Nissan Xterra Brake System BR 2000 Owner's Manual

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Page 1

BRAKE SYSTEM

CONTENTS

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

Supplemental Restraint System (SRS) ″AIR

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

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

Wiring Diagrams and Trouble Diagnosis.....................3

PREPARATION ...............................................................4

Special Service Tools..................................................4

Commercial Service Tools...........................................4

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING.....................................................5

NVH Troubleshooting Chart.........................................5

ON-VEHICLE SERVICE ..................................................6

Checking Brake Fluid Level.........................................6

Checking Brake Line ...................................................6

Changing Brake Fluid..................................................6

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

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

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

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

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

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

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

BRAKE PEDAL AND BRACKET..................................11

Removal and Installation...........................................11

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

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

MASTER CYLINDER.....................................................13

Removal.....................................................................13

Disassembly...............................................................13

Inspection...................................................................14

Assembly ...................................................................14

Installation..................................................................15

BRAKE BOOSTER........................................................16

On-vehicle Service.....................................................16

OPERATING CHECK AIRTIGHT CHECK

Removal.....................................................................16

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

OUTPUT ROD LENGTH CHECK

...............................................16

...................................................16

..............................16

SECTION

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

VACUUM PIPING...........................................................18

Removal and Installation...........................................18

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

HOSES AND CONNECTORS CHECK VALVE

FRONT DISC BRAKE ...................................................19

Pad Replacement......................................................19

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

Disassembly...............................................................20

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

CALIPER ROTOR

Assembly ...................................................................22

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

Brake Burnishing Procedure......................................22

REAR DRUM BRAKE ...................................................23

Components...............................................................23

Removal.....................................................................23

Inspection...................................................................24

WHEEL CYLINDER

Wheel Cylinder Overhaul...........................................24

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

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

DRUM

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

LINING

Installation..................................................................25

PARKING BRAKE CONTROL......................................27

Components...............................................................27

Removal and Installation...........................................27

Inspection...................................................................27

Adjustment.................................................................28

DESCRIPTION...............................................................29

Purpose......................................................................29

Operation...................................................................29

ABS Hydraulic Circuit................................................29

System Components .................................................30

System Description....................................................30

........................................................18

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

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

...................................18

..................................................24

ABS

IDX

Page 2

CONTENTS (Cont’d)

WHEEL SENSOR CONTROL UNIT (BUILT-IN ABS ACTUATOR AND ELECTRIC UNIT) ABS ACTUATOR AND ELECTRIC UNIT G SENSOR (4WD MODELS)

....................................................30

.....................................................30

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

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

Component Parts and Harness Connector

Location .....................................................................32

Schematic..................................................................33

2–WHEEL DRIVE 4–WHEEL DRIVE

....................................................33

....................................................34

Wiring Diagram - ABS - 2WD - .................................35

Wiring Diagram - ABS - 4WD - .................................38

ON BOARD DIAGNOSTIC SYSTEM

DESCRIPTION...............................................................41

Self-diagnosis ............................................................41

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

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

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

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

TROUBLE DIAGNOSIS - INTRODUCTION..................43

How to Perform Trouble Diagnoses for Quick

and Accurate Repair..................................................43

INTRODUCTION

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

TROUBLE DIAGNOSIS - BASIC INSPECTION...........44

Preliminary Check......................................................44

Ground Circuit Check................................................47

ABS ACTUATOR AND ELECTRIC UNIT GROUND

.....47

TROUBLE DIAGNOSIS - GENERAL

DESCRIPTION...............................................................48

Malfunction Code/Symptom Chart.............................48

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC

ITEMS.............................................................................49

Wheel Sensor or Rotor..............................................49

DIAGNOSTIC PROCEDURE

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

ABS Actuator Solenoid Valve or Solenoid Valve

Relay..........................................................................52

DIAGNOSTIC PROCEDURE

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

Motor Relay or Motor.................................................54

DIAGNOSTIC PROCEDURE

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

Low Voltage...............................................................56

DIAGNOSTIC PROCEDURE

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

G Sensor and Circuit.................................................58

DIAGNOSTIC PROCEDURE

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

Control Unit................................................................60

DIAGNOSTIC PROCEDURE

.....................................60

TROUBLE DIAGNOSES FOR SYMPTOMS.................61

1. ABS Works Frequently ..........................................61

2. Unexpected Pedal Action ......................................61

3. Long Stopping Distance........................................63

4. ABS Does Not Work..............................................63

5. Pedal Vibration and Noise.....................................64

6. Warning Lamp Does Not Come On When

Ignition Switch Is Turned On .....................................64

7. Warning Lamp Stays On When Ignition Switch

Is Turned On..............................................................66

REMOVAL AND INSTALLATION.................................69

Front Wheel Sensor...................................................69

Rear Wheel Sensor...................................................69

4WD MODELS 2WD MODELS

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

.........................................................70

Front Sensor Rotor....................................................70

REMOVAL INSTALLATION

...............................................................70

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

Rear Sensor Rotor (4WD).........................................71

REMOVAL INSTALLATION

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

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

Rear Sensor Rotor (2WD).........................................71

REMOVAL AND INSTALLATION

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

G Sensor....................................................................71

ABS Actuator and Electric Unit..................................72

REMOVAL INSTALLATION

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

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

SERVICE DATA AND SPECIFICATIONS (SDS).........73

General Specifications...............................................73

Disc Brake .................................................................73

Drum Brake................................................................73

Brake Pedal...............................................................73

Parking Brake Control ...............................................74

BR-2

Page 3

PRECAUTIONS

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

The supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-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 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, a crash zone sensor (4WD models), warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual.

WARNING:

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

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

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

sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, refer to

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

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

RS-16

NGBR0001

SBR686C

Precautions for Brake System

I Use brake fluid “DOT 3”. 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.

I To clean master cylinder parts, disc brake caliper parts or

wheel cylinder parts, use clean brake fluid.

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

will ruin rubber parts of hydraulic system.

I Use flare nut wrench when removing and installing brake

tubes. I Always torque brake lines when installing.

WARNING:

I Clean brakes with a vacuum dust collector to minimize

risk of health hazard from powder caused by friction.

NGBR0002

Wiring Diagrams and Trouble Diagnosis

When you read wiring diagrams, refer to the followings:

GI-10

I “HOW TO READ WIRING DIAGRAMS” refer to I “POWER SUPPLY ROUTING” for power distribution circuit refer to

When you perform trouble diagnosis, refer to the followings:

I “HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS” refer to I “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” refer to

EL-9

GI-34

BR-3

GI-23

NGBR0003

IDX

Page 4

Special Service Tools

PREPARATION

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name

KV40106500 (JS25852-B) Wheel bearing puller

Description

Removing rear wheel sensor rotor

NT724

Commercial Service Tools

Tool name Description 1 Flare nut crowfoot

2 Torque wrench

NT360

Brake fluid pressure gauge

Removing and installing each brake piping

a: 10 mm (0.39 in)

Measuring brake fluid pressure

NGBR0004

NGBR0005

Rear wheel sensor rotor drift

NT151

Installing rear wheel sensor rotor

a: 75 mm (2.95 in) dia. b: 63 mm (2.48 in) dia.

NT509

BR-4

Page 5

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

NGBR0085

NVH Troubleshooting Chart

NGBR0085S01

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

PD-40

Reference page

Possible cause and SUSPECTED PARTS

Noise ×××× Ч Ч ЧЧЧЧЧЧ

BR-25

BR-19, 25

Linings or pads - damaged

Linings or pads - uneven wear

BR-23

BR-18

Return spring damaged

Shims damaged

—

Rotor or drum imbalance

Rotor or drum damage

—

BR-21, 25

Rotor or drum runout

Rotor or drum deformation

—

Rotor or drum deflection

Rotor or drum rust

BR-21

BR-25

Rotor thickness variation

Drum out of round

PD-4

PD-14

NVH,

PROPELLER SHAFT

AX-3

NVH,

PD-62

DIFFERENTIAL

DRIVE SHAFT

AXLE

SU-3

NVH,

SUSPENSION

TIRES

ROAD WHEEL

ST-5

NVH,

STEERING

Symptom BRAKE

×: Applicable

Shake × × ЧЧЧЧЧЧ

Shimmy, Judder ЧЧЧЧЧЧЧЧ ЧЧЧЧЧ

BR-5

IDX

Page 6

Checking Brake Fluid Level

ON-VEHICLE SERVICE

SBR451D

SBR389C

SBR419C

Checking Brake Fluid Level

NGBR0006

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. I If the brake warning lamp comes on, check brake fluid level

switch and parking brake switch.

Checking Brake Line

NGBR0007

CAUTION:

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

1. Check brake lines (tubes and hoses) for cracks, deterioration

and other damage. Replace any damaged parts.

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

engine is running.

Changing Brake Fluid

NGBR0008

CAUTION:

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

ervoir tank.

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

may cause paint damage. If brake fluid is splashed on

painted areas, wash it away with water immediately.

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

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

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

brake pedal.

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

Use same procedure as in bleeding hydraulic system to refill

brake fluid.

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

BR-6

Page 7

ON-VEHICLE SERVICE

Brake Burnishing Procedure

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

CAUTION:

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

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

MPH).

2. Use medium brake pedal/foot effort to bring the vehicle to a

pressure such that vehicle stopping time equals to 3 to 5 sec-

onds.

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 burnish-

ing procedure.

=NGBR0120

BR-7

IDX

Page 8

Bleeding Brake System

ON-VEHICLE SERVICE

SBR995

SBR419C

Bleeding Brake System

=NGBR0009

CAUTION:

I Carefully monitor brake fluid level at master cylinder dur-

ing bleeding operation. I If master cylinder is suspected to have air inside, bleed air

from master cylinder first. Refer to “Installation”, “MAS-

TER CYLINDER”, BR-15. 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 Turn ignition switch OFF and disconnect ABS actuator

connectors or battery ground cable. I Bleed air in the following order.

1. Left rear brake

2. Right rear brake

3. Left front brake

4. Right front brake

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

2. Fully depress brake pedal several times.

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

air.

4. Close air bleeder valve.

5. Release brake pedal slowly.

6. Repeat steps 1. through 4. until clear brake fluid comes out of

air bleeder valve.

7. Tighten air bleeder valve to specified torque.

:7-9N·m(0.7 - 0.9 kg-m, 61 - 78 in-lb)

BR-8

Page 9

BRAKE HYDRAULIC LINE

Hydraulic Circuit

NGBR0010

SBR992

ABR676

Removal

CAUTION:

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

may cause paint damage. If brake fluid is splashed on

painted areas, wash it away with water immediately. I All hoses must be free from excessive bending, twisting

and pulling.

1. Connect vinyl tube to air bleeder valve.

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

brake pedal.

3. Remove flare nut connecting brake tube and hose, then with-

draw lock spring.

4. Cover openings to prevent entrance of dirt whenever discon-

necting brake line.

NGBR0011

BR-9

IDX

Page 10

Inspection

BRAKE HYDRAULIC LINE

SBR686C

Inspection

NGBR0012

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

Installation

NGBR0013

CAUTION:

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

1. Tighten all flare nuts and connecting bolts.

Flare nut:

: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

Connecting bolt:

: 17 - 19 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)

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

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

BR-10

Page 11

BRAKE PEDAL AND BRACKET

Removal and Installation

NGBR0016

SBR997

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

ABR824

NGBR0017

BR-11

IDX

Page 12

Adjustment

BRAKE PEDAL AND BRACKET

SBR278AB

SBR930

Adjustment

NGBR0018

Check brake pedal free height from metal floor.

H: Free height

Refer to SDS (BR-73).

D: Depressed height

Refer to SDS (BR-73). Under force of 490 N (50 kg, 110 lb) with engine run-

ning ,C2: Clearance between pedal stopper and

threaded end of stop lamp switch and ASCD switch

0.3 - 1.0 mm (0.012 - 0.039 in)

A: Pedal free play

1-3mm(0.04 - 0.12 in)

If necessary, adjust brake pedal free height.

1. Loosen lock nut and adjust pedal free height by turning brake

booster input rod. Then tighten lock nut.

Make sure that tip of input rod stays inside.

2. Adjust clearance “C

” and “C2” with stop lamp switch and

ASCD switch respectively. Then tighten lock nuts.

3. Check pedal free play.

Make sure that stop lamp is off when pedal is released.

4. Check brake pedal’s depressed height while engine is running.

If depressed height is below specified value, check brake sys-

tem for leaks, accumulation of air or any damage to compo-

nents (master cylinder, wheel cylinder, etc.). Then make nec-

essary repairs.

BR-12

Page 13

MASTER CYLINDER

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 In the case of brake fluid leakage from the master cylinder,

disassemble the cylinder. Then check piston cups for

deformation and scratches and replace necessary parts.

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.

NGBR0019

Disassembly

1. Bend claws of stopper cap outward.

ABR873

NGBR0020

SBR938A

IDX

BR-13

Page 14

Disassembly (Cont’d)

MASTER CYLINDER

2. Remove piston 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.

SBR939A

ABR767

Inspection

NGBR0021

Check master cylinder inner wall for pin holes and scratches. Replace if damaged.

Assembly

NGBR0022

1. Insert secondary piston assembly. Then insert primary piston

assembly.

I Pay attention to direction of piston cups in figure at left.

Also, insert pistons squarely to avoid scratches on cylin-

der bore.

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.

SBR940A

BR-14

Page 15

MASTER CYLINDER

Installation

ABR190

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 mount-

ing 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 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

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

=NGBR0023

BR-15

IDX

Page 16

On-vehicle Service

BRAKE BOOSTER

SBR002A

SBR365AA

On-vehicle Service

OPERATING CHECK

NGBR0024

NGBR0024S01

1. Depress brake pedal several times with engine off. After

exhausting vacuum, make sure there is no change in pedal

stroke.

2. Depress brake pedal, then start engine. If pedal goes down

slightly, operation is normal.

AIRTIGHT CHECK

NGBR0024S02

1. Start engine, and stop it after one or two minutes. Depress

brake pedal several times slowly. Booster is airtight if pedal

stroke is less each time.

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

NGBR0025

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.

ABR909

ABR908

Inspection

OUTPUT ROD LENGTH CHECK

NGBR0026

NGBR0026S01

1. Apply vacuum of −66.7 kPa (−500 mmHg, −19.69 inHg) to

brake booster with a hand vacuum pump.

2. Add preload of 19.6 N (2.0 kg, 4.4 lb) to output rod length.

3. Check output rod length.

Specified length:

10.275 - 10.525 mm (0.4045 - 0.4144 in)

BR-16

Page 17

BRAKE BOOSTER

Installation

SBR116BE

Installation

CAUTION:

I Be careful not to deform or bend brake pipes during instal-

lation 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 narrow angle of

installation, the threads can be damaged by the dash

panel.

A: 138.5 mm (5.45 in)

1. Before fitting booster, temporarily adjust clevis to dimension

shown.

2. Fit booster, then secure mounting nuts (brake pedal bracket to

brake booster) 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-15.

6. Adjust brake pedal height and free play. Refer to “Adjustment”

in “BRAKE PEDAL AND BRACKET”, BR-12.

7. Secure lock nut for clevis.

: 16 - 22 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)

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

=NGBR0027

BR-17

IDX

Page 18

Removal and Installation

VACUUM PIPING

SBR225B

SBR498A

Removal and Installation

NGBR0029

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

NGBR0030

NGBR0030S01

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

SBR943A

CHECK VALVE

Check vacuum with a vacuum pump.

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

BR-18

NGBR0030S02

Page 19

FRONT DISC BRAKE

Pad Replacement

WARNING:

Clean brakes 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,

or 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 Carefully monitor brake fluid level because brake fluid will

return to reservoir when pushing back piston.

1. Remove master cylinder reservoir cap.

2. Remove lower pin bolt.

NGBR0032

SBR081A

3. Open cylinder body upward. Then remove pad retainers, and

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.

SBR010B

IDX

BR-19

Page 20

Pad Replacement (Cont’d)

FRONT DISC BRAKE

ABR918

SBR083A

Removal

NGBR0033

WARNING:

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

CAUTION:

Suspend caliper assembly with wire so as not to stretch brake hose.

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

NGBR0034

WARNING:

Do not place your fingers in front of piston.

CAUTION:

Do not scratch or score cylinder wall.

1. Push out piston with dust seal with compressed air.

2. Remove piston seal with a suitable tool.

SBR085A

BR-20

Page 21

FRONT DISC BRAKE

Inspection

SBR089A

Inspection

CALIPER Cylinder Body

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

and presence of foreign objects. If any of the above conditions

are observed, replace cylinder body. I Minor damage from rust or foreign objects may be eliminated

by polishing surface with a fine emery paper. Replace cylinder

body if necessary.

CAUTION:

Use brake fluid to clean. Never use mineral oil.

Piston

CAUTION:

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

Check pistons for uneven surface, chips or cracks. Replace if any of these conditions are observed.

Slide Pin, Pin Bolt and Pin Boot

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

ROTOR Runout

1. Check runout using a dial indicator.

Make sure that wheel bearing axial end play is within the

AX-4

specifications before measuring. Refer to Bearing” in AX section. (“Front Wheel Bearing”,”ON VEHICLE SERVICE”).

Maximum runout:

0.07 mm (0.0028 in)

2. If the runout is out of specification, machine rotor with on-car

brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or

equivalent).

“Front Wheel

NGBR0035

NGBR0035S01

NGBR0035S0101

NGBR0035S0102

NGBR0035S0103

NGBR0035S02

NGBR0035S0201

SBR090A

Thickness

Thickness variation (At least 8 positions):

Maximum 0.02 mm (0.0008 in)

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

Rotor repair limit:

26.0 mm (1.024 in)

NGBR0035S0202

BR-21

IDX

Page 22

Assembly

FRONT DISC BRAKE

SBR178C

SBR179CA

Assembly

NGBR0036

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

CAUTION:

I Secure dust seal property. I Lubricate with new brake fluid before installing plastic pis-

tons into cylinder body.

Installation

NGBR0037

CAUTION:

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

1. Install caliper assembly.

2. Install brake hose to caliper securely.

3. Install all parts and secure all bolts.

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

SBR084A

Brake Burnishing Procedure

NGBR0088

When experiencing soft brake pedal feel at very low mileage, or after replacing the rotor, burnish the brake pad contact surfaces according to the following procedures.

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

pressure such that vehicle stopping time equals 3 to 5 sec-

onds.

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 burnish-

ing procedure.

BR-22

Page 23

REAR DRUM BRAKE

Components

NGBR0038

ABR768

Removal

WARNING:

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

CAUTION:

Make sure parking brake lever is released completely.

1. Release parking brake lever fully, then remove drum.

I If drum is hard to remove, the following procedures

should be carried out. a. Remove plug. Shorten adjuster to make clearance

between brake shoe and drum as shown

NGBR0039

SBR264CA

IDX

BR-23

Page 24

Removal (Cont’d)

REAR DRUM BRAKE

b. Install two bolts as shown. Tightenthe two bolts gradually.

SBR093A

2. After removing retainer, remove spring by rotating shoes.

Be careful not to damage wheel cylinder piston boots. Be careful not to damage parking brake cable when separating it.

3. Remove adjuster.

4. Disconnect parking brake cable from toggle lever.

ABR369

ABR408

ABR370

5. Remove retainer ring with a suitable tool. Then separate toggle

lever and brake shoe.

Inspection

WHEEL CYLINDER

NGBR0040

NGBR0040S01

I Check wheel cylinder for leakage. I Check for wear, damage and loose conditions.

Replace if any such condition exists.

SBR215B

Wheel Cylinder Overhaul

NGBR0041

I Check all internal parts for wear, rust and damage. Replace if

necessary. I Pay attention so as not to scratch cylinder when installing pis-

tons.

BR-24

Page 25

REAR DRUM BRAKE

Inspection

SBR095A

SBR021A

ABR371

Inspection

DRUM

Maximum inner diameter (Repair limit):

LT30A 296.5 mm (11.67 in)

I Contact surface should be fine finished with No. 120 to 150

emery paper. I Using a drum lathe, lathe brake drum if it shows scoring, par-

tial wear or stepped wear. I After brake drum has been completely reconditioned or

replaced, check drum and shoes for proper contact pattern.

LINING

Check lining thickness.

Standard lining thickness:

LT30A 5.8 mm (0.228 in)

Lining wear limit (A):

LT30A 1.5 mm (0.059 in)

Installation

Always perform shoe clearance adjustment. Refer to BR-28. 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-22

1. Fit toggle lever to brake shoe with retainer clip.

2. Apply brake grease to the contact areas shown at left.

3. Shorten adjuster by rotating it.

I Pay attention to direction of adjuster.

NGBR0042

NGBR0042S01

NGBR0042S02

NGBR0043

ABR396

ABR372

Wheel Screw depression Left Left-hand thread Yes Right Right-hand thread No

4. Connect parking brake cable to toggle lever.

5. Install all parts.

Be careful not to damage wheel cylinder piston boots.

6. Check all parts are installed properly.

I After installations completed, adjust shoe-to-drum clear-

ance.

Pay attention to direction of adjuster assembly.

7. Install brake drum.

8. When installing new wheel cylinder or overhauling wheel cylinder, bleed air. Refer to “Bleeding Brake System”, BR-8.

9. Adjust parking brake. Refer to “Adjustment”, “PARKING BRAKE CONTROL”, BR-28.

I Install all the parts by referring to to the figure below. I After installing crank lever on back plate, make sure that there

BR-25

IDX

Page 26

Installation (Cont’d)

REAR DRUM BRAKE

is no play between crank lever and back plate. If play exists, adjust bolt A and lock nut B.

ABR827

BR-26

Page 27

PARKING BRAKE CONTROL

Components

NGBR0044

ABR874

Removal and Installation

I Be careful not to damage cable. I Make sure there is no free play after installation.

Inspection

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

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

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

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

NGBR0045

NGBR0046

BR-27

IDX

Page 28

Adjustment

PARKING BRAKE CONTROL

ABR771

ABR405

Adjustment

NGBR0047

Adjust parking brake as follows:

1. Fully release parking brake lever.

2. Loosen A and rotate B until parking brake cable loosens.

3. Depress brake pedal several times until clicking sound does not occur from rear brakes.

4. Adjust clearance between rear brake shoe and drum.

5. Adjust parking lever stroke by rotating B.

6. Pull parking brake lever with specified force. Check lever stroke and ensure smooth operation.

7. Readjust clearance between rear brake shoe and drum.

BR-28

Page 29

DESCRIPTION

ABS

Purpose

The Anti-Lock Brake System (ABS) consists of electronic and hydraulic components. It allows for control of braking force so locking of the wheels can be avoided.

1) Improves proper tracking performance through steering wheel operation.

2) Eases obstacle avoidance through steering wheel operation.

3) Improves vehicle stability.

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 a self-test function. The system turns on the ABS warning lamp

for 1 second each time the ignition switch is turned ON. After the engine is started, the ABS warning lamp turns off. The system performs a test the first time the vehicle reaches 6 km/h (4 MPH).Amechanical noise may be heard as the ABS performs this 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 stay on.

I While driving, a mechanical noise may be heard during ABS operation. This is a normal condition.

ABS Hydraulic Circuit

NGBR0089

NGBR0090

NGBR0091

1. Inlet solenoid valve

2. Outlet solenoid valve

3. Pump

4. Motor

5. Bypass check valve

SBR859D

6. Damper

7. Solenoid valve relay actuator

BR-29

IDX

Page 30

System Components

DESCRIPTION

ABS

System Components

NGBR0092

SBR124B

ABR910

ABR857

System Description

WHEEL SENSOR

NGBR0093

NGBR0093S01

The sensor units consist of a gear-shaped sensor rotor and a sensor element. The element contains a bar magnet around which a coil is wound. The front sensors are installed on the back of the front brake rotors. For 2-wheel drive systems a single sensor is installed at the companion flange of the rear axle housing and for 4-wheel drive systemsthere is asensor installed ateach rear brake drum. As the wheel rotates, the sensor generates a sine-wave pattern. The frequency and voltage increase(s) as the rotating speed increases.

CONTROL UNIT (BUILT-IN ABS ACTUATOR AND ELECTRIC UNIT)

The control unit computes the wheel rotating speed by the signal current sent from the sensor. Then it supplies a DC current to the actuator solenoid valve. It also controls ON-OFF operation of the valve relay and motor relay. If any electrical malfunction should be detected in the system, the control unit causes the warning lamp to light up. In this condition, the ABS will be deactivated by the control unit, and the vehicle’s brake system reverts to normal operation. (For control unit layout, refer to ABS ACTUATOR AND ELECTRIC UNIT, BR-31.)

NGBR0093S02

BR-30

Page 31

DESCRIPTION

ABS

System Description (Cont’d)

ABS ACTUATOR AND ELECTRIC UNIT

The ABS actuator and electric unit contains:

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

— LH front — RH front — Rear

I ABS control unit

ABR858

This component controls the hydraulic circuit and increases, holds or decreases hydraulic pressure to all or individual wheels. The ABS actuator and electric unit is serviced as an assembly.

ABS Actuator Operation

Inlet solenoid valve

Normal brake operation OFF (Open) OFF (Closed)

Pressure hold ON (Closed) OFF (Closed)

ABS operation

Pressure decrease

Pressure increase

ON (Closed) ON (Open)

OFF (Open) OFF (Closed)

Outlet solenoid valve

G SENSOR (4WD MODELS)

The G sensor senses deceleration during braking to determine whether the vehicle is being driven on a high µ road (asphalt road, etc.) or a low µ road (snow-covered road, etc.). It then sends a signal to the ABS control unit.

NGBR0093S03

NGBR0093S0301

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.

NGBR0093S05

ABR859

This signal is recieved by the ABS control unit as a variable voltage signal. The input voltage varies from 1.3V ±0.125V during a hard deceleration condition, to 2.5V ±0.125V with the vehicle stopped and to 3.7V ±0.125Vduring a hard deceleration in reverse.

BR-31

IDX

Page 32

Component Parts and Harness Connector Location

DESCRIPTION

Component Parts and Harness Connector Location

ABS

NGBR0094

BR-32

ABR860

Page 33

DESCRIPTION

ABS

Schematic

2–WHEEL DRIVE

NGBR0095

NGBR0095S01

BR-33

ABR816

IDX

Page 34

Schematic (Cont’d)

DESCRIPTION

ABS

4–WHEEL DRIVE

NGBR0095S02

BR-34

ABR820

Page 35

DESCRIPTION

ABS

Wiring Diagram — ABS — 2WD —

NGBR0096

BR-35

ABR817

IDX

Page 36

Wiring Diagram — ABS — 2WD — (Cont’d)

DESCRIPTION

ABS

BR-36

ABR818

Page 37

DESCRIPTION

ABS

Wiring Diagram — ABS — 2WD — (Cont’d)

BR-37

ABR819

IDX

Page 38

Wiring Diagram — ABS — 4WD —

DESCRIPTION

ABS

Wiring Diagram — ABS — 4WD —

NGBR0122

BR-38

ABR821

Page 39

DESCRIPTION

ABS

Wiring Diagram — ABS — 4WD — (Cont’d)

BR-39

ABR822

IDX

Page 40

Wiring Diagram — ABS — 4WD — (Cont’d)

DESCRIPTION

ABS

BR-40

ABR823

Page 41

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

ABS

Self-diagnosis

FUNCTION

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

instrument panel comes on. [To start the self-diagnostic results mode, ground the self-diagnostic (check) terminal 8 located on the “Data link connector”. The location of the malfunction is indicated by the warning lamp flashing]

SELF-DIAGNOSIS PROCEDURE

NOTE:

CONSULT-II is not applicable to ABS. Use on board diagnostic system with ABS warning lamp.

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

2. Turn ignition switch OFF.

3. Ground terminal 8 of “Data link connector for CONSULT-II” with a suitable harness.

4. Turn ignition switch ON while grounding terminal 8.

Do not depress brake pedal.

NGBR0097

NGBR0097S01

NGBR0097S02

ABR847

ABR910

ABR847

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

6. Verify the location of the malfunction with the malfunction code chart. Refer to BR-48. 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-42.

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

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

NOTE:

The indication terminates after 5 minutes. However, when the ignition switch is turned from OFF to ON, the indication starts flashing again.

BR-41

IDX

Page 42

Self-diagnosis (Cont’d)

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)

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

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

3. The indication begins with the start code 12. After that a maximum of three code numbers appear in the order of the lowesr to highest. 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 page BR-48.

ABS

=NGBR0097S03

ABR256

SBR457D

HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)

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

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

3. Perform self-diagnosis again. Refer to BR-41. Only the startcode should appear, no malfunction codes.

NGBR0097S04

BR-42

Page 43

TROUBLE DIAGNOSIS — INTRODUCTION

How to Perform Trouble Diagnoses for Quick and Accurate Repair

INTRODUCTION

The ABS system has an electronic control unit to control major functions. The control unit accepts input signals from sensors and instantly drives the actuators. 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 booster 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 a few minutes to talk with a customer who approaches with anABS complaint. The customer is a very good source of information on such problems; especially intermittent ones. By talking to the customer, find out what symptoms are present and under what conditions they occur. Start your diagnosis by looking for “conventional” problems first. This is one of the best ways to troubleshoot brake problems on an ABS controlled vehicle.

Also check related Service bulletins for information.

ABS

NGBR0100

NGBR0100S01

BR-43

IDX

Page 44

Preliminary Check

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Preliminary Check

1 CHECK BRAKE FLUID

Check brake fluid for contamination.

Has brake fluid been contaminated?

Yes © Replace. GO TO 2. No © GO TO 2.

2 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 ?

Yes © GO TO 3. No © Fill up brake fluid. GO TO 3.

NGBR0101

SBR451D

3 CHECK BRAKE LINE

Check brake line for leakage.

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

Yes © Repair. GO TO 4. No © GO TO 4.

SBR389C

BR-44

Page 45

TROUBLE DIAGNOSIS — BASIC INSPECTION

4 CHECK BRAKE BOOSTER OPERATION

Check brake booster for operation and air tightness. Refer to “On-vehicle Service”, “BRAKE BOOSTER”, BR-16.

Is brake booster airtight and functioning properly?

Yes © GO TO 5. No © Replace. GO TO 5.

5 CHECK BRAKE PAD AND ROTOR

Check brake pad and rotor. Refer to BR-19, 20.

ABS

Preliminary Check (Cont’d)

SBR058C

Are brake pads and rotors functioning properly?

Yes © GO TO 6. No © Replace.

SBR059C

BR-45

IDX

Page 46

TROUBLE DIAGNOSIS — BASIC INSPECTION

Preliminary Check (Cont’d)

6 RECHECK BRAKE FLUID LEVEL

Check brake fluid level in reservoir tank again.

Is brake fluid filled between MAX and MIN lines on reservoir tank ?

Yes © GO TO 7. No © Fill up brake fluid.

7 CHECK WARNING LAMP ACTIVATION

Check warning lamp activation.

ABS

SBR451D

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

Yes © GO TO 8. No © Check fuse, warning lamp bulb and warning lamp circuit.

8 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 9. No © Go to Self-diagnosis, BR-41.

9 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 © INSPECTION END No © Go to Self-diagnosis, BR-41.

ABR838

BR-46

Page 47

TROUBLE DIAGNOSIS — BASIC INSPECTION

ABS

Ground Circuit Check

ABR882

Ground Circuit Check

ABS ACTUATOR AND ELECTRIC UNIT GROUND

I Check continuity between ABS actuator and electric unit con-

nector terminals and ground.

Continuity should exist.

=NGBR0102

NGBR0102S01

BR-47

IDX

Page 48

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION

Malfunction Code/Symptom Chart

ABS

Malfunction Code/Symptom Chart

Code No. (No. of warning lamp flashes) Malfunctioning part Reference Page

12 Self-diagnosis could not detect any malfunctions. — 17 ★1 G sensor and circuit (4WD) BR-58 18 ★1 Sensor rotor or abnormal tire size BR-49 21 ★1 Front right sensor BR-49 25 ★1 Front left sensor BR-49 31 ★1 Rear right sensor (4WD) BR-49 35 ★1 Rear left sensor (4WD) or Rear sensor (2WD) BR-49 57 ★2 Power supply (Low voltage) BR-56 61 ★3 Actuator motor or motor relay BR-54

63 Solenoid valve relay BR-52

71 Control unit or Actuator solenoid valve BR-52, 60

ABS works frequently — BR-61

Unexpected pedal action — BR-61

Long stopping distance — BR-63

ABS does not work — BR-63

NGBR0103

Pedal vibration and noise — BR-64

Warning lamp does not come on

when ignition switch is turned ON.

Warning lamp stays on when ignition

switch is turned ON.

★1: If one or more wheels spin on a rough or slippery road for 40 seconds or more, the ABS warning lamp will illuminate. This does not indicate a malfunction. Only in the case of the short-circuit (Code Nos. 26, 22, 32 and 36), after repair the ABS warning lamp also illuminates when the ignition switch is turned ON. In this case, drive the vehicle at speeds greater than 30 km/h (19 MPH) for approximately 1 minute as specified in “SELF-DIAGNOSIS PROCEDURE”, BR-41. Check to ensure that the ABS warning lamp goes out while the vehicle is being driven.

★2: The trouble code “57”, which refers to a low power supply voltage, does not indicate that the ABS control unit is malfunctioning. Do not replace the ABS control unit with a new one.

★3: The trouble code “61” can sometimes appear when the ABS motor is not properly grounded. If it appears, be sure to check the condition of the ABS motor ground circuit connection.

Fuse, warning lamp bulb or warning lamp circuit Control unit

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

BR-64

BR-66

BR-48

Page 49

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Wheel Sensor or Rotor

DIAGNOSTIC PROCEDURE

Malfunction code No. 21, 25, 31, 35, or 18 NOTE:

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

ABS

NGBR0104

1 INSPECTION START

Wheel sensor inspection

ABR883

2 CHECK CONNECTOR

1. Disconnect connectors from ABS actuator and electric unit and wheel sensor of malfunction code No. Check terminals for damage or loose connection. Then reconnect connectors.

2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes © GO TO 3. No © INSPECTION END

BR-49

IDX

Page 50

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Wheel Sensor or Rotor (Cont’d)

3 CHECK WHEEL SENSOR ELECTRICAL

1. Disconnect ABS actuator and electric unit connector.

2. Check resistance between ABS actuator and electric unit connector E39 terminals Code No. 21 (Front RH wheel) Terminals 19 and 20 Code No. 25 (Front LH wheel) Terminals 1 and 2 Code No. 31 (Rear RH wheel) (4WD) Terminals 22 and 23 Code No. 35 (4WD: Rear LH wheel, 2WD: Rear wheel) Terminals 5 and 6

Resistance:

Front 1.28 - 1.92 kΩ Rear

2WD: 1.05 - 1.35 kΩ 4WD: 1.28 - 1.92 kΩ

Are front and rear resistance values within range listed above?

Yes © GO TO 5. No © GO TO 4.

ABS

ABR919

4 CHECK WHEEL SENSOR

Check each sensor for resistance.

Resistance:

Front 1.28 - 1.92 kΩ Rear

2WD 1.05 - 1.35 kΩ 4WD 1.28 - 1.92 kΩ

Are front and rear resistance values within range listed above?

Yes © Check the following.

If NG, repair harness or connectors.

I Harness connectors E2, E16, C102 I Harness for open or short between wheel sensor connectors and ABS actuator and

electric unit

No © Replace wheel sensor.

ABR885

BR-50

Page 51

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

5 CHECK TIRE

Check for inflation pressure, wear and size of each tire. (See NOTE)

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

Yes 䊳 GO TO 6. No 䊳 Adjust tire pressure or replace tire(s). (See NOTE)

ABS

Wheel Sensor or Rotor (Cont’d)

6 CHECK WHEEL BEARING

Check wheel bearing axial end play. (See NOTE)

Is wheel bearing axial end play within specifications? Refer to “On-vehicle Service”, “FRONT AXLE”, AX-4 and

“REAR AXLE”, AX-25.

Yes 䊳 GO TO 7. No 䊳 Check wheel bearing. Refer to “On-vehicle Service”, “FRONT AXLE”, AX-4 and “REAR

AXLE”, AX-25.

7 CHECK SENSOR ROTOR

Check sensor rotor for teeth damage. (See NOTE)

Is sensor rotor free from damage?

Yes 䊳 Check ABS actuator and electric unit pin terminals for damage or the connection of ABS

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

No 䊳 Replace sensor rotor. (See NOTE)

BR-51

IDX

Page 52

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

ABS Actuator Solenoid Valve or Solenoid Valve Relay

DIAGNOSTIC PROCEDURE

Malfunction code No. 71

1 INSPECTION START

Solenoid valve relay inspection

ABS

=NGBR0105

2 CHECK FUSIBLE LINK

Check 40A fusible link c. For fusible link layout, refer to “POWER SUPPLY ROUTING”,

Is fusible link OK?

Yes © GO TO 3. No © GO TO 6.

3 CHECK CONNECTOR

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

2. Carry out self-diagnosis again.

Does warning lamp activate again?

Yes © GO TO 4. No © INSPECTION END

4 CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT

Refer to “ABS ACTUATOR AND ELECTRIC UNIT GROUND” in “Ground Circuit Check”, BR-47.

Is ground circuit OK?

EL-9

ABR886

BR-52

Page 53

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

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

5 CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector.

2. Check voltage between ABS actuator and electric unit connector E39 terminal 9 and ground.

ABS

Does battery voltage exist?

If NG, repair harness or connectors.

I Harness connector E39 I Harness for open or short between ABS actuator and electric unit and fusible link

6 REPLACE FUSIBLE LINK

Replace fusible link.

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

7 CHECK SOLENOID VALVE RELAY POWER SUPPLY CIRCUIT FOR SHORT

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

2. Check continuity between ABS actuator and electric unit connector E39 terminal 9 and ground.

ABR887

Continuity should not exist.

Does continuity exist?

If NG, repair harness or connector.

I Harness connector E39 I Harness for open or short between ABS actuator and electric unit and fusible link

BR-53

ABR888

IDX

Page 54

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Motor Relay or Motor

1 INSPECTION START

ABS motor relay inspection

Motor Relay or Motor

DIAGNOSTIC PROCEDURE

Malfunction code No. 61

ABS

=NGBR0106

ABR889

2 CHECK FUSIBLE LINK

Check 40A fusible link d. For fusible link layout, refer to “POWER SUPPLY ROUTING”,

Is fusible link OK?

3 CHECK CONNECTOR

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

2. Carry out self-diagnosis again.

Does warning lamp activate again?

4 CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT

Refer to “ABS ACTUATOR AND ELECTRIC UNIT GROUND” in “Ground Circuit Check”, BR-47.

Is ground circuit OK?

EL-9

BR-54

Page 55

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Motor Relay or Motor (Cont’d)

5 CHECK MOTOR RELAY POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector.

2. Check voltage between ABS actuator and electric unit connector E39 terminal 25 and ground.

ABS

Does battery voltage exist?

If NG, repair harness or connector.

I Harness connector E39 I Harness for open or short between ABS actuator and electric unit and fusible link

6 REPLACE FUSIBLE LINK

Replace fusible link.

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

7 CHECK ABS ACTUATOR MOTOR POWER SUPPLY CIRCUIT FOR SHORT

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

2. Check continuity between ABS actuator and electric unit connector E39 terminal 25 and ground.

ABR890

Continuity should not exist.

Does continuity exist?

If NG, repair harness or connector.

I Harness connector E39 I Harness for open or short between ABS actuator and electric unit and fusible link

BR-55

ABR891

IDX

Page 56

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Low Voltage

DIAGNOSTIC PROCEDURE

Malfunction code No. 57

1 INSPECTION START

ABS actuator and electric unit power supply and ground circuit inspection

2 CHECK FUSE

Check 10A fuse No. 8. For fuse layout, refer to “POWER SUPPLY ROUTING”,

Is fuse OK?

EL-9

ABS

NGBR0107

ABR892

3 CHECK CONNECTOR

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

2. Carry out self-diagnosis again.

Does warning lamp activate again?

4 CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT

Refer to “ABS ACTUATOR AND ELECTRIC UNIT GROUND” in “Ground Circuit Check”, BR-47.

Is ground circuit OK?

BR-56

Page 57

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

5 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector.

2. Check voltage between ABS actuator and electric unit connector E39 terminal 4 and ground.

ABS

Low Voltage (Cont’d)

Does battery voltage exist when ignition switch is turned ON?

If NG, repair harness or connector.

I Harness connector E39 I Harness for open or short between ABS actuator and electric unit and fuse

6 REPLACE FUSE

Replace fuse.

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

7 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT FOR SHORT

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

2. Check continuity between ABS actuator and electric unit connector E39 terminal 4 and ground.

ABR893

Continuity should not exist.

Does continuity exist?

If NG, repair harness or connector.

I Harness connector E39 I Harness for open or short between ABS actuator and electric unit and fuse

BR-57

ABR894

IDX

Page 58

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

G Sensor and Circuit

DIAGNOSTIC PROCEDURE

Malfunction code No. 17

1 INSPECTION START

G sensor inspection

2 CHECK G SENSOR POWER

1. Turn ignition switch OFF and disconnect G sensor harness connector.

2. Turn ignition switch ON.

3. Check voltage between G sensor harness connector M69 terminal 3 and ground.

ABS

NGBR0118

ABR895

ABR896

Does approx. 5V exist?

BR-58

Page 59

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

G Sensor and Circuit (Cont’d)

3 CHECK G SENSOR

1. Turn ignition switch OFF.

2. Remove G sensor from bracket.

3. Reconnect harness connector to G sensor and hold sensor in same attitude/position as when installed in vehicle.

I Check voltage between G sensor connector M69 terminal 1 and ground for the following tests. There should be approx. 2.5V.

4. Turn sensor 90° with connector point up.

I There should be approx. 3.7V.

5. Turn sensor 180° with connector pointing down.

I There should be approx. 1.3V.

ABS

ABR897

Were the voltage readings correct for steps 3, 4 and 5?

4 CHECK G SENSOR CIRCUIT

1. Disconnect ABS actuator and electric unit connector.

2. Check continuity from G sensor connector M69 terminal 3 to ABS actuator and electric unit connector E39 terminal 14.

3. Check continuity from G sensor connector M69 terminal 1 to ABS actuator and electric unit connector E39 terminal 13.

4. Check continuity from G sensor connector M69 terminal 2 to ABS actuator and electric unit connector E39 terminal 17.

ABR898

Does continuity exist?

BR-59

IDX

Page 60

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS

Control Unit

DIAGNOSTIC PROCEDURE

Malfunction code No. 71

1 INSPECTION START

ABS actuator and electric unit power supply and ground circuit inspection

2 CHECK CONNECTOR

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

2. Carry out self-diagnosis again.

Does warning lamp activate again?

ABS

=NGBR0108

ABR899

3 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

Check voltage. Refer to “5. CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT” in “DIAGNOSTIC PROCEDURE”, “Low Voltage”, BR-56.

Does battery voltage exist when ignition switch is turned ON?

4 CHECK WARNING LAMP INDICATION

Does warning lamp indicate code No. 71 again?

YesorNo

BR-60

Page 61

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

1. ABS Works Frequently

1 CHECK BRAKE FLUID PRESSURE

Check brake fluid pressure distribution.

Is brake fluid pressure distribution normal?

Refer to BR-44.

2 CHECK WHEEL SENSOR

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

2. Perform wheel sensor mechanical check. Refer to “7. CHECK SENSOR ROTOR” in “DIAGNOSTIC PROCEDURE”, “Wheel Sensor or Rotor”, BR-49.

Is wheel sensor mechanism OK?

3 CHECK FRONT AXLE

Check front axles for excessive looseness. Refer to “Front Wheel Bearing”, “ON-VEHICLE SERVICE”,

Is front axle installed properly?

BR-61.

No © Repair.

AX-4

NGBR0109

2. Unexpected Pedal Action

1 CHECK BRAKE PEDAL STROKE

Check brake pedal stroke.

Is brake pedal stroke excessively large?

NGBR0110

SBR540A

BR-61

IDX

Page 62

TROUBLE DIAGNOSES FOR SYMPTOMS

2. Unexpected Pedal Action (Cont’d)

2 CHECK MECHANICAL BRAKE SYSTEM PERFORMANCE

Disconnect ABS actuator and electric unit connector and check whether brake is effective.

Does brake system function properly when brake pedal is depressed?

3 CHECK WARNING LAMP INDICATION

Ensure warning lamp remains off while driving.

Is warning lamp turned off?

ABS

ABR838

4 CHECK WHEEL SENSOR

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

2. Perform wheel sensor mechanical check. Refer to “7. CHECK SENSOR ROTOR” in “DIAGNOSTIC PROCEDURE”, “Wheel Sensor or Rotor”, BR-49.

Is wheel sensor mechanism OK?

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

No © Repair.

BR-62

Page 63

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

3. Long Stopping Distance

1 CHECK MECHANICAL BRAKE SYSTEM PERFORMANCE

Disconnect ABS actuator and electric unit connector and check whether stopping distance is still long.

Does brake system function properly when brake pedal is depressed?

Yes © Perform Preliminary Check and air bleeding (if necessary). No © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”,

BR-61.

NOTE:

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

4. ABS Does Not Work

1 CHECK WARNING LAMP INDICATION

Does the ABS warning lamp activate?

YesorNo

Yes © Carry out self-diagnosis. Refer to BR-41. No © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”,

BR-61.

=NGBR0111

NGBR0112

NOTE:

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

BR-63

IDX

Page 64

5. Pedal Vibration and Noise

TROUBLE DIAGNOSES FOR SYMPTOMS

ABS

5. Pedal Vibration and Noise

1 INSPECTION START

Pedal vibration and noise inspection

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.

NGBR0113

SAT797A

2 CHECK SYMPTOM

1. Apply brake.

2. Start engine.

Does the symptom appear only when engine is started?

Yes © Carry out self-diagnosis. Refer to BR-41. No © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”,

BR-61.

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

1 INSPECTION START

Warning lamp circuit inspection

NGBR0114

ABR900

BR-64

Page 65

TROUBLE DIAGNOSES FOR SYMPTOMS

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

2 CHECK FUSE

Check 10A fuse No. 11. For fuse layout, refer to “POWER SUPPLY ROUTING”,

Is fuse OK?

EL-9

ABS

3 CHECK WARNING LAMP ACTIVATE

Disconnect ABS actuator and electric unit connector.

ABR838

Does the warning lamp activate?

4 CHECK HARNESS FOR SHORT

1. Disconnect ABS actuator and electric unit connector E39 and combination meter connector M38.

2. Check continuity between ABS actuator and electric unit connector E39 (body side) terminal 15 (2WD) or terminal 16 (4WD) and ground.

Continuity should not exist.

Does continuity exist?

Refer to “WARNING LAMPS”,

EL-87

ABR901

BR-65

IDX

Page 66

TROUBLE DIAGNOSES FOR SYMPTOMS

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

1 INSPECTION START

ABS control unit inspection

2 CHECK FUSE

Check 10A fuse No. 8. For fuse layout, refer to “POWER SUPPLY ROUTING”,

Is fuse OK?

EL-9

ABS

NGBR0115

ABR902

3 CHECK HARNESS CONNECTOR

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

Does warning lamp stay on when ignition switch is turned ON?

4 CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT

Refer to “ABS ACTUATOR AND ELECTRIC UNIT GROUND” in “Ground Circuit Check”, BR-47.

Is ground circuit OK?

BR-66

Page 67

TROUBLE DIAGNOSES FOR SYMPTOMS

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

5 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector.

2. Check voltage between ABS actuator and electric unit connector E39 terminal 4 and ground.

ABS

ABR893

Does battery voltage exist when ignition switch is turned ON?

If NG, repair harness or connector.

I Harness connector E39 I Harness for open or short between ABS actuator and electric unit and fuse

6 CHECK WARNING LAMP

1. Disconnect ABS actuator and electric unit connector.

2. Connect suitable wire between ABS actuator and electric unit connector E39 terminal 15 (2WD) terminal 16 (4WD) and ground.

ABR903

Does the warning lamp deactivate?

BR-67

IDX

Page 68

TROUBLE DIAGNOSES FOR SYMPTOMS

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

7 CHECK ABS WARNING LAMP CONTROL CIRCUIT FOR OPEN

1. Disconnect combination meter connector M38.

2. Check continuity between combination meter connector M38 (body side) terminal 10 and ABS actuator and electric unit connector E39 (body side) terminal 15 (2WD) or terminal 16 (4WD).

NOTE:

Connect positive lead of multimeter to combination meter connector M38 (body side) terminal 10 and negative lead to ABS actuator and electric unit connector E39 (body side) terminal 15 (2WD) or terminal 16 (4WD).

ABR921

Continuity should exist.

Does continuity exist?

Refer to “WARNING LAMPS”,

EL-87

ABS

8 REPLACE FUSE

Replace fuse.

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

9 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT FOR SHORT

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

2. Check continuity between ABS actuator and electric unit connector E39 (body side) terminal 4 and ground.

Continuity should not exist.

Does continuity exist?

If NG, repair harness or connector.

I Harness connector E39 I Harness for open or short between ABS actuator and electric unit and fuse

ABR894

BR-68

Page 69

REMOVAL AND INSTALLATION

CAUTION:

Be careful not to damage sensor edge and sensor rotor teeth. When removing the front or rear wheel hub assembly, disconnect the ABS wheel sensor from the assembly and move it away.

Front Wheel Sensor

NGBR0079

ABS

Front Wheel Sensor

NGBR0079S01

Rear Wheel Sensor

4WD MODELS

ABR869

NGBR0079S02

NGBR0079S0201

BR-69

ABR868

IDX

Page 70

Rear Wheel Sensor (Cont’d)

REMOVAL AND INSTALLATION

ABS

2WD MODELS

=NGBR0079S0202

ABR848

SBR873C

ABR849

Front Sensor Rotor

REMOVAL

1.Removethefrontwheelhub.Referto

AX-11

(“FRONTAXLE”).

NGBR0079S03

NGBR0079S0301

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

BR-70

Page 71

REMOVAL AND INSTALLATION

ABS

Front Sensor Rotor (Cont’d)

SBR400DA

ARA097

INSTALLATION

Install the sensor rotor using suitable drift and press.

I Always replace sensor rotor with new one. I Pay attention to the direction of front sensor rotor as shown in

figure.

Rear Sensor Rotor (4WD)

REMOVAL

I Remove the sensor rotor using Tool.

INSTALLATION

Install the sensor rotor using suitable drift and press.

I Always replace sensor rotor with new one. I Pay attention to the direction of front sensor rotor as shown in

figure.

NGBR0079S0302

NGBR0079S04

NGBR0079S0401

NGBR0079S0402

SBR402D

Rear Sensor Rotor (2WD)

REMOVAL AND INSTALLATION

CAUTION:

Be careful not to damage sensor edge and sensor rotor teeth. In case the final drive assembly needs to be removed, disconnect the ABS sensor from the final drive assembly and move it away. Failure to do so may result in damage to the sensor wires making the sensor inoperative. For final drive models using collapsible spacer (H190A, C200), bearing preload must be adjusted whenever companion flange is removed. Therefore, final drive overhaul is required.

G Sensor

Always replace G sensor if bumped or dropped. Otherwise, performance characteristics of G sensor will be changed, which in turn changes ABS control performance characteristics.

NGBR0079S08

NGBR0079S0801

NGBR0079S06

ABR859

IDX

BR-71

Page 72

ABS Actuator and Electric Unit

REMOVAL AND INSTALLATION

ABS

ABS Actuator and Electric Unit

=NGBR0079S07

ABR862

REMOVAL

NGBR0079S0701

1. Disconnect battery cable.

2. Drain brake fluid. Refer to “Changing Brake Fluid”, BR-6.

3. Remove mounting bracket fixing bolts and nuts.

4. Disconnect connector, brake pipes and remove fixing nuts and actuator ground cable.

INSTALLATION

NGBR0079S0702

CAUTION:

After installation, refill brake fluid. Then bleed air. Refer to “Bleeding Brake System”, BR-8.

1. Tighten actuator ground cable.

Place ground cable at a notch of mounting bracket.

2. Connect brake pipes temporarily.

3. Tighten fixing bolts and nuts.

4. Tighten brake pipes.

5. Connect connector and battery cable.

BR-72

Page 73

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

Unit: mm (in)

Applied model KA24DE VG33E

Brake model CL33VD Cylinder bore diameter × number of pistons 46.4 (1.827) × 2

Front brake

Rear brake

Master cylinder Bore diameter 25.40 (1)

Control valve

Brake booster

Recommended brake fluid DOT 3

Pad Length × width × thickness

Rotor outer diameter × thickness 283 x 28(11.14 × 1.10) Brake model LT30A Cylinder bore diameter 22.23 (7/8)

Lining length × width × thickness

Drum inner diameter 295.0 (11.61)

Valve model Proportioning valve within master cylinder Split point

kPa (kg/cm Booster model M215T

Diaphragm diameter

, psi) × reducing ratio

Pri: 230 (9.06)

Sec: 205 (8.07)

132.0 × 52.5 × 11

(5.20 × 2.067 × 0.43)

296 × 50 × 5.8

(11.65 × 1.97 × 0.228)

2,942 (30, 427) × 0.2

Pri: 230 (9.06) Sec: 230 (9.06)

NGBR0080

Disc Brake

Unit: mm (in)

Brake model CL33VD Pad wear limit Minimum thickness 2.0 (0.079) Rotor repair limit Minimum thickness 26.0 (1.024)

Drum Brake

Unit: mm (in)

Brake model LT30A Lining wear limit Minimum thickness 1.5 (0.059)

Drum repair limit

Maximum inner diameter 296.5 (11.67) Out-of-round limit 0.03 (0.0012)

Brake Pedal

Unit: mm (in)

Transmission M/T A/T

Free height “H”*

Depressed height “D” [under force of 490 N (50 kg, 110 lb) with engine running]

Clearance “C” between pedal stopper and threaded end of stop lamp switch or ASCD switch 0.3 - 1.0 (0.012 - 0.039) Pedal free play At pedal pad 1 - 3 (0.04 - 0.12)

191 - 201

(7.52 - 7.91)

100 (3.94) 110 (4.33)

201-211

(7.91 - 8.31)

NGBR0081

NGBR0082

NGBR0083

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

IDX

BR-73

Page 74

Parking Brake Control

SERVICE DATA AND SPECIFICATIONS (SDS)

Parking Brake Control

Control Type STICK Lever stroke

[under force of 196 N (20 kg, 44 lb)] Lever stroke when warning switch comes on 1

10-12

NGBR0084

Unit: notch

BR-74