Bleeding Brake System
CAUTION:
lCarefully monitor brake fluid level at master cylinder
during bleeding operation.
lIf master cylinder is suspected to have air inside, bleed
air from master cylinder first. Refer to ``Installation'',
``MASTER CYLINDER'', BR-14.
lFill reservoir with new brake fluid DOT 3 or DOT 4*1.
Make sure it is full at all times while bleeding air out of
system.
lPlace a container under master cylinder to avoid spillage
of brake fluid.
lFor models with ABS, turn ignition switch OFF and dis-
connect ABS actuator connector or battery cable.
lBleed air in the following order.
a. LSV air bleeder
b. Left rear brake
c. Right rear brake
d. Left front brake
e. Right front brake
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
1. Connect a transparent vinyl tube to air bleeder valve.
2. Fully depress brake pedal several times.
3. With brake pedal depressed, open air bleeder valve to
release air.
4. Close air bleeder valve.
5. Release brake pedal slowly.
6. Repeat steps 2 through 5 until clear brake fluid comes out of
air bleeder valve.
7. Tighten air bleeder to the specified torque.
:7-9N´m(0.7 - 0.9 kg-m, 61 - 78 in-lb)
SBR995
SBR419C
CHECK AND ADJUSTMENT
BR-4
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 character-
istics.
ABS ACTUATOR AND ELECTRIC UNIT
Removal
1. Disconnect battery cable.
2. Drain brake fluid. Refer to ``Changing Brake Fluid'', BR-3.
3. Remove mounting bracket fixing bolts and nuts.
4. Disconnect connector, brake pipes and remove fixing nuts.
Installation
CAUTION:
After installation, refill brake fluid. Then bleed air. Refer to
``Bleeding Brake System'', BR-4.
1. Connect brake pipes temporarily.
2. Tighten fixing bolts and nuts.
3. Tighten brake pipes.
4. Connect connector and battery cable.
SBR074E
SBR075E
ANTI-LOCK BRAKE SYSTEM
Removal and Installation (Cont'd)
BR-37
CONSULT
CONSULT APPLICATION TO ABS
EE960 program card is not applicable to ABS. Use on board diagnostic system with ABS warning lamp until
the next program card will be introduced. (Refer to ``Self-diagnosis'', BR-53.)
ITEMSELF-DIAGNOSTIC
RESULTSDATA MONITOR ACTIVE TEST
Front right wheel sensor X X Ð
Front left wheel sensor X X Ð
Rear wheel sensor.1X X Ð
Rear right wheel sensor.2X X Ð
Rear left wheel sensor.2X X Ð
G switch (G sensor).2XXX
Stop lamp switch Ð X Ð
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 inlet solenoid valve X X X
Rear outlet solenoid valve X X X
Actuator solenoid valve relay X X Ð
Actuator motor relay
(ABS MOTOR is shown on the Data Monitor
screen.)XXX
ABS warning lamp Ð X Ð
Battery voltage X X Ð
X : Applicable
Ð : Not applicable
.1: 2WD model only
.2: 4WD model only
ECU (ABS control unit) part number mode
Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order
the ECU.
TROUBLE DIAGNOSES
BR-56
SELF-DIAGNOSTIC RESULTS MODE
Diagnostic item Diagnostic item is detected when ...Diagnostic
procedure
FR RH SENSOR.1
[OPEN]
lCircuit for front right wheel sensor is open.
(An abnormally high input voltage is entered.)1
FR LH SENSOR.1
[OPEN]
lCircuit for front left wheel sensor is open.
(An abnormally high input voltage is entered.)1
RR SENSOR.1,.2
[OPEN]
lCircuit for rear sensor is open.
(An abnormal high input voltage is entered.)1
RR RH SENSOR.1,.3
[OPEN]
lCircuit for rear right sensor is open.
(An abnormally high input voltage is entered.)1
RR LH SENSOR.1,.3
[OPEN]
lCircuit for rear left sensor is open.
(An abnormally high input voltage is entered.)1
FR RH SENSOR.1
[SHORT]
lCircuit for front right wheel sensor is shorted.
(An abnormally low input voltage is entered.)1
FR LH SENSOR.1
[SHORT]
lCircuit for front left wheel sensor is shorted.
(An abnormally low input voltage is entered.)1
RR SENSOR.1,.2
[SHORT]
lCircuit for rear sensor is shorted.
(An abnormal low input voltage is entered.)1
RR RH SENSOR.1,.3
[SHORT]
lCircuit for rear right sensor is shorted.
(An abnormally low input voltage is entered.)1
RR LH SENSOR.1,.3
[SHORT]
lCircuit for rear left sensor is shorted.
(An abnormally low input voltage is entered.)1
ABS SENSOR.1
[ABNORMAL SIGNAL]
lTeeth damage on sensor rotor or improper installation of wheel sensor.
(Abnormal wheel sensor signal is entered.)1
FR RH IN ABS SOL
[OPEN]
lCircuit for front right inlet solenoid valve is open.
(An abnormally low output voltage is entered.)2
FR LH IN ABS SOL
[OPEN]
lCircuit for front left inlet solenoid valve is open.
(An abnormally low output voltage is entered.)2
RR IN ABS SOL
[OPEN]
lCircuit for rear inlet solenoid valve is open.
(An abnormally low output voltage is entered.)2
FR RH IN ABS SOL
[SHORT]
lCircuit for front right inlet solenoid valve is shorted.
(An abnormally high output voltage is entered.)2
FR LH IN ABS SOL
[SHORT]
lCircuit for front left inlet solenoid valve is shorted.
(An abnormally high output voltage is entered.)2
RR IN ABS SOL
[SHORT]
lCircuit for rear inlet solenoid valve is shorted.
(An abnormally high output voltage is entered.)2
FR RH OUT ABS SOL
[OPEN]
lCircuit for front right outlet solenoid valve is open.
(An abnormally low output voltage is entered.)2
FR LH OUT ABS SOL
[OPEN]
lCircuit for front left outlet solenoid valve is open.
(An abnormally low output voltage is entered.)2
RR OUT ABS SOL
[OPEN]
lCircuit for rear outlet solenoid valve is open.
(An abnormally low output voltage is entered.)2
FR RH OUT ABS SOL
[SHORT]
lCircuit for front right outlet solenoid valve is shorted.
(An abnormally high output voltage is entered.)2
FR LH OUT ABS SOL
[SHORT]
lCircuit for front left outlet solenoid valve is shorted.
(An abnormally high output voltage is entered.)2
RR OUT ABS SOL
[SHORT]
lCircuit for rear outlet solenoid valve is shorted.
(An abnormally high output voltage is entered.)2
ABS ACTUATOR RELAY
[ABNORMAL]
lActuator solenoid valve relay is ON, even if control unit sends off signal.lActuator solenoid valve relay is OFF, even if control unit sends on signal.2
ABS MOTOR RELAY
[ABNORMAL]
lCircuit for ABS motor relay is open or shorted.lCircuit for actuator motor is open or shorted.lActuator motor relay is stuck.3
BATTERY VOLT
[VB-LOW]
lPower source voltage supplied to ABS control unit is abnormally low. 4
CONTROL UNIT
lFunction of calculation in ABS control unit has failed. 6
G-SENSOR.3
[ABNORMAL]
lG sensor circuit is open or shorted. 5
.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 warn-
ing 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-53. Check to ensure that the ABS
warning lamp goes out while the vehicle is being driven.
.2: 2WD model only
.3: 4WD model only
TROUBLE DIAGNOSES
CONSULT Inspection Procedure (Cont'd)
BR-58
DATA MONITOR MODE
MONITOR ITEM CONDITION SPECIFICATION
FR RH SENSOR
FR LH SENSOR
RR SENSOR.1
RR RH SENSOR.2
RR LH SENSOR.2Drive vehicle.
(Each wheel is rotating.)Wheel speed signal
(Almost the same speed as speedometer.)
STOP LAMP SW Brake is depressed.Depress the pedal: ON
Release the pedal: OFF
G-SWITCH.2Vehicle is driven.
Vehicle is stopped.
Brake is applied.During sudden braking while driving on high roads (asphalt
roads, etc.): OFF
While vehicle is stopped or during constant-speed driving: ON
FR RH IN SOL
FR RH OUT SOL
FR LH IN SOL
FR LH OUT SOL
RR IN SOL
RR OUT SOL1. Drive vehicle at speeds over
30 km/h (19 MPH) for at
least one minute.
2. Engine is running.Operating conditions for each solenoid valve are indicated.
ABS is not operating: OFF
MOTOR RELAYABS is not operating: OFF
ABS is operating: ON
ACTUATOR RELAY
Ignition switch is ON or
engine is running.Ignition switch ON (Engine stops): OFF
Engine running: ON
WARNING LAMPABS warning lamp is turned on: ON
ABS warning lamp is turned off: OFF
BATTERY VOLT Power supply voltage for control unit
.1: 2WD model only
.2: 4WD model only
ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT
FR RH SOLENOID
FR LH SOLENOID
REAR SOLENOID
Engine is running.Brake fluid pressure control operation
IN SOL OUT SOL
UP (Increase):
KEEP (Hold):
DOWN (Decrease):OFF
ON
ONOFF
OFF
ON
ABS MOTORABS actuator motor
ON: Motor runs (ABS motor relay ON)
OFF: Motor stops (ABS motor relay OFF)
G SWITCH.Ignition switch is ON.G SWITCH (G SENSOR),
ON: Set G SWITCH MONITOR ``ON''
(G switch circuit is closed.)
OFF: Set G SWITCH MONITOR ``OFF''
(G switch circuit is open.)
.: 4WD model only
Note: Active test will automatically stop ten seconds after the test starts. (LIMIT SIGNAL monitor
shows ON.)
TROUBLE DIAGNOSES
CONSULT Inspection Procedure (Cont'd)
BR-61
Diagnostic Procedure 2 (ABS actuator
solenoid valve and solenoid valve relay)
Malfunction code No. 41, 45, 55, 42, 46, 56, 63
CHECK FUSIBLE LINK.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Check 30A fusible link
e
. For fusible link
layout, refer to POWER SUPPLY ROUT-
ING in EL section.
OK
cNG
VA(Go to next page.)
CHECK FUSE.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Check 10A fuse
14. For fuse layout, refer
to POWER SUPPLY ROUTING in EL
section.
OK
cNG
VB(Go to next page.)
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?
Yes
cNo
Inspection end
CHECK ABS ACTUATOR AND ELEC-
TRIC UNIT GROUND CIRCUIT.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Refer to ABS ACTUATOR AND ELEC-
TRIC UNIT GROUND in Ground Circuit
Check, BR-62.
OK
cNG
Repair harness and con-
nector.
CHECK SOLENOID VALVE RELAY
POWER SUPPLY CIRCUIT.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1. Disconnect ABS actuator and electric
unit connector.
2. Check voltage between ABS actuator
and electric unit connector
E4(body
side) terminal
V18and ground.
Battery voltage should exist.
OK
cNG
Check the following.
lHarness connectorE4
lHarness for open or
short between ABS
actuator and electric unit
and fusible link
If NG, repair harness or
connector.
REPLACE.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Replace ABS actuator and electric unit.
SBR050E
SBR052E
.
.
.
.
.
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
BR-65
Diagnostic Procedure 3 (Motor relay or
motor)
Malfunction code No. 61
CHECK FUSIBLE LINK.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Check 30A fusible link
f. For fusible link
layout, refer to POWER SUPPLY ROUT-
ING in EL section.
OK
cNG
VA(Go to next page.)
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?
Yes
cNo
Inspection end
CHECK MOTOR RELAY POWER SUP-
PLY CIRCUIT.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1. Disconnect ABS actuator and electric
unit connector.
2. Check voltage between ABS actuator
and electric unit connector
E4(body
side) terminal
V17and ground.
Battery voltage should exist.
OK
cNG
Check the following.
lHarness connectorE4
lHarness for open or
short between ABS
actuator and electric unit
and fusible link
If NG, repair harness or
connector.
CHECK ABS ACTUATOR AND ELEC-
TRIC UNIT GROUND.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Refer to ABS ACTUATOR AND ELEC-
TRIC UNIT GROUND in Ground Circuit
Check, BR-62.
OK
cNG
Repair harness and termi-
nals.
REPLACE.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Replace ABS actuator and electric unit.
SBR054E
SBR055E
.
.
.
.
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
BR-67
VA
REPLACE.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Replace fusible link.
Does the fusible link blow out when
ignition switch is turned ``ON''?
Yes
cNo
Inspection end
CHECK ABS ACTUATOR MOTOR
POWER SUPPLY CIRCUIT.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1. Disconnect battery cable and ABS
actuator and electric unit connector
E4.
2. Check continuity between ABS actuator
and electric unit connector
E4(body
side) terminal
V17and ground.
Continuity should not exist.
OK
cNG
Check the following.
lHarness connectorE4
lHarness for open or
short between ABS
actuator and electric unit
and fusible link
If NG, repair harness or
connector.
CHECK HARNESS CONNECTOR.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector.
Reconnect ABS actuator and electric unit
harness connector. Then retest.
SBR056EC
.
.
.
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS
Diagnostic Procedure 3 (Motor relay or
motor) (Cont'd)
BR-68