BR–1

BRAKE SYSTEM
BR–2
BRAKE SYSTEM – GENERAL DESCRIPTION, DESCRIPTION

GENERAL DESCRIPTION
BR03E–01
1. Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the parts with parts of the same part number or
equivalent.
2. It is very important to keep parts and the area clean when repairing the brake system.
DESCRIPTION
BR03F–01
The service brakes consist of a foot brake which changes rotational energy to thermal energy to stop the
vehicle while it is being driven and a parking brake to keep the vehicle from moving while it is parked.
BR–2
BRAKE SYSTEM – GENERAL DESCRIPTION, DESCRIPTION

GENERAL DESCRIPTION
BR03E–01
1. Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the parts with parts of the same part number or
equivalent.
2. It is very important to keep parts and the area clean when repairing the brake system.
DESCRIPTION
BR03F–01
The service brakes consist of a foot brake which changes rotational energy to thermal energy to stop the
vehicle while it is being driven and a parking brake to keep the vehicle from moving while it is parked.
 BR–3
BRAKE SYSTEM – OPERATION

OPERATION
BR03G–01

FOOT BRAKE
When the brake pedal is depressed, a vacuum builds up in the booster which amplifies the pedal force,
pressing on the piston in the master cylinder. The piston raises the hydraulic pressure in the cylinder. This
hydraulic pressure is then applied to each respective brake cylinder, and acts to press the brake pads
against the rotating rotor discs. The resulting friction converts the rotational energy to thermal energy, stop-
ping the vehicle.
BR–4
BRAKE SYSTEM – OPERATION

PARKING BRAKE
BR03H–01
When the parking brake lever is pulled up, the parking brake shoe lever is pulled via the parking brake wire.
This causes the shoe strut to push the front shoe, which expands and is pressed against the rotor disc.
If the parking brake lever continues to be pulled up, the contact point of the parking brake shoe lever and
shoe strut then becomes the fulcrum so that the parking brake shoe lever causes the rear shoe to expand.
This results in the rotor disc being locked by the front shoe and rear shoe.
 BR–5
BRAKE SYSTEM – PREPARATION

PREPARATION
BR03J–01

SST(SPECIAL SERVICE TOOLS)

BR–6
BRAKE SYSTEM – PREPARATION

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EQUIPMENT
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BR03K–01
Torque wrench

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Micrometer ÑÑÑÑÑÑÑÑÑÑÑÑÑ
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Brake disc rotor

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Dial indicator
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Vernier calipers Brake disc rotor

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Voltmeter
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Ohmmeter

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LUBRICANT
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BR03L–01
Item Capacity Classification

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Brake fluid – SAEJ1703 or FMVSS No. 116, DOT 3
 BR–7
BRAKE SYSTEM – TROUBLESHOOTING

TROUBLESHOOTING
You will find the troubles easier using the table well shown below. In this table, each number shows the
priority of causes in troubles. Check each part in order. If necessary, replace these parts.
BR03M–01

BR–19, 27

BR–19, 27

BR–19, 27
BR–19, 27

BR–19, 27

BR–19, 27

BR–19, 27

BR–19, 27
BR–19, 27
BR–19, 27
BR–19, 27
BR–19, 27
BR–19, 27

BR–19, 27
BR–36

BR–36
BR–11

BR–18
BR–41
BR–12
BR–8
BR–8
BRAKE SYSTEM – CHECK AND ADJUSTMENT

CHECK AND ADJUSTMENT

BR03N–02

BRAKE PEDAL CHECK AND

ADJUSTMENT
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from asphalt sheet:
147.5–157.5 mm (5.81–6.20 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Remove the under cover.
(b) Remove the lower pad and air duct.
(c) Disconnect the connector from the stop light switch.
(d) Loosen the stop light switch lock nut and remove the stop
light switch.
(e) Loosen the push rod lock nut.
(f) Adjust the pedal height by turning the pedal push rod.
(g) Tighten the push rod lock nut.
Torque: 25 N⋅m (260 kgf⋅cm, 19 ft⋅lbf)
(h) Install the stop light switch and turn it until it lightly contacts
the pedal stopper.
(i) Return the stop light switch one turn.

(j) Check that the clearance (A) between stop light switch and
pedal.
Clearance:
0.5–2.4 mm (0.02–0.09 in.)
(k) Tighten the stop light switch lock nut.
(l) Connect the connector to the stop light switch.
(m) Check that the stop lights come on when the brake pedal is
depressed, and go off when the brake pedal is released.
(n) After adjusting the pedal height, check the pedal freeplay.
HINT: If clearance (A) between the stop light switch and the
brake pedal stopper has been adjusted correctly, the pedal
freeplay will meet the specifications.
 BR–9
BRAKE SYSTEM – CHECK AND ADJUSTMENT

3. CHECK THAT PEDAL FREEPLAY IS CORRECT, AS

SHOWN
(a) Stop the engine and depress the brake pedal several times
until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the beginning of the second
point of resistance is felt, then measure the distance as
shown.
Pedal freeplay:
1–6 mm (0.04–0.24 in.)
If incorrect, check the stop light switch clearance. And if the
clearance is OK, then troubleshoot the brake system.
HINT: The freeplay to the first point of resistance is due to the
play between the clevis and pin. It is 1–3 mm (0.04–0.12 in.)
on the pedal.
(c) Install the air duct and lower pad.
(d) Install the under cover.

4. CHECK THAT PEDAL RESERVE DISTANCE IS CORRECT,

AS SHOWN
Release the parking brake.
With the engine running, depress the pedal and measure the
pedal reserve distance, as shown.
Pedal reserve distance at 490 N (50 kgf, 110.2 lbf):
More than 70 mm (2.76 in.)
If the reserve distance is incorrect, troubleshoot the brake
system.

BRAKE BOOSTER OPERATIONAL TEST

BR03P–01
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
goes down slightly, operation is normal.

2. AIR TIGHTNESS
(a) Start the engine and stop it after one or two minutes. Depress
the brake pedal several times slowly. If the pedal goes down
the farthest the first time, but gradually rises after the second
or third time, the booster is air tight.
BR–10
BRAKE SYSTEM – CHECK AND ADJUSTMENT

(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed. If there is no
change in the pedal reserve travel after holding the pedal for
thirty seconds, the booster is air tight.

BRAKE SYSTEM BLEEDING

BR03Q–01
HINT: If any work is done on the brake system or if air in the
brake lines is suspected, bleed the system of air.
NOTICE: Do not let brake fluid remain on painted sur-
faces. Wash it off immediately.
1. FILL RESERVOIR TANK WITH BRAKE FLUID
Fluid: SAE J1703 or FMVSS NO. 116DOT3

2. BLEED MASTER CYLINDER

HINT: If the master cylinder has been disassembled or if the
reservoir tank becomes empty, bleed the air from the master
cylinder.
(a) Disconnect the brake tubes from the master cylinder.
(b) Slowly depress the brake pedal and hold it.

(c) Block off the outer holes with your fingers, and release the
brake pedal.
(d) Repeat (b) and (c) three or four times.

3. BLEED BRAKE LINE

(a) Connect the vinyl tube to the brake cylinder.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
(c) At the point when fluid stops coming out, tighten the bleeder
plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
 BR–11
BRAKE SYSTEM – CHECK AND ADJUSTMENT

(e) Repeat the above procedure to bleed the air out of the brake
line for each wheel.
Torque: 8.3 N⋅m (85 kgf⋅cm, 74 in.⋅lbf)
4. CHECK FLUID LEVEL IN RESERVOIR TANK
Check the fluid level and add fluid if necessary.
Fluid: SAE J1703 or FMVSS NO.116DOT3

PARKING BRAKE CHECK AND

ADJUSTMENT
BR03R–01
1. CHECK THAT PARKING BRAKE LEVER TRAVEL IS
CORRECT
Pull the parking brake lever all the way up, and count the
number of clicks.
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf):
5–8 clicks
If incorrect, adjust the parking brake.

2. IF NECESSARY, ADJUST PARKING BRAKE LEVER

TRAVEL
(a) Remove the rear wheel.
(b) Temporarily install the hub nuts.
(c) Remove the hole plug.
(d) Turn the adjuster and expand the shoes until the rotor disc
locks.
(e) Return the adjuster eight notches.
(f) Install the hole plug and hub nuts.
(g) Install the rear wheel.
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)

(h) Remove the rear console box.

(i) Loosen the lock nut and turn the adjusting nut until the lever
travel is correct.
(j) Tighten the lock nut.
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
(k) Install the rear console box.
BR–12
BRAKE SYSTEM – MASTER CYLINDER

MASTER CYLINDER
BR03S–01

MASTER CYLINDER REMOVAL

1. DISCONNECT LEVEL WARNING SWITCH CONNECTOR

2. TAKE OUT FLUID WITH SYRINGE
NOTICE: Do not let brake fluid remain on a painted sur-
face. Wash it off immediately.
3. DISCONNECT BRAKE TUBES
Using SST, disconnect the brake tubes from the master cylin-
der.
SST 09023–00100

4. REMOVE MASTER CYLINDER

Remove the mounting nuts and pull out the master cylinder
and gasket.
 BR–13
BRAKE SYSTEM – MASTER CYLINDER

COMPONENTS
BR03T–01

MASTER CYLINDER DISASSEMBLY

BR03U–01
1. REMOVE MASTER CYLINDER BOOT
Using a screwdriver, remove the master cylinder boot.

2. REMOVE RESERVOIR TANK

(a) Remove the set screw and pull out the reservoir tank.
(b) Remove the cap and strainer from the reservoir tank.
3. REMOVE TWO GROMMETS
4. PLACE CYLINDER IN VISE
BR–14
BRAKE SYSTEM – MASTER CYLINDER

5. REMOVE PISTON STOPPER BOLT

Using a screwdriver, push the pistons in all the way and re-
move the piston stopper bolt and gasket.
HINT: Tape the screwdriver tip before use.

6. REMOVE TWO PISTONS

(a) Push in the piston with a screwdriver and remove the snap
ring with snap ring pliers.
(b) Remove the No. 1 piston and spring by hand, pulling straight
out, not at an angle.
NOTICE: if pulled out at an angle, there is possibility that
the cylinder bore could be damaged.

(c) Place a rag and two wooden blocks on the work table and
lightly tap the cylinder flange against the block edges until the
piston drops out of the cylinder.
HINT: Make sure the distance (A) from the rag to the top of
the blocks is at least 100 mm (3.94 in.).

MASTER CYLINDER COMPONENTS

INSPECTION
BR03V–01
HINT: Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.

MASTER CYLINDER ASSEMBLY

BR03W–01
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
RUBBER PARTS INDICATED BY ARROWS
 BR–15
BRAKE SYSTEM – MASTER CYLINDER

2. INSTALL TWO PISTONS

NOTICE: Be careful not to damage the rubber lips on the
pistons.
(a) Insert the two pistons straight in, no at an angle.
NOTICE: If inserted at an angle, there is a possibility that
the cylinder bore could be damaged.
(b) Push in the piston with a screwdriver and install the snap ring
with snap ring pliers.
HINT: Tape the screwdriver tip before use.

3. INSTALL PISTON STOPPER BOLT

Using a screwdriver, push the piston in all the way and install
the piston stopper bolt over the gasket. Torque the bolt.
Torque: 10 N⋅m (100 kgf⋅cm, 7 ft⋅lbf)
4. INSTALL TWO GROMMETS

5. INSTALL RESERVOIR TANK

(a) Install the cap and strainer to the reservoir tank.
(b) Push the reservoir tank onto the cylinder.
(c) Install the set screw while pushing on the reservoir tank.
Torque: 1.7 N⋅m (17.5 kgf⋅cm, 15.2 in.⋅lbf)

6. INSTALL MASTER CYLINDER BOOT

With the UP mark on the master cylinder boot facing up-
wards, install the cylinder boot on the master cylinder.

MASTER CYLINDER INSTALLATION

BR03X–01
1. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install the gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip
slightly touches the piston.
SST 09737–00010
BR–16
BRAKE SYSTEM – MASTER CYLINDER

(c) Turn the SST upside down, and set it on the booster.
SST 09737–00010
(d) Measure the clearance between the booster push rod and
pin head (SST).
Clearance:
0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod lightly
touches the pin head.

2. INSTALL MASTER CYLINDER

Install the master cylinder and gasket on the brake booster
with three nuts.
Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf)

3. CONNECT TWO BRAKE TUBES

Using SST, connect the brake tubes to the master cylinder.
Torque the union nuts.
SST 09023–00100
Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf)
4. CONNECT LEVEL WARNING SWITCH CONNECTOR
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See brake system bleeding)
6. CHECK FOR FLUID LEAKAGE
7. CHECK AND ADJUST BRAKE PEDAL
(See brake pedal check and adjustment)
 BR–17
BRAKE SYSTEM – BRAKE BOOSTER

BRAKE BOOSTER
BR03Y–01

BRAKE BOOSTER REMOVAL

1. REMOVE MASTER CYLINDER

2. REMOVE CHARCOAL CANISTER
3. REMOVE WIRING HARNESS BRACKET
4. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER
5. REMOVE PEDAL RETURN SPRING
6. REMOVE CLIP AND CLEVIS PIN

7. REMOVE BRAKE BOOSTER

(a) Remove the four booster installation nuts.
(b) Pull out the brake booster and gasket.
BR–18
BRAKE SYSTEM – BRAKE BOOSTER

BRAKE BOOSTER INSTALLATION

BR03Z–01
1. INSTALL BRAKE BOOSTER
(a) Install the clevis to the operating rod.
(b) Install the booster and gasket.
(c) Install and torque the booster installation nuts.
Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf)
(d) Insert the clevis pin into the clevis and brake pedal, and install
the clip to the clevis pin.
(e) Install the pedal return spring.

2. ADJUST LENGTH OF BOOSTER PUSH ROD

(a) Install the gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip
slightly touches the piston.
SST 09737–00010

(c) Turn the SST upside down, and set it on the booster.
SST 09737–00010
(d) Measure the clearance between the booster push rod and
pin head (SST).
Clearance:
0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod lightly
touches the pin head.
3. INSTALL WIRING HARNESS BRACKET
4. INSTALL CHARCOAL CANISTER
5. INSTALL MASTER CYLINDER
6. CONNECT VACUUM HOSE TO BRAKE BOOSTER
7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See brake system bleeding)
8. CHECK FOR FLUID LEAKAGE
9. CHECK AND ADJUST BRAKE PEDAL
(See brake pedal check and adjustment)
10. PERFORM OPERATIONAL CHECK
(See brake booster operational test)
 BR–19
BRAKE SYSTEM – FRONT BRAKE

FRONT BRAKE
BR040–01

COMPONENTS

BRAKE PADS REPLACEMENT

BR041–01
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the rotor disc with
the hub nuts.
BR–20
BRAKE SYSTEM – FRONT BRAKE

2. INSPECT PAD LINING THICKNESS

Check the pad thickness through the cylinder inspection hole
and replace the pads if it is not within the specification.
Minimum thickness:
1.0 mm (0.039 in.)

3. LIFT UP CYLINDER
(a) Hold the sliding pin on the bottom and loosen the installation
bolt.
(b) Remove the installation bolt.

(c) Lift up the brake cylinder and suspend the cylinder with string.
HINT: Do not disconnect the flexible hose from the brake cyl-
inder.

4. REMOVE FOLLOWING PARTS:

(a) Two brake pads
(b) Four anti–squeal shims
(c) Four pad support plates
(d) Pad wear indicator
5. CHECK ROTOR DISC THICKNESS AND RUNOUT
(See front brake components inspection and repair)

6. INSTALL PAD SUPPORT PLATES

Install the four pad support plates.
 BR–21
BRAKE SYSTEM – FRONT BRAKE

7. INSTALL NEW PADS

(a) Install the pad wear indicator plate on the pad.
(b) Apply disc brake grease to both sides of the inner anti–squeal
shim.
(c) Install the two anti–squeal shims on each pad.

(d) Install two pads with the pad wear indicator plates facing
upward.
NOTICE: There should be no oil or grease adhering to the
friction surfaces of the pads or the rotor disc.

8. INSTALL CYLINDER
(a) Draw out a small amount of brake fluid from the reservoir
tank.
(b) Press in the piston with water pump pliers or similar
implement.
HINT: If the piston is difficult to push in, loosen the bleeder
plug and push in the piston while letting some brake fluid es-
cape.

(c) Install the cylinder.

(d) Hold the sliding pin and torque the installation bolt.
Torque: 34 N⋅m (350 kgf⋅cm, 25 ft⋅lbf)
9. INSTALL FRONT WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE

CYLINDER REMOVAL
BR042–01
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and two gaskets from the brake
cylinder, then disconnect the flexible hose from the brake
cylinder.
(b) Use a container to catch the brake fluid as it drains out.
BR–22
BRAKE SYSTEM – FRONT BRAKE

2. REMOVE CYLINDER
(a) Hold the sliding pin and loosen the two installation bolts.
(b) Remove the two installation bolts.
(c) Remove the cylinder from the torque plate.

3. REMOVE TWO BRAKE PADS

Remove the inside and outside pads.

CYLINDER DISASSEMBLY
BR043–01
1. REMOVE CYLINDER BOOT SET RINGS AND CYLINDER
BOOT
Using a screwdriver, remove the cylinder boot set ring and
cylinder boot from the cylinder.

2. REMOVE PISTON
(a) Place a piece of cloth or similar article between the piston and
the cylinder.
(b) Use compressed air to remove the piston from the cylinder.
CAUTION: Do not place your fingers in front of the piston
when using compressed air.

3. REMOVE PISTON SEAL

Using a screwdriver, remove the piston seal from the cylinder.
 BR–23
BRAKE SYSTEM – FRONT BRAKE

4. REMOVE SLIDING PINS AND DUST BOOTS

(a) Remove the two sliding pins from the torque plate.

(b) Using a chisel and hammer, tap out the two dust boots.

BR044–01

FRONT BRAKE COMPONENTS

INSPECTION AND REPAIR
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness:
11.0 mm (0.433 in.)
Minimum thickness:
1.0 mm (0.039 in.)
Replace the pad if the pad’s thickness is at the minimum
thickness or less, or if the pad has severely uneven wear.

2. MEASURE ROTOR DISC THICKNESS

Using a micrometer, measure the rotor disc thickness.
Standard thickness:
28 mm (1.102 in.)
Minimum thickness:
26 mm (1.024 in.)
BR–24
BRAKE SYSTEM – FRONT BRAKE

Replace the rotor disc if the thickness of the rotor disc is at

the minimum thickness or less. Replace the rotor disc or grind
it on a lathe if it is scored or is worn unevenly.

3. MEASURE ROTOR DISC RUNOUT

Using a dial indicator, measure the rotor disc runout at a posi-
tion 10 mm (0.39 in.) from the outside edge.
Maximum disc runout:
0.05 mm (0.0020 in.)
If the rotor disc’s runout is at the maximum value or greater,
check the bearing play in the axial direction and check the
axle hub runout (See SA section). If the bearing play and axle
hub runout are not abnormal, adjust the rotor disc runout.
4. IF NECESSARY, ADJUST ROTOR DISC RUNOUT
(a) Remove the torque plate from the knuckle.
(b) Remove the hub nuts of the temporarily installed disc and pull
off the rotor disc.
(c) Install the rotor disc and measure the disc runout, then shift
the rotor disc one fifth of a turn and measure the disc runout.
Similarly measure the runout at each position, and select the
position where the runout is minimum.

(d) In this position, if the runout is within specification, install the

torque plate and torque the mounting bolts.
Torque: 107 N⋅m (1,090 kgf⋅cm, 79 ft⋅lbf)
(e) If not within specification, replace the rotor disc, and repeat
(c) and (d).

CYLINDER ASSEMBLY
BR045–01
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
PARTS INDICATED WITH ARROWS
 BR–25
BRAKE SYSTEM – FRONT BRAKE

2. INSTALL DUST BOOTS AND SLIDING PINS

(a) Using a 19 mm socket wrench and hammer, tap in two new
dust boots into the torque plate.
(b) Confirm that the metal plate portion of the dust boot fits
snugly in the torque plate.

(c) Insert two sliding pins into the torque plate.

NOTICE: Insert the sliding pin with sliding bushing into
the bottom side.

3. INSTALL PISTON SEAL AND PISTON IN CYLINDER

4. INSTALL CYLINDER BOOT AND CYLINDER BOOT SET

RING

CYLINDER INSTALLATION
BR046–01
1. INSTALL TWO BRAKE PADS
Install the inside and outside pads.
BR–26
BRAKE SYSTEM – FRONT BRAKE

2. INSTALL CYLINDER
(a) Temporarily install the cylinder on the torque plate with two
installation bolts.
(b) Hold the sliding pin and torque the installation bolt.
Torque: 34 N⋅m (350 kgf⋅cm, 25 ft⋅lbf)

3. CONNECT FLEXIBLE HOSE

Install the flexible hose on the brake cylinder with two new
gaskets.
Torque: 27 N⋅m (300 kgf⋅cm, 21 ft⋅lbf)
HINT: Insert the flexible hose lock securely in the lock hole in
the brake cylinder.
4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See brake system bleeding)
5. CHECK FOR LEAKS
 BR–27
BRAKE SYSTEM – REAR BRAKE (DISC BRAKE)

REAR BRAKE
(DISC BRAKE)
BR047–01

COMPONENTS

BRAKE PADS REPLACEMENT

BR048–01
1. REMOVE REAR WHEEL
Remove the wheel and temporarily fasten the rotor disc with
the hub nuts.
BR–28
BRAKE SYSTEM – REAR BRAKE (DISC BRAKE)
4

2. INSPECT PAD LINING THICKNESS

Check the pad thickness through the cylinder inspection hole
and replace pads if not within specification.
Minimum thickness:
1.0 mm (0.039 in.)

3. LIFT UP CYLINDER
(a) Remove the flexible hose bracket.

(b) Remove the installation bolt.

(c) Lift up the brake cylinder and suspend the cylinder with string.
HINT: Do not disconnect the flexible hose from the brake cyl-
inder.

4. REMOVE FOLLOWING PARTS:

(a) Two brake pads
(b) Four anti–squeal shims
(c) Four pad support plates
5. CHECK ROTOR DISC THICKNESS AND RUNOUT
(See rear brake components inspection and repair)
 BR–29
BRAKE SYSTEM – REAR BRAKE (DISC BRAKE)

6. INSTALL PAD SUPPORT PLATES

Install the four pad support plates.

7. INSTALL NEW PADS

(a) Apply disc brake grease to both sides of the inner anti–squeal
shims.
(b) Install the two anti–squeal shims on each pad.
(c) Install two pads with the pad wear indicator plates facing
upward.
NOTICE: There should be no oil or grease adhering to the
friction surfaces of the pads or the rotor disc.

8. INSTALL CYLINDER
(a) Draw out a small amount of brake fluid from the reservoir
tank.
(b) Press in the piston with water pump pliers or similar
implement.
HINT: If the piston is difficult to push in, loosen the bleeder
plug and push in the piston while letting some brake fluid es-
cape.

(c) Install the brake cylinder and torque the installation bolt.
Torque: 20 N⋅m (200 kgf⋅cm, 14 ft⋅lbf)

(d) Install the flexible hose bracket.

Torque: 29 N⋅m (300 kgf⋅cm, 29 ft⋅lbf)
9. INSTALL REAR WHEEL
10. CHECK THAT FLUID LEVEL IS AT MAX LINE
BR–30
BRAKE SYSTEM – REAR BRAKE (DISC BRAKE)

CYLINDER REMOVAL
BR049–01
1. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and two gaskets from the brake
cylinder, then disconnect the flexible hose from the brake
cylinder.
(b) Use a container to catch the brake fluid as it drains out.

2. REMOVE CYLINDER
(a) Remove the installation bolt.
(b) Remove the cylinder from the torque plate.

3. REMOVE TWO PADS

4. REMOVE MAIN PIN

Loosen the main pin installation bolt and remove the main
pin.

CYLINDER DISASSEMBLY
BR04A–01
1. REMOVE SLIDING BUSHING
Pull out the sliding bushing.
 BR–31
BRAKE SYSTEM – REAR BRAKE (DISC BRAKE)

2. REMOVE MAIN PIN BOOT

Pull out the main pin boot.

3. REMOVE DUST BOOTS

(a) Place the cylinder in vise.
(b) Using a chisel and hammer, tap out the two dust boots.

4. REMOVE CYLINDER BOOT SET RING AND CYLINDER

BOOT
Using a screwdriver, remove the cylinder boot set ring and
cylinder boot from the cylinder.

5. REMOVE PISTON
(a) Place a piece of cloth or similar article between the piston and
the cylinder.
(b) Use compressed air to remove the piston from the cylinder.
CAUTION: Do not place your fingers in front of the piston
when using compressed air.

6. REMOVE PISTON SEAL

Using a screwdriver, remove the piston seal from the cylinder.
BR–32
BRAKE SYSTEM – REAR BRAKE (DISC BRAKE)

REAR BRAKE COMPONENTS

INSPECTION AND REPAIR
BR04B–01
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness:
10.0 mm (0.394 in.)
Minimum thickness:
1.0 mm (0.039 in.)
Replace the pad if the pad’s thickness is at the minimum
thickness or less, or if the pad has severely uneven wear.

2. MEASURE ROTOR DISC THICKNESS

Using a micrometer, measure the rotor disc thickness.
Standard thickness:
10.0 mm (0.394 in.)
Minimum thickness:
9.0 mm (0.354 in.)
Replace the rotor disc if the thickness of the rotor disc is at
the minimum thickness or less. Replace the rotor disc or grind
it on a lathe if it is scored or is worn unevenly.

3. MEASURE ROTOR DISC RUNOUT

Measure the rotor disc runout at 10 mm (0.39 in.) from the
outer edge of the rotor disc.
Maximum disc runout:
0.15 mm (0.0059 in.)
If the runout is greater than the maximum, replace the disc.
HINT: Before measuring the runout, confirm that the hub
bearing play is within specification.
 BR–33
BRAKE SYSTEM – REAR BRAKE (DISC BRAKE)

4. IF NECESSARY, REPLACE ROTOR DISC

(a) Remove the torque plate.
(b) Remove the hub nuts of the temporarily installed disc and pull
off the rotor disc.
(c) Install a new rotor disc and loosely install the hub nuts.
(d) Install the torque plate and tighten the mounting bolt.
Torque: 47 N⋅m (475 kgf⋅cm, 34 ft⋅lbf)

CYLINDER ASSEMBLY
BR04C–01
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
PARTS INDICATED WITH ARROWS

2. INSTALL PISTON SEAL AND PISTON IN CYLINDER

3. INSTALL CYLINDER BOOT AND SET RING IN CYLINDER

4. INSTALL DUST BOOTS

(a) Place the cylinder in vise.
(b) Using a 19 mm socket wrench and hammer, tap in two new
dust boots into the torque plate.
(c) Confirm that the metal plate portion of the dust boot fits
snugly in the torque plate.
BR–34
BRAKE SYSTEM – REAR BRAKE (DISC BRAKE)

5. INSTALL MAIN PIN BOOT

6. INSTALL SLIDING BUSHING

CYLINDER INSTALLATION
BR04D–01
1. INSTALL MAIN PIN
Install the main pin and torque the main pin installation bolt.
Torque: 27 N⋅m (270 kgf⋅cm, 19 ft⋅lbf)

2. INSTALL TWO PADS

Install two pads with the pad wear indicator plate facing up-
ward.
NOTICE: There should be no oil or grease adhering to the
friction surfaces of the pads or the rotor disc.

3. INSTALL CYLINDER
Install the brake cylinder and torque the installation bolt.
Torque: 20 N⋅m (200 kgf⋅cm, 14 ft⋅lbf)
 BR–35
BRAKE SYSTEM – REAR BRAKE (DISC BRAKE)

4. CONNECT FLEXIBLE HOSE

Install the flexible hose on the brake cylinder with two new
gaskets.
Torque: 29 N⋅m (300 kgf⋅cm, 14 ft⋅lbf)
HINT: Insert the flexible hose lock securely in the lock hole in
the brake cylinder.
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See brake system bleeding)
6. CHECK FOR LEAKS
BR–36
BRAKE SYSTEM – REAR BRAKE (PARKING BRAKE)

REAR BRAKE
(PARKING BRAKE)
BR04E–01

COMPONENTS

PARKING BRAKE DISASSEMBLY

BR04F–01
1. REMOVE REAR WHEEL
2. REMOVE REAR DISC BRAKE ASSEMBLY
(a) Remove the two mounting bolts and remove the disc brake
assembly.
(b) Suspend the disc brake so the hose is not stretched.

3. REMOVE ROTOR DISC

HINT: If the rotor disc cannot be removed easily, return the
shoe adjuster until the wheel turns freely.
 BR–37
BRAKE SYSTEM – REAR BRAKE (PARKING BRAKE)

4. REMOVE SHOE RETURN SPRINGS

Using needle–nose pliers, remove the two shoe return
springs.

5. REMOVE SHOE STRUT WITH SPRING

6. REMOVE FRONT SHOE ADJUSTER AND TENSION

SPRING
(a) Slide out the front shoe and remove the shoe adjuster.
(b) Disconnect the tension spring and remove the front shoe.

7. REMOVE REAR SHOE

(a) Slide out the rear shoe.
(b) Remove the tension spring from the rear shoe.

(c) Disconnect the parking brake cable from the parking brake
shoe lever.
(d) Remove the shoe hold–down spring cups, springs and pins.
BR–38
BRAKE SYSTEM – REAR BRAKE (PARKING BRAKE)

PARKING BRAKE COMPONENTS

INSPECTION AND REPAIR
BR04G–01
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.

2. MEASURE BRAKE SHOE LINING THICKNESS

Using a scale, measure the thickness of the shoe lining.
Standard thickness:
2.0 mm (0.079 in.)
Minimum thickness:
1.0 mm (0.039 in.)
If the lining thickness is at the minimum thickness or less, or
if there is extremely uneven wear, replace the brake shoe.

3. MEASURE BRAKE DISC INSIDE DIAMETER

Using a vernier caliper, measure the inside diameter of the ro-
tor disc.
Standard inside diameter:
170 mm (6.69 in.)
Minimum inside diameter:
171 mm (6.73 in.)
Replace the rotor disc if the inside diameter is at the maxi-
mum value or more. Replace the rotor disc or grind it with a
lathe if the rotor disc is scored or is worn unevenly.

4. INSPECT PARKING BRAKE LINING AND DISC FOR

PROPER CONTACT
Apply chalk to the inside surface of the rotor, then grind down
the brake shoe lining to fit. If the contact between the rotor
disc and the brake shoe lining is improper, repair it using a
brake shoe grinder or replace the brake shoe assembly.
 BR–39
BRAKE SYSTEM – REAR BRAKE (PARKING BRAKE)

5. MEASURE CLEARANCE BETWEEN PARKING BRAKE

SHOE AND LEVER
Using a feeler gauge, measure the clearance.
Standard clearance:
Less than 0.35 mm (0.0138 in.)
If the clearance is not within the specification, replace the
shim with one of the correct size.

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Thickness mm(in.) Thickness mm(in.)

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0.3 (0.012) 0.9 (0.035)

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0.6 (0.024)

6. IF NECESSARY, REPLACE SHIM

(a) Remove the parking brake shoe lever, and install the correct
size shim.

(b) Install the parking brake shoe lever with a new C–washer.
(c) Remeasure the clearance.

PARKING BRAKE ASSEMBLY

BR04H–01
HINT: Assemble the parts in the correct direction as shown.
BR–40
BRAKE SYSTEM – REAR BRAKE (PARKING BRAKE)

1. APPLY HIGH TEMPERATURE GREASE ON BACKING

PLATE AS SHOWN
Apply high temperature grease to the sliding surfaces of the
shoe.

2. APPLY HIGH TEMPERATURE GREASE TO ADJUSTER

AS SHOWN

3. CONNECT PARKING BRAKE CABLE TO PARKING

BRAKE LEVER
(a) Install the shoe hold–down springs, cups and pins.
(b) Connect the parking brake cable to the parking brake shoe
lever of the rear shoe.

4. INSTALL REAR SHOE

Slide in the rear shoe between the shoe hold–down spring
cup and the backing plate.
NOTICE: Do not allow oil or grease to get on the rubbing
face.

5. INSTALL TENSION SPRING, FRONT SHOE AND

ADJUSTER
(a) Install the tension spring on the rear shoe.
(b) Install the front shoe on the tension spring.
(c) Install the adjuster between the front and rear shoes.
 BR–41
BRAKE SYSTEM – REAR BRAKE (PARKING BRAKE)

(d) Slide in the front shoe between the shoe hold–down spring
cup and the backing plate.

6. INSTALL STRUT WITH SPRING

Install the strut with the spring forward.

7. INSTALL SHOE RETURN SPRINGS

Using needle–nose pliers, install the shoe return springs.

8. INSTALL ROTOR DISC

(a) Before installing, polish the disc and shoe surfaces with
sandpaper.
(b) Align the hole on the rear axle shaft flange and service hole
on the disc.

9. ADJUST PARKING BRAKE SHOE CLEARANCE

(a) Temporarily install the hub nuts.
(b) Remove the hole plug.
(c) Turn the adjuster and expand the shoes until the rotor disc
locks.
(d) Return the adjuster eight notches.
(e) Install the hole plug.
BR–42
BRAKE SYSTEM – REAR BRAKE (PARKING BRAKE)

10. INSTALL REAR DISC BRAKE ASSEMBLY

Install the disc brake assembly and torque the two mounting
bolts.
Torque: 47 N⋅m (475 kgf⋅cm, 34 ft⋅lbf)
11. INSTALL REAR WHEEL
12. SETTLING PARKING BRAKE SHOES AND DISC
(a) Drive the vehicle at about 50 km/h (31 mph) on a safe, level
and dry road.
(b) With the parking brake release button pushed in, pull on the
lever with 98 N (10 kgf, 19.8 lbf) of force.
(c) Drive the vehicle for about 400 meters (0.25 mile) in this
condition.
(d) Repeat this procedure two or three times.
13. CHECK AND ADJUST PARKING BRAKE LEVER TRAVEL
(See parking brake check and adjustment)
 BR–43
BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV)

LOAD SENSING PROPORTIONING

VALVE (LSPV)
BR04J–01

COMPONENTS

FLUID PRESSURE CHECK AND

ADJUSTMENT
BR04K–01
1. SET REAR AXLE LOAD
(a) Set the vehicle to its curb weight.
(b) Measure the rear axle load and note the value.
(c) Set the rear axle load.
Rear axle load: Rear axle curb weight + 31 kg (68 lb)

2. INSTALL LSPV GAUGE (SST) AND BLEED BRAKE

SYSTEM
SST 09709–29017
BR–44
BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV)

3. RAISE FRONT BRAKE PRESSURE TO 1,787 kpa (110

kgf/cm2, 1,565 psi) CHECK REAR BRAKE PRESSURE
Brake pressure:
6,227–7,208 kpa (63.5–73.5 kgf/cm2, 903–1,045 psi)
HINT: The brake pedal should not be depressed twice and/or
returned while setting to the specified pressure. Read the val-
ue of rear pressure two seconds after adjusting the specified
fluid pressure.

4. IF NECESSARY, ADJUST FLUID PRESSURE

(a) Adjust the fluid pressure by changing the shaft length.
Low pressure–Lengthen A
High pressure–Shorten A
HINT: The fluid pressure is adjusted 245 kpa (2.5 kgf/cm2, 36
psi) per each turn of the adjusting nut.

(b) Torque the lock nut.

Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf)
If it cannot be adjusted, replace the valve assembly.

LSPV REMOVAL
BR04L–01
1. DISCONNECT BRAKE TUBES
Using SST, disconnect the brake tubes from the valve body.
SST 09751–36011

2. REMOVE LSPV ASSEMBLY

(a) Remove the lock nut and disconnect the adjusting bolt from
the rear suspension arm.
 BR–45
BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV)

(b) Remove the two mounting bolts and remove the LSPV
assembly.

LSPV INSTALLATION
BR04M–01
1. INSTALL LSPV ASSEMBLY
(a) Install the valve assembly with the two mounting bolts.
Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf)
(b) Install the adjusting nut to the adjusting bolt and then install
the adjusting bolt lock bolt to the rear suspension arm with the
adjusting bolt lock nut.

(c) Set the shaft length A to initial set length and temporarily
tighten the adjusting bolt lock nut.
Initial set length:
27.5 mm (1.08 in.)

2. CONNECT BRAKE TUBES

Using SST, connect the brake tubes.
SST 09751–36011
Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf)
3. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See brake system bleeding)
4. CHECK FOR FLUID LEAKAGE
5. CHECK AND ADJUST FLUID PRESSURE
6. REMOVE SST AND BLEED BRAKE SYSTEM
SST 09709–29017
7. CHECK FOR FLUID LEAKAGE
BR–46
BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LPSV)

–MEMO–
 BR–47
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

ANTI–LOCK BRAKE SYSTEM (ABS)

BR–48
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

ANTI–LOCK BRAKE SYSTEM (ABS)

Description

The ABS is a brake system which controls the wheel cylinder hydraulic pressure of all four wheels
during sudden braking and braking on slippery road surfaces, preventing the wheels from locking.
This ABS provides the following benefits:
(1) Enables steering round an obstacle with a greater degree of certainty even when panic braking.
(2) Enables stopping in a panic brake while keeping the effect upon stability and steerability to a
minimum, even on curves.

The function of the ABS is to help maintain directional stability and vehicle steerability on most road
conditions. However, the system cannot prevent the vehicle from skidding if the cornering speed limit
is exceeded.

In case a malfunction occurs, a diagnosis function and fail–safe system have been adopted for the
ABS to increase serviceability.
LOCATION OF SYSTEM PARTS
 BR–49
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

WIRING DIAGRAM
BR–50
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

TERMINALS OF ECM (w/o TRAC)

 BR–51
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

STANDARD VALUE OF ECM TERMINALS

BR–52
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

ABS Actuator
ABS ACTUATOR REMOVAL AND
INSTALLATION
Remove and install the parts as shown.
 BR–53
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

(MAIN POINT OF REMOVAL AND

INSTALLATION)
1. DISCONNECT AND CONNECT BRAKE TUBE
Using SST, disconnect and connect the brake tubes from/to
the ABS actuator.
SST 09023–00100
Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lb)
2. BLEED BRAKE SYSTEM
(See brake system bleeding)
BR–54
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

ABS ACTUATOR OPERATION

INSPECTION
1. INSPECT BATTERY VOLTAGE
Battery positive voltage: 10–14 V
2. REMOVE WASHER TANK

3. DISCONNECT CONNECTORS
(a) Disconnect the connector from the actuator.
(b) Remove control relay and disconnect the connectors from
the control relay.

4. CONNECT ACTUATOR CHECKER (SST) TO ACTUATOR

(a) Connect the actuator checker (SST) to the actuator, control
relay and body side wire harness through the sub–wire
harness (SST) as shown.
SST 09990–00150, 09990–00200 and 09990–00210
(b) Connect the red cable of the checker to the battery positive
(+) terminal and black cable to the negative (–) terminal.
Connect the black cable of the sub–wire harness to the
battery negative (–) terminal or body ground.
(c) Place the “SHEET A” (SST) on the actuator checker.
SST 09990–00163
 BR–55
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

5. INSPECT BRAKE ACTUATOR OPERATION

(a) Start the engine, and run it at idle.
(b) Turn the selector switch of the actuator checker to “FRONT
RH” position.
(c) Push and hold in the MOTOR switch for a few seconds.
(d) Depress the brake pedal and hold it until the step (g) is
completed.

(e) Push the POWER SWITCH, and check that the brake pedal
does not go down.
NOTICE: Do not keep the POWER SWITCH pushing more
than 10 seconds.
(f) Release the switch, and check that the pedal go down.

(g) Push and hold in the MOTOR switch for a few seconds, and
check that the pedal returns.
(h) Release the brake pedal.

(i) Push and hold in the MOTOR switch for a few seconds.
(j) Depress the brake pedal and hold it for about 15 seconds.
As you hold the pedal down, push the MOTOR switch for a
few seconds. Check that the brake pedal does not pulsate.

6. INSPECT FOR OTHER WHEELS

(a) Turn the selector switch to “FRONT LH” position.
(b) Repeating (c) to (j) of the step 5, check the actuator operation
similarly.
(c) Similarly, inspect “REAR RH” and “REAR LH” position.
HINT: When inspecting “REAR LH” position, push the REAR
LH switch instead of the POWER SWITCH, and you can in-
spect in any selector switch position.
BR–56
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

7. PUSH MOTOR SWITCH

Push and hold in the MOTOR switch for a few seconds.
8. DISCONNECT ACTUATOR CHECKER (SST) FROM
ACTUATOR
Remove the “SHEET A” (SST) and disconnect the actuator
checker (SST) and sub–wire harness (SST) from the actua-
tor, control relay and body side wire harness.
SST 09990–00150, 09990–00200, 09990–00210 and
09990–00163

9. CONNECT ACTUATOR CONNECTORS

Connect the three connectors to actuator and control relay.
10. INSTALL CONTROL RELAY

11. CLEAR DIAGNOSTIC TROUBLE CODES

(a) Using SST, connect terminals Tc and E1 of DCL2 or DCL1.
SST 09843–18020
(b) IG switch ON.

(c) Clear the diagnostic trouble codes stored in ECU by

depressing the brake pedal 8 or more times within 3 seconds.
(d) Check that the warning light shows the normal code.
(e) Remove the SST from the terminals of DCL2 or DCL1.
 BR–57
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

Speed Sensor
SPEED SENSOR REMOVAL AND
INSTALLATION
Remove and install the parts as shown.
BR–58
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

Troubleshooting
HOW TO PROCEED WITH TROUBLESHOOTING
Perform troubleshooting in accordance with the procedure on the following pages.

CUSTOMER PROBLEM ANALYSIS
Using the customer problem analysis check sheet for reference, ask the customer in as much detail as
possible about the problem.
CHECK AND CLEAR THE DIAGNOSTIC TROUBLE CODES (PRECHECK)
If the ABS warning light lights up, and the ABS does not operate, the ECU stores diagnostic trouble codes
corresponding to the problem in memory.
Before confirming the trouble, first check the diagnostic trouble codes to see if there are any malfunction
codes stored in memory. When there are malfunction codes, make a note of them, then clear them and
proceed to “ Problem Symptom Confirmation”.
 PROBLEM SYMPTOM CONFIRMATION,  SYMPTOM SIMULATION
Confirm the problem symptoms. If the problem does not reoccur, be sure to simulate the problem by mainly
checking the circuits indicated by the diagnostic trouble code in step , using “Problem simulation meth-
od”.
 DIAGNOSTIC TROUBLE CODE CHECK
Check the diagnostic trouble codes.
If a malfunction code is output, proceed to “ Diagnostic Trouble Code Chart”. If the normal code is output,
proceed to “ Problem Symptoms Chart”.
Be sure to proceed to “ Diagnostic trouble Code Chart” after the steps and  are completed.
If troubleshooting is attempted only by following the malfunction code stored in the memory, errors could
be made in the diagnosis.
 DIAGNOSTIC TROUBLE CODE CHART
If a malfunction code is confirmed in the diagnostic trouble code check, proceed to the inspection proce-
dure indicated by the matrix chart for each diagnostic trouble code.
 PROBLEM SYMPTOMS CHART
If the normal code is confirmed in the diagnostic trouble code check, perform inspection in accordance with
the inspection order in the problem symptoms chart.
 CIRCUIT INSPECTION
Proceed with diagnosis of each circuit in accordance with the inspection order confirmed in  and . De-
termine whether the cause of the problem is in the sensor, actuators, wire harness and connectors, or the
ECU.
 SENSOR CHECK
Use the ABS warning light to check if each of the signals from the speed sensors are being input correctly
to the ECU. Instructions for this check are given in the circuit inspection.

REPAIRS
After the cause of the problem is located, perform repairs by following the inspection and replacement pro-
cedures in this manual.
[11] CONFIRMATION TEST
After completing repairs, confirm not only that the malfunction is eliminated, but also conduct a test drive,
etc., to make sure the entire ABS system is operating correctly. (In vehicles with the TRC system, also
check the TRC system.)
 BR–59
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

BR–60

BR–61 BR–62

IN–20

BR–61

BR–63 BR–66

BR–73 BR–101 BR–103

BR–60
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

CUSTOMER PROBLEM ANALYSIS CHECK SHEET

 BR–61
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

DIAGNOSIS SYSTEM
INDICATOR CHECK
When the ignition switch is turned on, check that the ABS
warning light goes on for 3 seconds.
HINT: If the indicator check result is not normal, proceed to
troubleshooting (see BE–118) for the combination meter sec-
tion.

DIAGNOSTIC TROUBLE CODE CHECK

1. Turn the ignition switch to ON.
2. Disconnect the Short Pin from DCL1.

3. Using SST, connect terminals Tc and E1 of DCL2 or DCL1.

SST 09843–18020
4. Read the diagnostic trouble code from the ABS warning light
on the combination meter.
HINT: If no code appears, inspect the diagnostic circuit (see
page BR–98).

As an example, the blinking patterns for normal code and

codes 11 and 21 are shown on the left.
5. Codes are explained in the code table on page BR–63.
6. After completing the check, disconnect terminals Tc and E1,
and turn off the display.
If two or more malfunctions are indicated at the same time,
the lowest numbered diagnostic trouble code will be dis-
played first.
BR–62
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

DIAGNOSTIC TROUBLE CODE

CLEARANCE
1. Using SST, connect terminals Tc and E1 of DCL2 or DCL1.
SST 09843–18020
2. IG switch ON.
3. Clear the diagnostic trouble codes stored in ECU by
depressing the brake pedal 8 or more times within 3 seconds.
4. Check that the warning light shows the normal code.

5. Remove the SST from the terminals of DCL2 or DCL1.

6. Connect the Short Pin to DCL1.
 BR–63
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

DIAGNOSTIC TROUBLE CODE CHART

If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that
code, in the table below and proceed to the page given.
BR–64
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

SPEED SENSOR SIGNAL CHECK

1. Turn the ignition switch to OFF.
2. Using SST, connect terminals Ts and E1 of DCL1.
SST 09843–18020
3. Start the engine.

4. Check that the ABS warning light blinks.

HINT: If the ABS warning light does not blink, inspect the ABS
warning light circuit (see page BR–95).
5. Drive vehicle straight forward.
HINT: Drive vehicle faster than 80 km/h (50 mph) for several
seconds.
6. Stop the vehicle.
7. Using SST, connect terminals Tc and E1 of DCL1.
SST 09843–18020
8. Read the number of blinks of the ABS warning light.
HINT: See the list of diagnostic trouble codes shown on the
next page.
If every sensor is normal, a normal code is output. (A cycle
of 0.25 sec. on and 0.25 sec. OFF is repeated)
If two or more malfunctions are indicated at the same time,
the lowest numbered code will be displayed first.

9. After performing the check, disconnect terminals Ts and E1,

Tc and E1 of DCL1, and ignition switch turned off.
 BR–65
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

Diagnostic Trouble Code of Speed Sensor Check Function

Code No. Diagnosis Trouble Area

Front right speed sensor
71 Low output voltage of front right speed sensor

Sensor installation

Front left speed sensor
72 Low output voltage of front left speed sensor

Sensor installation

Rear right speed sensor
73 Low output voltage of rear right speed sensor

Sensor installation

Rear left speed sensor
74 Low output voltage of rear left speed sensor

Sensor installation
Abnormal change in output voltage of front right
75
Front right speed sensor rotor
speed sensor.
Abnormal change in output voltage of front left
76
Front left speed sensor rotor
speed sensor
Abnormal change in output voltage of rear right
77
Rear right speed sensor rotor
speed sensor
Abnormal change in output voltage of rear left
78
Rear left speed sensor rotor
speed sensor
BR–66
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

PROBLEM SYMPTOMS CHART

If a normal code is displayed during the diagnostic trouble code check but the problem still occurs, check the
circuits for each problem symptom in the order given in the table below and proceed to the page for troubleshoot-

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ing.

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Symptoms Inspection Circuit See page

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ABS does not 1. Check the diagnostic trouble code, reconfirming that the normal code is output. BR–61

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operate. 2. IG Power Source Circuit BR–88

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3. Speed sensor circuit. BR–84

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4. Check the ABS actuator with a checker. BR–54

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If abnormal, check the hydraulic circuit for leakage (see page BR–103).

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If 1.~4. are all normal and the problem is still occurring, replace the ABS ECU.

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ABS does not operate 1. Check the diagnostic trouble code, reconfirming that the normal code is output. BR–61

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efficiently. 2. Speed sensor circuit. BR–88

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3. Stop light switch circuit. BR–93

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4. Check the ABS actuator with a checker. BR–54

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If abnormal, check the hydraulic circuit for leakage (see page BR–103).

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If 1.~4. are all normal and the problem is still occurring, replace the

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ABS ECU.

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ABS warning light 1. ABS warning light circuit. BR–95

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abnormal. 2. ABS ECU.

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Diagnostic trouble 1. ABS warning light circuit. BR–95

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code check cannot 2. Tc terminal circuit. BR–99

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be performed. 3. ABS ECU.

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Speed sensor signal 1. Ts terminal circuit. BR–101

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check cannot be per- 2. ABS ECU.

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formed
 BR–67
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

LOCATION OF CONNECTORS
Location of Connectors in Engine Compartment
BR–68
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
 BR–69
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

Location of Connectors in Instrument Panel

BR–70
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
 BR–71
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

Location of Connectors in Instrument Panel

BR–72
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

Location of Connectors in Body

 BR–73
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

CIRCUIT INSPECTION
DTC 11, 12 ABS Control (Solenoid) Relay Circuit
CIRCUIT DESCRIPTION
This relay supplies power to each ABS solenoid. After the ignition switch is turned on, if the initial check is OK,
the relay goes on.
Code No. Diagnostic Trouble Code Detecting Condition Trouble Area
Conditions (1) and (2) continue for 0.2 sec. or more:
ABS control (solenoid) relay.
(1) ABS control (solenoid) relay: ON
Open or short in ABS control (solenoid) relay
11
(2) ABS control (solenoid) relay monitor terminal circuit.
(AST) voltage: 0
ECU
Conditions (1) and (2) continue for 0.2 sec. or more:

ABS control (solenoid) relay.
(1) ABS control (solenoid) relay: OFF
12
B+ short in ABS control (solenoid) relay circuit
(2) ABS control (solenoid) relay monitor terminal

ECU
(AST) voltage: Battery positive voltage.

Fail safe function: If trouble occurs in the control (solenoid) relay circuit, the ECU cuts off current to the ABS
control (solenoid) relay and prohibits ABS control.

DIAGNOSTIC CHART
BR–74
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

WIRING DIAGRAM
 BR–75
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

INSPECTION PROCEDURE
1 Check voltage between terminals A7 2 and A7 6 of ABS control relay.
P 1. Remove the washer tank and control relay.
2. Disconnect the ABS control relay connector.

C Measure voltage between terminals A7 2 and

A7 6 of ABS control relay harness side connector.

OK Voltage: 10 – 14 V

OK NG Check and repair harness or connector.

Check continuity between terminal A7 5 and A5 4, A5 4 and A4 2, A4 2 and

2 A21 18
P Disconnect the two connectors from ABS actuator.

C Check continuity terminal A7 5 and A5 4, A5 4

and A4 2, A4 2 and A21 18.

OK Continuity

Hint There is a resistance of 4
6
between terminals

A5 4 and A4 2.

OK NG Repair or replace harness or ABS actuator

BR–76
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

3 Check ABS control relay.

C Check continuity between each terminal of ABS control
relay shown below.

OK

C 1. Apply battery positive voltage between terminals

A7 1 and A6 3.
2. Check continuity between each terminal of ABS
control relay shown below.

OK

OK NG Replace ABS control relay.

Check for open and short in harness and connector between ABS control relay and ABS ECU
4 (See page IN–27).

OK NG Repair or replace harness or connector.

If the same code is still output after the diagnostic trouble code is detected, check the contact condi-
tion of each connection. If the connections are normal, the ECU may be defective.
 BR–77
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

DTC 13, 14 ABS Control (Motor) Relay Circuit

CIRCUIT DESCRIPTION
The ABS control (motor) relay supplies power to the ABS pump motor. If the accumulator pressure drops, the
ECU switches the control (motor) relay ON and operates the ABS pump motor.
Code No. Diagnostic Trouble Code Detecting Condition Trouble Area
Conditions (1) and (2) continued for 0.2 sec. or
more:
ABS control (motor) relay.
13 (1) ABS control (motor) relay: ON
Open or short in ABS control (motor) relay circuit.
(2) ABS control (motor) relay monitor terminal
ECU.
(MT) voltage: 0 V
Conditions (1) and (2) continued for 4 sec. or more:

ABS monitor relay.
(1) ABS control (motor) relay: OFF
14
B+ short in ABS control (motor) relay circuit.
(2) ABS control (motor) relay monitor terminal

ECU.
(MT) voltage: Battery positive voltage.
Fail safe function: If trouble occurs in the control (motor) relay circuit, the ECU cuts off the current to the ABS
control (motor) relay and prohibits ABS control.

DIAGNOSTIC CHART
BR–78
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

WIRING DIAGRAM
 BR–79
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

INSPECTION PROCEDURE
1 Check voltage between terminals A6 1 of ABS control relay and body ground.
P 1. Remove the washer tank and control relay.
2. Disconnect the ABS control relay connector.

C Measure voltage between terminals A6 1 of ABS con-

trol relay harness side connector and body ground.

OK Voltage: 10 – 14 V

OK NG Check and repair harness or connector.

Check continuity between terminal A6 1 and A5 3, A5 3 and A4 5, A4 5 and

2 A21 6.
P Disconnect the two connectors from ABS actuator.

C Check continuity terminal A6 1 and A5 3, A5 3

and A4 5, A4 5 and A21 6.

OK Continuity

Hint There is a resistance of 4
6
between terminals A5

3 and A4 5.

OK NG Repair or replace harness or ABS actuator.

BR–80
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

3 Check ABS control relay

C Check continuity between each terminal of ABS control
relay shown below.

OK

C 1. Apply battery positive voltage between terminals

A6 3 and A6 4.
2. Check continuity between each terminal of ABS
control relay shown below.

OK

OK NG Replace ABS control relay

Check for open and short in harness and connector between ABS control relay and ABS ECU
4 (See page IN–27)

OK NG Repair or replace harness or connector.

If the same code is still output after the diagnostic trouble code is deleted, check the contact condition
of each connection.
If the connections are normal, the ECU may be defective.
 BR–81
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

21, 22,
DTC ABS Actuator Solenoid Circuit
23, 24
CIRCUIT DESCRIPTION
This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel
cylinders, thus controlling the turning of the wheels.
Code No. Diagnostic Trouble Code Detecting Condition Trouble Area
Conditions (1) through (3) continue for 0.05 sec. or more:
(1) ABS control (solenoid) relay: ON

ABS actuator.
(2) Voltage of ABS ECU terminal AST: Battery positive
21
Open or short in SFR circuit.
voltage.

ECU.
(3) When power transistor of ECU is ON, voltage of ter-
minal SFR is 0 V or battery positive voltage.
Conditions (1) through (3) continue for 0.05 sec. or more:
(1) ABS control (solenoid) relay: ON

ABS actuator.
(2) Voltage of ABS ECU terminal AST: Battery positive
22
Open or short in SFL circuit.
voltage.

ECU.
(3) When power transistor of ECU is ON, voltage of ter-
minal SFLR is 0 V or battery positive voltage.
Conditions (1) through (3) continue for 0.05 sec. or more:
(1) ABS control (solenoid) relay: ON

ABS actuator.
(2) Voltage of ABS ECU terminal AST: Battery positive
23
Open or short in SRR circuit.
voltage.

ECU.
(3) When power transistor of ECU is ON, voltage of ter-
minal SRR is 0 V or battery positive voltage.
Conditions (1) through (3) continue for 0.05 sec. or more:
(1) ABS control (solenoid) relay: ON

ABS actuator.
(2) Voltage of ABS ECU terminal AST: Battery positive
24
Open or short in SRL circuit.
voltage.

ECU.
(3) When power transistor of ECU is ON, voltage of ter-
minal SRL is 0 V or battery positive voltage.
Fail safe function: If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the control (sole-
noid) relay and prohibits ABS control.
DIAGNOSTIC CHART
BR–82
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

WIRING DIAGRAM
 BR–83
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

INSPECTION PROCEDURE
1 Check ABS actuator solenoid.
P 1. Remove the washer tank.
2. Disconnect the two connectors from ABS actuator.

C Check continuity between terminal A5 4 and A4 1,

3, 4, 6 of ABS actuator connector.

OK Continuity

Hint Resistance of each solenoid coil is 1.2
.

OK NG Replace ABS actuator.

Check for open and short in harness and connector between ABS ECU and actuator (See page
2 IN–27).

OK NG Repair or replace harness or connector.

If the same code is still output after the diagnostic trouble code is deleted, check the contact condition
of each connection.
If the connections are normal, the ECU may be defective.
BR–84
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

31, 32, 33,

DTC Speed Sensor Circuit
34, 35, 36
CIRCUIT DESCRIPTION
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The speed sensor detects the wheel speed and sends

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the appropriate signals to the ECU. These signals are

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used for control of both the ABS and system. The front
rotor and rear rotor have 48 serrations. When the rotors
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
rotate, the magnetic field emitted by the permanent mag-

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ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
net in the speed sensor generates an AC voltage.

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Since the frequency of this AC voltage changes in pro-

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portion to the speed of the rotors (wheels), the frequency

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is used by the ECU to detect the speed of each wheel.

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ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
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Code No.
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Diagnostic Trouble Code Detecting Condition Trouble Area
Detection of any of conditions (1) through (3):
(1) At vehicle speed of 10 km/h (6 mph) or more,
pulses are not input for 5 sec.
(2) Momentary interruption of the vehicle speed
Right front, left front, right rear and left rear speed
31, 32 sensor signal occurs at least 7 times in the sensor.
33, 34 time between switching the ignition switch ON
Open or short in each speed sensor circuit.
and switching it OFF.
ECU
(3) Abnormal fluctuation of speed sensor signals
with the vehicle speed 20 km/h (12 mph) or
more.
Vehicle speed sensor signal is not input for about 1
sec. while the left front and right rear vehicle speed
Open in left front, right rear speed sensor circuit.
35
sensor signals are being checked when the IG
ECU.
switch is turned ON.
Vehicle speed sensor signal is not input for about 1
sec. while the right front and left rear vehicle speed
Open in right front, left rear speed sensor circuit.
36
sensor signals are being checked with the IG switch
ECU.
ON.
HINT: DTC 31 is for the right front wheel speed sensor.
DTC 32 is for the left front wheel speed sensor.
DTC 33 is for the right rear wheel speed sensor.
DTC 34 is for the left rear wheel speed sensor.
Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control
(solenoid) relay and prohibits ABS control.
 BR–85
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

DIAGNOSTIC CHART

(See page BR–64).

WIRING DIAGRAM
BR–86
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

INSPECTION PROCEDURE
1 Speed sensor check.
P See speed sensor check on page BR–64.

NG OK When diag. Code 31 – 36 are displayed, check and re-

place ABS ECU.

2 Check speed sensor.

Front

P 1. Remove front fender liner.

2. Disconnect speed sensor connector.

C Measure resistance between terminals 1 and 2 of speed

sensor connector.

OK Resistance: 0.9 – 1.3 k

C Measure resistance between terminals 1 and 2 of speed

sensor connector and body ground.

OK Resistance: 1 M
or higher

Rear

P 1. Remove the seat cushion and side seat back.

2. Disconnect speed sensor connector.

C Measure resistance between terminals 1 and 2 of speed

sensor connector.
OK Resistance: 0.9 – 1.3 k

C Measure resistance between terminals 1 and 2 of speed

sensor connector and body ground.

OK Resistance: 1 M
of higher

OK NG Replace speed sensor

Check for open and short in harness and connector between each speed sensor and ECU (See
3 page IN–27).

OK NG Repair or replace harness or connector.

 BR–87
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

4 Check sensor rotor and sensor installation.

Front
P Remove front speed sensor. (See SA section)

C Check sensor rotor serrations.

OK No scratches or missing teeth.

C Check the front speed sensor installation.

OK The installation bolts are tightened properly

Rear
P Remove the drive shaft. (See the SA section)

C Check the sensor rotor serrations.

OK No scratches or missing teeth.

C Check the speed sensor installation.

OK The installation bolt is tightened properly and there

is no clearance between the sensor and rear axle
carrier.

OK NG Replace speed sensor or rotor.

Check and replace ABS ECU.

BR–88
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

CIRCUIT INSPECTION
DTC 41 IG Power Source Circuit
CIRCUIT DESCRIPTION
This is the power source for the ECU and becomes power source for the CPU and actuators.
Code No. Diagnostic Trouble Code Detecting Condition Trouble Area
Battery
Vehicle speed is 3 km/h (1.9 mph) or more and voltage
IC regulator
41 of ECU terminal IG remains at more than 17 V or below
Open or short in power source circuit.
9.5 V for more than 10 sec.
ECU
Fail safe function: If trouble occurs in the power source circuit, the ECU cuts off current to the ABS control (sole-
noid) relay and prohibits ABS control.

DIAGNOSTIC CHART
First check battery positive voltage. If the voltage is not between 10 V and 14 V, check and repair the charging
system.

(See page IN–27).

 BR–89
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

WIRING DIAGRAM
BR–90
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

INSPECTION PROCEDURE
1 Check voltage between terminals IG and GND of ABS ECU connector.
P Remove ABS ECU with connectors still connected.

C 1. Turn ignition switch on,

2. Measure voltage between terminals IG and GND of
ABS connector.

OK Voltage: 10 – 14 V

NG OK When diag. code 41 is displayed, check and replace ABS

ECU.

2 Check continuity between terminal GND of ECU connector and body ground.
C Measure resistance between terminal GND of ABS con-
nector and body ground.
OK Resistance: 1
or less.

OK NG Repair or replace harness or connector.

Go to step
.
 BR–91
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

3 Check ECU–IG fuse.

P Remove ECU–IG fuse from J/B No. 1.

C Check continuity of ECU–IG fuse.

OK Continuity

OK NG Check for short in all the harness and components con-

nected to ECU–IG fuse (See attached wiring diagram).

Check for open in harness and connector between

ABS ECU and battery.
BR–92
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

DTC 51 ABS Pump Motor Lock

CIRCUIT DESCRIPTION
Code No. Diagnostic Trouble Code Detecting Condition Trouble Area
Pump motor is not operating normally during initial
51
ABS pump motor.
check.
Fail safe function: If trouble occurs in the ABS pump motor, the ECU cuts off the current to the control (motor)
relay and prohibits ABS control.

DIAGNOSTIC CHART
See inspection of ABS pump motor (See page BR–54).

WIRING DIAGRAM
(Reference)
 BR–93
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

Stop Light Switch Circuit

CIRCUIT DESCRIPTION
This stop light switch senses whether the brake pedal is depressed or released, and send the signal to the ECU.

DIAGNOSTIC CHART

(See page BE–65).

(See page BR–66).

(See page IN–27).

WIRING DIAGRAM
BR–94
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

INSPECTION PROCEDURE
1 Check operation of stop light.
C Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is re-
leased.

OK NG Repair stop light circuit (See page BE–65).

2 Check voltage between terminal STP of ABS ECU and body ground.
P Remove ABS ECU with connectors still connected.

C Measure voltage between terminal.

OK Voltage: 10 – 14 V

NG OK Proceed to next circuit inspection shown on problem

symptoms chart (See page BR–66).

Check for open in harness and connector between ABS ECU and stop light switch (See page
3 IN–27).

OK NG Repair or replace harness or connector.

Check and replace ABS ECU.

 BR–95
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

ABS Warning Light Circuit

CIRCUIT DESCRIPTION
If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this
time, the ECU records a diagnostic trouble code in memory.
After removing the short pin of the DCL1, connect a DCL1 or connect between Tc and E1 of the DCL2 to cause
the ABS warning light to blink and output the diagnostic trouble code is output.

DIAGNOSTIC CHART
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Perform troubleshooting in accordance with the chart below for each trouble symptom.
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ABS warning light does not light up
ABS warning light remains on
Go to step

Go to step 

WIRING DIAGRAM
BR–96
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
 BR–97
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

INSPECTION PROCEDURE
1 Check ABS warning light.
See Combination Meter Troubleshooting on page BE–118.

OK NG Replace bulb or combination meter assembly.

2 Check ABS (control) relay.

P 1. Remove the washer tank and control relay.
2. Disconnect the connectors from control relay.

C Check continuity between each terminal of ABS control

relay shown below.
OK

C 1. Apply battery positive voltage between terminals

A7 1 and A6 3.
2. Check continuity between each terminal of ABS
control relay shown below.

OK

C Connect the
test lead to terminal 4 of A7 and the

 lead to terminal 5 of A7 . Check continuity between
the terminals.
OK Continuity
If there is no continuity, connect the  test lead to termi-
nal 4 of A7 and the
lead to terminal 5 of A7 . Re-
check continuity between terminals.

OK NG Replace ABS control relay.

Repair or replace and check for open in harness and connector between DCL1 and ABS control relay
and body ground (See page IN–27).
BR–98
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

3 Is diagnostic trouble code output?

Perform diagnostic trouble code check on page BR–61.

NO YES Repair circuit indicated by the code output.

4 Does ABS warning light go off if short pin is removed?

YES NO Check for short in harness and connector between warn-

ing light and DCL1 and ECU. (see page IN–27).

5 Check ABS control relay (See step No. 2).

OK NG Replace ABS control relay.

Repair or replace and check for short in harness

and connector between DCL1 and ABS control
relay (See page IN–27).
 BR–99
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

Tc Terminal Circuit
CIRCUIT DESCRIPTION
Connecting between terminals Tc and E1 of the DCL1 or the DCL2 causes the ECU to display the diagnostic
trouble code by flashing the ABS warning light.

DIAGNOSTIC CHART

(See page IN–27).

WIRING DIAGRAM
BR–100
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

INSPECTION PROCEDURE
1 Check voltage between terminals Tc and E1 of DCL2 or DCL1.
C 1.
Turn ignition switch ON.
2.
Measure voltage between terminals Tc and E1 of
DCL2 or DCL1.
OK Voltage: 10 – 14 V

NG OK If ABS warning light does not blink even after Tc and E1

are connected, the ECU may be defective.

Check for open and short in harness and connector between ABS ECU and DCL2 or DCL1, DCL2
2 or DCL1 and body ground (See page IN–27).

OK NG Repair or replace harness or connector.

Check and replace ABS ECU.

 BR–101
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

Ts Terminal Circuit
CIRCUIT DESCRIPTION
The sensor check circuit detects abnormalities in the speed sensor signal which can not be detected with the
diagnostic trouble code check.
Connecting terminals Tc and E1 of the DCL1 in the engine compartment starts the check.

DIAGNOSTIC CHART

(See page IN–27).

WIRING DIAGRAM
BR–102
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

INSPECTION PROCEDURE
1 Check voltage between terminal Ts and E1 of DCL1.
C 1.
Turn ignition switch ON.
2.
Measure voltage between terminal Ts and E1 of
DCL1.
OK Voltage: 10 – 14 V

NG OK If ABS warning light does not blink even after Ts and E1

are connected, the ECU may be defective.

Check for open and short in harness and connector between ABS ECU and DCL1, DCL1 and
2 body ground (See page IN–27).

OK NG Repair or replace harness or connector.

Check and replace ABS ECU.

 BR–103
BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)

Check for Fluid Leakage

BR–104
BRAKE SYSTEM – SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS
BR04N–01

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SERVICE DATA
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ÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
Brake pedal height (from asphalt sheet) 147.5–157.5 mm (5.81–6.20 in.)

ÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑ
Brake pedal freeplay
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ 1–6 mm (0.04–0.24 in.)

ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
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Brake pedal reserve distance at 490N (50kgf,110.2lbf) More than 70 mm (2.76 in.)

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Brake booster push rod to piston clearance

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Front brake pad thickness STD
(w/SST) 0 mm (0 in.)
11.0 mm (0.433 in.)

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Front brake pad thickness Limit 1.0 mm (0.039 in.)

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Front brake disc thickness

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Front brake disc thickness
STD
Limit
28.0 mm (1.102 in.)
26.0 mm (1.063 in.)

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Front brake disc runout Limit 0.05 mm (0.0020 in.)

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Rear brake pad thickness STD 10.0 mm (0.394 in.)

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Rear brake pad thickness

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Rear brake disc thickness
Limit
STD
1.0 mm (0.039 in.)
10.0 mm (0.394 in.)

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Rear brake disc runoutÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ
Rear brake disc thickness

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Limit
Limit
9.0 mm (0.354 in.)
0.15 mm (0.0059 in.)

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Rear brake disc inner diameter STD 170 mm (6.69 in.)

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Rear brake disc inner diameter

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Parking brake lining thickness
Limit
STD
171 mm (6.73 in.)
2.0 mm (0.079 in.)

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Parking brake lining thickness

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Parking brake lever travel at 196 N (20 kgf, 44.1 lbf)
Limit 1.0 mm (0.039 in.)
5–8 clicks

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Parking brake clearance between rear shoe and lever Less than 0.35 mm (0.0138 in.)

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Parking ÑÑÑÑ
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g brake adjusting
j g shim thickness
0.3mm (0.012 in.)
0.6 mm (0.024 in.)

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ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ 0.9 mm (0.035 in.)
 BR–105
BRAKE SYSTEM – SERVICE SPECIFICATIONS

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TORUE SPECIFICATIIONS
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BR04P–01

Part tightened N⋅m kgf⋅cm ft⋅lbf

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Master cylinder X Reservoir tank 1.7 17.5 15.2 in.⋅lbf

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Piston stopper bolt X Master cylinder 10 100 7

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Master cylinder X Brake booster 13 130 9

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Brake blister X Clevis lock nut 25 260 19

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Brake booster X pedal bracket

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Front disc brake torque plate X Steering knuckle
13
107
130
1,090
9
79

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Front disc brake cylinder installation bolt 34 350 25

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Brake tube union nut
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Front disc brake cylinder X Flexible hose union bolt

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29
15
300
155
21
11

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Bleeder plug
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ÑÑÑÑÑÑÑ 8.3 85 74 in.⋅lbf

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Rear disc brake torque plate X Axle carrier 47 475 34

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Rear disc brake cylinder installation bolt

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Rear disc brake cylinder main pin installation bolt
20
27
200
270
14
19

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Rear disc brake X Flexible hose 29 300 21

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LSPV X Body
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ÑÑÑÑÑÑÑ 39 400 29

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LSPV adjusting bolt lock nut X Suspension arm 13 130 9

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ABS actuator X Actuator bracket 5.4 55 48 in.⋅lbf

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ABS actuator bracket X Body

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Front speed sensor installation bolt
19
7.8
195
80
14
69 in.⋅lbf

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Rear speed sensor installation bolt 7.8 80 69 in.⋅lbf