Infiniti G20 P11 (2000) Service Manual – BRAKE SYSTEM

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Page 1

EXIT

PRECAUTIONS ...............................................................3

Supplemental Restraint System (SRS) ″AIR

BAG″ and ″SEAT BELT PRE-TENSIONER″...............3

Precautions for Brake System.....................................3

Wiring Diagrams and Trouble Diagnosis.....................4

PREPARATION ...............................................................5

Commercial Service Tools...........................................5

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING.....................................................6

NVH Troubleshooting Chart.........................................6

ON-VEHICLE SERVICE ..................................................7

Checking Brake Fluid Level.........................................7

Checking Brake Line ...................................................7

Changing Brake Fluid..................................................7

Brake Burnishing Procedure........................................7

Bleeding Brake System...............................................8

BRAKE HYDRAULIC LINE.............................................9

Hydraulic Circuit...........................................................9

Removal.......................................................................9

Inspection.....................................................................9

Installation..................................................................10

DUAL PROPORTIONING VALVE.................................11

Inspection...................................................................11

BRAKE PEDAL AND BRACKET..................................12

Removal and Installation...........................................12

Inspection...................................................................12

Adjustment.................................................................12

MASTER CYLINDER.....................................................14

Removal.....................................................................14

Disassembly...............................................................14

Inspection...................................................................15

Assembly ...................................................................15

Installation..................................................................16

BRAKE BOOSTER........................................................17

On-vehicle Service.....................................................17

OPERATING CHECK AIRTIGHT CHECK

Removal.....................................................................17

Inspection...................................................................17

...............................................17

...................................................17

SECTION

CONTENTS

OUTPUT ROD LENGTH CHECK

Installation..................................................................18

VACUUM HOSE.............................................................19

Removal and Installation...........................................19

Inspection...................................................................19

HOSES AND CONNECTORS CHECK VALVE

FRONT DISC BRAKE ...................................................20

Component ................................................................20

Pad Replacement......................................................20

Removal.....................................................................21

Disassembly...............................................................21

Inspection...................................................................21

CALIPER ROTOR

Assembly ...................................................................23

Installation..................................................................23

REAR DISC BRAKE......................................................24

Component ................................................................24

Pad Replacement......................................................24

Removal.....................................................................26

Disassembly...............................................................27

Inspection...................................................................28

CALIPER ROTOR

Assembly ...................................................................29

Installation..................................................................31

PARKING BRAKE CONTROL......................................32

Components...............................................................32

Removal and Installation...........................................32

Inspection...................................................................33

Adjustment.................................................................33

DESCRIPTION...............................................................34

Purpose......................................................................34

ABS (Anti-Lock Brake System) Operation ................34

ABS Hydraulic Circuit................................................34

System Components .................................................35

BRAKE SYSTEM

..............................17

...................................19

........................................................19

.................................................................21

...................................................................22

.................................................................28

...................................................................28

ABS

IDX

Page 2

CONTENTS (Cont’d)

EXIT

System Description....................................................35

SENSOR CONTROL UNIT ABS ACTUATOR AND ELECTRIC UNIT

.................................................................35

......................................................35

....................35

Component Parts and Harness Connector

Location .....................................................................37

Schematic..................................................................38

Wiring Diagram - ABS -.............................................39

ON BOARD DIAGNOSTIC SYSTEM

DESCRIPTION...............................................................42

Self-diagnosis ............................................................42

FUNCTION SELF-DIAGNOSIS PROCEDURE HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)

..............................................................42

..............................42

........................................42

........................................43

CONSULT-II...............................................................44

CONSULT-II APPLICATION TO ABS ECU (ABS CONTROL UNIT) PART NUMBER

.....................................................................44

MODE

..........................44

CONSULT-II Inspection Procedure............................44

SELF-DIAGNOSIS PROCEDURE SELF-DIAGNOSTIC RESULTS MODE DATA MONITOR PROCEDURE ACTIVE TEST PROCEDURE DATA MONITOR MODE ACTIVE TEST MODE

...........................................49

...............................................49

..............................44

.......................46

................................47

....................................48

TROUBLE DIAGNOSIS - INTRODUCTION..................50

How to Perform Trouble Diagnoses for Quick

and Accurate Repair..................................................50

INTRODUCTION

TROUBLE DIAGNOSIS - BASIC INSPECTION...........51

......................................................50

Preliminary Check......................................................51

Ground Circuit Check................................................54

ABS ACTUATOR AND ELECTRIC UNIT GROUND

TROUBLE DIAGNOSIS - GENERAL

DESCRIPTION...............................................................55

Malfunction Code/Symptom Chart.............................55

.....54

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC

ITEMS.............................................................................56

Wheel Sensor or Rotor..............................................56

DIAGNOSTIC PROCEDURE

.....................................56

ABS Actuator Solenoid Valve or Solenoid Valve

Relay..........................................................................59

DIAGNOSTIC PROCEDURE

.....................................59

Motor Relay or Motor.................................................62

DIAGNOSTIC PROCEDURE

.....................................62

Low Voltage...............................................................64

DIAGNOSTIC PROCEDURE

.....................................64

Control Unit................................................................66

DIAGNOSTIC PROCEDURE

.....................................66

TROUBLE DIAGNOSES FOR SYMPTOMS.................67

1. ABS Works Frequently ..........................................67

2. Unexpected Pedal Action ......................................67

3. Long Stopping Distance........................................68

4. ABS Does Not Work..............................................69

5. Pedal Vibration and Noise.....................................70

6. ABS Warning Lamp Does Not Come On

When Ignition Switch Is Turned On...........................71

7. ABS Warning Lamp Stays On When Ignition

Switch Is Turned On..................................................73

REMOVAL AND INSTALLATION.................................75

Front Wheel Sensors.................................................75

Rear Wheel Sensors .................................................76

ABS Actuator and Electric Unit..................................77

REMOVAL INSTALLATION

...............................................................77

........................................................77

Sensor Rotor..............................................................78

REMOVAL INSTALLATION

...............................................................78

........................................................78

SERVICE DATA AND SPECIFICATIONS (SDS).........79

General Specifications...............................................79

Disc Brake .................................................................79

Brake Pedal...............................................................79

Parking Brake............................................................79

BR-2

Page 3

PRECAUTIONS

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELTPRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to INFINITI G20 is as follows:

I For a frontal collision

The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.

I For a side collision

The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), satellite sensor, diagnosis sensor unit (one ofcomponents of air bags for a frontal collision),wiring harness, warning lamp (one of components of air bags for a frontal collision).

Information necessary to service the system safely is included in the RS section of this Service Manual.

WARNING:

I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death

in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized INFINITI dealer.

I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-

sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section.

I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this

Service Manual. Spiral cable and wiring harnesses (except “SEAT BELT PRE-TENSIONER”) covered with yellow insulation tape either just before the harness connectors or for the complete harness are related to the SRS.

NCBR0081

EXIT

SBR686C

Precautions for Brake System

I Recommended fluid is brake fluid “DOT 3”. I Never reuse drained brake fluid. I Be careful not to splash brake fluid on painted areas. I To clean or wash all parts of master cylinder, disc brake

caliper and wheel cylinder, use clean brake fluid.

I Never use mineral oils such as gasoline or kerosene. They

will ruin rubber parts of the hydraulic system.

I Use flare nut wrench when removing and installing brake

tube.

I Always torque brake lines when installing. I Burnish the brake contact surfaces after refinishing or

replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “ON-VEHICLE SERVICE”, BR-7.

WARNING:

I Clean brake pads and shoes with a waste cloth, then wipe

with a dust collector.

NCBR0002

IDX

BR-3

Page 4

Wiring Diagrams and Trouble Diagnosis

PRECAUTIONS

EXIT

Wiring Diagrams and Trouble Diagnosis

When you read wiring diagrams, refer to the following:

I GI-11, “HOW TO READ WIRING DIAGRAMS” I EL-9, “POWER SUPPLY ROUTING”

When you perform trouble diagnosis, refer to the following:

I GI-36, “HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS” I GI-25, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”

NCBR0003

BR-4

Page 5

PREPARATION

Commercial Service Tools

EXIT

Tool name Description 1 Flare nut crowfoot

2 Torque wrench

NT360

Brake fluid pressure gauge

NT151

Commercial Service Tools

Removing and installing each brake piping

a: 10 mm (0.39 in)

Measuring brake fluid pressure

NCBR0004

BR-5

IDX

Page 6

X: Applicable

Symptom BRAKE

Noise X X X XXXXXX

Shake X XXXXXX

Shimmy, Judder XXXXXXX XXXXX

Possible cause and

SUSPECTED PARTS

Reference page

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

NVH Troubleshooting Chart

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

BR-6

Pads - damaged Pads - uneven wear Shims damaged Rotor imbalance Rotor damage Rotor runout Rotor deformation Rotor deflection Rotor rust Rotor thickness variation DRIVE SHAFT AXLE SUSPENSION TIRES ROAD WHEEL STEERING

BR-20, 24 BR-20, 24 BR-20, 24

— —

BR-22, 28

— — —

BR-22, 28 NVH in AX section NVH in AX section NVH in SU section NVH in SU section NVH in SU section NVH in ST section

NVH Troubleshooting Chart

NCBR0005S01

NCBR0005

EXIT

Page 7

ON-VEHICLE SERVICE

Checking Brake Fluid Level

EXIT

SBR451D

SBR389C

SBR419C

Checking Brake Fluid Level

I Check fluid level in reservoir tank. It should be between Max

and Min lines on reservoir tank.

I If fluid level is extremely low, check brake system for leaks. I Release parking brake lever and see if brake warning lamp

goes off. If not, check brake system for leaks.

Checking Brake Line

CAUTION:

If leakage occurs around joints, retighten or, if necessary, replace damaged parts.

1. Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts.

2. Check for oil leakage by fully depressing brake pedal while engine is running.

Changing Brake Fluid

CAUTION:

I Refill with new brake fluid “DOT 3”. I Always keep fluid level higher than minimum line on res-

ervoir tank.

I Never reuse drained brake fluid. I Be careful not to splash brake fluid on painted areas; it

may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately.

1. Clean inside of reservoir tank, and refill with new brake fluid.

2. Connect a vinyl tube to each air bleeder valve.

3. Drain brake fluid from each air bleeder valve by depressing brake pedal.

4. Refill until brake fluid comes out of each air bleeder valve. Use same procedure as in bleeding hydraulic system to refill brake fluid. Refer to “Bleeding Brake System”, BR-8.

NCBR0006

NCBR0007

NCBR0008

Brake Burnishing Procedure

Burnish the brake contact surfaces according to the following procedure after refinishing or replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.

CAUTION:

Only perform this procedure under safe road and traffic conditions. Use extreme caution.

1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).

2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot

NCBR0036

BR-7

IDX

Page 8

Brake Burnishing Procedure (Cont’d)

ON-VEHICLE SERVICE

pressure such that vehicle stopping time equals 3 to 5 seconds.

3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.

4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

EXIT

SBR995

SBR419C

Bleeding Brake System

NCBR0009

CAUTION:

I Carefully monitor brake fluid level at master cylinder dur-

ing bleeding operation.

I Fill reservoir with new brake fluid “DOT 3”. Make sure it is

full at all times while bleeding air out of system.

I Place a container under master cylinder to avoid spillage

of brake fluid.

I For models with ABS, turn ignition switch OFF and dis-

connect ABS actuator connectors or battery ground cable.

I Bleed air in the following order.

Right rear brake , Left front brake , Left rear brake , Right front brake

1. Connect a transparent vinyl tube to air bleeder valve.

2. Fully depress brake pedal several times.

3. With brake pedal depressed, open air bleeder valve to release air.

4. Close air bleeder valve.

5. Release brake pedal slowly.

6. Repeat steps 2. through 5. until clear brake fluid comes out of air bleeder valve.

BR-8

Page 9

BRAKE HYDRAULIC LINE

Hydraulic Circuit

EXIT

SBR992

Hydraulic Circuit

Removal

CAUTION:

I Be careful not to splash brake fluid on painted areas; it

may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately.

I All hoses must be free from excessive bending, twisting

and pulling.

1. Connect vinyl tube to air bleeder valve.

2. Drain brake fluid from each air bleeder valve by depressing brake pedal.

3. Remove flare nut connecting brake tube and hose, then withdraw lock spring.

4. Cover openings to prevent entrance of dirt whenever disconnecting brake line.

NCBR0010

SBR322E

NCBR0011

Inspection

Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts.

NCBR0012

BR-9

IDX

Page 10

Installation

BRAKE HYDRAULIC LINE

EXIT

SBR686C

Installation

CAUTION:

I Refill with new brake fluid “DOT 3”. I Never reuse drained brake fluid.

1. Tighten all flare nuts and connecting bolts.

Specification:

Flare nut

15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

Connecting bolt

17 - 20 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)

2. Refill until new brake fluid comes out of each air bleeder valve.

3. Bleed air. Refer to “Bleeding Brake System”, BR-8.

NCBR0013

BR-10

Page 11

DUAL PROPORTIONING VALVE

Inspection

EXIT

SBR822BA

SBR823BA

Inspection

CAUTION:

I Carefully monitor brake fluid level at master cylinder. I Use new brake fluid “DOT 3”. I Be careful not to splash brake fluid on painted areas; it

may cause paint damage. If brake fluid is splashed on paint areas, wash it away with water immediately.

1. Connect Tool to air bleeders of front and rear brakes on either LH and RH side.

2. Bleed air from the Tool.

3. Check fluid pressure by depressing brake pedal.

Unit: kPa (kg/cm2, psi) Applied pressure (Front brake) 7,355 (75, 1,067) Output pressure (Rear brake) 5,100 - 5,492 (52 - 56, 739 - 796)

If output pressure is out of specification, replace dual proportioning valve.

4. Bleed air after disconnecting the Tool. Refer to “Bleeding Brake System”, BR-8.

NCBR0014

BR-11

IDX

Page 12

Removal and Installation

BRAKE PEDAL AND BRACKET

EXIT

Removal and Installation

Inspection

Check brake pedal for following items.

I Brake pedal bend I Clevis pin deformation I Crack of any welded portion I Crack or deformation of clevis pin stopper

NCBR0015

SBR109E

NCBR0016

SBR997

SBR323E

Adjustment

NCBR0017

Check brake pedal free height from metal panel. Adjust if necessary.

H: Free height

Refer to SDS, BR-79.

: Clearance between pedal stopper and threaded

1,C2

end of stop lamp switch and ASCD switch

0.3 - 1.0 mm (0.012 - 0.039 in)

BR-12

Page 13

BRAKE PEDAL AND BRACKET

1. Loosen lock nut and adjust pedal free height by turning brake booster input rod. Then tighten lock nut.

2. Check pedal free play.

Make sure that stop lamps go off when pedal is released.

3. Check brake pedal’s depressed height while engine is running. If lower than specification, check brake system for leaks, accumulation of air or any damage to components (master cylinder, wheel cylinder, etc.); then make necessary repairs.

Adjustment (Cont’d)

EXIT

SBR229E

BR-13

IDX

Page 14

Removal

MASTER CYLINDER

EXIT

Removal

NCBR0018

1. Reservor cap

2. Oil filter

3. Reservor tank

4. Seal

5. Cylinder body

6. O-ring

7. Piston stopper

8. Secondary piston assembly

9. Primary piston assembly

10. Stopper cap

CAUTION:

Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately.

1. Connect a vinyl tube to air bleeder valve.

2. Drain brake fluid from each air bleeder valve, depressing brake pedal to empty fluid from master cylinder.

3. Remove brake pipe flare nuts.

4. Remove master cylinder mounting nuts.

Disassembly

1. Bend claws of stopper cap outward.

SBR324E

NCBR0019

SBR938A

BR-14

Page 15

MASTER CYLINDER

Disassembly (Cont’d)

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

3. Remove piston assemblies.

If it is difficult to remove secondary piston assembly, gradually apply compressed air through fluid outlet.

4. Draw out reservoir tank.

EXIT

SBR231C

SBR354C

Inspection

Check for the following items.

Replace any part if damaged. Master cylinder:

I Pin holes or scratches on inner wall.

Piston:

I Deformation of or scratches on piston cups.

Assembly

1. Insert secondary piston assembly. Then insert primary piston assembly.

I Pay attention to alignment of secondary piston slit with valve

stopper mounting hole of cylinder body.

2. Install stopper cap.

Before installing stopper cap, ensure that claws are bent inward.

3. Push reservoir tank seals into cylinder body.

4. Push reservoir tank into cylinder body.

NCBR0020

NCBR0021

SBR940A

SBR435B

5. Install valve stopper while piston is pushed into cylinder.

BR-15

IDX

Page 16

Installation

MASTER CYLINDER

EXIT

SBR453C

Installation

CAUTION:

I Refill with new brake fluid “DOT 3”. I Never reuse drained brake fluid.

1. Place master cylinder onto brake booster and secure mounting nuts lightly.

2. Torque mounting nuts.

: 12 - 15 N·m (1.2 - 1.5 kg-m,9-11ft-lb)

3. Fill up reservoir tank with new brake fluid.

4. Plug all ports on master cylinder with fingers to prevent air suction while releasing brake pedal.

5. Have driver depress brake pedal slowly several times until no air comes out of master cylinder.

6. Fit brake lines to master cylinder.

7. Tighten flare nuts.

: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

8. Bleed air from brake system. Refer to “Bleeding Brake System”, BR-8.

NCBR0022

BR-16

Page 17

BRAKE BOOSTER

On-vehicle Service

EXIT

SBR002A

SBR365AA

On-vehicle Service

OPERATING CHECK

1. Stop engine and depress brake pedal several times. Check that pedal stroke does not change.

2. Depress brake pedal, then start engine. If pedal goes down slightly, operation is normal.

AIRTIGHT CHECK

1. Start engine, and stop it after one or two minutes. Depress brake pedal several times slowly. The pedal should go further down the first time, and then it should gradually rise thereafter.

2. Depress brake pedal while engine is running, and stop engine with pedal depressed. The pedal stroke should not change after holding pedal down for 30 seconds.

Removal

CAUTION:

I Be careful not to splash brake fluid on painted areas; it

may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately.

I Be careful not to deform or bend brake pipes, during

removal of booster.

NCBR0023

NCBR0023S01

NCBR0023S02

NCBR0024

SBR232CB

SBR208E

Inspection

OUTPUT ROD LENGTH CHECK

1. Apply vacuum of −66.7 kPa (−500 mmHg, −19.69 inHg) to brake booster with a handy vacuum pump.

2. Add preload of 19.6 N (2 kg, 4.4 lb) to output rod.

3. Check output rod length.

Specified length:

10.275 - 10.525 mm (0.4045 - 0.4144 in)

NCBR0025

NCBR0025S01

IDX

BR-17

Page 18

Installation

BRAKE BOOSTER

EXIT

SBR237EA

Installation

CAUTION:

I Be careful not to deform or bend brake pipes, during

installation of booster.

I Replace clevis pin if damaged. I Refill with new brake fluid “DOT 3”. I Never reuse drained brake fluid. I Take care not to damage brake booster mounting bolt

thread when installing. Due to the acute angle of installation, the threads can be damaged with the dash panel.

1. Before fitting booster, temporarily adjust clevis to dimension shown.

2. Fit booster, then secure mounting nuts (brake pedal bracket to master cylinder) lightly.

3. Connect brake pedal and booster input rod with clevis pin.

4. Secure mounting nuts.

Specification:

13 - 16 N·m (1.3 - 1.6 kg-m,9-12ft-lb)

5. Install master cylinder. Refer to “Installation” in “MASTER CYLINDER”, BR-16.

6. Bleed air. Refer to “Bleeding Brake System”, BR-8.

NCBR0026

BR-18

Page 19

VACUUM HOSE

Removal and Installation

EXIT

SBR225B

Removal and Installation

CAUTION:

When installing vacuum hoses, pay attention to the following points.

I Do not apply any oil or lubricants to vacuum hose and

check valve.

I Insert vacuum tube into vacuum hose as shown. I Install check valve, paying attention to its direction.

Inspection

HOSES AND CONNECTORS

Check vacuum lines, connections and check valve for airtightness, improper attachment chafing and deterioration.

CHECK VALVE

Check vacuum with a vacuum pump.

NCBR0027

NCBR0028

NCBR0028S01

NCBR0028S02

SBR844B

Connect to booster side Vacuum should exist. Connect to engine side Vacuum should not exist.

BR-19

IDX

Page 20

Component

FRONT DISC BRAKE

EXIT

1. Main pin

2. Pin boot

3. Torque member fixing bolt

4. Torque member

5. Shim cover

6. Inner shim

Component

7. Inner pad

8. Pad retainer

9. Outer pad

10. Outer shim

11. Connecting bolt

12. Copper washer

NCBR0030

SBR579E

13. Main pin bolt

14. Bleed valve

15. Cylinder body

16. Piston seal

17. Piston

18. Piston boot

Pad Replacement

NCBR0029

WARNING:

Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials.

CAUTION:

I When cylinder body is open, do not depress brake pedal

because piston will pop out.

I Be careful not to damage piston boot or get oil on rotor.

Always replace shims when replacing pads.

I If shims are rusted or show peeling of the rubber coat,

replace them with new shims.

I It is not necessary to remove connecting bolt except for

disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose.

I Burnish the brake contact surfaces after refinishing or

replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “ON-VEHICLE SERVICE”, BR-7.

BR-20

Page 21

SBR976B

FRONT DISC BRAKE

Pad Replacement (Cont’d)

1. Remove master cylinder reservoir cap.

2. Remove pin bolt.

3. Open cylinder body upward. Then remove pad with retainers, inner and outer shims.

Standard pad thickness:

11 mm (0.43 in)

Pad wear limit:

2.0 mm (0.079 in)

Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.

EXIT

SBR932C

SBR979B

SBR772

Removal

WARNING:

Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials.

Remove torque member fixing bolts and connecting bolt.

It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose.

Disassembly

WARNING:

Do not place your fingers in front of piston.

CAUTION:

Do not scratch or score cylinder wall.

1. Push out piston with piston boot with compressed air.

2. Remove piston seal with a suitable tool.

NCBR0031

NCBR0032

Inspection

CALIPER Cylinder Body

I Check inside surface of cylinder for score, rust, wear, damage

or presence of foreign materials. If any of the above conditions are observed, replace cylinder body.

I Minor damage from rust or foreign materials may be eliminated

by polishing surface with a fine emery paper. Replace cylinder body if necessary.

NCBR0033

NCBR0033S01

NCBR0033S0101

BR-21

IDX

Page 22

Inspection (Cont’d)

FRONT DISC BRAKE

CAUTION:

Use brake fluid to clean. Never use mineral oil.

EXIT

SBR219C

Piston

NCBR0033S0102

CAUTION:

Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are stuck to sliding surface.

Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.

Slide Pin, Pin Bolt and Pin Boot

NCBR0033S0103

Check for wear, cracks or other damage. Replace if any of the above conditions are observed.

ROTOR Rubbing Surface

NCBR0033S02

NCBR0033S0201

Check rotor for roughness, cracks or chips.

Runout

NCBR0033S0202

1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).

2. Check runout using a dial indicator.

Make sure that wheel bearing axial end play is within the specifications before measuring. Refer to AX section (“Front Wheel Bearing”, “ON-VEHICLE SERVICE”).

Maximum runout:

0.07 mm (0.0028 in)

3. If the runout is out of specification, find minimum runout position as follows:

a. Remove nuts and rotor from wheel hub. b. Shift the rotor one hole and secure rotor to wheel hub with

nuts.

c. Measure runout. d. Repeat steps a. to c. so that minimum runout position can be

found.

4. If the runout is still out of specification, turn rotor with on-car brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or equivalent).

Thickness

NCBR0033S0203

Thickness variation (At least 8 positions):

Maximum 0.01 mm (0.0004 in)

If thickness variation exceeds the specification, turn rotor with oncar brake lathe.

Rotor repair limit:

20.0 mm (0.787 in)

BR-22

Page 23

FRONT DISC BRAKE

Assembly

EXIT

SBR574

SBR980B

Assembly

1. Insert piston seal into groove on cylinder body.

2. With piston boot fitted to piston, insert piston boot into groove on cylinder body and install piston.

3. Properly secure piston boot.

Installation

CAUTION:

I Refill with new brake fluid “DOT 3”. I Never reuse drained brake fluid.

1. Install brake hose to caliper securely.

2. Install all parts and secure all bolts.

3. Bleed air. Refer to “Bleeding Brake System”, BR-8.

NCBR0034

NCBR0035

BR-23

IDX

Page 24

Component

REAR DISC BRAKE

EXIT

Component

NCBR0038

1. Cable guide

2. Cylinder

3. Toggle lever

4. Pin

5. Pin boot

6. Torque member

7. Inner shim

8. Inner pad

9. Pad retainer

10. Outer pad

11. Outer shim

12. Strut

13. O-ring

14. Push rod

15. Key plate

16. Snap ring C

17. Seat

18. Spring

19. Spring cover

20. Snap ring B

21. Piston seal

22. Snap ring A

23. Spacer

24. Wave washer

25. Spacer

26. Bearing

27. Adjuster

28. Cup

29. Piston

30. Piston boot

Pad Replacement

WARNING:

Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials.

CAUTION:

I When cylinder body is open, do not depress brake pedal

because piston will pop out.

I Be careful not to damage piston boot or get oil on rotor.

Always replace shims in replacing pads.

I If shims are rusted or show peeling of rubber coat, replace

them with new shims.

SBR895D

NCBR0037

BR-24

Page 25

SBR938C

REAR DISC BRAKE

Pad Replacement (Cont’d)

I It is not necessary to remove connecting bolt except for

disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose.

I Burnish the brake contact surfaces after refinishing or

replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. Refer to “Brake Burnishing Procedure”, “ON-VEHICLE SERVICE”, BR-7.

1. Remove master cylinder reservoir cap.

2. Remove brake cable mounting bolt and lock spring.

3. Release parking brake control lever, then disconnect cable from the caliper.

4. Remove upper pin bolt.

5. Open cylinder body downward. Then remove pad retainers, and inner and outer shims.

Standard pad thickness:

10 mm (0.39 in)

Pad wear limit:

1.5 mm (0.059 in)

EXIT

SBR916C

SBR641

6. When installing new pads, push piston into cylinder body by gently turning piston clockwise, as shown.

Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.

SBR868C

IDX

BR-25

Page 26

Pad Replacement (Cont’d)

SBR306E

REAR DISC BRAKE

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

8. As shown in the figure, align the piston’s concave to the pad’s convex, then install the cylinder body to the torque member.

EXIT

SBR307E

SBR939C

Removal

NCBR0039

WARNING:

Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials.

1. Remove brake cable mounting bolt and lock spring.

2. Release parking brake control lever, then disconnect cable from the caliper.

3. Remove torque member fixing bolts and connecting bolt.

It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose.

BR-26

Page 27

REAR DISC BRAKE

Disassembly

EXIT

SBR868C

SBR646

Disassembly

1. Remove piston by turning it counterclockwise with suitable commercial service tool or long nose pliers.

2. Pry off ring A from piston with suitable pliers and remove adjusting nut.

NCBR0040

SBR889

SBR088B

3. Disassemble cylinder body.

a. Pry off ring B with suitable pliers, then remove spring cover,

spring and seat.

b. Pry off ring C, then remove key plate, push rod and rod.

c. Remove piston seal.

Be careful not to damage cylinder body.

SBR656

IDX

BR-27

Page 28

Disassembly (Cont’d)

SBR026D

REAR DISC BRAKE

4. Remove return spring, toggle lever and cable guide.

EXIT

Inspection

CALIPER

NCBR0041

NCBR0041S01

CAUTION:

Use brake fluid to clean cylinder. Never use mineral oil.

Cylinder Body

NCBR0041S0101

I Check inside surface of cylinder for score, rust, wear, damage

or presence of foreign materials. If any of the above conditions are observed, replace cylinder body.

I Minor damage from rust or foreign materials may be eliminated

by polishing surface with a fine emery paper. Replace cylinder body if necessary.

Torque Member

NCBR0041S0102

Check for wear, cracks or other damage. Replace if necessary.

Piston

NCBR0041S0103

CAUTION:

Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign matter is stuck to sliding surface.

Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above conditions are observed.

Pin and Pin Boot

NCBR0041S0104

Check for wear, cracks or other damage. Replace if any of the above conditions are observed.

SBR219C

ROTOR Rubbing Surface

NCBR0041S02

NCBR0041S0201

Check rotor for roughness, cracks or chips.

Runout

NCBR0041S0202

1. Secure rotor to wheel hub with two nuts (M12 x 1.25).

2. Check runout using a dial indicator.

Make sure that axial end play is within the specifications before measuring. Refer to AX section (“REAR WHEEL BEARING”, “On-vehicle Service”).

BR-28

Page 29

REAR DISC BRAKE

Inspection (Cont’d)

3. Change relative positions of rotor and wheel hub so that runout is minimized.

Maximum runout:

0.07 mm (0.0028 in)

EXIT

Thickness

Rotor repair limit:

Standard thickness

9 mm (0.35 in)

Minimum thickness

8 mm (0.31 in)

Thickness variation (At least 8 portions)

Maximum 0.02 mm (0.0008 in)

Assembly

1. Insert cam with depression facing towards open end of cylinder.

NCBR0041S0203

NCBR0042

SBR247B

SBR248B

2. Generously apply rubber grease to strut and push rod to make insertion easy.

3. Fit push rod into square hole in key plate. Also match convex portion of key plate with concave portion of cylinder.

IDX

SBR893

BR-29

Page 30

Assembly (Cont’d)

SBR878

REAR DISC BRAKE

4. Install ring C with a suitable tool.

5. Install seat, spring, spring cover and ring B with suitable press and drift.

EXIT

SBR869C

SBR879

6. Install cup in the specified direction.

SBR892

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

SBR100B

BR-30

Page 31

REAR DISC BRAKE

Assembly (Cont’d)

8. Insert piston seal into groove on cylinder body.

9. With piston boot fitted to piston, insert piston boot into groove on cylinder body and fit piston by turning it clockwise with long nose pilers, or suitable tool.

EXIT

SBR646

SBR868C

SBR027D

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

11. Adjust the piston to the right angle as shown in the figure.

SBR306E

SBR307E

Installation

CAUTION:

I Refill with new brake fluid “DOT 3”. I Never reuse drained brake fluid.

1. Install caliper assembly.

I As shown in the figure, align the piston’s concave to the pad’s

convex, then install the cylinder body to the torque member.

2. Install brake hose to caliper securely.

3. Install all parts and secure all bolts.

4. Bleed air. Refer to “Bleeding Brake System”, BR-8.

NCBR0043

BR-31

IDX

Page 32

Components

PARKING BRAKE CONTROL

EXIT

Components

NCBR0044

SBR897D

SBR325E

Removal and Installation

NCBR0045

1. To remove parking brake cable, first remove center console.

2. Disconnect warning switch connector.

3. Remove bolts, slacken off and remove adjusting nut.

4. Remove lock plate and disconnect cable.

SBR025D

BR-32

Page 33

PARKING BRAKE CONTROL

Inspection

EXIT

SBR029D

SBR042D

Inspection

1. Check control lever for wear or other damage. Replace if necessary.

2. Check wires for discontinuity or deterioration. Replace if necessary.

3. Check warning lamp and switch. Replace if necessary.

4. Check parts at each connecting portion and, if found deformed or damaged, replace.

Adjustment

Pay attention to the following points after adjustment.

1) There is no drag when control lever is being released.

2) Besure that toggle lever returns to stopper when parking brake lever is released.

1. Loosen parking brake cable.

2. Depress brake pedal fully more than five times.

3. Operate control lever 10 times or more with a full stroke [203.5 mm (8.01 in)].

4. Adjust control lever by turning adjusting nut.

5. Pull control lever with specified amount of force. Check lever stroke and ensure smooth operation.

Number of notches:

6 - 7 [196 N (20 kg, 44 lb)]

6. Bend warning lamp switch plate. Warning lamp should come on when lever is pulled “A” notches. It should go off when the lever is fully released.

Number of “A” notches: 1

NCBR0046

NCBR0047

BR-33

IDX

Page 34

Purpose

DESCRIPTION

ABS

EXIT

Purpose

NCBR0082

The ABS consists of electronic and hydraulic components. It allows for control of braking force so that locking of the wheels can be avoided. The ABS:

1) Ensures proper tracking performance through steering wheel operation.

2) Enables obstacles to be avoided through steering wheel operation.

3) Ensures vehicle stability by preventing flat spins.

ABS (Anti-Lock Brake System) Operation

NCBR0083

I When the vehicle speed is less than 10 km/h (6 MPH) this system does not work. I The Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS warning lamp

for 1 second after turning the ignition switch ON.The system performs another test the firsttime the vehicle reaches 6 km/h (4 MPH). A mechanical noise may be heard as the ABS performs a self-test. This is a normal part of the self-test feature. If a malfunction is found during this check, the ABS warning lamp will come on.

I During ABS operation, a mechanical noise may be heard. This is a normal condition.

ABS Hydraulic Circuit

NCBR0084

1. Inlet solenoid valve

2. Outlet solenoid valve

3. Reservoir

4. Pump

5. Motor

6. Inlet valve

SBR984D

7. Outlet valve

8. Bypass check valve

9. Damper

BR-34

Page 35

DESCRIPTION

ABS

System Components

EXIT

System Components

System Description

SENSOR

The sensor unit consists of a gear-shaped sensor rotor and a sensor element. The element contains a bar magnet around which a coil is wound. The sensor is installed on the back side of the brake rotor. Sine-wave current is generated by the sensor as the wheel rotates. The frequency and voltage increase(s) as the rotating speed increases.

NCBR0086

SBR470E

NCBR0087

NCBR0087S01

SBR124B

SBR326E

SBR176E

CONTROL UNIT

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

ABS ACTUATOR AND ELECTRIC UNIT

The ABS actuator and electric unit contains:

I An electric motor and pump I Two relays I Eight solenoid valves, each inlet and outlet for

— LH front — RH front — LH rear — RH rear

I ABS control unit

NCBR0087S02

NCBR0087S03

IDX

BR-35

Page 36

System Description (Cont’d)

DESCRIPTION

ABS

This components controls the hydraulic circuit and increases, holds or decreases hydraulic pressure to all or individual wheels. The ABS actuator and electric unit are not disassemble.

EXIT

ABS Actuator Operation

Inlet solenoid valve

Normal brake operation OFF (Open) OFF (Closed)

Pressure hold ON (Closed) OFF (Closed)

ABS operation

Pressure decrease

Pressure increase

ON (Closed) ON (Open)

OFF (Open) OFF (Closed)

Outlet solenoid valve

NCBR0087S0301

Master cylinder brake fluid pressure is directly transmitted to caliper via the inlet solenoid valve.

Hydraulic circuit is shut off to hold the caliper brake fluid pressure.

Caliper brake fluid is sent to reservoir via the outlet solenoid valve. Then it is pushed up to the master cylinder by pump.

Master cylinder brake fluid pressure is transmitted to caliper.

BR-36

Page 37

DESCRIPTION

Component Parts and Harness Connector Location

ABS

NCBR0088

EXIT

BR-37

IDX

SBR475E

Page 38

Schematic

DESCRIPTION

ABS

EXIT

Schematic

NCBR0089

TBR166

BR-38

Page 39

DESCRIPTION

ABS

Wiring Diagram — ABS —

EXIT

Wiring Diagram — ABS —

NCBR0090

BR-39

IDX

TBR167

Page 40

Wiring Diagram — ABS — (Cont’d)

DESCRIPTION

ABS

EXIT

TBR168

BR-40

Page 41

DESCRIPTION

ABS

Wiring Diagram — ABS — (Cont’d)

EXIT

BR-41

IDX

TBR169

Page 42

Self-diagnosis

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ABS

EXIT

SAT845J

Self-diagnosis

FUNCTION

NCBR0091

NCBR0091S01

I When a problem occurs in the ABS, the ABS warning lamp on

the instrument panel comes on. To start the self-diagnostic results mode, ground the self-diagnostic (check) terminal located on “Data link connector”. The location of the malfunction is indicated by the ABS warning lamp flashing.

SELF-DIAGNOSIS PROCEDURE

NCBR0091S02

1. Drive vehicle over 30 km/h (19 MPH) for at least one minute.

2. Turn ignition switch “OFF”.

3. Ground terminal “8” of “Data link connector” with a suitable harness.

4. Turn ignition switch “ON” while grounding terminal “8”.

Do not depress brake pedal. Do not start engine.

5. After 3.0 seconds, the ABS warning lamp starts flashing to indicate the malfunction code No. (See NOTE.)

6. Verify the location of the malfunction with the malfunction code chart. Refer to BR-55. Then make the necessary repairs following the diagnostic procedures.

7. After the malfunctions are repaired, erase the malfunction codes stored in the control unit. Refer to BR-43.

8. Rerun the self-diagnostic results mode to verify that the malfunction codes have been erased.

SBR326E

SAT845J

9. Disconnect the check terminal from the ground. The self-diagnostic results mode is now complete.

10. Check ABS warning lamp for deactivation after driving vehicle over 30 km/h (19 MPH) for at least one minute.

11. After making certain thatABS warning lamp does not come on, test the ABS SELF-DIAGNOSIS in a safe area to verify that it functions properly.

NOTE:

The indication terminates after five minutes. However,when the ignition switch is turned from “OFF” to “ON”, the indication starts flashing again.

HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)

1. Determine the code No. by counting the number of times the ABS warning lamp flashes on and off.

2. When several malfunctions occur at one time, up to three code numbers can be stored; the latest malfunction will be indicated first.

3. The indication begins with the start code 12. After that a maximum of three code numbers appear in the order of the latest one first. The indication then returns to the start code 12 to repeat (the indication will stay on for five minutes at the most).

NCBR0091S03

BR-42

Page 43

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

4. The malfunction code chart is given on the BR-55 page.

ABS

Self-diagnosis (Cont’d)

EXIT

ABR256

SBR457D

HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)

1. Disconnect the check terminal from ground (ABS warning lamp will stay lit).

2. Within 12.5 seconds, ground the check terminal 3 times. Each terminal ground must last more than 1 second. The ABS warning lamp goes out after the erase operation has been completed.

3. Perform self-diagnosis again. Refer to BR-42. Only the start code should appear, no malfunction codes.

NCBR0091S04

BR-43

IDX

Page 44

CONSULT-II

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ABS

EXIT

CONSULT-II

CONSULT-II APPLICATION TO ABS

ITEM

Front right wheel sensor X X — Front left wheel sensor X X — Rear right wheel sensor X X — Rear left wheel sensor X X — Stop lamp switch — X — Front right inlet solenoid valve X X X Front right outlet solenoid valve X X X Front left inlet solenoid valve X X X Front left outlet solenoid valve X X X Rear right inlet solenoid valve X X X Rear right outlet solenoid valve X X X Rear left inlet solenoid valve X X X Rear left outlet solenoid valve X X X

SELF-DIAGNOSTIC

RESULTS

DATA MONITOR ACTIVE TEST

NCBR0092

NCBR0092S01

Actuator solenoid valve relay X X — Actuator motor relay

(ABS MOTOR is shown on the ACTIVE TEST screen.)

ABS warning lamp — X — Battery voltage X X — Control unit X — —

X: Applicable —: Not applicable

XXX

ECU (ABS CONTROL UNIT) PART NUMBER MODE

Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order the ABS actuator and electric unit.

CONSULT-II Inspection Procedure

SELF-DIAGNOSIS PROCEDURE

1. Turn ignition switch OFF.

2. Connect CONSULT-II to Data Link Connector.

3. Start engine.

4. Drive vehicle over 30 km/h (19 MPH) for at least one minute.

NCBR0092S02

NCBR0093

NCBR0093S01

SAT845J

BR-44

Page 45

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II Inspection Procedure (Cont’d)

5. Stop vehicle with engine running and touch “START” on CONSULT-II screen.

ABS

EXIT

PBR455D

PBR385C

PST412B

6. Touch “ABS”.

7. Touch “SELF-DIAG RESULTS”.

I The screen shows the detected malfunction and how many

times the ignition switch has been turned since the malfunction.

8. Make the necessary repairs following the diagnostic procedures.

9. After the malfunctions are repaired, erase the self-diagnostic results stored in the control unit by touching “ERASE”.

10. Check ABS warning lamp for deactivation after driving vehicle over 30 km/h (19 MPH) for at least one minute.

NOTE:

“SELF-DIAG RESULTS” screen shows the detected malfunction and how many times the ignition switch has been turned since the malfunction.

SBR561E

IDX

BR-45

Page 46

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II Inspection Procedure (Cont’d)

ABS

EXIT

Diagnostic item Diagnostic item is detected when ...

FR RH SENSOR [OPEN]*1

FR LH SENSOR [OPEN]*1

RR RH SENSOR [OPEN]*1

RR LH SENSOR [OPEN]*1

FR RH SENSOR [SHORT]*1

FR LH SENSOR [SHORT]*1

RR RH SENSOR [SHORT]*1

RR LH SENSOR [SHORT]*1

ABS SENSOR [ABNORMAL SIGNAL]

SELF-DIAGNOSTIC RESULTS MODE

I Circuit for front right wheel sensor is open.

(An abnormally high input voltage is entered.)

I Circuit for front left wheel sensor is open.

(An abnormally high input voltage is entered.)

I Circuit for rear right sensor is open.

(An abnormally high input voltage is entered.)

I Circuit for rear left sensor is open.

(An abnormally high input voltage is entered.)

I Circuit for front right wheel sensor is shorted.

(An abnormally low input voltage is entered.)

I Circuit for front left wheel sensor is shorted.

(An abnormally low input voltage is entered.)

I Circuit for rear right sensor is shorted.

(An abnormally low input voltage is entered.)

I Circuit for rear left sensor is shorted.

(An abnormally low input voltage is entered.)

I Teeth damage on sensor rotor or improper installation of wheel sensor.

(Abnormal wheel sensor signal is entered.)

=NCBR0093S02

Reference

Page

BR-56

FR RH IN ABS SOL [OPEN]

FR LH IN ABS SOL [OPEN]

RR RH IN ABS SOL [OPEN]

RR LH IN ABS SOL [OPEN]

FR RH IN ABS SOL [SHORT]

FR LH IN ABS SOL [SHORT]

RR RH IN ABS SOL [SHORT]

RR LH IN ABS SOL [SHORT]

FR RH OUT ABS SOL [OPEN]

FR LH OUT ABS SOL [OPEN]

RR RH OUT ABS SOL [OPEN]

I Circuit for front right inlet solenoid valve is open.

(An abnormally low output voltage is entered.)

I Circuit for front left inlet solenoid valve is open.

(An abnormally low output voltage is entered.)

I Circuit for rear right inlet solenoid valve is open.

(An abnormally low output voltage is entered.)

I Circuit for rear left inlet solenoid valve is open.

(An abnormally low output voltage is entered.)

I Circuit for front right inlet solenoid valve is shorted.

(An abnormally high output voltage is entered.)

I Circuit for front left inlet solenoid valve is shorted.

(An abnormally high output voltage is entered.)

I Circuit for rear right inlet solenoid valve is shorted.

(An abnormally high output voltage is entered.)

I Circuit for rear left inlet solenoid valve is shorted.

(An abnormally high output voltage is entered.)

I Circuit for front right outlet solenoid valve is open.

(An abnormally low output voltage is entered.)

I Circuit for front left outlet solenoid valve is open.

(An abnormally low output voltage is entered.)

I Circuit for rear right outlet solenoid valve is open.

(An abnormally low output voltage is entered.)

BR-59

RR LH OUT ABS SOL [OPEN]

FR RH OUT ABS SOL [SHORT]

FR LH OUT ABS SOL [SHORT]

I Circuit for rear left outlet solenoid valve is open.

(An abnormally low output voltage is entered.)

I Circuit for front right outlet solenoid valve is shorted.

(An abnormally high output voltage is entered.)

I Circuit for front left outlet solenoid valve is shorted.

(An abnormally high output voltage is entered.)

BR-46

BR-59

Page 47

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II Inspection Procedure (Cont’d)

ABS

EXIT

Diagnostic item Diagnostic item is detected when ...

RR RH OUT ABS SOL [SHORT]

RR LH OUT ABS SOL [SHORT]

ABS ACTUATOR RELAY [ABNORMAL]

ABS MOTOR RELAY [ABNORMAL]

BATTERY VOLT [ABNORMAL]

CONTROL UNIT I Function of calculation in ABS control unit has failed. BR-66

*1: Be sure to confirm theABS warning lamp illuminates when the ignition switch is turned ON after repairing the shorted sensor circuit, but the lamp goes out when driving the vehicle over 30 km/h (19 MPH) for one minute in accordance with SELF-DIAGNOSIS PROCEDURE.

I Circuit for rear right outlet solenoid valve is shorted.

(An abnormally high output voltage is entered.)

I Circuit for rear left outlet solenoid valve is shorted.

(An abnormally high output voltage is entered.)

I Actuator solenoid valve relay is ON, even control unit sends off signal. I Actuator solenoid valve relay is OFF, even control unit sends on signal.

I Circuit for actuator motor is open or shorted. I Actuator motor relay is stuck.

I Power source voltage supplied to ABS control unit is abnormally low. BR-64

DATA MONITOR PROCEDURE

Reference

Page

BR-59

BR-62

NCBR0093S03

1. Turn ignition switch OFF.

2. Connect CONSULT-II to data link connector.

3. Turn ignition switch ON.

4. Touch “START” on CONSULT-II screen.

PBR455D

PBR385C

5. Touch “ABS”.

6. Touch “DATA MONITOR”.

7. Touch “SETTING” on “SELECT MONITOR ITEM” screen.

8. Touch “LONG TIME” on “SET RECORDING COND” screen.

9. Touch “START” on “SELECT MONITOR ITEM”.

IDX

PST412B

BR-47

Page 48

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II Inspection Procedure (Cont’d)

ABS

EXIT

PBR455D

PBR385C

ACTIVE TEST PROCEDURE

NCBR0093S04

I When conducting Active test, vehicle must be stationary. I When ABS warning lamp stays on, never conduct Active test.

1. Turn ignition switch OFF.

2. Connect CONSULT-II to Data Link Connector.

3. Start engine.

4. Touch “START” on CONSULT-II screen.

5. Touch “ABS”.

6. Touch “ACTIVE TEST”.

PST412B

7. Select active test item by touching screen.

PBR976C

8. Touch “START”.

9. Carry out the active test by touching screen key.

PBR934C

BR-48

Page 49

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II Inspection Procedure (Cont’d)

ABS

EXIT

DATA MONITOR MODE

MONITOR ITEM CONDITION SPECIFICATION FR RH SENSOR

FR LH SENSOR RR RH SENSOR RR LH SENSOR

STOP LAMP SW

FR RH IN SOL FR RH OUT SOL FR LH IN SOL FR LH OUT SOL RR IN SOL RR OUT SOL RL IN SOL RL OUT SOL

ACTUATOR RLY

MOTOR RELAY

WARNING LAMP

BATTERY VOLT Power supply voltage for control unit

Drive vehicle. (Each wheel is rotating.)

Turn ignition switch ON and depress brake pedal.

Ignition switch is turned ON or engine is running.

Displays computed vehicle speed from wheel sensor signal. Almost the same speed as speedometer.

Depress the pedal: ON Release the pedal: OFF

Operating conditions for each solenoid valve are indicated. ABS is not operating: OFF

Displays ON/OFF condition of ABS actuator relay. When turning ignition switch ON, ABS actuator relay is operated.

ABS is not operating: OFF ABS is operating: ON

Warning lamp is turned on: ON Warning lamp is turned off: OFF

NCBR0093S05

ACTIVE TEST MODE

TEST ITEM CONDITION JUDGEMENT

Brake fluid pressure control operation

FR RH SOLENOID FR LH SOLENOID

RR RH SOLENOID RR LH SOLENOID

ABS MOTOR

NOTE:

Active test will automatically stop ten seconds after the test starts. (TEST IS STOPPED monitor shows ON.)

Ignition switch is turned ON.

UP (Increase): OFF OFF KEEP (Hold): ON OFF DOWN (Decrease): ON ON ABS actuator motor

ON: Motor runs OFF: Motor stops

NCBR0093S06

IN SOL OUT SOL

BR-49

IDX

Page 50

TROUBLE DIAGNOSIS — INTRODUCTION

How to Perform Trouble Diagnoses for Quick and Accurate Repair

INTRODUCTION

The ABS system has an electronic control unit to control major functions. The control unit accepts input signals from sensors and instantly drives actuator. It is essential that both kinds of signals are proper and stable. It is also important to check for conventional problems: such as air leaks in the booster or lines, lack of brake fluid, or other problems with the brake system. It is much more difficult to diagnose a problem that occurs intermit-

SEF233G

SEF234G

tently rather than continuously. Most intermittent problems are caused by poor electric connections or faulty wiring. In this case, careful checking of suspicious circuits may help prevent the replacement of good parts. A visual check only may not find the cause of the problems, so a road test should be performed. Before undertaking actual checks, take just a few minutes to talk with a customer who approaches with a ABS complaint. The customer is a very good source of information on such problems; especially intermittent ones. Through the talks with the customer, find out what symptoms are present and under what conditions they occur. Start your diagnosis by looking for “conventional” problems first. This is one of the best ways to troubleshoot brake problems on an ABS controlled vehicle. Also check related Service Bulletins for information.

ABS

NCBR0094

NCBR0094S01

EXIT

BR-50

Page 51

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Preliminary Check

EXIT

Preliminary Check

1 CHECK BRAKE FLUID LEVEL

Check brake fluid level in reservoir tank.

Low fluid level may indicate brake pad wear or leakage from brake line.

Is brake fluid filled between MAX and MIN lines on reservoir tank and/or has brake fluid been contaminated?

Yes © GO TO 2. No © Repair. GO TO 2.

2 CHECK BRAKE LINE

Check brake line for leakage.

NCBR0095

SBR451D

Is leakage present at or around brake lines, tubes or hoses or are any of these parts cracked or damaged?

Yes © GO TO 3. No © Repair. GO TO 3.

SBR389C

BR-51

IDX

Page 52

TROUBLE DIAGNOSIS — BASIC INSPECTION

Preliminary Check (Cont’d)

3 CHECK BRAKE BOOSTER OPERATION

Check brake booster for operation and air tightness. Refer to BR-17.

Is brake booster airtight and functioning properly?

Yes © GO TO 4. No © Replace. GO TO 4.

ABS

SBR058C

EXIT

4 CHECK BRAKE PAD AND ROTOR

Check brake pad and rotor. Refer to BR-20, 22, 24, 28.

Yes © GO TO 5. No © Replace.

SBR059C

Are brake pads and rotors functioning properly?

BR-52

Page 53

TROUBLE DIAGNOSIS — BASIC INSPECTION

5 RECHECK BRAKE FLUID LEVEL

Check brake fluid level in reservoir tank again.

ABS

Preliminary Check (Cont’d)

EXIT

Is brake fluid filled between MAX and MIN lines on reservoir tank and/or has brake fluid been contaminated?

Yes © GO TO 6. No © Fill up brake fluid.

6 CHECK WARNING LAMP ACTIVATION

Check warning lamp activation.

Yes © GO TO 7. No © Check fuse, warning lamp bulb and warning lamp circuit.

Does warning lamp turn on when ignition switch is turned “ON”?

SBR451D

SBR326E

7 CHECK WARNING LAMP DEACTIVATION

Check warning lamp for deactivation after engine is started.

Does warning lamp turn off when engine is started?

Yes © GO TO 8. No © Go to Self-diagnosis. Refer to BR-42, 44.

8 DRIVE VEHICLE

Drive vehicle at speeds over 30 km/h (19 MPH) for at least one minute.

Does warning lamp remain off after vehicle has been driven at 30 km/h (19 MPH) for at least one minute?

Yes © END No © Go to Self-diagnosis. Refer to BR-42, 44.

BR-53

IDX

Page 54

Ground Circuit Check

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

EXIT

SBR045EF

Ground Circuit Check

ABS ACTUATOR AND ELECTRIC UNIT GROUND

NCBR0096

NCBR0096S04

I Check continuity between ABS actuator and electric unit con-

nector terminals and ground.

Continuity should exist.

BR-54

Page 55

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

Malfunction Code/Symptom Chart

ABS

EXIT

Malfunction Code/Symptom Chart

Code No. (No. of LED flashes) Malfunctioning part Reference page

12 Self-diagnosis could not detect any malfunctions. — 18 Sensor rotor BR-56 21 Front right sensor (open-circuit) BR-56 22 Front right sensor (short-circuit) BR-56 25 Front left sensor (open-circuit) BR-56 26 Front left sensor (short-circuit) BR-56 31 Rear right sensor (open-circuit) BR-56 32 Rear right sensor (short-circuit) BR-56 35 Rear left sensor (open-circuit) BR-56 36 Rear left sensor (short-circuit) BR-56 41 Actuator front right outlet solenoid valve BR-59 42 Actuator front right inlet solenoid valve BR-59 45 Actuator front left outlet solenoid valve BR-59 46 Actuator front left inlet solenoid valve BR-59 51 Actuator rear right outlet solenoid valve BR-59 52 Actuator rear right inlet solenoid valve BR-59

NCBR0097

55 Actuator rear left outlet solenoid valve BR-59 56 Actuator rear left inlet solenoid valve BR-59

57* Power supply (Low voltage) BR-64

61 Actuator motor or motor relay BR-62

ABS warning lamp stays on when ignition switch is turned on.

ABS warning lamp stays on, during self-diagnosis.

ABS warning lamp does not come on when ignition switch is turned on.

ABS warning lamp does not come on during self-diagnosis.

Pedal vibration and noise — BR-70 Long stopping distance — BR-68 Unexpected pedal action — BR-67

63 Solenoid valve relay BR-59 71 Control unit BR-66

Control unit power supply circuit Warning lamp bulb circuit Control unit or control unit connector Solenoid valve relay stuck Power supply for solenoid valve relay coil

Control unit —

Fuse, warning lamp bulb or warning lamp circuit Control unit

Control unit —

BR-73

BR-71

ABS does not work. — BR-69 ABS works frequently. — BR-67

*: Under voltage that is too low,the control unit disable the ABS. It does not set theABS in fail-safe condition. Instead, the ABS becomes a conventional brake system. After the power supply has resumed, the warning lamp goes off, making it possible for the ABS to be re-engaged.

BR-55

IDX

Page 56

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Wheel Sensor or Rotor

ABS

EXIT

Wheel Sensor or Rotor

DIAGNOSTIC PROCEDURE

Malfunction code No. 21, 22, 25, 26, 31, 32, 35, 36 or 18 NOTE:

Wheel position should be identified by code No. except code No. 18 (sensor rotor).

1 INSPECTION START

Wheel sensor inspection

SBR476EA

2 CHECK CONNECTOR

1. Disconnect connectors from control unit and wheel sensor of malfunction code No. Check terminals for damage or loose connections. Then reconnect connectors.

2. Carry out self-diagnosis again.

Does warning lamp activate again?

NCBR0098

NCBR0098S01

BR-56

Page 57

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

3 CHECK WHEEL SENSOR CIRCUIT

1. Disconnect control unit connector.

2. Check resistance between control unit connector terminals. Code No. 21 or 22 (Front RH wheel) Terminals 4 and 5 Code No. 25 or 26 (Front LH wheel) Terminals 6 and 7 Code No. 31 or 32 (Rear RH wheel) Terminals 1 and 3 Code No. 35 or 36 (Rear LH wheel) Terminals 8 and 9

Resistance: 1.44 - 1.76 kΩ

ABS

Wheel Sensor or Rotor (Cont’d)

EXIT

Is resistance 1.44 - 1.76 kΩ?

4 CHECK WHEEL SENSOR

Check resistance of each sensor. (See NOTE.)

Resistance: 1.44 - 1.76 kΩ

Is resistance 1.44 - 1.76 kΩ?

nector.

SBR477EA

SBR478EA

5 CHECK TIRE

Check for inflation pressure, wear and size of each tire.

Are tire pressure and size correct and is tire wear within specifications?

BR-57

IDX

Page 58

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Wheel Sensor or Rotor (Cont’d)

6 CHECK WHEEL BEARING

Check wheel bearing axial end play. Check clearance between sensor and rotor.

Clearance:

Front

0.7 - 1.5 mm (0.028 - 0.059 in)

Rear

0.58 - 1.20 mm (0.228 - 0.0472 in)

ABS

SBR333E

EXIT

Is axial end play and clearance within specifications?

Yes © GO TO 7.

7 CHECK SENSOR ROTOR

Check sensor rotor for teeth damage.

Is sensor rotor free from damage?

connector. Reconnect control unit harness connector. Then retest.

SBR069CA

BR-58

Page 59

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

1 INSPECTION START

Solenoid valve relay inspection

ABS

ABS Actuator Solenoid Valve or Solenoid Valve Relay

DIAGNOSTIC PROCEDURE

Malfunction code No. 41, 45, 55, 42, 46, 56, 63, 51, 52

=NCBR0100

NCBR0100S01

EXIT

2 CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT

Check 40A [f] fusible link (ABS ACTR) for ABS solenoid valve relay. For fusible link layout, refer to POWER SUPPLY ROUTING in EL section.

Is fusible link OK?

3 CHECK FUSE

Check 7.5A fuse No. 3. For fuse layout, refer to “POWER SUPPLY ROUTING” in EL section.

Is fuse OK?

SBR580E

4 CHECK CONNECTOR

1. Disconnect connectors from control unit and ABS actuator. Check terminals for damage or loose connection. Then reconnect connectors.

2. Carry out self-diagnosis again.

Does warning lamp activate again?

BR-59

IDX

Page 60

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS Actuator Solenoid Valve or Solenoid Valve Relay (Cont’d)

5 CHECK GROUND CIRCUIT

Refer to ABS ACTUATOR AND ELECTRIC UNIT in Ground Circuit Check, BR-54.

Is ground circuit OK?

6 CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector.

2. Check voltage between ABS actuator and electric unit connector terminal 18 and ground.

ABS

EXIT

Does battery voltage exist?

I Harness connector E55 I Harness for open or short between ABS actuator and electric unit and fusible link

If NG, repair harness or connectors.

7 REPLACE FUSIBLE LINK

Replace fusible link.

Does the fusible link blow out when ignition switch is turned “ON”?

SBR052EE

BR-60

Page 61

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS Actuator Solenoid Valve or Solenoid Valve Relay (Cont’d)

8 CHECK RELAY UNIT POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector.

2. Check continuity between ABS actuator and electric unit connector terminal 18 and ground.

ABS

EXIT

Does continuity exist?

I Harness connector E55 I Harness for open or short between ABS actuator and electric unit and fusible link

If NG, repair harness or connectors.

9 REPLACE FUSE

Replace fuse.

Does the fuse blow out when ignition switch is turned “ON”?

I Harness connector E55 I Harness for open or short between ABS actuator and electric unit and fuse

If NG, repair harness or connectors.

SBR052EE

BR-61

IDX

Page 62

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Motor Relay or Motor

ABS

EXIT

1 INSPECTION START

ABS motor relay inspection

Motor Relay or Motor

DIAGNOSTIC PROCEDURE

Malfunction code No. 61

=NCBR0101

NCBR0101S01

2 CHECK MOTOR POWER SUPPLY CIRCUIT

Check 40A [h] fusible link (ABS MTR) for ABS motor relay. For fusible link layout, refer to POWER SUPPLY ROUTING in

EL section.

Is fusible link OK?

3 CHECK CONNECTOR

1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connection. Then reconnect connectors.

2. Carry out self-diagnosis again.

Does warning lamp activate again?

SBR581E

BR-62

Page 63

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

4 CHECK MOTOR RELAY POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector.

2. Check voltage between ABS actuator and electric unit connector terminal 17 and ground.

ABS

Motor Relay or Motor (Cont’d)

EXIT

Does battery voltage exist?

I Harness connector E55 I Harness for open or short between ABS actuator and electric unit and fusible link

If NG, repair harness or connectors.

5 CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT

Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check, BR-54.

Is ground circuit OK?

I Harness connector E55 I Harness for open or short between ABS actuator and electric unit and ground

If NG, repair harness or connectors.

6 REPLACE FUSIBLE LINK

Replace fusible link.

Does the fusible link blow out when ignition switch is turned “ON”?

SBR055EE

BR-63

IDX

Page 64

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Motor Relay or Motor (Cont’d)

7 CHECK ABS ACTUATOR MOTOR POWER SUPPLY CIRCUIT

1. Disconnect battery cable and ABS actuator and electric unit connector.

2. Check continuity between ABS actuator and electric unit connector terminal 17 and ground.

SBR055EE

Does continuity exist?

actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.

I Harness connector E55 I Harness for open or short between ABS actuator and electric unit and fusible link

If NG, repair harness or connectors.

ABS

EXIT

Low Voltage

DIAGNOSTIC PROCEDURE

Malfunction code No. 57

1 INSPECTION START

ABS actuator and electric unit power supply and ground circuit inspection

NCBR0102

NCBR0102S01

SBR582E

BR-64

Page 65

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Low Voltage (Cont’d)

2 CHECK CONNECTOR

1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connections. Then reconnect connector.

2. Carry out self-diagnosis again.

Does warning lamp activate again?

ABS

EXIT

3 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector.

2. Check voltage between ABS actuator and electric unit connector terminal 15 and ground.

Does battery voltage exist when ignition switch is turned ON?

4 CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND

Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check, BR-54.

actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.

I Harness connector E55 I Harness for open or short between ABS actuator and electric unit and ground

If NG, repair harness or connectors.

5 CHECK FUSE

Check 7.5A fuse 3 (Engine control) for control unit. Refer to POWER SUPPLY ROUTING in EL section.

Is ground circuit OK?

Is fuse OK?

SBR058EG

BR-65

IDX

Page 66

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Low Voltage (Cont’d)

6 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

Check continuity between battery and ABS actuator and electric unit connector terminal 15.

Does continuity exist?

I Harness connector E55 I Harness for open or short between ABS actuator and electric unit and fuse

If NG, repair harness or connectors.

ABS

EXIT

Control Unit

DIAGNOSTIC PROCEDURE

Malfunction code No. 71

1 INSPECTION START

ABS actuator and electric unit power supply and ground circuit inspection

2 CHECK CONNECTOR

1. Disconnect ABS actuator and electric unit connector.

Check terminals for damage or loose connections. Then reconnect connectors.

2. Carry out self-diagnosis again.

Does warning lamp activate again?

NCBR0103

NCBR0103S01

SBR583E

3 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

Check voltage. Refer to “3. CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT” in “Low Voltage”, BR-64.

Does battery voltage exist when ignition switch is turned ON?

4 CHECK WARNING LAMP INDICATION

Does warning lamp indicate code No. 71 again? Yes © Replace ABS actuator and electric unit. No © Inspect the system according to the code No.

BR-66

Page 67

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

1. ABS Works Frequently

EXIT

1. ABS Works Frequently

1 CHECK BRAKE FLUID PRESSURE

Check brake fluid pressure distribution. Refer to dual proportioning valve inspection in “DUAL PROPORTIONING VALVE”, BR-11.

Is brake fluid pressure distribution normal?

2 CHECK WHEEL SENSOR

1. Check wheel sensor connector for terminal damage or loose connections.

2. Perform wheel sensor mechanical check. Refer to “Wheel Sensor or Rotor”, BR-56.

Are wheel sensors functioning properly?

3 CHECK FRONT AXLE

Check front and rear axles for excessive looseness. Refer to AX section, “Front Wheel Bearing”, “ON-VEHICLE SERVICE” and “Rear Wheel Bearing”, “ON-VEHICLE SERVICE”.

Is front axle installed properly?

BR-67.

No © Repair.

NCBR0104

2. Unexpected Pedal Action

1 CHECK BRAKE PEDAL STROKE

Check brake pedal stroke. Is stroke excessively large?

NCBR0105

SBR540A

IDX

BR-67

Page 68

TROUBLE DIAGNOSES FOR SYMPTOMS

2. Unexpected Pedal Action (Cont’d)

2 CHECK CONNECTOR AND PERFORMANCE

1. Disconnect ABS actuator and electric unit connector.

2. Check whether brake is effective.

OK or NG

3 CHECK WARNING LAMP INDICATION

Ensure warning lamp remains off while driving.

ABS

EXIT

Is warning lamp turned off?

4 CHECK WHEEL SENSOR

1. Check wheel sensor connector for terminal damage or loose connection.

2. Perform wheel sensor mechanical check.

Is wheel sensor mechanism OK?

actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.

No © Repair.

SBR326E

3. Long Stopping Distance

1 CHECK CONNECTOR AND PERFORMANCE

1. Cancel ABS by disconnecting ABS actuator and electric unit connector.

2. Check whether stopping distance is still long.

OK or NG

OK © Perform Preliminary Check and air bleeding. NG © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”,

BR-67.

BR-68

NCBR0106

Page 69

TROUBLE DIAGNOSES FOR SYMPTOMS

3. Long Stopping Distance (Cont’d)

NOTE:

Stopping distance may be longer than vehicles without ABS when road condition is slippery.

4. ABS Does Not Work

1 CHECK WARNING LAMP INDICATION

Does the ABS warning lamp activate? Yes © Carry out self-diagnosis. Refer to BR-42, BR-44. No © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”,

BR-67.

NOTE:

ABS does not work when vehicle speed is under 10 km/h (6 MPH).

ABS

NCBR0107

EXIT

BR-69

IDX

Page 70

5. Pedal Vibration and Noise

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

EXIT

5. Pedal Vibration and Noise

1 INSPECTION START

Pedal vibration and noise inspection

2 CHECK SYMPTOM

1. Apply brake.

2. Start engine.

Does the symptom appear only when engine is started?

=NCBR0108

SAT797A

3 RECHECK SYMPTOM

Does the symptom appear when electrical equipment switches (such as headlamp) are operated? Yes © GO TO 4. No © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”,

BR-67.

4 CHECK WHEEL SENSOR

Check wheel sensor shield ground. For location of shield ground, refer to wiring diagram and “HARNESS LAYOUT” in EL section.

Is wheel sensor shield grounded properly?

actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.

No © Repair.

NOTE:

ABS may operate and cause vibration under any of the following conditions.

I Applying brake gradually when shifting or operating clutch. I Low friction (slippery) road. I High speed cornering. I Driving over bumps and pot holes. I Engine speed is over 5,000 rpm with vehicle stopped.

BR-70

Page 71

TROUBLE DIAGNOSES FOR SYMPTOMS

1 INSPECTION START

Warning lamp circuit inspection

ABS

6. ABS Warning Lamp Does Not Come On When Ignition Switch Is Turned On

=NCBR0109

EXIT

2 CHECK FUSE

Check 10A fuse No. 11 for warning lamp. For fuse layout, refer to “POWER SUPPLY ROUTING” in EL section.

Is fuse OK?

3 CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT

1. Install 10A fuse.

2. Remove solenoid valve relay.

3. Disconnect connectors from control unit and actuator.

4. Check voltage between control unit connector terminal 30 and ground after turning ignition switch “ON”.

SBR205EB

Does battery voltage exist after turning ignition switch “ON”?

SBR715DD

IDX

BR-71

Page 72

TROUBLE DIAGNOSES FOR SYMPTOMS

6. ABS Warning Lamp Does Not Come On When Ignition Switch Is Turned On (Cont’d)

4 CHECK WARNING LAMP INDICATION

Disconnect ABS actuator and electric unit connector.

Does the ABS warning lamp activate?

5 CHECK HARNESS FOR SHORT

1. Disconnect ABS actuator and electric unit connector.

2. Check voltage between ABS actuator and electric unit connector terminal 10 and ground.

ABS

SBR326E

EXIT

Does battery voltage exist?

Yes © Check combination meter. Refer to WARNING LAMPS in EL section. No © Repair harness and connectors between fuse and ABS actuator and electric unit connec-

tor terminal 10.

6 CHECK HARNESS CONNECTOR

Check ABS actuator and electric unit pin terminals for damage or connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then reset.

SBR144EE

BR-72

Page 73

1 INSPECTION START

ABS control unit inspection

TROUBLE DIAGNOSES FOR SYMPTOMS

7. ABS Warning Lamp Stays On When Ignition Switch Is Turned On

ABS

=NCBR0110

EXIT

2 CHECK WARNING LAMP

1. Disconnect ABS actuator and electric unit connector.

2. Connect suitable wire between ABS actuator and electric unit connector terminal 10 and ground.

Does warning lamp activate?

I Harness connector E55 I Harness for open or short between ABS actuator and electric unit and fuse

If NG, repair harness or connector.

3 CHECK HARNESS CONNECTOR

Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest.

SBR206EB

SBR146ED

BR-73

IDX

Page 74

TROUBLE DIAGNOSES FOR SYMPTOMS

7. ABS Warning Lamp Stays On When Ignition Switch Is Turned On (Cont’d)

4 CHECK ABS MOTOR GROUND

1. Turn ignition switch “OFF”.

2. Disconnect ABS actuator and electric unit connector.

3. Check continuity between ABS actuator and electric unit connector terminal 16 and ground.

Does continuity exist?

I Harness connector E55 I Harness for open or short between ABS actuator and electric unit and ground

If NG, repair harness or connector.

ABS

SBR147EB

EXIT

BR-74

Page 75

REMOVAL AND INSTALLATION

CAUTION:

Be careful not to damage sensor edge and sensor rotor teeth. When removing the front or rear wheel hub assembly, first remove the ABS wheel sensor from the assembly. Failure to do so may result in damage to the sensor wires making the sensor inoperative.

NCBR0111

ABS

EXIT

Front Wheel Sensors

NCBR0111S01

SBR472E

IDX

BR-75

Page 76

Rear Wheel Sensors

REMOVAL AND INSTALLATION

ABS

EXIT

Rear Wheel Sensors

NCBR0111S09

SBR473E

BR-76

Page 77

REMOVAL AND INSTALLATION

ABS

ABS Actuator and Electric Unit

EXIT

ABS Actuator and Electric Unit

NCBR0111S10

SBR474E

REMOVAL

1. Disconnect battery cable.

2. Drain brake fluid.

3. Remove mounting bracket fixing bolts and nuts.

4. Disconnect connector, brake pipes and remove fixing nuts.

INSTALLATION

CAUTION:

After installation, refill brake fluid. Then bleed air.

1. Connect brake pipes temporarily.

2. Tighten fixing bolts and nuts.

3. Tighten brake pipes.

4. Connect connector and battery cable.

NCBR0111S1001

NCBR0111S1002

BR-77

IDX

Page 78

Sensor Rotor

REMOVAL AND INSTALLATION

ABS

EXIT

SBR984C

SBR873CA

Sensor Rotor

REMOVAL

NCBR0111S02

NCBR0111S0201

1. Remove the drive shaft and rear wheel hub. Refer to “Drive Shaft” and “Wheel Hub” in AX section.

2. Remove the sensor rotor using suitable puller, drift and bearing replacer.

INSTALLATION

NCBR0111S0202

Install the sensor rotor. For front sensor rotor, use hammer and wooden block. For rear sensor rotor, use suitable drift and press.

I Always replace sensor rotor with new one.

SBR985C

I Pay attention to the dimension of rear sensor rotor as show in

figure.

h: 22.7 - 23.7 mm (0.894 - 0.933 in)

SBR986C

BR-78

Page 79

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

EXIT

General Specifications

Brake model CL25VB disc brake Cylinder bore diameter 57.2 (2.252)

Front brake

Rear brake

Master cylinder Cylinder bore diameter 23.81 (15/16)

Control valve

Brake booster

Recommended brake fluid DOT 3

Pad Length × width × thickness

Rotor outer diameter × thickness 280 × 22 (11.02 × 0.87) Brake model CL9HC disc brake Cylinder bore diameter 33.96 (1.3370) Pad

Length × width × thickness Rotor outer diameter × thickness 258 × 9 (10.16 × 0.35)

Valve model Dual proportioning valve Split point

kPa (kg/cm

Booster model

Diaphragm diameter

, psi) × reducing ratio

M195T M210T Primary 205 (8.07) 230 (9.06) Secondary 180 (7.09) 180 (7.09)

125.6 × 45.3 × 11

(4.94 × 1.783 × 0.43)

89.1 × 39.5 × 10

(3.508 × 1.555 × 0.39)

3,923 (40, 569) × 0.4

M/T A/T

Disc Brake

Brake model CL25VB CL9HC Pad wear limit Minimum thickness 2.0 (0.079) 1.5 (0.059)

Rotor repair limit

Maximum runout 0.07 (0.0028) 0.07 (0.0028) Minimum thickness 20.0 (0.787) 8 (0.31)

Brake Pedal

Free height “H”*

Clearance “C” between pedal stopper and threaded end of stop lamp switch or ASCD switch 0.3 - 1.0 (0.012 - 0.039)

M/T 151 - 161 (5.94 - 6.34) A/T 159 - 169 (6.26 - 6.65)

NCBR0077

Unit: mm (in)

NCBR0078

Unit: mm (in)

NCBR0079

Unit: mm (in)

*: Measured from surface of dash reinforcement panel to surface of pedal pad

Parking Brake

Type Center lever Number of notches

[under force of 196 N (20 kg, 44 lb)] Number of notches

when warning lamp switch comes on

6-7

BR-79

NCBR0080

IDX

Page 80

NOTES

EXIT

Infiniti G20 P11 (2000) Service Manual – BRAKE SYSTEM

Specifications and Main Features

Frequently Asked Questions

User Manual

PRECAUTIONS

Precautions for Brake System

Wiring Diagrams and Trouble Diagnosis

PREPARATION

Commercial Service Tools

NVH Troubleshooting Chart

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

ON-VEHICLE SERVICE

Checking Brake Fluid Level

Checking Brake Line

Changing Brake Fluid

Brake Burnishing Procedure

Bleeding Brake System

BRAKE HYDRAULIC LINE

Hydraulic Circuit

Removal

Inspection

Installation

DUAL PROPORTIONING VALVE

Inspection

Removal and Installation

BRAKE PEDAL AND BRACKET

Inspection

Adjustment

Removal

MASTER CYLINDER

Disassembly

Inspection

Assembly

Installation

BRAKE BOOSTER

On-vehicle Service

OPERATING CHECK

AIRTIGHT CHECK

Removal

Inspection

OUTPUT ROD LENGTH CHECK

Installation

VACUUM HOSE

Removal and Installation

Inspection

HOSES AND CONNECTORS

CHECK VALVE

Component

FRONT DISC BRAKE

Pad Replacement

Removal

Disassembly

Inspection

Assembly

Installation

Component

REAR DISC BRAKE

Pad Replacement

Removal

Disassembly

Inspection

CALIPER

Assembly

Installation

Components

PARKING BRAKE CONTROL

Removal and Installation

Inspection

Adjustment

Purpose

DESCRIPTION

ABS (Anti-Lock Brake System) Operation

ABS Hydraulic Circuit

System Components

System Description

SENSOR

CONTROL UNIT

ABS ACTUATOR AND ELECTRIC UNIT

Component Parts and Harness Connector Location

Schematic