Nissan Maxima Brake System BR 2000 Owner's Manual

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EXIT

CONTENTS

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

DUAL PROPORTIONING VALVE.................................12

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

BRAKE PEDAL AND BRACKET..................................13

Removal and Installation...........................................13

Inspection...................................................................13

Adjustment.................................................................13

MASTER CYLINDER (TOKICO)...................................15

Removal.....................................................................15

Disassembly...............................................................16

Inspection...................................................................16

Assembly ...................................................................16

Installation..................................................................17

MASTER CYLINDER (NABCO)....................................18

Removal.....................................................................18

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

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

Assembly ...................................................................19

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

BRAKE SYSTEM

SECTION

BRAKE BOOSTER........................................................21

On-vehicle Service.....................................................21

OPERATING CHECK AIRTIGHT CHECK

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

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

OUTPUT ROD LENGTH CHECK

Installation..................................................................22

VACUUM HOSE.............................................................23

Removal and Installation...........................................23

Inspection...................................................................23

HOSES AND CONNECTORS CHECK VALVE

FRONT DISC BRAKE ...................................................24

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

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

Removal.....................................................................25

Disassembly...............................................................25

Inspection...................................................................26

CALIPER ROTOR

Assembly ...................................................................27

Installation..................................................................27

REAR DISC BRAKE......................................................28

Component ................................................................28

Pad Replacement......................................................28

Removal.....................................................................30

Disassembly...............................................................31

Inspection...................................................................32

CALIPER ROTOR

Assembly ...................................................................33

Installation..................................................................35

PARKING BRAKE CONTROL......................................37

Components...............................................................37

Removal and Installation...........................................37

Inspection...................................................................37

Adjustment.................................................................38

........................................................23

.................................................................26

...................................................................26

.................................................................32

...................................................................32

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

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

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

...................................23

IDX

CONTENTS (Cont’d)

EXIT

ABS/TCS

DESCRIPTION...............................................................39

Purpose......................................................................39

ABS (Anti-Lock Brake System) Operation ................39

ABS Hydraulic Circuit................................................39

TCS (Traction Control System) Operation................40

System Components .................................................40

System Description....................................................40

SENSOR CONTROL UNIT ACTUATOR

.................................................................40

......................................................41

.............................................................41

Component Parts and Harness Connector

Location .....................................................................42

Schematic..................................................................43

Wiring Diagram - ABS/TCS -.....................................44

ON BOARD DIAGNOSTIC SYSTEM

DESCRIPTION...............................................................49

Self-diagnosis ............................................................49

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

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

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

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

CONSULT-II...............................................................51

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

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

MODE

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

CONSULT-II Inspection Procedure............................52

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

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

...............................................57

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

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

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

....................................55

TROUBLE DIAGNOSIS - INTRODUCTION..................58

How to Perform Trouble Diagnoses for Quick

and Accurate Repair..................................................58

INTRODUCTION

......................................................58

TROUBLE DIAGNOSIS - BASIC INSPECTION...........59

Preliminary Check......................................................59

Ground Circuit Check................................................62

ACTUATOR MOTOR GROUND CONTROL UNIT GROUND ABS SOLENOID VALVE RELAY GROUND

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

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

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

TROUBLE DIAGNOSIS - GENERAL

DESCRIPTION...............................................................63

Malfunction Code/Symptom Chart.............................63

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC

ITEMS.............................................................................65

Wheel Sensor or Rotor..............................................65

DIAGNOSTIC PROCEDURE

.....................................65

ABS Actuator Solenoid Valve....................................68

DIAGNOSTIC PROCEDURE

.....................................68

Solenoid Valve Relay.................................................72

DIAGNOSTIC PROCEDURE

.....................................72

Motor Relay or Motor.................................................78

DIAGNOSTIC PROCEDURE

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

Low Voltage...............................................................84

DIAGNOSTIC PROCEDURE

.....................................84

Control Unit................................................................86

DIAGNOSTIC PROCEDURE

.....................................86

TCS

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC

ITEMS.............................................................................87

ENGINE CHECK SIGNAL - Engine System.............87

DIAGNOSTIC PROCEDURE

.....................................87

ENG SPEED SIG - Engine Speed Signal.................87

DIAGNOSTIC PROCEDURE

.....................................87

LAN SIGNAL 1 - LAN Monitoring..............................89

DIAGNOSTIC PROCEDURE

.....................................89

LAN SIGNAL 2 - LAN Communication Start

Procedures Incomplete..............................................91

DIAGNOSTIC PROCEDURE

.....................................91

LAN CIRCUITS 1, LAN CIRCUITS2-LAN

Communication System Failure.................................92

DIAGNOSTIC PROCEDURE

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

LAN SIGNAL 3 - Continued Reception After LAN

Communication Starts ...............................................93

DIAGNOSTIC PROCEDURE

.....................................93

ABS/TCS

TROUBLE DIAGNOSES FOR SYMPTOMS.................94

1. ABS Works Frequently ..........................................94

2. Unexpected Pedal Action ......................................94

3. Long Stopping Distance........................................95

4. ABS Does Not Work..............................................96

5. Pedal Vibration and Noise.....................................97

6. ABS Warning Lamp Does Not Come On

When Ignition Switch Is Turned On...........................98

7. ABS Warning Lamp Stays On When Ignition

Switch Is Turned On................................................101

TCS

TROUBLE DIAGNOSES FOR SYMPTOMS...............106

8. SLIP Indicator Lamp Does Not Come On

When Ignition Switch Is Turned On.........................106

9. TCS OFF Indicator Lamp Does Not Come On

When Ignition Switch Is Turned On.........................107

10. TCS OFF Switch Is Inoperative ........................109

11. Poor Acceleration...............................................112

BR-2

CONTENTS (Cont’d)

EXIT

ABS/TCS

REMOVAL AND INSTALLATION...............................113

Wheel Sensors ........................................................113

Sensor Rotor............................................................113

REMOVAL INSTALLATION

Control Unit..............................................................114

Actuator....................................................................114

REMOVAL INSTALLATION

.............................................................113

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

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

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

SERVICE DATA AND SPECIFICATIONS (SDS).......115

General Specifications.............................................115

Disc Brake ...............................................................115

Brake Pedal.............................................................115

Parking Brake..........................................................115

Control Valve ...........................................................115

Brake Booster..........................................................116

ABS Wheel Sensor..................................................116

BR-3

IDX

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 NISSAN MODEL A33 is as follows (The composition varies according to optional equipment.):

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 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 NISSAN dealer.

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

sonal injury caused by intentional 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 covered with yellow insulation or tape either just before the harness connectors or for the complete harness are related to the SRS.

NFBR0001

EXIT

SBR686C

Precautions for Brake System

NFBR0002

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.

BR-4

PRECAUTIONS

Wiring Diagrams and Trouble Diagnosis

EXIT

Wiring Diagrams and Trouble Diagnosis

When you read wiring diagrams, refer to the followings:

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 followings:

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

NFBR0003

BR-5

IDX

Commercial Service Tools

PREPARATION

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

NFBR0004

BR-6

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

NFBR0005

EXIT

NVH Troubleshooting Chart

NFBR0005S01

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-24, 28

Pads - damaged

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

—

BR-24, 28

Shims damaged

Rotor imbalance

—

BR-26, 32

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

BR-7

IDX

Checking Brake Fluid Level

ON-VEHICLE SERVICE

EXIT

SBR451D

SBR389C

SBR419C

Checking Brake Fluid Level

NFBR0006

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

NFBR0007

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

NFBR0008

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

NFBR0036

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

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.

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.

SBR995

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.

SBR419C

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

Brake Burnishing Procedure (Cont’d)

NFBR0009

EXIT

BR-9

IDX

Hydraulic Circuit

BRAKE HYDRAULIC LINE

EXIT

SBR992

Hydraulic Circuit

Removal

NFBR0010

MBR151A

NFBR0011

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

NFBR0012

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

BR-10

BRAKE HYDRAULIC LINE

Installation

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-9.

NFBR0013

BR-11

IDX

Inspection

DUAL PROPORTIONING VALVE

EXIT

SBR822BA

SBR823BA

Inspection

NFBR0014

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-9.

BR-12

BRAKE PEDAL AND BRACKET

Removal and Installation

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

NFBR0015

SBR525E

NFBR0016

SBR997

SBR526E

Adjustment

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

H: Free height

Refer to SDS, BR-115.

: 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)

NFBR0017

IDX

BR-13

Adjustment (Cont’d)

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

EXIT

BR-14

MASTER CYLINDER (TOKICO)

Removal

EXIT

Removal

NFBR0018

1. Reservoir cap

2. Oil filter

3. Reservoir tank

4. Seal

5. Cylinder body

6. O-ring

7. Piston stopper

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

SBR554E

BR-15

IDX

Disassembly

MASTER CYLINDER (TOKICO)

EXIT

SBR938A

SBR231C

Disassembly

NFBR0019

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

NFBR0020

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.

SBR354C

SBR940A

Assembly

NFBR0021

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.

BR-16

MASTER CYLINDER (TOKICO)

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

Assembly (Cont’d)

EXIT

SBR222B

SBR704C

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-9.

NFBR0022

BR-17

IDX

Removal

MASTER CYLINDER (NABCO)

EXIT

Removal

NFBR0095

1. Reservoir cap

2. Oil filter

3. Float

4. Reservoir tank

5. Seal

6. Cylinder body

7. Spring pin

8. Piston stopper pin

9. Secondary piston assembly

10. Primary piston assembly

11. 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 and remove stopper cap.

SBR555E

NFBR0096

SBR234E

BR-18

MASTER CYLINDER (NABCO)

2. Drive out spring pin from cylinder body.

3. Draw out reservoir tank and seals.

Disassembly (Cont’d)

EXIT

SBR231E

SBR232E

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.

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.

NFBR0097

SBR233E

SBR232E

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 piston stopper pin while piston is pushed into cylinder.

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

4. Install spring pin.

NFBR0098

BR-19

IDX

Assembly (Cont’d)

MASTER CYLINDER (NABCO)

5. Install stopper cap.

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

SBR235E

EXIT

SBR236E

Installation

NFBR0099

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.

BR-20

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.

NFBR0023

NFBR0023S01

NFBR0023S02

NFBR0024

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)

NFBR0025

NFBR0025S01

IDX

BR-21

Installation

BRAKE BOOSTER

EXIT

SBR237EB

Installation

NFBR0026

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-17.

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

BR-22

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.

NFBR0027

NFBR0028

NFBR0028S01

NFBR0028S02

SBR844B

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

BR-23

IDX

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

7. Inner pad

Component

8. Pad retainer

9. Outer pad

10. Outer shim

11. Shim cover

12. Connecting bolt

13. Copper washer

NFBR0030

SBR527EA

14. Main pin bolt

15. Bleed valve

16. Cylinder body

17. Piston seal

18. Piston

19. Piston boot

Pad Replacement

NFBR0029

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.

BR-24

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.

CAUTION:

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

NFBR0031

NFBR0032

SBR556E

IDX

BR-25

Inspection

FRONT DISC BRAKE

EXIT

Inspection

CALIPER Cylinder Body

NFBR0033

NFBR0033S01

NFBR0033S0101

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

NFBR0033S0102

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

NFBR0033S0103

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

ROTOR Rubbing Surface

NFBR0033S02

NFBR0033S0201

Check rotor for roughness, cracks or chips.

SBR219C

Runout

NFBR0033S0202

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).

BR-26

FRONT DISC BRAKE

Inspection (Cont’d)

EXIT

SBR574

Thickness

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:

24.0 mm (0.945 in)

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-9.

NFBR0033S0203

NFBR0034

NFBR0035

SBR980B

SBR557E

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.

IDX

BR-27

Component

REAR DISC BRAKE

EXIT

Component

NFBR0038

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.

SBR558E

NFBR0037

BR-28

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-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)

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-29

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

NFBR0039

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-30

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.

NFBR0040

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-31

Disassembly (Cont’d)

SBR877

REAR DISC BRAKE

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

EXIT

Inspection

CALIPER

NFBR0041

NFBR0041S01

CAUTION:

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

Cylinder Body

NFBR0041S0101

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

NFBR0041S0102

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

Piston

NFBR0041S0103

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

NFBR0041S0104

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

SBR219C

ROTOR Rubbing Surface

NFBR0041S02

NFBR0041S0201

Check rotor for roughness, cracks or chips.

Runout

NFBR0041S0202

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-32

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.

NFBR0041S0203

NFBR0042

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-33

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

SBR892

6. Install cup in the specified direction.

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

SBR100B

BR-34

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-9.

NFBR0043

BR-35

IDX

Installation (Cont’d)

SBR559E

REAR DISC BRAKE

CAUTION:

The pad retainer is built so the pad returns to its original position. Be careful to install the pad so the pad-return lever is against the inner side of the pad, as shown in the left figure.

EXIT

BR-36

PARKING BRAKE CONTROL

Components

EXIT

Components

Removal and Installation

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.

NFBR0044

SBR550E

NFBR0045

SBR025D

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.

NFBR0046

IDX

BR-37

Adjustment

PARKING BRAKE CONTROL

EXIT

SBR264B

Adjustment

=NFBR0047

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 or pedal by turning adjusting nut.

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

Number of notches:

10 - 11 [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

BR-38

DESCRIPTION

ABS/TCS

Purpose

EXIT

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

NFBR0048

NFBR0049

NFBR0050

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

BR-39

IDX

TCS (Traction Control System) Operation

DESCRIPTION

ABS/TCS

EXIT

TCS (Traction Control System) Operation

=NFBR0081

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 the ABS/TCS control unit may result in a combination of fuel cutoff 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 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

NFBR0051

SBR124B

SBR342E

System Description

SENSOR

NFBR0052

NFBR0052S01

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.

BR-40

DESCRIPTION

ABS/TCS

System Description (Cont’d)

EXIT

SBR529E

SBR530E

SBR531E

Inlet solenoid valve

CONTROL UNIT ABS Function

NFBR0052S02

NFBR0052S0201

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

NFBR0052S0202

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, a fuel-cut signal to be 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 to cancel 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.

ACTUATOR

NFBR0052S03

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

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

Outlet solenoid valve

NFBR0052S0301

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)

BR-41

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.

IDX

Component Parts and Harness Connector Location

DESCRIPTION

ABS/TCS

Component Parts and Harness Connector Location

NFBR0053

EXIT

BR-42

SBR534E

DESCRIPTION

ABS/TCS

Schematic

EXIT

Schematic

NFBR0054

BR-43

IDX

MBR372A

Wiring Diagram — ABS/TCS —

DESCRIPTION

ABS/TCS

EXIT

Wiring Diagram — ABS/TCS —

NFBR0055

BR-44

MBR373A

DESCRIPTION

ABS/TCS

Wiring Diagram — ABS/TCS — (Cont’d)

EXIT

BR-45

IDX

MBR374A

Wiring Diagram — ABS/TCS — (Cont’d)

DESCRIPTION

ABS/TCS

EXIT

BR-46

MBR375A

DESCRIPTION

ABS/TCS

Wiring Diagram — ABS/TCS — (Cont’d)

EXIT

BR-47

IDX

MBR376A

Wiring Diagram — ABS/TCS — (Cont’d)

DESCRIPTION

ABS/TCS

EXIT

BR-48

SBR560E

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ABS/TCS

Self-diagnosis

EXIT

Self-diagnosis

FUNCTION

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

the instrument panel comes on. When a problem occurs in the TCS, the TCS OFF indicator lamp and SLIP indicator lamp on the instrument panel comes on. To actuate 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 or SLIP indicator lamp flashing.

I Without TCS ...... A self-diagnostic result is indicated by

means of the ABS warning lamp.

I With TCS ......... A self-diagnostic result is indicated by

means of the SLIP indicator lamp.

SELF-DIAGNOSIS PROCEDURE

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

2. Turn ignition switch “OFF”.

3. Ground terminal “9” of “Data link connector” with a suitable harness.

4. Turn ignition switch “ON” while grounding terminal “9”.

Do not depress brake pedal. Do not start engine.

NFBR0056

NFBR0056S01

NFBR0056S02

SBR535E

SBR536E

5. After 3.0 seconds, the ABS warning lamp or SLIP indicator 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-63. 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-50.

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

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

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

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

IDX

SBR535E

BR-49

Self-diagnosis (Cont’d)

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

NOTE:

The indication terminates after five minutes. However,when the ignition switch is turned from “OFF” to “ON”, the SLIP indication starts flashing again. The TCS OFF indicator lamp and ABS warning lamp remain lighted.

HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)

1. Determine the code No. by counting the number of times the ABS warning lamp or SLIP indicator 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).

4. The malfunction code chart is given on the BR-63 page.

ABS/TCS

NFBR0056S03

EXIT

SBR631D

SBR457D

HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)

1. Under the self-diagnostic results mode, the malfunction memory erase mode starts when the check terminal is disconnected from the ground.

2. The self-diagnostic results (malfunction codes) can be erased by grounding the check terminal more than three times in succession within 12.5 seconds afterthe erase mode starts. (Each grounding must be longer than one second.) The ABS warning lamp or SLIP indicator lamp stays on while the self-diagnosis is in the erase mode, and goes out after the erase operation has been completed.

3. The self-diagnosis is also completed at the same time. (Refer to BR-49.)

After the erase operation is completed, it is necessary to rerun the self-diagnostic mode to verify that malfunction codes no longer appear. Only the start code (12) should be indicated when erase operation is completed and system is functioning normally.

NOTE:

The TCS OFF indicator lamp and ABS warning lamp remain lighted.

NFBR0056S04

BR-50

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ABS/TCS

CONSULT-II

EXIT

CONSULT-II

CONSULT-II APPLICATION TO ABS/TCS

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 — ABS sensor 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

NFBR0057

NFBR0057S01

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 — — Engine speed signal — X — ABS motor X — X A/T gear position signal — X — TCS OFF indicator lamp — X — SLIP indicator lamp — X — ECM X — — LAN signal X — —

X: Applicable —: Not applicable

ECU (ABS CONTROL UNIT) PART NUMBER MODE

XXX

NFBR0057S02

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

BR-51

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II Inspection Procedure

ABS/TCS

EXIT

SBR535E

PBR455D

CONSULT-II Inspection Procedure

SELF-DIAGNOSIS PROCEDURE

NFBR0058

NFBR0058S01

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.

6. Touch “ABS”.

PBR385C

PST412B

SBR561E

7. Touch “SELF DIAGNOSIS”.

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, 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.

BR-52

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II Inspection Procedure (Cont’d)

ABS/TCS

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]

FR RH IN ABS SOL [OPEN]

FR LH IN ABS SOL [OPEN]

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.)

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.)

=NFBR0058S02

Reference

Page

BR-65

BR-68

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]

RR LH OUT ABS SOL [OPEN]

FR RH OUT ABS SOL [SHORT]

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.)

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.)

BR-68

IDX

FR LH OUT ABS SOL [SHORT]

I Circuit for front left outlet solenoid valve is shorted.

(An abnormally high output voltage is entered.)

BR-53

BR-68

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II Inspection Procedure (Cont’d)

ABS/TCS

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 [ABNORMAL]

BATTERY VOLTAGE [ABNORMAL]

CONTROL UNIT I Function of calculation in ABS control unit has failed. BR-86 LAN SIGNAL 1

[ABNORMAL] LAN SIGNAL 2

[ABNORMAL] LAN SIGNAL 3

[ABNORMAL] ENGINE SPEED SIG

[ABNORMAL]

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-84

I ECM judges that communication signal between ABS/TCS control unit and

ECM is abnormal.

I On the Local Area Network (LAN) between ABS/TCS control unit and ECM,

ECM does not transmit the LAN start signal to ABS/TCS control unit.

I The communication start signal output is not terminated and the ordinary sig-

nals are not entered to ABS/TCS control unit.

I Engine speed signal from ECM is not entered. BR-87

Reference

Page

BR-68

BR-72

BR-78

BR-89

BR-91

BR-93

ENGINE CHECK SIGNAL

LAN CIRCUIT 1 [ABNORMAL]

LAN CIRCUIT 2 [ABNORMAL]

*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 Based on the signal from ECM, the ABS/TCS control unit judges that the

engine control system is malfunctioning.

I The communication line between ABS/TCS control unit and ECM is open or

shorted.

I An instantaneous signal interruption occurs repeatedly on the communication

line between ABS/TCS control unit and ECM.

DATA MONITOR PROCEDURE

BR-87

BR-92

NFBR0058S03

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

5. Touch “ABS”.

PBR385C

BR-54

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II Inspection Procedure (Cont’d)

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”.

ABS/TCS

EXIT

PST412B

PBR455D

PBR385C

ACTIVE TEST PROCEDURE

I When conducting Active test, vehicle must be stationary. I When ABS warning lamp or SLIP indicator 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”.

NFBR0058S04

PST412B

PBR976C

7. Select active test item by touching screen.

BR-55

IDX

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT-II Inspection Procedure (Cont’d)

8. Touch “START”.

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

PBR934C

DATA MONITOR MODE

MONITOR ITEM CONDITION SPECIFICATION FR RH SENSOR

FR LH SENSOR RR RH SENSOR RR LH SENSOR

Drive vehicle. (Each wheel is rotating.)

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

ABS/TCS

NFBR0058S05

EXIT

STOP LAMP SW

ENGINE SPEED Engine is running. (rpm) Engine speed: 0 - 8,000 (rpm) 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

THRTL OPENING

TRQ RDUC SIG

Turn ignition switch ON and depress brake pedal.

Ignition switch is turned ON or engine is running.

The throttle valve opening rate (%)

The operating cylinder ratio to fuel injected, calculated and sent by ABS/TCS control unit to ECM, is displayed.

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

Opening rate: 0 - 100%

TCS is not operating: 0 TCS is operating:0-6* * Displays the number of cylinders to which fuel supply is cut.

GEAR

TCS SW

TCS OFF LAMP

A/T gear position signal detected by TCM via ECM is displayed.

ON/OFF condition of signal from TCS switch is displayed.

I TCS OFF condition is dis-

played.

I The condition of malfunction-

ing TCS is displayed.

BR-56

Gear position: P, N: N.P 1st: 1 2nd: 2 3rd: 3 4th: 4

TCS OFF S/W (all the time switch is pressed): ON TCS OFF S/W (released): OFF

TCS OFF indicator “OFF”: OFF TCS OFF indicator “ON”: ON

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

MONITOR ITEM CONDITION SPECIFICATION

ABS/TCS

CONSULT-II Inspection Procedure (Cont’d)

EXIT

The TCS functioning state is

SLIP LAMP

TCS OPR SIG TCS operating condition

displayed by detecting rear wheel slip.

SLIP indicator “ON”: ON SLIP indicator “OFF”: OFF

TCS is not operating: OFF TCS is operating: ON

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

NFBR0058S06

IN SOL OUT SOL

BR-57

IDX

TROUBLE DIAGNOSIS — INTRODUCTION

How to Perform Trouble Diagnoses for Quick and Accurate Repair

INTRODUCTION

TheABS/TCS system has an electronic control unit to controlmajor 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/TCS 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/TCS controlled vehicle. Also check related Service Bulletins for information.

ABS/TCS

NFBR0059

NFBR0059S01

EXIT

BR-58

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS/TCS

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.

NFBR0060

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-59

IDX

TROUBLE DIAGNOSIS — BASIC INSPECTION

Preliminary Check (Cont’d)

3 CHECK BRAKE BOOSTER OPERATION

Check brake booster for operation and air tightness. Refer to BR-21.

Is brake booster airtight and functioning properly?

Yes © GO TO 4. No © Replace. GO TO 4.

ABS/TCS

SBR058C

EXIT

4 CHECK BRAKE PAD AND ROTOR

Check brake pad and rotor. Refer to BR-24, 26, 28, 32.

Are brake pads and rotors functioning properly?

Yes © GO TO 5. No © Replace.

SBR059C

BR-60

TROUBLE DIAGNOSIS — BASIC INSPECTION

5 RECHECK BRAKE FLUID LEVEL

Check brake fluid level in reservoir tank again.

ABS/TCS

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.

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

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

SBR451D

SBR536E

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-49, 52.

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-49, 52.

BR-61

IDX

Ground Circuit Check

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS/TCS

EXIT

SBR792D

SBR714DE

Ground Circuit Check

ACTUATOR MOTOR GROUND

NFBR0061

NFBR0061S01

I Check resistance between actuator motor ground terminal and

body ground.

Resistance: 0Ω

CONTROL UNIT GROUND

NFBR0061S02

I Check resistance between the terminals and ground.

Resistance: 0Ω

ABS SOLENOID VALVE RELAY GROUND

NFBR0061S03

I Check resistance between solenoid valve relay terminal 4 and

ground.

Resistance: 0Ω

SBR764DH

BR-62

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

Malfunction Code/Symptom Chart

ABS/TCS

EXIT

Code No.

(No. of SLIP indicator flashes)

12 Self-diagnosis could not detect any malfunctions OFF OFF OFF — — 21 Front right sensor (open-circuit) ON ON ON X BR-65 22 Front right sensor (short-circuit)*2 ON ON ON X BR-65 25 Front left sensor (open-circuit) ON ON ON X BR-65 26 Front left sensor (short-circuit)*2 ON ON ON X BR-65 31 Rear right sensor (open-circuit) ON ON ON X BR-65 32 Rear right sensor (short-circuit)*2 ON ON ON X BR-65 35 Rear left sensor (open-circuit) ON ON ON X BR-65 36 Rear left sensor (short-circuit)*2 ON ON ON X BR-65 41 Actuator front right outlet solenoid valve ON ON ON X BR-68 42 Actuator front right inlet solenoid valve ON ON ON X BR-68 45 Actuator front left outlet solenoid valve ON ON ON X BR-68 46 Actuator front left inlet solenoid valve ON ON ON X BR-68

Malfunction Code/Symptom Chart

Warn-

Malfunctioning part

ing

lamp

ABS

Indicator

TCS OFF

SLIP

Failsafe

NFBR0062

Refer-

ence Page

51 Actuator rear right outlet solenoid valve ON ON ON X BR-68 52 Actuator rear right inlet solenoid valve ON ON ON X BR-68 55 Actuator rear left outlet solenoid valve ON ON ON X BR-68 56 Actuator rear left inlet solenoid valve ON ON ON X BR-68 57 Power supply (Low or high voltage)*3 ON ON OFF —*1 BR-84 61 Actuator motor or motor relay*4 ON ON ON X BR-78 63 Solenoid valve relay ON ON ON X BR-72 71 Control unit ON ON ON*5 X BR-86 98 LAN communication system failure OFF ON ON X BR-92 81 Engine speed signal OFF ON ON X BR-87 96 LAN is monitoring OFF ON ON X BR-89 87 Engine parts are under fail-safe condition OFF ON ON X BR-87 92 LAN communication start procedures are incomplete OFF ON ON X BR-91 94 Continued reception after LAN communication starts OFF ON ON X BR-93

ABS works frequently. — ————BR-94 Unexpected pedal action — ————BR-94

ECM determines the ABS/TCS control unit is malfunctioning.

OFF ON ON X BR-89

Long stopping distance — ————BR-95 ABS does not work. — ————BR-96 Pedal vibration and noise — ————BR-97

BR-63

IDX

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

Malfunction Code/Symptom Chart (Cont’d)

Code No.

(No. of SLIP indicator flashes)

Control unit power supply circuit

SLIP indicator stays on when engine is running

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

Malfunctioning part

ABS/TCS

Warn-

ing

lamp

ABS

ON ON ON X*6 —

Indicator

TCS OFF

Failsafe

SLIP

Refer-

ence Page

EXIT

SLIP indicator does not come on when engine is running

Poor acceleration TCM is the cause of the symptom. OFF OFF OFF — BR-112

X: Available —: Not available *1: Fail-safe operation does not activate. A signal from control unit suspends TCS and ABS control operation. Brakes operate conven-

tionally. After specified power supply voltage resumes, TCS OFF indicator and ABS warning lamp go out, allowing for TCS and ABS control operation.

*2: If a wheel or wheels spin on bad or slippery road surfaces for a period of approximately 10 to 80 seconds, the ABS warning lamp and the TCS OFF indicator lamp light. But this is not a malfunction. When the ignition switch is turned “ON” after a shorted wheel sensor circuit has been repaired, the ABS warning lamp and the TCS OFF indicator lamp light. Drive the vehicle at about 30 km/h (19 MPH) to ensure these lamps go out within 1 minute.

*3: When the BATTERY VOLTAGE [ABNORMAL] code No. appears on the display, it does not indicate a malfunction related to the ABS/TCS control unit. Do not replace the ABS/TCS control unit even if the code No. appears.

*4: The BATTERY VOLTAGE [ABNORMAL] code No. can sometimes appear when the ABS motor ground circuit is loose or disconnected. When it does, always check the ground circuit for improper installation.

*5: Only the SLIP indicator lamp goes out depending on the type of ECM malfunction. *6: If failure occurs in self-diagnostic check terminal (terminal No. 4 of data link connector) circuit and/or TCS operation (SLIP indica-

tor) circuit, fail-safe operation will not activate.

Fuse, warning lamp bulb or warning lamp circuit Control unit

ON ON ON X —

BR-64

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Wheel Sensor or Rotor

ABS/TCS

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

SBR769DD

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?

Yes © GO TO 3. No © INSPECTION END

NFBR0064

NFBR0064S01

BR-65

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Wheel Sensor or Rotor (Cont’d)

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 14 and 15 Code No. 25 or 26 (Front LH wheel) Terminals 9 and 10 Code No. 31 or 32 (Rear RH wheel) Terminals 11 and 38 Code No. 35 or 36 (Rear LH wheel) Terminals 12 and 13

Resistance: 0.8 - 1.85 kΩ

ABS/TCS

EXIT

SBR247DI

Is resistance 0.8 - 1.85 kΩ?

4 CHECK WHEEL SENSOR

Check resistance of each sensor. (See NOTE)

Resistance: 0.8 - 1.85 kΩ

SBR761DE

Is resistance 0.8 - 1.85 kΩ?

nector.

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-66

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

6 CHECK WHEEL BEARING

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

Clearance:

Front

0.273 - 0.925 mm (0.0107 - 0.0364 in)

Rear

0.387 - 0.992 mm (0.0152 - 0.0391 in)

ABS/TCS

Wheel Sensor or Rotor (Cont’d)

EXIT

SBR605AA

SBR069CA

Is axial end play and clearance within specifications?

7 CHECK SENSOR ROTOR

Check sensor rotor for teeth damage.

Is sensor rotor free from damage?

connector. Reconnect control unit harness connector. Then retest.

BR-67

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS Actuator Solenoid Valve

ABS/TCS

EXIT

1 INSPECTION START

ABS actuator solenoid valve inspection

ABS Actuator Solenoid Valve

DIAGNOSTIC PROCEDURE

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

=NFBR0063

NFBR0063S01

SBR334EA

2 CHECK CONNECTOR

1. Disconnect connectors from control unit, ABS actuator and ABS solenoid valve relay. Check terminals for damage or loose connections. Then reconnect connectors.

2. Carry out self-diagnosis again.

Does warning lamp activate again?

BR-68

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS Actuator Solenoid Valve (Cont’d)

3 CHECK ABS ACTUATOR SOLENOID VALVE

1. Disconnect connectors from control unit and ABS actuator.

2. Check resistance between control unit connector terminals and ABS actuator 2-pin connector E5 (ABS actuator side) terminals.

ABS/TCS

MTBL0084

EXIT

Is resistance within specifications?

SBR766DH

BR-69

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS Actuator Solenoid Valve (Cont’d)

ABS/TCS

4 CHECK ABS ACTUATOR SOLENOID VALVE

1. Disconnect ABS actuator 8-pin connector.

2. Check resistance between ABS actuator 8-pin connector E127 or E7 (ABS actuator side) terminals and ABS actuator 2-pin connector E5 (ABS actuator side) terminals.

MTBL0085

EXIT

Is resistance within specifications?

I Harness connectors E127 or E7, E5 I Harness for open or short between actuator connector and control unit I Harness for open or short between actuator 8-pin connector and actuator 2-pin con-

nector If NG, repair harness or connectors.

No © GO TO 5.

SBR767DG

BR-70

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

5 CHECK ABS ACTUATOR SOLENOID VALVE

Check resistance between solenoid valve terminals 1, 3, 5, 7, 14, 15, 16, 17.

Is resistance within specifications?

I Harness connectors E127 or E7, E5 I Harness for open or short between actuator connector and control unit I Harness for open or short between actuator 8-pin connector and actuator 2-pin con-

nector If NG, repair harness or connectors.

ABS/TCS

ABS Actuator Solenoid Valve (Cont’d)

MTBL0086

EXIT

6 CHECK ABS ACTUATOR SOLENOID VALVE RELAY

1. Remove solenoid valve relay.

2. Check continuity between ABS actuator 2-pin connector E18 (body side) terminal 19 and solenoid valve relay terminal

Continuity should exist.

SBR768DG

Does continuity exist?

I Harness connectors E118 or E33, E5 I Harness for open or short between actuator connector and solenoid valve relay termi-

nal (relay box side) If NG, repair harness or connectors.

BR-71

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Solenoid Valve Relay

ABS/TCS

EXIT

1 INSPECTION START

Solenoid valve relay inspection

Solenoid Valve Relay

DIAGNOSTIC PROCEDURE

Malfunction code No. 63

NFBR0066

NFBR0066S01

SBR334EA

2 CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT

Check 40A [e] 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 10A fuse No. 30. For fuse layout, refer to “POWER SUPPLY ROUTING” in EL section.

Is fuse OK?

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-72

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Solenoid Valve Relay (Cont’d)

5 CHECK GROUND CIRCUIT

Refer to CONTROL UNIT GROUND and ACTUATOR MOTOR GROUND in Ground Circuit Check, BR-62.

Is ground circuit OK?

ABS/TCS

EXIT

6 CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Remove solenoid valve relay.

2. Check voltage between solenoid valve relay terminal 5 and ground.

Does battery voltage exist?

I Harness connector E118 or E33 I Harness for open or short between solenoid valve terminal (relay box side) and fusible

link If NG, repair harness or connectors.

SBR777DH

BR-73

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Solenoid Valve Relay (Cont’d)

7 CHECK CIRCUIT

1. Disconnect control unit connector.

2. Check continuity between control unit connector terminals and solenoid valve relay terminals.

ABS/TCS

MTBL0089

EXIT

Does continuity exist?

I Harness connector E9 or E91 I Harness for open or short between solenoid valve relay terminal (relay box side) and

control unit If NG, repair harness or connectors.

SBR778DG

BR-74

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

8 CHECK SOLENOID VALVE RELAY

ABS/TCS

Solenoid Valve Relay (Cont’d)

EXIT

While applying battery voltage to relay terminals, insert fuse into the circuit.

Is solenoid valve relay OK?

9 REPLACE FUSIBLE LINK

Replace fusible link.

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

MTBL0090

SBR776D

BR-75

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Solenoid Valve Relay (Cont’d)

10 CHECK RELAY UNIT POWER SUPPLY CIRCUIT

1. Remove solenoid valve relay.

2. Check continuity between solenoid valve relay terminal 5 and ground.

Does continuity exist?

I Harness connector E118 or E33 I Harness for open or short between solenoid valve terminal (relay box side) and fusible

link If NG, repair harness or connectors.

ABS/TCS

SBR779DH

EXIT

11 CHECK ABS SOLENOID VALVE RELAY

1. Disconnect ABS actuator 2-pin connectors and control unit connector.

2. Check continuity between ABS actuator 2-pin connector E5 (body side) terminal 19 and ground.

Does continuity exist?

SBR493DH

BR-76

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Solenoid Valve Relay (Cont’d)

12 CHECK ABS SOLENOID VALVE

Check continuity between ABS actuator 2-pin connector E5 (ABS actuator side) terminal 19 and ground.

ABS/TCS

EXIT

Does continuity exist?

13 REPLACE FUSE

Replace fuse.

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

I Harness connector E9 or E91 I Harness for open or short between ABS control unit connector and fuse

If NG, repair harness or connectors.

SBR494DH

BR-77

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Motor Relay or Motor

ABS/TCS

EXIT

1 INSPECTION START

ABS motor relay inspection

Motor Relay or Motor

DIAGNOSTIC PROCEDURE

Malfunction code No. 61

=NFBR0065

NFBR0065S01

SBR335EA

2 CHECK MOTOR POWER SUPPLY CIRCUIT

Check 40A [d] 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 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-78

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

4 CHECK ABS RELAY UNIT POWER SUPPLY CIRCUIT

1. Remove motor relay.

2. Check voltage between motor relay terminal 5 and ground.

ABS/TCS

Motor Relay or Motor (Cont’d)

EXIT

Does battery voltage exist?

I Harness connector E119 or E29 I Harness for open or short between motor relay terminal (relay box side) and fusible

link If NG, repair harness or connectors.

SBR771DH

BR-79

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Motor Relay or Motor (Cont’d)

5 CHECK CIRCUIT

1. Disconnect control unit connector.

2. Check continuity between control unit connector terminals and motor relay terminals.

ABS/TCS

MTBL0087

EXIT

Does continuity exist?

I Harness connectors E119 or E29, E9 or E91 I Harness for open or short between motor relay terminal (relay box side) and control

unit If NG, repair harness or connectors.

SBR772DG

BR-80

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

6 CHECK MOTOR RELAY

ABS/TCS

Motor Relay or Motor (Cont’d)

EXIT

While applying battery voltage to relay terminals, insert fuse into the circuit.

Is motor relay OK?

7 CHECK ACTUATOR MOTOR GROUND CIRCUIT

Refer to ACTUATOR MOTOR GROUND in Ground Circuit Check, BR-62.

Is ground circuit OK?

I Harness connector E119 or E29 I Harness for open or short between solenoid valve relay terminal (relay box side) and

ground If NG, repair harness or connectors.

MTBL0088

SBR776D

BR-81

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Motor Relay or Motor (Cont’d)

ABS/TCS

8 CHECK ABS ACTUATOR CIRCUIT

Check continuity between ABS actuator 2-pin connector E5 (ABS actuator side) terminal 21 and actuator motor ground terminal.

Does continuity exist?

I Harness connector E5 I Harness for open or short between actuator connector and motor terminal

If NG, repair harness or connectors.

SBR793DF

EXIT

9 CHECK MOTOR

1. Remove motor relay.

2. Connect actuator connectors.

3. Connect suitable wire between motor relay connector terminals 3 and 5.

Do not connect wire for more than 5 seconds.

Does motor operate?

10 REPLACE FUSIBLE LINK

Replace fusible link.

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

SBR773DH

BR-82

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

11 CHECK MOTOR POWER SUPPLY CIRCUIT

1. Remove motor relay.

2. Check continuity between motor relay terminal 5 and ground.

ABS/TCS

Motor Relay or Motor (Cont’d)

EXIT

Does continuity exist?

I Harness connector E119 or E29 I Harness for open or short between motor relay terminal (relay box side) and fusible

link If NG, repair harness or connectors.

12 CHECK ABS MOTOR RELAY

1. Disconnect control unit connector.

2. Check continuity between motor relay terminal 3 and ground.

Does continuity exist?

I Harness connector E119 or E29 I Harness for open or short between motor relay terminal (relay box side) and fusible

link If NG, repair harness or connectors.

No © GO TO 13.

SBR774DH

SBR775DI

BR-83

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Motor Relay or Motor (Cont’d)

ABS/TCS

13 CHECK ABS MOTOR POWER SUPPLY CIRCUIT

1. Remove motor ground.

2. Check continuity between ABS actuator 2-pin connector E5 (ABS actuator side) terminal 21 and ground.

Does continuity exist?

14 CHECK MOTOR

Go to “9 CHECK MOTOR” in “Motor Relay or Motor” (preceding page).

Does motor operate?

connector. Reconnect control unit harness connector. Then retest.

SBR489DH

EXIT

Low Voltage

DIAGNOSTIC PROCEDURE

Malfunction code No. 57

1 INSPECTION START

ABS control unit power supply and ground circuit inspection

BR-84

NFBR0067

NFBR0067S01

SBR337EA

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Low Voltage (Cont’d)

2 CHECK CONNECTOR

1. Disconnect control unit connectors. Check terminals for damage or loose connections. Then reconnect connectors.

2. Carry out self-diagnosis again.

Does warning lamp activate again?

3 CHECK ABS CONTROL UNIT POWER SUPPLY

1. Disconnect control unit connector.

2. Check voltage between control unit connector terminal 1 and ground.

ABS/TCS

EXIT

SBR726DE

Does battery voltage exist when ignition switch is turned ON?

4 CHECK CONTROL UNIT GROUND

Refer to CONTROL UNIT GROUND in Ground Circuit Check, BR-62.

Is ground circuit OK?

connector. Reconnect control unit harness connector. Then retest.

I Harness connector E9 or E91 I Harness for open or short between control unit and ground

If NG, repair harness or connectors.

5 CHECK FUSE

Check 10A fuse 31 (Engine control) for control unit. Refer to POWER SUPPLY ROUTING in EL section.

Is fuse OK?

6 CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT

Check continuity between battery and control unit connector terminal 1.

Does continuity exist?

I Harness connector E9 or E91 I Harness for open or short between control unit and fuse

If NG, repair harness or connectors.

BR-85

IDX

Control Unit

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS/TCS

EXIT

Control Unit

DIAGNOSTIC PROCEDURE

Malfunction code No. 71

1 INSPECTION START

ABS control unit power supply and ground circuit inspection

2 CHECK CONNECTOR

1. Disconnect control unit connector. Check terminals for damage or loose connections. Then reconnect connectors.

2. Carry out self-diagnosis again.

Does warning lamp activate again?

NFBR0068

NFBR0068S01

SBR337EA

3 CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT

Check voltage. Refer to “3. CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT” in “Low Voltage”, BR-84.

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 control unit. No © Inspect the system according to the code No.

BR-86

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ENGINE CHECK SIGNAL — Engine System

TCS

EXIT

ENGINE CHECK SIGNAL — Engine System

DIAGNOSTIC PROCEDURE

NFBR0082

NFBR0082S01

Malfunction code No. 87

1 INSPECTION START

Self-diagnostic item “ENGINE CHECK SIGNAL” appears on display.

2 CHECK ENGINE SYSTEM

Perform self-diagnostic procedures for ECM.

Does any of following self-diagnostic items appear on display?

[P1335 CRANK POS SEN (REF)]*1, [P0100 MAF SEN/CIRCUIT]*1, [P0115 COOLANT T SEN/CIRC]*1, [P0125 COOLANT T SEN/CIRC]*1, [P1320 IGN SIGNAL-PRIMARY]*1, [P0120 THRTL POS SEN/CIRC]*1, [P0605 ECM]*1 *1: Out of ECM diagnostic items, 7 items shown at left cause TCS to be suspended (TCS OFF indicator “ON” and SLIP indicator “ON”) and allow control unit to indicate “ENGINE CHECK SIGNAL”.

3 CHECK CONTROL UNIT TO ECM CIRCUIT

Do “ECM — ABSTCS COMM NG” and/or “ABS-TCS C/U SIGNAL” [ECM self-diagnostic items]*2 appear on display? *2: Items which cause TCS to be suspended (TCS OFF indicator “ON” and SLIP indicator “ON”) and allow ABS/TCS control unit to indicate “ENGINE CHECK SIGNAL”.

communication system failure”.

No © GO TO 4.

4 CHECK DIAGNOSTIC ITEMS

Does any other diagnostic items appears? Yes © Repair or replace affected engine control system parts. No © INSPECTION END

ENG SPEED SIG — Engine Speed Signal

DIAGNOSTIC PROCEDURE

Malfunction code No. 81

1 INSPECTION START

Self-diagnostic item “ENGINE SPEED SIG” appears on display.

NFBR0083

NFBR0083S01

SBR539E

IDX

BR-87

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ENG SPEED SIG — Engine Speed Signal (Cont’d)

2 CHECK ENGINE SYSTEM

Perform self-diagnostic procedures for ECM.

Does [P1335 CRANK POS SEN (REF)]*1 (Self-diagnostic item) appear on display?

*1: Out of ECM diagnostic item, only [P1335 CRANK POS SEN (REF)] causes TCS to be suspended (SLIP indicator lamp “ON” and TCS OFF indicator lamp “ON”) and allows control unit to indicate “ENGINE SPEED SIG”.

3 CHECK CONTROL UNIT TO ECM CIRCUIT

Perform self-diagnostic procedures for ECM.

Does [ECM-ABSTCS COMM NG] and [ABS-TCS C/U SIGNAL]*1 (self-diagnostic items) appears on display?

communication system failure”.

No © GO TO 4.

4 CHECK CONNECTOR

1. Disconnect control unit and ECM connectors, then reconnect them securely.

2. Carry out self-diagnosis again.

Does warning lamp activate again?

TCS

EXIT

5 CHECK CONTROL UNIT TO ECM HARNESS CONNECTORS

1. Disconnect control unit and ECM connectors.

2. Check continuity between control unit terminal 20 and ECM terminal 25.

Continuity should exist?

I Harness connectors E91 and F48 I Harness for open or short between control unit connector and ECM connector

If NG, repair harness or connectors.

6 CHECK SELF-DIAGNOSIS

Connect connectors, then repeat self-diagnostic procedures.

Does self-diagnostic item appears on display?

SBR540E

BR-88

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

LAN SIGNAL 1 — LAN Monitoring

TCS

EXIT

LAN SIGNAL 1 — LAN Monitoring

DIAGNOSTIC PROCEDURE

Malfunction code No. 85

1 INSPECTION START

Self-diagnostic item “LAN SIGNAL 1” appears on display.

2 CHECK ENGINE SYSTEM

Perform self-diagnostic procedures for ECM.

Does self-diagnostic item [ECM-ABSTCS COMM NG] appear on display?

NFBR0084

NFBR0084S01

SBR541E

3 CHECK SELF-DIAGNOSIS

Does “ABS-TCS C/U SIGNAL” appear on display?

4 CHECK SELF-DIAGNOSIS

Does any other control unit self-diagnostic items appears on display?

5 CHECK VOLTAGE

Check if battery voltage is too low (less than 9V) or battery terminals are loose. OK © Repeat self-diagnostic procedures. NG © Faulty control unit

BR-89

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

LAN SIGNAL 1 — LAN Monitoring (Cont’d)

6 CHECK LAN CIRCUIT

Check continuity between connector terminals.

TCS

EXIT

Does continuity exist?

I Harness connectors E91, F48, F50 I Harness for open or short between control unit connector and TCM connector I Harness for open or short between ECM connector and TCM connector

If NG, repair harness or connectors.

SBR542E

MTBL0320

BR-90

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

LAN SIGNAL 2 — LAN Communication Start Procedures Incomplete

DIAGNOSTIC PROCEDURE

Malfunction code No. 92

1 INSPECTION START

Self-diagnostic item “LAN SIGNAL 2” appears on display.

TCS

LAN SIGNAL 2 — LAN Communication Start Procedures Incomplete

=NFBR0085

NFBR0085S01

SBR541E

EXIT

2 CHECK ENGINE SYSTEM

Is self-diagnosis for ECM able to start?

I Faulty ECM. (Malfunction indicator lamp remains “ON” during operation.)

3 CHECK SELF-DIAGNOSIS

Does [ECM-ABSTCS COMM NG] (self-diagnostic item) appear on display?

4 CHECK STARTER SIGNAL

Is starter signal input to ECM?

I Repeat self-diagnostic procedures for control unit.

BR-91

IDX

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

LAN CIRCUITS 1, LAN CIRCUITS 2 — LAN Communication System Failure

LAN CIRCUITS 1, LAN CIRCUITS2—LAN Communication System Failure

DIAGNOSTIC PROCEDURE

Malfunction code No. 96, 98

1 INSPECTION START

Self-diagnostic item “LAN CIRCUITS 1” or “LAN CIRCUITS 2” appears on display.

TCS

=NFBR0086

NFBR0086S01

SBR541E

EXIT

2 CHECK SELF-DIAGNOSIS

Perform self-diagnostic procedures for ECM.

Does “ABS-TCS communication” (self-diagnostic item) appears on display?

3 CHECK CIRCUIT

Check ECM to battery power circuits, harness and connectors.

OK or NG

I If NG, replace control unit.

BR-92

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

LAN SIGNAL 3 — Continued Reception After LAN Communication Starts

DIAGNOSTIC PROCEDURE

Malfunction code No. 94

1 INSPECTION START

Self-diagnostic item “LAN SIGNAL 3” appears on display.

TCS

=NFBR0087

NFBR0087S01

SBR541E

EXIT

2 CHECK SELF-DIAGNOSIS

Perform self-diagnostic procedures for ECM.

Does self-diagnostic item [ECM-ABSTCS COMM NG] appear on display?

3 CHECK SELF-DIAGNOSIS

Does self-diagnostic item [ABS-TCS C/U SIGNAL] appears on display?

I Repeat self-diagnostic procedures for control unit.

BR-93

IDX

1. ABS Works Frequently

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS/TCS

EXIT

1. ABS Works Frequently

NFBR0073

1 CHECK BRAKE FLUID PRESSURE

Check brake fluid pressure distribution. Refer to dual proportioning valve inspection in “DUAL PROPORTIONING VALVE”, BR-12.

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-65.

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-94.

No © Repair.

2. Unexpected Pedal Action

1 CHECK BRAKE PEDAL STROKE

Check brake pedal stroke. Is stroke excessively large?

BR-94

NFBR0071

SBR540A

TROUBLE DIAGNOSES FOR SYMPTOMS

2 CHECK CONNECTOR AND PERFORMANCE

1. Disconnect ABS solenoid valve relay.

2. Check whether brake is effective.

OK or NG

3 CHECK WARNING LAMP INDICATION

Ensure warning lamp remains off while driving.

ABS/TCS

2. Unexpected Pedal Action (Cont’d)

EXIT

SBR536E

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. Refer to “Wheel Sensor Rotor”, BR-65.

Is wheel sensor mechanism OK?

connector. Reconnect control unit harness connector. Then retest.

No © Repair.

3. Long Stopping Distance

1 CHECK CONNECTOR AND PERFORMANCE

1. Cancel ABS by disconnecting ABS solenoid valve relay.

2. Check stopping distance.

OK or NG

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

BR-94.

BR-95

NFBR0070

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS

3. Long Stopping Distance (Cont’d)

ABS/TCS

NOTE:

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

EXIT

4. ABS Does Not Work

1 CHECK WARNING LAMP INDICATION

Does the ABS warning lamp activate? Yes © Carry out self-diagnosis. Refer to BR-49, 52. No © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”,

BR-94.

NOTE:

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

NFBR0072

BR-96

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS/TCS

5. Pedal Vibration and Noise

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?

=NFBR0069

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-94.

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?

connector. Reconnect control 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-97

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS

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

1 INSPECTION START

Warning lamp circuit inspection

ABS/TCS

=NFBR0074

EXIT

2 CHECK FUSE

Check 10A fuse No. 30 for warning lamp. For fuse layout, refer to “POWER SUPPLY ROUTING” in EL section.

Is fuse OK?

SBR334EA

BR-98

TROUBLE DIAGNOSES FOR SYMPTOMS

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

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”.

ABS/TCS

EXIT

SBR715DD

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

4 CHECK WARNING LAMP

Check warning lamp bulb.

Is warning lamp bulb OK?

(including combination meter).

BR-99

IDX

TROUBLE DIAGNOSES FOR SYMPTOMS

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

5 CHECK CIRCUIT

1. Remove solenoid valve relay.

2. Check continuity between control unit terminals and solenoid valve relay terminals.

NOTE:

Pay attention to tester polarity. Specifications may vary depending on the type of tester. Before performing this inspection, refer to the instruction manual of the tester.

ABS/TCS

MTBL0091

EXIT

Does continuity exist?

I Harness connectors E33, E91 I Harness for open or short between solenoid valve relay terminal (relay box side) and

control unit

6 CHECK SOLENOID VALVE RELAY

Refer to “8. CHECK SOLENOID VALVE RELAY”, “Solenoid Valve Relay”, BR-72.

Is solenoid valve relay OK?

SBR105EF

BR-100

Nissan Maxima Brake System BR 2000 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

PRECAUTIONS

Precautions for Brake System

Wiring Diagrams and Trouble Diagnosis

Commercial Service Tools

PREPARATION

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

Checking Brake Fluid Level

ON-VEHICLE SERVICE

Checking Brake Line

Changing Brake Fluid

Brake Burnishing Procedure

Bleeding Brake System

Hydraulic Circuit

BRAKE HYDRAULIC LINE

Removal

Inspection

Installation

Inspection

DUAL PROPORTIONING VALVE

BRAKE PEDAL AND BRACKET

Removal and Installation

Inspection

Adjustment

MASTER CYLINDER (TOKICO)

Removal

Disassembly

Inspection

Assembly

Installation

Removal

MASTER CYLINDER (NABCO)

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

PARKING BRAKE CONTROL

Components

Removal and Installation

Inspection

Adjustment

DESCRIPTION

ABS/TCS

Purpose

ABS (Anti-Lock Brake System) Operation

ABS Hydraulic Circuit