Refer to “Hydraulic Brake the ABS system. Select Special Functions. Select
System Bleeding (Pressure): ” “Hydraulic Automated Bleed from the Special Functions menu.
Brake System Bleeding (Manual): ”. The 9. Raise and support the vehicle. Refer to “Lifting and

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automated bleed procedure is recommended Jacking the Vehicle: ”.
when one of the following conditions exist:
10. Following the directions given on the scan tool,
• Base brake system bleeding does not pressure bleed the base brake system. Refer to
achieve the desired pedal height or feel “Hydraulic Brake System Bleeding (Pressure): ”
• Extreme loss of brake fluid has occurred “Hydraulic Brake System Bleeding (Manual): ”.
• Air ingestion is suspected in the 11. Follow the scan tool directions until the desired
secondary circuits of the brake modulator brake pedal height is achieved.
assembly 12. If the bleed procedure is aborted, a malfunction
exists. Perform the following steps before resuming
The ABS Automated Bleed Procedure uses a scan tool
the bleed procedure:
to cycle the system solenoid valves and run the pump in
order to purge any air from the secondary circuits. These – If a DTC is detected, refer to “Diagnostic Trouble
circuits are normally closed off, and are only opened Code (DTC) List - Vehicle Diagnostic Information:
during system initialization at vehicle start up and during ”, and diagnose the appropriate DTC.
ABS operation. The automated bleed procedure opens – If the brake pedal feels spongy, perform the
these secondary circuits and allows any air trapped in conventional brake bleed procedure again. Refer
these circuits to flow out toward the brake corners. to “Hydraulic Brake System Bleeding (Pressure): ”
“Hydraulic Brake System Bleeding (Manual): ”.
! CAUTION
13. When the desired pedal height is achieved, press
The Auto Bleed Procedure may be terminated the brake pedal to inspect for firmness.
at any time during the process by pressing 14. Lower the vehicle.
the EXIT button. No further Scan Tool
15. Remove the scan tool.
prompts pertaining to the Auto Bleed
procedure will be given. After exiting the 16. Install the tire and wheel assemblies. Refer to “Tire
bleed procedure, relieve bleed pressure and and Wheel Removal and Installation: ”.
disconnect bleed equipment per 17. Inspect the brake fluid level. Refer to “Master
manufacturers instructions. Failure to Cylinder Reservoir Filling: ”.
properly relieve pressure may result in 18. Road test the vehicle while inspecting that the pedal
spilled brake fluid causing damage to remains high and firm.
components and painted surfaces.
 ABS: 4E-47

Steering Angle Sensor Centering NOTE

The steering wheel position sensor does not require Before performing the calibration procedure,
centering often. Centering of the steering position sensor confirm that the steering wheel is centered,
might be required after certain service procedures are and the tires/wheels are in a straight ahead
performed. Some of these procedures are as follows: position.
• Steering gear replacement
2. Install the scan tool to the data link connector (DLC).
• Steering column replacement
3. Set the transmission in the park position.
• Steering position sensor replacement
4. Turn ON the ignition, with the engine running.
• Intermediate shaft replacement
5. Select Chassis/EBCM control system vehicle
• Antilock brake system (ABS) controller replacement
stability enhancement system (VSES), special
• Collision or other physical damage function test, and Steering Position Sensor
The steering position sensor centering procedure can be Calibration.
preformed with a scan tool in the automated center
6. Follow the scan tool directions to complete the
procedure by the following:
automated centering procedure this should include
1. Road test the vehicle at a constant highway speed turning the steering wheel left 180 degrees and right
on a typical straight road. Verify the proper operating 180 degrees, and then straight forward.
condition of the suspension or alignment, and the
7. Clear any DTCs that may be set. Perform the
steering wheel is centered correctly. If the
Diagnostic System Check to verify no current DTCs.
suspension or alignment repairs are required, then
Refer to “Diagnostic System Check - Vehicle
make the necessary repairs, and adjustments prior

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Diagnostic Information: ”.
to the steering position sensor calibration. Refer to
“Symptoms - Suspension General Diagnosis: ”. 8. Centering of the steering position sensor is
complete.

Electronic Brake Control Module Replacement

4E-48 ABS:

Callout Component Name

Preliminary Procedures
1. Place the ignition switch in the OFF position.
2. Remove the underhood electrical center. Refer to “Underhood Electrical Center or Junction Block Replacement:
”.
3. Clean the electronic brake control module (EBCM) to brake pressure modulator valve (BPMV) area of any dirt or
debris.
Electronic Brake Control Module (EBCM) Electrical Connector
1
Tip: Release the locking tab and rotate the electrical connector cover upward to release.
EBCM to Brake Pressure Modulator Valve (BPMV) Screw (Qty: 4)

! CAUTION
Refer to “Fastener Notice: ”.
2
Tightening torque
3 N⋅m (27 lb in)
Tip: Tighten the screws in a cross pattern.
3 Electronic Brake Control Module
EBCM to BPMV Seal (Qty: 12)

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Tip:
• If installing a new EBCM, program the EBCM. Refer to “Control Module References: ”.
• Without starting the engine, place the ignition switch in the ON position.
4 • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ”.
• Observe the feel of the brake pedal after performing the diagnostic system check. If the pedal now
feels spongy, air may have been in the secondary circuit of the brake modulator assembly, which
may have been introduced into the primary circuit. If the pedal feels spongy, perform the “Antilock
Brake System Automated Bleed Procedure”.

Electronic Brake Control Module Programming and Setup

EBCM Replacement
If the electronic brake control module (EBCM) is replaced, the following procedures must be performed:
EBCM Reprogramming—Refer to “Service Programming System (SPS): ”.

EBCM Reprogramming
If the EBCM needs to be reprogrammed, refer to “Service Programming System (SPS): ”.

Setup for Component Replacement

The replacement of ABS components such as the steering wheel position sensor may require a setup procedure for
complete repair. Refer to “Steering Angle Sensor Centering”
 ABS: 4E-49

Brake Pressure Modulator Valve Replacement

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Callout Component Name
! WARNING
Refer to “Brake Fluid Irritant Caution: ”.

! CAUTION
Refer to “Brake Fluid Effects on Paint and Electrical Components Notice: ”.

! CAUTION
Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition
switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/
EBTCM.

Preliminary Procedures
1. Place the ignition switch in the OFF position.
2. Clean the brake pipe fittings of any dirt or debris.
3. Remove the underhood electrical center. Refer to “Underhood Electrical Center or Junction Block Replacement:
”.
4. Place a clean cloth under the brake modulator assembly to catch any brake fluid loss.
Electronic Brake Control Module (EBCM) Electrical Connector
1
Tip: Release the locking tab and rotate the electrical connector cover upward to release.
4E-50 ABS:

Callout Component Name

Master Cylinder Brake Pipe Fitting (Qty: 2)

! CAUTION
Refer to “Fastener Notice: ”.

2 Tip:
• Cap the brake pipe fittings to prevent brake fluid loss and contamination.
• Plug the brake modulator assembly inlet ports to prevent brake fluid loss and contamination.
Tightening torque
21 N⋅m (16 lb ft)
Front Brake Pipe Fitting (Qty: 2)
Tip:
• Cap the brake pipe fittings to prevent brake fluid loss and contamination.
3
• Plug the brake modulator assembly outlet ports to prevent brake fluid loss and contamination.
Tightening torque
21 N⋅m (16 lb ft)
Rear Brake Pipe Fitting (Qty: 2)
Tip:

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• Cap the brake pipe fittings to prevent brake fluid loss and contamination.
4
• Plug the brake modulator assembly outlet ports to prevent brake fluid loss and contamination.
Tightening torque
21 N⋅m (16 lb ft)
EBCM to Brake Pressure Modulator Valve (BPMV) Screw (Qty: 4)
Tip: Tighten the screws in a cross pattern.
5
Tightening torque
3 N⋅m (27 lb in)
6 Electronic Brake Control Module (EBCM)
7 EBCM to BPMV Seal (Qty: 12)
Brake Modulator Assembly Bolt
8 Tightening torque
20 N⋅m (15 lb ft)
Brake Pressure Modulator Valve
Tip:
• Bleed the hydraulic brake system. Refer to “Hydraulic Brake System Bleeding (Pressure): ”
“Hydraulic Brake System Bleeding (Manual): ”.
9 • Turn the ignition switch to the ON position. DO NOT start the engine.
• Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ”.
• Observe the feel of the brake pedal after performing the diagnostic system check. If the pedal now
feels spongy, air may have been in the secondary circuit of the brake modulator assembly, which
may have been introduced into the primary circuit. If the pedal feels spongy, perform the “Antilock
Brake System Automated Bleed Procedure”.
10 Brake Modulator Assembly Insulator (Qty: 3)
 ABS: 4E-51

Brake Pressure Modulator Valve Bracket Replacement

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Callout Component Name
Preliminary Procedure
Place the ignition switch in the OFF position.
Brake Modulator Assembly Bracket Bolt

! CAUTION
1 Refer to “Fastener Notice: ”.

Tightening torque
20 N⋅m (15 lb ft)
Brake Modulator Assembly Bracket Nut (Qty: 2)
2 Tightening torque
10 N⋅m (89 lb in)
Brake Modulator Assembly Bracket
3 Tip: Without disconnecting the brake pipe fittings, carefully remove and support the brake modulator
assembly.
4E-52 ABS:

Front Wheel Speed Sensor Replacement

Callout Component Name

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! WARNING
Refer to “Brake Dust Caution: ”.

Preliminary Procedures
1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
3. Remove the brake rotor. Refer to “Front Brake Rotor Replacement: ”.
Wheel Speed Sensor Electrical Connector
1 Procedure
Release the electrical connector from the bracket.
Wheel Speed Sensor Bolt

! CAUTION
2 Refer to “Fastener Notice: ”.

Tightening torque
8 N⋅m (71 lb in)
Wheel Speed Sensor
3 Procedure
Route the wheel speed sensor electrical harness through the splash shield.
 ABS: 4E-53

Rear Wheel Speed Sensor Replacement

Callout Component Name

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! WARNING
Refer to “Brake Dust Caution: ”.

Preliminary Procedures
1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
2. Remove the tire and wheel. Refer to “Tire and Wheel Removal and Installation: ”.
3. Remove the park brake shoes. Refer to “Park Brake Shoe Replacement: ”.
1 Wheel Speed Sensor Electrical Connector
Wheel Speed Sensor Bolt

! CAUTION
2 Refer to “Fastener Notice: ”.

Tightening torque
8 N⋅m (71 lb in)
Wheel Speed Sensor
Procedure
3
1. Release the wheel speed sensor electrical harness grommet from the backing plate.
2. Route the wheel speed sensor electrical harness through the backing plate.
4E-54 ABS:

Electronic Traction Control Switch Replacement

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Callout Component Name
Preliminary Procedure
Remove the Instrument Panel Lower Brace Bezel. Refer to “Instrument Panel Lower Brace Bezel Replacement: ”.
Traction Control Switch Assembly
1 Tip: Release the tabs securing the traction control switch to the trim plate and remove the switch from
the plate.
 ABS: 4E-55

Vehicle Yaw Sensor Replacement

Callout Component Name

Preliminary Procedure

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Remove the right front seat. Refer to “Front Seat Replacement - Bucket: ”.
Yaw Rate Sensor Nut (Qty: 2)

! CAUTION
1 Refer to “Fastener Notice: ”.

Tightening torque
6 N⋅m (53 lb in)
2 Yaw Rate Sensor Cover (If equipped)
Yaw Rate Sensor
3 Procedure
Disconnect the electrical connector.

Specifications
Fastener Tightening Specifications - Antilock Brake System
Specification
Application
Metric English
Brake Modulator Assembly Bracket Bolt 20 N⋅m 15 lb ft
Brake Modulator Assembly Bracket Nuts 10 N⋅m 89 lb in
Brake Modulator Assembly Bolt 20 N⋅m 15 lb ft
Brake Pipe Fittings at the Brake Modulator Assembly 21 N⋅m 16 lb ft
Electronic Brake Control Module (EBCM) to Brake Modulator
3 N⋅m 27 lb in
Assembly Screws
Yaw Rate Sensor Nuts 9 N⋅m 80 lb in
 4E-56 ABS:

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