REAR DISC BRAKE
BR-39
< ON-VEHICLE REPAIR >
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REAR DISC BRAKE
BRAKE PAD
BRAKE PAD : Exploded ViewINFOID:0000000003811211
BRAKE PAD : Removal and InstallationINFOID:0000000003811212
REMOVAL
WARNING:
Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with
compressed air.
CAUTION:
Never depress the brake pedal while removing the brake pads or the cylinder body because the pis-
ton may pop out.
Never spill or splash brake fluid on the disc rotor.
1. Remove tires.
2. Remove the upper sliding pin bolt.
3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Remove the brake
pads and shims from the torque member.
CAUTION:
Never deform the pad retainers if removing the pad retainers.
Never damage the piston boot.
Never drop the brake pad and shims.
INSTALLATION
WARNING:
Clean any dust from the brake caliper and brake pads with a vacuum dust collector. Never blow with
compressed air.
CAUTION:
1. Sliding pin bolt 2. Cylinder body 3. Inner shim
4. Inner pad (only RH side with pad
wear sensor)5. Pad retainer 6. Torque member
7. Outer pad 8. Outer shim
1: Apply rubber grease.
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
Refer to GI-4, "
Components" for symbols not described on the above.
JPFIA0354GB
BRC-1
BRAKES
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SECTION BRC
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BRC
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CONTENTS
BRAKE CONTROL SYSTEM
ABS
BASIC INSPECTION ....... .............................
6
DIAGNOSIS AND REPAIR WORK FLOW .... .....6
Work Flow ........................................................... ......6
Diagnostic Work Sheet ..............................................8
FUNCTION DIAGNOSIS ...............................9
ABS ................................................................ .....9
System Diagram .................................................. ......9
System Description ...................................................9
Component Parts Location ......................................10
Component Description ...........................................10
EBD ....................................................................11
System Diagram .................................................. ....11
System Description .................................................11
Component Parts Location ......................................12
Component Description ...........................................12
DIAGNOSIS SYSTEM [ABS ACTUATOR
AND ELECTRIC UNIT (CONTROL UNIT)] ........
13
CONSULT-III Function ........................................ ....13
COMPONENT DIAGNOSIS .........................16
C1101, C1102, C1103, C1104 WHEEL SEN-
SOR ................................................................ ....
16
Description .......................................................... ....16
DTC Logic ...............................................................16
Diagnosis Procedure ...............................................16
Component Inspection ............................................18
C1105, C1106, C1107, C1108 WHEEL SEN-
SOR ....................................................................
19
Description .......................................................... ....19
DTC Logic ...............................................................19
Diagnosis Procedure ...............................................19
Component Inspection ............................................21
C1109 POWER AND GROUND SYSTEM ........22
Description ........................................................... ....22
DTC Logic ................................................................22
Diagnosis Procedure ...............................................22
C1110 ABS ACTUATOR AND ELECTRIC
UNIT (CONTROL UNIT) ....................................
24
DTC Logic ................................................................24
Diagnosis Procedure ...............................................24
C1111 ABS MOTOR, MOTOR RELAY SYS-
TEM ...................................................................
25
Description ...............................................................25
DTC Logic ................................................................25
Diagnosis Procedure ...............................................25
Component Inspection .............................................26
C1115 WHEEL SENSOR ..................................27
Description ...............................................................27
DTC Logic ................................................................27
Diagnosis Procedure ...............................................27
Component Inspection .............................................29
C1116 STOP LAMP SWITCH ...........................30
Description ...............................................................30
DTC Logic ................................................................30
Diagnosis Procedure ...............................................30
Component Inspection .............................................30
C1120, C1122, C1124, C1126 IN ABS SOL .....32
Description ...............................................................32
DTC Logic ................................................................32
Diagnosis Procedure ...............................................32
Component Inspection .............................................33
C1121, C1123, C1125, C1127 OUT ABS SOL ...34
Description ........................................................... ....34
DTC Logic ................................................................34
Diagnosis Procedure ...............................................34
Component Inspection .............................................35
C1140 ACTUATOR RELAY SYSTEM ..............36
BRC-2
Description ..............................................................36
DTC Logic ...............................................................36
Diagnosis Procedure ..............................................36
Component Inspection ............................................37
U1000, U1002 CAN COMM CIRCUIT ...............38
Description ..............................................................38
DTC Logic ...............................................................38
Diagnosis Procedure ..............................................38
POWER SUPPLY AND GROUND CIRCUIT .....39
Description ..............................................................39
Diagnosis Procedure ..............................................39
ABS WARNING LAMP ......................................40
Description ..............................................................40
Component Function Check ...................................40
Diagnosis Procedure ..............................................40
BRAKE WARNING LAMP .................................41
Description ..............................................................41
Component Function Check ...................................41
Diagnosis Procedure ..............................................41
ECU DIAGNOSIS ........................................42
ABS ACTUATOR AND ELECTRIC UNIT
(CONTROL UNIT) ..............................................
42
Reference Value .....................................................42
Wiring Diagram - BRAKE CONTROL SYSTEM - ...44
Fail-Safe .................................................................47
DTC No. Index ........................................................48
SYMPTOM DIAGNOSIS .............................49
EXCESSIVE ABS FUNCTION OPERATION
FREQUENCY .....................................................
49
Diagnosis Procedure ..............................................49
UNEXPECTED PEDAL REACTION ..................50
Diagnosis Procedure ..............................................50
THE BRAKING DISTANCE IS LONG ...............51
Diagnosis Procedure ..............................................51
ABS FUNCTION DOES NOT OPERATE ..........52
Diagnosis Procedure ..............................................52
PEDAL VIBRATION OR ABS OPERATION
SOUND OCCURS ..............................................
53
Diagnosis Procedure ..............................................53
NORMAL OPERATING CONDITION ................54
Description ..............................................................54
PRECAUTION .............................................55
PRECAUTIONS .................................................55
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .................................................................
55
Precaution for Procedure without Cowl Top Cover ...55
Precaution for Brake System ..................................55
Precaution for Brake Control ...................................56
Precautions for Harness Repair ..............................56
ON-VEHICLE REPAIR ...............................57
WHEEL SENSOR ..............................................57
FRONT WHEEL SENSOR ........................................57
FRONT WHEEL SENSOR : Exploded View ...........57
FRONT WHEEL SENSOR : Removal and Instal-
lation .......................................................................
57
REAR WHEEL SENSOR ...........................................58
REAR WHEEL SENSOR : Exploded View .............58
REAR WHEEL SENSOR : Removal and Installa-
tion ..........................................................................
58
SENSOR ROTOR ..............................................59
FRONT SENSOR ROTOR ........................................59
FRONT SENSOR ROTOR : Exploded View ...........59
FRONT SENSOR ROTOR : Removal and Instal-
lation .......................................................................
59
REAR SENSOR ROTOR ...........................................59
REAR SENSOR ROTOR : Exploded View .............59
REAR SENSOR ROTOR : Removal and Installa-
tion ..........................................................................
59
ABS ACTUATOR AND ELECTRIC UNIT
(CONTROL UNIT) ..............................................
60
Exploded View ........................................................60
Removal and Installation .........................................60
VDC/TCS/ABS
BASIC INSPECTION ..................................
62
DIAGNOSIS AND REPAIR WORK FLOW ........62
Work Flow ...............................................................62
Diagnostic Work Sheet ...........................................65
INSPECTION AND ADJUSTMENT ...................66
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT ........................................................
66
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT : Description ................................
66
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT : Special Repair Requirement .....
66
ADJUSTMENT OF STEERING ANGLE SENSOR
NEUTRAL POSITION ................................................
66
ADJUSTMENT OF STEERING ANGLE SENSOR
NEUTRAL POSITION : Description ........................
66
ADJUSTMENT OF STEERING ANGLE SENSOR
NEUTRAL POSITION : Special Repair Require-
ment ........................................................................
66
FUNCTION DIAGNOSIS ............................68
VDC ....................................................................68
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System Description .................................................68
Component Parts Location ......................................69
Component Description ...........................................70
TCS .....................................................................71
System Diagram ......................................................71
System Description .................................................71
Component Parts Location ......................................72
Component Description ...........................................73
ABS ....................................................................74
System Diagram ......................................................74
System Description .................................................74
Component Parts Location ......................................75
Component Description ...........................................76
EBD ....................................................................77
System Diagram ......................................................77
System Description .................................................77
Component Parts Location ......................................78
Component Description ...........................................79
DIAGNOSIS SYSTEM [ABS ACTUATOR
AND ELECTRIC UNIT (CONTROL UNIT)] ........
80
CONSULT-III Function ............................................80
COMPONENT DIAGNOSIS .........................85
C1101, C1102, C1103, C1104 WHEEL SEN-
SOR ....................................................................
85
Description ..............................................................85
DTC Logic ...............................................................85
Diagnosis Procedure ...............................................85
Component Inspection ............................................87
Special Repair Requirement ...................................87
C1105, C1106, C1107, C1108 WHEEL SEN-
SOR ....................................................................
88
Description ..............................................................88
DTC Logic ...............................................................88
Diagnosis Procedure ...............................................88
Component Inspection ............................................90
Special Repair Requirement ...................................90
C1109 POWER AND GROUND SYSTEM .........91
Description ..............................................................91
DTC Logic ...............................................................91
Diagnosis Procedure ...............................................91
Special Repair Requirement ...................................92
C1110, C1153, C1170 ABS ACTUATOR AND
ELECTRIC UNIT (CONTROL UNIT) ..................
93
DTC Logic ...............................................................93
Diagnosis Procedure ...............................................93
Special Repair Requirement ...................................93
C1111 ABS MOTOR, MOTOR RELAY SYS-
TEM ....................................................................
94
Description ..............................................................94
DTC Logic ...............................................................94
Diagnosis Procedure ...............................................94
Component Inspection .............................................95
Special Repair Requirement ....................................95
C1115 WHEEL SENSOR ..................................96
Description ...............................................................96
DTC Logic ................................................................96
Diagnosis Procedure ...............................................96
Component Inspection .............................................98
Special Repair Requirement ....................................98
C1116 STOP LAMP SWITCH ...........................99
Description ...............................................................99
DTC Logic ................................................................99
Diagnosis Procedure ...............................................99
Component Inspection .............................................99
Special Repair Requirement ..................................100
C1120, C1122, C1124, C1126 IN ABS SOL ...101
Description .............................................................101
DTC Logic ..............................................................101
Diagnosis Procedure .............................................101
Component Inspection ...........................................102
Special Repair Requirement ..................................102
C1121, C1123, C1125, C1127 OUT ABS SOL .103
Description .............................................................103
DTC Logic ..............................................................103
Diagnosis Procedure .............................................103
Component Inspection ...........................................104
Special Repair Requirement ..................................104
C1130 ENGINE SIGNAL .................................105
Description .............................................................105
DTC Logic ..............................................................105
Diagnosis Procedure .............................................105
Special Repair Requirement ..................................105
C1140 ACTUATOR RELAY SYSTEM ............106
Description .............................................................106
DTC Logic ..............................................................106
Diagnosis Procedure .............................................106
Component Inspection ...........................................107
Special Repair Requirement ..................................107
C1142 PRESS SENSOR .................................108
Description .............................................................108
DTC Logic ..............................................................108
Diagnosis Procedure .............................................108
Component Inspection ...........................................108
Special Repair Requirement ..................................109
C1143 STEERING ANGLE SENSOR .............110
Description .............................................................110
DTC Logic ..............................................................110
Diagnosis Procedure .............................................110
Component Inspection ...........................................111
Special Repair Requirement ..................................111
C1144 STEERING ANGLE SENSOR .............112
DTC Logic ..............................................................112
BRC-4
Diagnosis Procedure .............................................112
Special Repair Requirement ..................................112
C1145, C1146 YAW RATE/SIDE G SENSOR .113
Description .............................................................113
DTC Logic ..............................................................113
Diagnosis Procedure .............................................113
Component Inspection ...........................................114
Special Repair Requirement ..................................115
C1155 BRAKE FLUID LEVEL SWITCH ..........116
Description .............................................................116
DTC Logic ..............................................................116
Diagnosis Procedure .............................................116
Component Inspection ...........................................117
Special Repair Requirement ..................................117
C1164, C1165 CV SYSTEM ............................118
Description .............................................................118
DTC Logic ..............................................................118
Diagnosis Procedure .............................................118
Component Inspection ...........................................119
Special Repair Requirement ..................................119
C1166, C1167 SV SYSTEM .............................120
Description .............................................................120
DTC Logic ..............................................................120
Diagnosis Procedure .............................................120
Component Inspection ...........................................121
Special Repair Requirement ..................................121
U1000, U1002 CAN COMM CIRCUIT .............122
Description .............................................................122
DTC Logic ..............................................................122
Diagnosis Procedure .............................................122
Special Repair Requirement ..................................122
POWER SUPPLY AND GROUND CIRCUIT ...123
Description .............................................................123
Diagnosis Procedure .............................................123
PARKING BRAKE SWITCH ............................124
Component Function Check ..................................124
Diagnosis Procedure .............................................124
Component Inspection ...........................................124
VDC OFF SWITCH ..........................................126
Description .............................................................126
Component Function Check ..................................126
Diagnosis Procedure .............................................126
Component Inspection ...........................................127
ABS WARNING LAMP ....................................128
Description .............................................................128
Component Function Check ..................................128
Diagnosis Procedure .............................................128
BRAKE WARNING LAMP ...............................129
Description .............................................................129
Component Function Check ..................................129
Diagnosis Procedure .............................................129
VDC OFF INDICATOR LAMP ..........................130
Description ............................................................130
Component Function Check .................................130
Diagnosis Procedure .............................................130
SLIP INDICATOR LAMP ..................................131
Description ............................................................131
Component Function Check .................................131
Diagnosis Procedure .............................................131
ECU DIAGNOSIS ......................................132
ABS ACTUATOR AND ELECTRIC UNIT
(CONTROL UNIT) .............................................
132
Reference Value ...................................................132
Wiring Diagram - BRAKE CONTROL SYSTEM - .136
Fail-Safe ................................................................139
DTC No. Index ......................................................140
SYMPTOM DIAGNOSIS ...........................142
EXCESSIVE ABS FUNCTION OPERATION
FREQUENCY ....................................................
142
Diagnosis Procedure .............................................142
UNEXPECTED PEDAL REACTION .................143
Diagnosis Procedure .............................................143
THE BRAKING DISTANCE IS LONG ..............144
Diagnosis Procedure .............................................144
ABS FUNCTION DOES NOT OPERATE .........145
Diagnosis Procedure .............................................145
PEDAL VIBRATION OR ABS OPERATION
SOUND OCCURS .............................................
146
Diagnosis Procedure .............................................146
VEHICLE JERKS DURING VDC/TCS/ABS
CONTROL ........................................................
147
Diagnosis Procedure .............................................147
NORMAL OPERATING CONDITION ...............148
Description ............................................................148
PRECAUTION ...........................................149
PRECAUTIONS ................................................149
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...............................................................
149
Precaution for Procedure without Cowl Top Cover .149
Precaution for Brake System ................................149
Precaution for Brake Control .................................150
Precautions for Harness Repair ............................150
ON-VEHICLE REPAIR ..............................151
WHEEL SENSOR .............................................151
FRONT WHEEL SENSOR ......................................151
FRONT WHEEL SENSOR : Exploded View .........151
BRC-5
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lation ......................................................................
151
REAR WHEEL SENSOR .........................................152
REAR WHEEL SENSOR : Exploded View ...........152
REAR WHEEL SENSOR : Removal and Installa-
tion ........................................................................
152
SENSOR ROTOR .............................................153
FRONT SENSOR ROTOR .......................................153
FRONT SENSOR ROTOR : Exploded View .........153
FRONT SENSOR ROTOR : Removal and Instal-
lation ......................................................................
153
REAR SENSOR ROTOR .........................................153
REAR SENSOR ROTOR : Exploded View ...........153
REAR SENSOR ROTOR : Removal and Installa-
tion .........................................................................
153
ABS ACTUATOR AND ELECTRIC UNIT
(CONTROL UNIT) ...........................................
154
Exploded View .......................................................154
Removal and Installation .......................................154
YAW RATE/SIDE G SENSOR ........................156
Exploded View .......................................................156
Removal and Installation .......................................156
STEERING ANGLE SENSOR .........................157
Exploded View .......................................................157
Removal and Installation .......................................157
BRC-10
< FUNCTION DIAGNOSIS >[ABS]
ABS
Component Parts Location
INFOID:0000000003766724
Component DescriptionINFOID:0000000003766725
1. ABS warning lamp 2. Brake warning lamp 3.ABS actuator and electric unit (con-
trol unit)
4. Front wheel sensor 5. Rear wheel sensor
A. Combination meter B. Engine room right side C. Steering knuckle
D. Rear axle
JSFIA0258ZZ
Component parts Reference
ABS actuator and electric unit (control unit)Pump
BRC-25, "
Description"Motor
Actuator relay (main relay)BRC-36, "
Description"
Solenoid valveBRC-32, "Description"
Wheel sensorBRC-16, "Description"
ABS warning lampBRC-40, "Description"
Brake warning lampBRC-41, "Description"
BRC-12
< FUNCTION DIAGNOSIS >[ABS]
EBD
Component Parts Location
INFOID:0000000003767310
Component DescriptionINFOID:0000000003767311
1. ABS warning lamp 2. Brake warning lamp 3.ABS actuator and electric unit (con-
trol unit)
4. Front wheel sensor 5. Rear wheel sensor
A. Combination meter B. Engine room right side C. Steering knuckle
D. Rear axle
JSFIA0258ZZ
Component parts Reference
ABS actuator and electric unit (control unit)Pump
BRC-25, "
Description"Motor
Actuator relay (main relay)BRC-36, "
Description"
Solenoid valveBRC-32, "Description"
Wheel sensorBRC-16, "Description"
ABS warning lampBRC-40, "Description"
Brake warning lampBRC-41, "Description"