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SERVICE DATA AND SPECIFICATIONS (SDS)BR-45
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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
General SpecificationINFOID:0000000004894499
Unit: mm (in)
Brake PedalINFOID:0000000004894500
Unit: mm (in)
CAUTION:
When equipped with adjustable pedal, the pedal must be in the forward most position (closest to the floor) for pedal height
adjustment. Front brake Brake model
AD41VA
Rotor outer diameter × thickness 350 x 30 (13.78 x 1.181)
Pad Length × width × thickness 151.6 x 56.5 x 12.0 (5.97 x 2.22 x 0.476)
Cylinder bore diameter 50.8 (2.00)
Rear brake Brake model AD14VE
Rotor outer diameter × thickness 320 x 14 (12.60 x 0.551)
Pad Length × width × thickness 83.0 x 33.0 x 12.0 (3.268 x 1.299 x 0.472)
Cylinder bore diameter 48 (1.89)
Control valve Valve model Electric brake force distribution
Brake booster Booster model C215T
Diaphragm diameter 215 (8.46)
Recommended brake fluid Refer to MA-12, "
Fluids and Lubricants".
Pedal free height (H) with pedal in forward most position 182.3 - 192.3 (7.18 - 7.57)
Pedal travel (T) 153.3 (6.04)
Stop lamp switch and ASCD cancel switch threaded end to brake pedal bracket gap 0.74 - 1.96 (0.029 - 0.077)
ALFIA0149ZZ
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BR-46
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Brake Booster
INFOID:0000000004894501
Unit: mm (in)
Check ValveINFOID:0000000004894502
Front Disc BrakeINFOID:0000000004894503
Unit: mm (in)
Rear Disc BrakeINFOID:0000000004894504
Unit: mm (in)
Output rod length [at -66.7 kPa (-500 mmHg, -19.69 inHg) vacuum] 15.6 - 15.9 (0.614 - 0.626)
Input rod installation length (B) 151 (5.94)
SBR208E
WFIA0382E
Vacuum leakage
[at vacuum of – 66.7 kPa(– 500 mmHg, – 19.69 inHg)]Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
Brake model
AD41VA
Brake pad Standard thickness (new)
12.0 (0.476)
Repair limit thickness 1.0 (0.039)
Disc rotor Standard thickness (new)
30 (1.181)
Repair limit thickness 28 (1.102)
Maximum uneven wear (measured at 8 positions) 0.015 (0.0006)
Runout limit (with it attached to the vehicle) 0.03 (0.001)
Brake model AD14VE
Brake pad Standard thickness (new)
12.0 (0.472)
Repair limit thickness 1.0 (0.039)
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SERVICE DATA AND SPECIFICATIONS (SDS)BR-47
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Disc rotor Standard thickness (new)
14.0 (0.551)
Repair limit thickness 12.5 (0.492)
Maximum uneven wear (measured at 8 positions) 0.015 (0.0006)
Runout limit (with it attached to the vehicle) 0.05 (0.002)
Brake model
AD14VE
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BRC-1
BRAKES
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CONTENTS
BRAKE CONTROL SYSTEM
VDC/TCS/ABS
BASIC INSPECTION ....... .............................
4
DIAGNOSIS AND REPAIR WORKFLOW ..... .....4
Work Flow ........................................................... ......4
Diagnostic Work Sheet ..............................................7
INSPECTION AND ADJUSTMENT .....................8
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT .................................................... ......
8
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT : Description ..................................
8
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT : Special Repair Requirement .......
8
ADJUSTMENT OF STEERING ANGLE SENSOR
NEUTRAL POSITION ............................................ ......
8
ADJUSTMENT OF STEERING ANGLE SENSOR
NEUTRAL POSITION : Description ..........................
8
ADJUSTMENT OF STEERING ANGLE SENSOR
NEUTRAL POSITION : Special Repair Require-
ment ..........................................................................
8
CALIBRATION OF DECEL G SENSOR ............... ......9
CALIBRATION OF DECEL G SENSOR : Descrip-
tion ............................................................................
9
CALIBRATION OF DECEL G SENSOR : Special
Repair Requirement ..................................................
9
FUNCTION DIAGNOSIS ..............................11
VDC ................................................................ ....11
System Diagram .................................................. ....11
Hydraulic Circuit Diagram .......................................12
System Description ............................................. ....12
Component Parts Location ......................................13
Component Description ...........................................14
TCS .....................................................................15
System Diagram .................................................. ....15
System Description .................................................15
Component Parts Location .................................. ....16
Component Description ...........................................17
ABS ...................................................................18
System Diagram ......................................................18
System Description ..................................................18
Component Parts Location ......................................19
Component Description ...........................................20
EBD ...................................................................21
System Diagram ......................................................21
System Description ..................................................21
Component Parts Location ......................................22
Component Description ...........................................23
DIAGNOSIS SYSTEM [ABS ACTUATOR
AND ELECTRIC UNIT (CONTROL UNIT)] .......
24
CONSULT-III Function (ABS) ..................................24
COMPONENT DIAGNOSIS .........................29
C1101, C1102, C1103, C1104 WHEEL SEN-
SOR-1 ................................................................
29
Description ........................................................... ....29
DTC Logic ................................................................29
Diagnosis Procedure ...............................................29
Component Inspection .............................................31
Special Repair Requirement ....................................31
C1105, C1106, C1107, C1108 WHEEL SEN-
SOR-2 ................................................................
32
Description ...............................................................32
DTC Logic ................................................................32
Diagnosis Procedure ...............................................32
Component Inspection .............................................34
Special Repair Requirement ....................................34
C1109 POWER AND GROUND SYSTEM ........35
Description ...............................................................35
DTC Logic ................................................................35
Diagnosis Procedure ...............................................35
Special Repair Requirement ....................................36
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BRC-2
C1110, C1170 ABS ACTUATOR AND ELEC-
TRIC UNIT (CONTROL UNIT) ...........................
37
DTC Logic ...............................................................37
Diagnosis Procedure ..............................................37
Special Repair Requirement ...................................37
C1111 ABS MOTOR, MOTOR RELAY SYS-
TEM ................................................................. ...
38
Description ........................................................... ...38
DTC Logic ...............................................................38
Diagnosis Procedure ..............................................38
Component Inspection ............................................39
Special Repair Requirement ...................................39
C1113, C1145, C1146 YAW RATE/SIDE/DE-
CEL G SENSOR ............................................. ...
40
Description ........................................................... ...40
DTC Logic ...............................................................40
Diagnosis Procedure ..............................................40
Component Inspection ............................................41
Special Repair Requirement ...................................41
C1115 WHEEL SENSOR ................................ ...43
Description ........................................................... ...43
DTC Logic ...............................................................43
Diagnosis Procedure ..............................................43
Component Inspection ............................................44
Special Repair Requirement ...................................45
C1116 STOP LAMP SWITCH ......................... ...46
Description ........................................................... ...46
DTC Logic ...............................................................46
Diagnosis Procedure ..............................................46
Special Repair Requirement ...................................47
C1120, C1122, C1124, C1126 IN ABS SOL .....48
Description ........................................................... ...48
DTC Logic ...............................................................48
Diagnosis Procedure ..............................................48
Component Inspection ............................................49
Special Repair Requirement ...................................50
C1121, C1123, C1125, C1127 OUT ABS SOL ...51
Description ........................................................... ...51
DTC Logic ...............................................................51
Diagnosis Procedure ..............................................51
Component Inspection ............................................52
Special Repair Requirement ...................................53
C1130, C1131, C1132, C1133, C1136 EN-
GINE SIGNAL ................................................. ...
54
Description ........................................................... ...54
DTC Logic ...............................................................54
Diagnosis Procedure ..............................................54
Special Repair Requirement ...................................54
C1140 ACTUATOR RLY ................................ ...56
Description ........................................................... ...56
DTC Logic ...............................................................56
Diagnosis Procedure ..............................................56
Component Inspection ......................................... ...57
Special Repair Requirement ...................................57
C1142 PRESS SENSOR ...................................58
Description ........................................................... ...58
DTC Logic ...............................................................58
Diagnosis Procedure ...............................................58
Component Inspection ............................................60
Special Repair Requirement ...................................60
C1143, C1144 STEERING ANGLE SENSOR ...61
Description ..............................................................61
DTC Logic ...............................................................61
Diagnosis Procedure ...............................................61
Component Inspection ............................................62
Special Repair Requirement ...................................62
C1155 BRAKE FLUID LEVEL SWITCH ...........64
Description ........................................................... ...64
DTC Logic ...............................................................64
Diagnosis Procedure ...............................................64
Component Inspection ............................................65
Special Repair Requirement ...................................65
C1156 ST ANG SEN COM CIR .........................67
Description ..............................................................67
DTC Logic ...............................................................67
Diagnosis Procedure ...............................................67
C1160 DECEL G SEN SET ...............................68
Description ..............................................................68
DTC Logic ...............................................................68
Diagnosis Procedure ...............................................68
C1163 ST ANGLE SEN SAFE ..........................69
Description ........................................................... ...69
DTC Logic ...............................................................69
Diagnosis Procedure ...............................................69
C1164, C1165, C1166, C1167 CV/SV SYS-
TEM ....................................................................
70
Description ........................................................... ...70
DTC Logic ...............................................................70
Diagnosis Procedure ...............................................70
Component Inspection ............................................71
Special Repair Requirement ...................................72
C1178, C1181, C1184, C1189 ABS ACTIVE
BOOSTER .........................................................
73
Description ........................................................... ...73
DTC Logic ...............................................................73
Diagnosis Procedure ...............................................73
Component Inspection ............................................74
Special Repair Requirement ...................................75
C1179 ABS DELTA S SEN NG .........................76
Description ........................................................... ...76
DTC Logic ...............................................................76
Diagnosis Procedure ...............................................76
Component Inspection ............................................77
Special Repair Requirement ...................................77
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BRC-3
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C1185 ICC UNIT .................................................78
Description .......................................................... ....78
DTC Logic ...............................................................78
Diagnosis Procedure ...............................................78
Special Repair Requirement ...................................79
U1000 CAN COMM CIRCUIT .............................80
Description .......................................................... ....80
DTC Logic ...............................................................80
Diagnosis Procedure ...............................................80
Special Repair Requirement ...................................80
VDC OFF SWITCH ......................................... ....81
Description .......................................................... ....81
Component Function Check ....................................81
Diagnosis Procedure ...............................................81
Component Inspection ............................................82
ABS WARNING LAMP ................................... ....83
Description .......................................................... ....83
Component Function Check ....................................83
Diagnosis Procedure ...............................................83
BRAKE WARNING LAMP ............................. ....84
Description .......................................................... ....84
Component Function Check ....................................84
Diagnosis Procedure ...............................................84
VDC OFF INDICATOR LAMP ............................85
Description .......................................................... ....85
Component Function Check ....................................85
Diagnosis Procedure ...............................................85
SLIP INDICATOR LAMP ....................................86
Description .......................................................... ....86
Component Function Check ....................................86
Diagnosis Procedure ...............................................86
ECU DIAGNOSIS .........................................87
ABS ACTUATOR AND ELECTRIC UNIT
(CONTROL UNIT) .......................................... ....
87
Reference Value ................................................. ....87
Wiring Diagram .......................................................92
Fail-Safe ..................................................................99
DTC No. Index ......................................................100
SYMPTOM DIAGNOSIS ............................102
VDC/TCS/ABS ................................................ ..102
Symptom Table ................................................... ..102
EXCESSIVE ABS FUNCTION OPERATION
FREQUENCY ...................................................
103
Diagnosis Procedure ........................................... ..103
UNEXPECTED PEDAL REACTION ...............104
Diagnosis Procedure ........................................... ..104
THE BRAKING DISTANCE IS LONG .............105
Diagnosis Procedure .............................................105
ABS FUNCTION DOES NOT OPERATE .......106
Diagnosis Procedure .............................................106
PEDAL VIBRATION OR ABS OPERATION
SOUND OCCURS ...........................................
107
Diagnosis Procedure ........................................... ..107
VEHICLE JERKS DURING VDC/TCS/ABS
CONTROL .......................................................
108
Diagnosis Procedure .............................................108
NORMAL OPERATING CONDITION .............109
Description .............................................................109
PRECAUTION ............................................110
PRECAUTIONS ...............................................110
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ..
110
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect .................................
110
Precaution for Brake System .................................111
Precaution for Brake Control .................................111
Precaution for CAN System ...................................112
PREPARATION .........................................113
PREPARATION ...............................................113
Special Service Tool ............................................ ..113
Commercial Service Tool ......................................113
REMOVAL AND INSTALLATION .............114
WHEEL SENSORS .........................................114
Removal and Installation ..................................... ..114
SENSOR ROTOR ............................................115
Removal and Installation .......................................115
ACTUATOR AND ELECTRIC UNIT (ASSEM-
BLY) ................................................................
116
Removal and Installation .......................................116
STEERING ANGLE SENSOR .........................118
Removal and Installation .......................................118
G SENSOR ......................................................119
Removal and Installation .......................................119
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BRC-4
< BASIC INSPECTION >[VDC/TCS/ABS]
DIAGNOSIS AND REPAIR WORKFLOW
BASIC INSPECTION
DIAGNOSIS AND REPAIR WORKFLOW
Work FlowINFOID:0000000001686231
PRECAUTIONS FOR DIAGNOSIS
If steering angle sensor, steering system parts, suspension system parts, ABS actuator and electric unit (con-
trol unit) or tires have been replaced, or if wheel a
lignment has been adjusted, be sure to adjust neutral posi-
tion of steering angle sensor before driving. Refer to BRC-8, "
ADJUSTMENT OF STEERING ANGLE
SENSOR NEUTRAL POSITION : Description".
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DIAGNOSIS AND REPAIR WORKFLOWBRC-5
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OVERALL SEQUENCE
DETAIED FLOW
1.COLLECT THE INFORMATION FROM THE CUSTOMER
Get the detailed information from the customer about the symptom (the condition and the environment when
the incident/malfunction occurred) usi ng the diagnosis worksheet. Refer to BRC-7, "
Diagnostic Work Sheet".
>> GO TO 2
JSFIA0010GB
Revision: March 2010 2008 QX56