Infiniti I35 A33 (2002) Service Manual – BRAKE SYSTEM

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BRAKE SYSTEM

PRECAUTIONS ...............................................................4

Supplemental Restraint System (SRS) ″AIR

BAG″ and ″SEAT BELT PRE-TENSIONER″...............4

Precautions for Brake System.....................................4

Wiring Diagrams and Trouble Diagnosis.....................5

PREPARATION ...............................................................6

Commercial Service Tools...........................................6

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING.....................................................7

NVH Troubleshooting Chart.........................................7

ON-VEHICLE SERVICE ..................................................8

Checking Brake Fluid Level.........................................8

Checking Brake Line ...................................................8

Changing Brake Fluid..................................................8

Brake Burnishing Procedure........................................8

Bleeding Brake System...............................................9

BRAKE HYDRAULIC LINE...........................................10

Hydraulic Circuit.........................................................10

Removal.....................................................................10

Inspection...................................................................10

Installation..................................................................11

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

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

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

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

MASTER CYLINDER (TOKICO)...................................14

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

Disassembly...............................................................15

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

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

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

MASTER CYLINDER [BOSCH (NABCO)] ...................17

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

Disassembly...............................................................18

Inspection...................................................................18

Assembly ...................................................................18

Installation..................................................................19

BRAKE BOOSTER........................................................20

On-vehicle Service.....................................................20

SECTION

CONTENTS

OPERATING CHECK AIRTIGHT CHECK

Removal.....................................................................20

Inspection...................................................................20

OUTPUT ROD LENGTH CHECK

Installation..................................................................20

VACUUM HOSE.............................................................22

Removal and Installation...........................................22

Inspection...................................................................22

HOSES AND CONNECTORS CHECK VALVE

FRONT DISC BRAKE ...................................................23

Component ................................................................23

Pad Replacement......................................................23

Removal.....................................................................24

Disassembly...............................................................24

Inspection...................................................................25

CALIPER ROTOR

Assembly ...................................................................26

Installation..................................................................26

REAR DISC BRAKE......................................................27

Component ................................................................27

Pad Replacement......................................................27

Removal.....................................................................29

Disassembly...............................................................30

Inspection...................................................................31

CALIPER ROTOR

Assembly ...................................................................32

Installation..................................................................34

PARKING BRAKE CONTROL......................................35

Components...............................................................35

Removal and Installation...........................................35

Inspection...................................................................35

Adjustment.................................................................36

DESCRIPTION...............................................................37

...............................................20

...................................................20

..............................20

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

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

.................................................................25

...................................................................25

.................................................................31

...................................................................31

TCS

IDX

CONTENTS (Cont’d)

Purpose......................................................................37

ABS (Anti-Lock Brake System) Operation ................37

ABS Hydraulic Circuit................................................37

TCS (Traction Control System) Operation................38

System Components .................................................38

System Description....................................................39

SENSOR CONTROL UNIT ACTUATOR

.................................................................39

......................................................39

.............................................................39

Component Parts and Harness Connector

Location .....................................................................41

Schematic..................................................................42

Wiring Diagram - TCS -.............................................43

ON BOARD DIAGNOSTIC SYSTEM

DESCRIPTION...............................................................47

CONSULT-II Functions ..............................................47

CONSULT-II MAIN FUNCTION ECU (ABS/TCS CONTROL UNIT) PART NUMBER

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

MODE

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

CONSULT-II Inspection Procedure............................47

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

...........................................52

...............................................53

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

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

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

....................................51

TROUBLE DIAGNOSIS - INTRODUCTION..................54

How to Perform Trouble Diagnoses for Quick

and Accurate Repair..................................................54

INTRODUCTION

......................................................54

TROUBLE DIAGNOSIS - BASIC INSPECTION...........55

Preliminary Check......................................................55

Ground Circuit Check................................................58

ABS ACTUATOR AND ELECTRIC UNIT GROUND

TROUBLE DIAGNOSIS - GENERAL

DESCRIPTION...............................................................59

Malfunction Code/Symptom Chart.............................59

CAN COMMUNICATION...............................................61

System Description....................................................61

FOR TCS MODELS

.................................................61

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC

ITEMS.............................................................................62

Wheel Sensor or Rotor..............................................62

DIAGNOSTIC PROCEDURE

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

ABS Actuator Solenoid Valve or Solenoid Valve

Relay..........................................................................66

DIAGNOSTIC PROCEDURE

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

Motor Relay or Motor.................................................69

DIAGNOSTIC PROCEDURE

.....................................69

Low Voltage...............................................................71

DIAGNOSTIC PROCEDURE

.....................................71

Control Unit................................................................73

DIAGNOSTIC PROCEDURE

.....................................73

CAN Communication System....................................74

.....58

INSPECTION PROCEDURE

.....................................74

Engine System...........................................................74

DIAGNOSTIC PROCEDURE

.....................................74

A/T System................................................................75

DIAGNOSTIC PROCEDURE

.....................................75

TROUBLE DIAGNOSES FOR SYMPTOMS.................76

1. ABS Works Frequently ..........................................76

2. Unexpected Pedal Action ......................................76

3. Long Stopping Distance........................................77

4. ABS Does Not Work..............................................78

5. Pedal Vibration and Noise.....................................79

6. ABS Warning Lamp Does Not Come On

When Ignition Switch Is Turned On...........................80

7. ABS Warning Lamp Stays On When Ignition

Switch Is Turned On..................................................81

8. SLIP Indicator Lamp Does Not Come On

When Ignition Switch Is Turned On...........................83

9. TCS OFF Indicator Lamp Does Not Come On

When Ignition Switch Is Turned On...........................84

10. TCS OFF Switch Is Inoperative ..........................86

11. Poor Acceleration.................................................89

ABS ACTUATOR AND ELECTRIC UNIT.....................90

Removal.....................................................................90

Installation..................................................................90

VDC

PRECAUTIONS .............................................................91

Supplemental Restraint System (SRS) ″AIR

BAG″ and ″SEAT BELT PRE-TENSIONER″.............91

Precautions for Brake System...................................91

Precautions for Brake Control...................................92

Precautions for CAN System.....................................92

FOR INSPECTION FOR HARNESS REPAIR

...................................................92

..........................................92

ON-VEHICLE SERVICE ................................................94

Adjustment of Neutral Position of Steering Angle

Sensor........................................................................94

GENERAL INFORMATION ...........................................96

Fail-safe.....................................................................96

ABS SYSTEM VDC/TCS SYSTEM

..........................................................96

..................................................96

Hydraulic Circuit.........................................................97

ABS Functions...........................................................97

TCS Functions...........................................................98

VDC Functions...........................................................98

System Diagram........................................................99

CAN COMMUNICATION.............................................100

System Description..................................................100

FOR VDC MODELS

...............................................100

TROUBLE DIAGNOSIS - INTRODUCTION................101

How to Perform Trouble Diagnoses for Quick

and Accurate Repair................................................101

BR-2

CONTENTS (Cont’d)

INTRODUCTION WORK FLOW ASKING COMPLAINTS EXAMPLE OF DIAGNOSIS SHEET

Component Parts and Harness Connector

Location ...................................................................104

Schmatic..................................................................105

Wiring Diagram -VDC/TCS/ABS- ............................106

Control Unit Input/Output Signal Standard..............114

STANDARDS USING A CIRCUIT TESTER AND OSCILLOSCOPE STANDARDS WITH CONSULT-II

CONSULT-II Functions ............................................119

CONSULT-II MAIN FUNCTION SELF-DIAGNOSIS DATA MONITOR ACTIVE TEST

For Correct and Quick Diagnosis............................130

PRECAUTIONS FOR TROUBLE DIAGNOSIS

TROUBLE DIAGNOSIS - BASIC INSPECTION.........132

Preliminary Check 1: (Brake Fluid Level and

Leak Inspection) ......................................................132

Preliminary Check 2: (Inspection for Loose

Power Supply Terminal)...........................................132

Preliminary Check 3: (Inspection for ABS Warning Lamp, VDC OFF Indicator Lamp, and

SLIP Indicator Lamp)...............................................132

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC

ITEMS...........................................................................134

Inspection 1 Wheel Speed Sensor and Circuit.......134

Inspection 2 Engine System....................................136

Inspection 3 VDC/TCS/ABS Control Unit System...137 Inspection 4 Pressure Sensor and The Circuit Between Pressure Sensor and VDC/TCS/ABS

Control Unit..............................................................138

Inspection 5 Steering Angle Sensor and The Circuit Between Steering Angle Sensor and

VDC/TCS/ABS.........................................................140

Inspection 6 Yaw Rate/Side G and The Circuit Between Yaw Rate/Side G and VDC/TCS/ABS

Control Unit..............................................................142

Inspection 7 Solenoid Valve, VDC Switch-over

Solenoid Valve and Circuit ......................................143

Inspection 8 Actuator Motor, Motor Relay and

Circuit.......................................................................147

Inspection 9 Actuator Relay and Circuit..................149

Inspection 10 Stop Lamp Switch and Circuit..........151

Inspection 11 VDC/TCS/ABS Control Unit Power

Supply Circuit...........................................................152

Inspection 12 When ″EMERGENCY BRAKE″ Is

Indicated in The Self-diagnosis Results..................155

Inspection 13 When ″ST ANG SEN SIGNAL″ is

Indicated in The Self-diagnosis Results..................155

....................................................101

........................................................102

..........................................103

.........................103

...................................................114

............................117

................................119

.................................................120

....................................................124

........................................................126

..........130

Inspection 14 Brake Fluid Level of Reservoir

Tank.........................................................................156

Inspection 15 CAN Communication System, VDC/TCS/ABS Control Unit and Steering Angle

Sensor......................................................................157

Component Check...................................................158

VDC OFF SWITCH VDC/TCS/ABS RELAY BOX VDC/TCS/ABS ACTUATOR

TROUBLE DIAGNOSES FOR SYMPTOMS...............162

Symptom 1: ABS Works Frequently........................162

Symptom 2: Unexpected Pedal Action....................162

Symptom 3: Longer Stopping Distance...................163

Symptom 4: ABS Does Not Work ...........................164

Symptom 5: Pedal Vibration and Noise..................164

Symptom 6: VDC OFF Indicator Lamp Does Not

Illuminate..................................................................165

Symptom 7: SLIP Indicator Lamp Does Not

Illuminate..................................................................166

Symptom 8: During VDC/TCS/ABS Control,

Vehicle Behavior is Jerky ........................................166

VDC/TCS/ABS CONTROL UNIT.................................168

Removal and Installation.........................................168

REMOVAL INSTALLATION

VDC/TCS/ABS ACTUATOR AND RELAY BOX ........169

Removal and Installation.........................................169

YAW RATE/SIDE G SENSOR.....................................170

Removal and Installation.........................................170

REMOVAL INSTALLATION

VDC OFF SWITCH......................................................171

Removal and Installation.........................................171

REMOVAL INSTALLATION

REMOVAL AND INSTALLATION...............................172

Wheel Sensors ........................................................172

Sensor Rotor............................................................172

REMOVAL INSTALLATION

SERVICE DATA AND SPECIFICATIONS (SDS).......174

General Specifications.............................................174

Disc Brake ...............................................................174

Brake Pedal.............................................................174

Parking Brake..........................................................174

Brake Booster..........................................................174

ABS Wheel Sensor..................................................174

.............................................................168

.............................................................170

.............................................................171

.............................................................172

................................................158

...................................158

....................................159

......................................................168

......................................................170

......................................................171

TCS/VDC

......................................................173

IDX

BR-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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. The SRS system composition which is available to INFINITI I35 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, crash zone sensor, warning lamp, wiring harness and spiral cable.

I For a side collision

The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), satellite sensor, diagnosis sensor unit (one of components 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 should 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. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors).

NHBR0127

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-8.

WARNING:

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

with a dust collector.

NHBR0002

BR-4

PRECAUTIONS

Wiring Diagrams and Trouble Diagnosis

When you read wiring diagrams, refer to the following:

I “HOW TO READ WIRING DIAGRAMS” in GI section I “POWER SUPPLY ROUTING” for power distribution circuit in EL section

When you perform trouble diagnosis, refer to the following:

I “HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS” in GI section I “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” in GI section I For trouble diagnoses of models with TCS. Refer to BR-37. I For trouble diagnoses of models with VDC. Refer to BR-96.

NHBR0003

IDX

BR-5

Commercial Service Tools

PREPARATION

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

NHBR0004

BR-6

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

NHBR0005

NVH Troubleshooting Chart

NHBR0005S01

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

Reference page

Possible cause and SUSPECTED PARTS

Symptom BRAKE

X: Applicable

BR-23, 27

Pads - damaged

Pads - uneven wear Noise X X X XXXXXX Shake X XXXXXX Shimmy, Judder XXXXXXX XXXXX

—

BR-23, 27

Shims damaged

Rotor imbalance

—

BR-25, 31

Rotor damage

Rotor runout

—

Rotor deformation

Rotor deflection

—

Rotor rust

BR-26, 32

NVH in AX section

Rotor thickness variation

DRIVE SHAFT

NVH in AX section

NVH in SU section

AXLE

SUSPENSION

NVH in SU section

TIRES

NVH in SU section

ROAD WHEEL

NVH in ST section

STEERING

IDX

BR-7

Checking Brake Fluid Level

ON-VEHICLE SERVICE

SBR451D

SBR389C

SBR419C

Checking Brake Fluid Level

NHBR0006

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

NHBR0007

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

NHBR0008

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-9.

Brake Burnishing Procedure

NHBR0036

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

BR-8

ON-VEHICLE SERVICE

Brake Burnishing Procedure (Cont’d)

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.

SBR995

SBR419C

Bleeding Brake System

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.

NHBR0009

BR-9

IDX

Hydraulic Circuit

BRAKE HYDRAULIC LINE

SBR992

Hydraulic Circuit

Removal

NHBR0010

SBR885EA

NHBR0011

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.

Inspection

NHBR0012

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

BR-10

BRAKE HYDRAULIC LINE

Installation

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

M10: 14.8 - 17.6 N·m (1.5 - 1.7 kg-m, 11 - 12 ft-lb) M12: 16.7 - 19.6 N·m (1.7 - 1.9 kg-m, 13 - 14 ft-lb)

Connecting bolt

17 - 20 N·m (1.8 - 2.0 kg-m, 13 - 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-9.

NHBR0013

IDX

BR-11

Removal and Installation

BRAKE PEDAL AND BRACKET

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

NHBR0015

SBR525EB

NHBR0016

SBR997

SBR526E

Adjustment

NHBR0017

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

H: Free height

Refer to SDS, BR-174.

: Clearance between pedal stopper and threaded

1,C2

end of stop lamp switch and ASCD switch

0.74 - 1.96 mm (0.0291 - 0.0772 in)

D: Depressed height

82.5 mm (3.248 in) Under force of 490 N (50 kg, 110 lb) with engine run-

ning.

BR-12

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.

SBR229E

Adjustment (Cont’d)

BR-13

IDX

Removal

MASTER CYLINDER (TOKICO)

Removal

NHBR0018

1. Reservoir cap

2. Oil filter

3. Reservoir 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.

SBR886E

BR-14

MASTER CYLINDER (TOKICO)

Disassembly

SBR938A

SBR231C

Disassembly

1. Bend claws of stopper cap outward and remove stopper cap.

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.

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.

NHBR0019

NHBR0020

SBR354C

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.

NHBR0021

IDX

SBR940A

BR-15

Assembly (Cont’d)

MASTER CYLINDER (TOKICO)

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

SBR222B

SBR704C

Installation

NHBR0022

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 (1.3 - 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.

M10: M12:

14.8 - 17.6 N·m (1.5 - 1.7 kg-m, 11 - 12 ft-lb)

16.7 - 19.6 N·m (1.7 - 1.9 kg-m, 13 - 14 ft-lb)

8. Bleed air from brake system. Refer to “Bleeding Brake System”, BR-9.

BR-16

MASTER CYLINDER [BOSCH (NABCO)]

Removal

NHBR0095

1. Reservoir cap

2. Oil filter

3. Reservoir tank

4. Seal

5. Cylinder body

6. Spring pin

7. Piston stopper pin

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.

8. Secondary piston assembly

9. Primary piston assembly

10. Stopper cap

SBR976E

IDX

BR-17

Disassembly

MASTER CYLINDER [BOSCH (NABCO)]

SBR234E

SBR231E

Disassembly

NHBR0096

1. Bend claws of stopper cap outward and remove stopper cap.

2. Drive out spring pin from cylinder body.

3. Draw out reservoir tank and seals.

4. Remove piston stopper pin while piston is pushed into cylinder.

5. Remove piston assemblies.

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

SBR232E

SBR233E

Inspection

NHBR0097

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

NHBR0098

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.

BR-18

MASTER CYLINDER [BOSCH (NABCO)]

2. Install piston stopper pin while piston is pushed into cylinder.

3. Push reservoir tank seals and reservoir tank into cylinder body.

4. Install spring pin.

SBR232E

5. Install stopper cap.

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

Assembly (Cont’d)

SBR235E

SBR236E

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 (1.3 - 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.

M10: M12:

8. Bleed air from brake system.

14.8 - 17.6 N·m (1.5 - 1.7 kg-m, 11 - 12 ft-lb)

16.7 - 19.6 N·m (1.7 - 1.9 kg-m, 13 - 14 ft-lb)

NHBR0099

BR-19

IDX

On-vehicle Service

BRAKE BOOSTER

SBR002A

SBR365AA

On-vehicle Service

OPERATING CHECK

NHBR0023

NHBR0023S01

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

NHBR0023S02

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

NHBR0024

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.

SBR888E

SBR208E

Inspection

OUTPUT ROD LENGTH CHECK

NHBR0025

NHBR0025S01

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)

Installation

NHBR0026

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.

BR-20

SBR889E

BRAKE BOOSTER

Installation (Cont’d)

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

Specification:

130 mm (5.12 in)

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:

15.7 - 21.6 N·m (1.6 - 2.2 kg-m, 12 - 15 ft-lb)

5. Install master cylinder. Refer to “Installation” in “MASTER CYLINDER”, BR-16 or BR-19.

6. Bleed air. Refer to “Bleeding Brake System”, BR-9.

BR-21

IDX

Removal and Installation

VACUUM HOSE

SBR225B

Removal and Installation

NHBR0027

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

NHBR0028

NHBR0028S01

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

CHECK VALVE

NHBR0028S02

Check vacuum with a vacuum pump.

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

SBR844B

BR-22

FRONT DISC BRAKE

Component

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. Connecting bolt

11. Copper washer

12. Main pin bolt

13. Bleed valve

14. Cylinder body

15. Piston seal

16. Piston

17. Piston boot

NHBR0030

SBR890E

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 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-8.

NHBR0029

IDX

BR-23

Pad Replacement (Cont’d)

SBR976B

FRONT DISC BRAKE

1. Remove master cylinder reservoir cap.

2. Remove pin bolt.

3. Open cylinder body upward. Then remove pad with retainers, inner shim.

Standard pad thickness:

9.5 mm (0.374 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.

SBR932C

SBR979B

SBR772

Removal

NHBR0031

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

NHBR0032

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.

CAUTION:

When removing the pad retainer from the torque member, lift it up and out in the direction of the arrows in the figure.

SBR556E

BR-24

FRONT DISC BRAKE

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.

CAUTION:

Use brake fluid to clean. Never use mineral oil.

Piston

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

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

ROTOR Rubbing Surface

Check rotor for roughness, cracks or chips.

NHBR0033

NHBR0033S01

NHBR0033S0101

NHBR0033S0102

NHBR0033S0103

NHBR0033S02

NHBR0033S0201

SBR219C

Runout

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).

NHBR0033S0202

IDX

BR-25

Inspection (Cont’d)

FRONT DISC BRAKE

SBR574

Thickness

NHBR0033S0203

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:

22.0 mm (0.866 in)

Assembly

NHBR0034

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

NHBR0035

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-9.

SBR980B

CAUTION:

The upper pad retainer is built so the pad returns to its original position. Be careful to install the pad-return lever securely to the pad wear sensor, as shown in the left figure.

SBR557E

BR-26

REAR DISC BRAKE

Component

NHBR0038

1. Nut

2. Washer

3. Return spring

4. Parking brake lever

5. Cam boot

6. Cam

7. Brake hose

8. Connecting bolt

9. Copper washer

10. Bleed screw

11. Pin bolt

12. Cable mounting bracket

13. Cylinder

14. Strut

15. O-ring

16. Push rod

17. Key plate

18. Ring C

19. Seat

20. Spring

21. Spring cover

22. Ring B

23. Piston seal

24. Ring A

25. Spacer

26. Wave washer

27. Spacer

28. Ball bearing

29. Adjust nut

30. Cup

31. Piston

32. Dust seal

33. Inner shim

34. Inner pad

35. Outer pad

36. Outer shim

37. Pin

38. Pin boot

39. Pad retainer

40. Torque member

41. Torque member fixing bolt

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.

SBR897E

NHBR0037

IDX

BR-27

Pad Replacement (Cont’d)

SBR938C

REAR DISC BRAKE

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-8.

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)

SBR916C

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.

SBR641

SBR868C

BR-28

SBR306E

REAR DISC BRAKE

Pad Replacement (Cont’d)

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.

SBR307E

SBR939C

Removal

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.

NHBR0039

BR-29

IDX

Disassembly

REAR DISC BRAKE

SBR868C

SBR646

Disassembly

NHBR0040

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.

SBR889

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.

SBR088B

c. Remove piston seal.

Be careful not to damage cylinder body.

SBR656

BR-30

SBR877

REAR DISC BRAKE

Disassembly (Cont’d)

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

Inspection

CALIPER

CAUTION:

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

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.

Torque Member

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

Piston

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

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

NHBR0041

NHBR0041S01

NHBR0041S0101

NHBR0041S0102

NHBR0041S0103

NHBR0041S0104

SBR219C

ROTOR Rubbing Surface

Check rotor for roughness, cracks or chips.

Runout

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”).

NHBR0041S02

NHBR0041S0201

NHBR0041S0202

BR-31

IDX

Inspection (Cont’d)

REAR DISC BRAKE

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

Maximum runout:

0.07 mm (0.0028 in)

Thickness

NHBR0041S0203

Rotor repair limit:

Standard thickness

9 mm (0.35 in)

Minimum thickness

8 mm (0.315 in)

Thickness variation (At least 8 portions)

Maximum 0.02 mm (0.0008 in)

Assembly

NHBR0042

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

SBR247B

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

SBR248B

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

SBR893

BR-32

SBR878

REAR DISC BRAKE

Assembly (Cont’d)

4. Install ring C with a suitable tool.

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

SBR869C

SBR879

SBR892

6. Install cup in the specified direction.

7. Install cup, adjuster, bearing, spacers, washers and ring Awith a suitable tool.

IDX

SBR100B

BR-33

Assembly (Cont’d)

REAR DISC BRAKE

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.

SBR646

SBR868C

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

SBR027D

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

SBR306E

SBR307E

Installation

NHBR0043

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-9.

BR-34

PARKING BRAKE CONTROL

Components

Removal and Installation

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

2. To remove parking brake pedal, remove lower instrument panel on driver side.

3. Disconnect warning switch connector.

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

5. Remove lock plate and disconnect cable.

NHBR0128

SBR892E

NHBR0129

SBR025D

Inspection

1. Check parking brake pedal assembly 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.

NHBR0130

IDX

BR-35

Adjustment

PARKING BRAKE CONTROL

SBR264B

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 pedal is released.

1. Loosen parking brake cable.

2. Depress brake pedal fully more than five times.

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

4. Adjust control lever or pedal by turning adjusting nut.

5. Depress pedal with specified amount of force. Check lever stroke and ensure smooth operation.

Number of notches:

4 - 5 [196 N (20 kg, 44 lb)]

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

Number of “A” notches: 1

=NHBR0131

BR-36

DESCRIPTION

TCS

Purpose

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

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

NHBR0048

NHBR0049

NHBR0050

1. Inlet solenoid valve

2. Outlet solenoid valve

3. Reservoir

4. Pump

5. Motor

6. Inlet valve

7. Outlet valve

8. Bypass check valve

9. Damper

SBR984D

IDX

BR-37

TCS (Traction Control System) Operation

DESCRIPTION

TCS

TCS (Traction Control System) Operation

I This system is designed to limit wheel slip during acceleration by cutting fuel to selected cylinders and

changing transmission shift schedule. The ABS/TCS control unit monitors wheel speed slips through the ABS wheel sensors and determines the desired torque reduction needed to minimize wheel spin. The torque reduction by theABS/TCS control unit may result in a combination of fuel cutoff, throttle control, and change shift timing of the transmission. The torque reduction is sent from the ABS/TCS control unit through the data link to the ECM and TCM. The ECM will cut off fuel and/or close throttle valve little bit, and/or TCM change shift schedule to achieve torque reduction. The TCS will be enabled when the TCS switch is in the ON position (TCS OFF indicator not illuminated), and if the catalytic converter temperature is within normal operating range.

I This system has a self-diagnostic function. When the ignition switch is initially turned “ON”, the SLIP indi-

cator lamp and TCS OFF indicator lamp light. If there is no problem with the ABS and TCS, both indicator lamps will go out as soon as the engine starts.

I The TCS OFF switch cancels the TCS function. The TCS OFF indicator lamp then lights to indicate that

the TCS is not operating.

I This system utilizes a fuel-cut function to control drive torque. If fuel cut continues for an extended period

of time during high-speed operations, the catalyst may melt and deteriorate. During continued TCS operations, the system will sometimes suspend the drive torque control function, preventing catalyst melting and deterioration.

System Components

=NHBR0145

NHBR0146

SBR931E

BR-38

DESCRIPTION

TCS

System Description

SFIA0289E

SFIA0290E

SBR655E

System Description

SENSOR

The front sensor units consist of a gear-shaped sensor rotor and a sensor element. the element contains a magnet and IC. The front wheel sensors are installed on the front of the wheel knuckles. As the wheel rotates, the sensor generates a square-wave signal. The frequency increase as the wheel speed increases.

CONTROL UNIT ABS Function

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 warning lamp is turned on. In this condition, the ABS will be deactivated, and the vehicle’s brake system reverts to normal operation.

TCS Function

Drive wheel slippage is detected by the 4-wheel rotating speed signal. When the wheel slip becomes excessive, theTCS operates, causing the SLIP indicator lamp to flash. And, at the same time, fuel-cut and throttle opening signals are sent to the ECM and a signal requiring a change in the shift schedule is sent to the TCM. When the TCS OFF switch is used tocancel TCS function,the TCS OFF indicator lamp will light. (TCS does not activate.) In case of a malfunction in the TCS, both the SLIP indicator lamp and the TCS OFF indicator lamp will light, while shutting down the TCS system operation. The vehicle will operate in the same way as a vehicle not equipped with the TCS.

NHBR0147

NHBR0147S01

NHBR0147S02

NHBR0147S0201

NHBR0147S0202

SBR645EB

ACTUATOR

The actuator 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

BR-39

NHBR0147S03

IDX

System Description (Cont’d)

DESCRIPTION

TCS

These components control the hydraulic circuit. The ABS control unit directs the actuator to increase, hold or decrease hydraulic pressure to all or individual wheels.

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

NHBR0147S0301

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-40

DESCRIPTION

Component Parts and Harness Connector Location

TCS

NHBR0053

SBR036F

BR-41

IDX

Schematic

DESCRIPTION

TCS

Schematic

NHBR0148

MBR519A

BR-42

DESCRIPTION

TCS

Wiring Diagram — TCS —

NHBR0149

IDX

BR-43

MBR520A

Wiring Diagram — TCS — (Cont’d)

DESCRIPTION

TCS

MBR521A

BR-44

DESCRIPTION

TCS

Wiring Diagram — TCS — (Cont’d)

BR-45

IDX

MBR522A

Wiring Diagram — TCS — (Cont’d)

DESCRIPTION

TCS

SBR904EA

BR-46

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

TCS

CONSULT-II Functions

CONSULT-II MAIN FUNCTION

NHBR0151

NHBR0151S01

In a diagnosis function (main function), there are “SELF-DIAGNOSTIC RESULTS”, “DATA MONITOR”, “CAN DIAG SUPPORT MNTR”, “ACTIVE TEST”, “FUNCTION TEST”, “ECU PART NUMBER”.

Diagnostic test mode

SELF-DIAGNOSTIC RESULTS

DATA MONITOR

CAN DIAG SUPPORT MNTR

ACTIVE TEST

FUNCTION TEST

ECU PART NUMBER

Self-diagnostic results can be read and erased quickly. Refer to BR-47.

Input/Output data in the ABS actuator and electric unit (control unit) can be read.

The results of transmit/receive diagnosis of communication can be read. —

Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ABS actuator and electric unit (control unit) and also shifts some parameters in a specified range.

Conducted by CONSULT-II instead of a technician to determine whether each system is “OK” or “NG”.

ABS actuator and electric unit (control unit) part number can be read. —

ECU (ABS/TCS CONTROL UNIT) PART NUMBER MODE

Function Reference

Refer to BR-50.

Refer to BR-51.

—

NHBR0151S02

Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order the ECU.

SBR535E

CONSULT-II Inspection Procedure

SELF-DIAGNOSIS PROCEDURE

NHBR0152

NHBR0152S01

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.

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

IDX

SBR905E

BR-47

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II Inspection Procedure (Cont’d)

PBR385C

TCS

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.

SFIA2435E

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

10. Check ABS warning lamp, SLIP indicator lamp, TCS OFF indicator 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

BR-48

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II Inspection Procedure (Cont’d)

TCS

Diagnostic item Diagnostic item is detected when ...

FR RH SENSOR-1

FR LH SENSOR-1

RR RH SENSOR-1

RR LH SENSOR-1

FR RH SENSOR-2

FR LH SENSOR-2

RR RH SENSOR-2

RR LH SENSOR-2

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.)

=NHBR0152S02

Reference

Page

BR-62

FR RH IN ABS SOL

FR LH IN ABS SOL

RR RH IN ABS SOL

RR LH IN ABS SOL

FR RH OUT ABS SOL

FR LH OUT ABS SOL

RR RH OUT ABS SOL

RR LH OUT ABS SOL

ABS ACTUATOR RELAY [ABNORMAL]

PUMP MOTOR

BATTERY VOLTAGE [ABNORMAL]

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 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.)

I Circuit for rear left outlet solenoid valve is open.

(An abnormally low 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/TCS control unit is abnormally low or

high.

BR-66

BR-69

BR-71

IDX

CONTROLER FAILURE I Function of calculation in ABS/TCS control unit has failed. BR-73

FR LH IN ABS SOL

FR LH OUT ABS SOL

I Circuit of the front LH wheel inlet solenoid valve is open or short, or the

control line is open or short to the power supply or the ground.

I Circuit of the front LH wheel outlet solenoid valve is open or short, or the

control line is open or short to the power supply or the ground.

BR-66

BR-49

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II Inspection Procedure (Cont’d)

TCS

Diagnostic item Diagnostic item is detected when ...

RR RH IN ABS SOL

RR RH OUT ABS SOL

FR RH IN ABS SOL

FR RH OUT ABS SOL RR LH IN ABS SOL RR LH OUT ABS SOL

ENGINE SIGNAL 1, 2, 3, 4 Engine related part has malfunction. EC-136

CAN COMM CIRCUIT*2

A/T SIGNAL CAN communication with TCM is not normal. AT-209

*1: When “## ## SENSOR 2” is displayed, check power supply for TCS/ABS control unit in addition to wheel sensor circuit. *2: When any diagnosis results is detested with “CAN COMM CIRCUIT” CAN communication circuit first.