Page 937 of 5121
REAR DISC BRAKE
BR-41
< ON-VEHICLE REPAIR >
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DISASSEMBLY
BRAKE CALIPER ASSEMBLY : Removal and InstallationINFOID:0000000003811215
REMOVAL
WARNING:
1. Brake caliper assembly
Refer to GI-4, "
Components" for symbols in the figure.
JPFIA0311GB
1. Sliding pin bolt 2. Bushing 3. Cap
4. Bleeder valve 5. Cylinder body 6. Piston seal
7. Piston 8. Piston boot 9. Sliding pin boot
10. Torque member
1: Apply rubber grease.
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
: Apply brake fluid.
Refer to GI-4, "
Components" for symbols not described on the above.
JPFIA0355GB
Page 938 of 5121

BR-42
< ON-VEHICLE REPAIR >
REAR DISC BRAKE
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. Brake fluid may splash while removing the brake hose.
1. Remove tires.
2. Fix the disc rotor using wheel nuts.
3. Drain brake fluid. Refer to BR-9, "
Draining".
CAUTION:
Never spill or splash brake fluid on the disc rotor.
4. Remove union bolt and copper washers then disconnect brake hose from caliper assembly.
5. Remove torque member mounting bolts, and remove brake caliper assembly.
CAUTION:
Never drop brake pads and caliper assembly.
6. Remove disc rotor.
CAUTION:
Put matching marks on the wheel hub and bearing assembly and the disc rotor before removing
the disc rotor.
Never drop disc rotor.
INSTALLATION
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. Brake fluid may splash while removing the brake hose.
1. Install disc rotor.
CAUTION:
Align the matching marks put during removal when reusing the disc rotor.
2. Install the brake caliper assembly to the vehicle and tighten the torque member mounting bolts to the
specified torque.
CAUTION:
Never spill or splash any grease and moisture on the brake caliper assembly mounting face,
threads, mounting bolts, and washers. Wipe out any grease and moisture.
3. Install brake hose and copper washers to brake caliper assembly, and tighten union bolts to the specified
torque. Refer to BR-22, "
REAR : Exploded View".
CAUTION:
Never reuse copper washer.
4. Refill with new brake fluid and perform the air bleeding. Refer to BR-10, "
Bleeding Brake System".
CAUTION:
Never reuse drained brake fluid.
Never spill or splash brake fluid on the disc rotor.
5. Check that no drag feel is present for the rear disc brake. Refer to BR-44, "
BRAKE CALIPER ASSEMBLY
: Inspection".
BRAKE CALIPER ASSEMBLY : Disassembly and AssemblyINFOID:0000000003811216
DISASSEMBLY
NOTE:
Never remove the torque member and pad retainers when disassembling and assembling the cylinder body.
1. Remove the sliding pin bolts and remove the cylinder body from the torque member.
2. Remove brake pads and shims. Refer to BR-39, "
BRAKE PAD : Exploded View".
3. Remove sliding pin boots from torque member.
4. Remove bushing from sliding pin bolt.
Page 939 of 5121
REAR DISC BRAKE
BR-43
< ON-VEHICLE REPAIR >
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5. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove piston and piston boot.
CAUTION:
Never get fingers caught in the piston.
6. Remove piston seal from cylinder body using suitable tool.
CAUTION:
Be careful not to damage a cylinder inner wall.
7. Remove bleeder valve and cap.
ASSEMBLY
1. Install bleeder valve and cap.
2. Apply rubber grease to piston seal (1), and install to cylinder
body.
CAUTION:
Never reuse piston seal.
3. Apply rubber grease to piston boot (1). Cover the piston (2) end
with the piston boot, and then install cylinder side lip on the pis-
ton boot securely into the groove on cylinder body.
CAUTION:
Never reuse piston boot.
BRD0041D
JPFIA0038ZZ
JPFIA0039ZZ
JPFIA0040ZZ
Page 940 of 5121

BR-44
< ON-VEHICLE REPAIR >
REAR DISC BRAKE
4. Apply brake fluid to piston (1). Push piston into cylinder body by
hand and push piston boot (2) piston side lip into the piston
groove.
CAUTION:
Press the piston evenly and vary the pressing point to pre-
vent cylinder inner wall from being rubbed.
5. Apply rubber grease to bushing, install bushing to sliding pin
bolt.
6. Apply rubber grease to the sliding pin bolts and the sliding pin
boots, install sliding pin boot to torque member.
7. Install the cylinder body to the torque member and tighten the
sliding pin bolts to the specified torque.
BRAKE CALIPER ASSEMBLY : InspectionINFOID:0000000003811217
INSPECTION AFTER DISASSEMBLY
Cylinder Body
Check the inner wall of the cylinder for rust, wear, cracks or damage. Replace the cylinder if any abnormal
condition is detected.
CAUTION:
Always clean with new brake fluid. Never clean with mineral oil such as gasoline and light oil.
Torque Member
Check the torque member for rust, wear, cracks or damage. Replace the member if any abnormal condition is
detected.
Piston
Check the piston for rust, wear, cracks or damage. Replace the piston if any abnormal condition is detected.
CAUTION:
A piston sliding surface is plated. Never polish with sandpaper.
Sliding Pin Bolt, Sliding Pin Boot and Bushing
Check the sliding pin bolts and sliding pin boots for rust, wear, cracks or damage. Replace the parts if any
abnormal condition is detected.
INSPECTION AFTER INSTALLATION
1. Check a drag of rear disc brake. If any drag is found, follow the procedure described below.
2. Remove brake pads.
3. Press the piston.
CAUTION:
Never damage the piston boot.
When replacing a pad with new one, check a brake fluid level in the reservoir tank because brake
fluid returns to master cylinder reservoir tank when pressing piston in.
NOTE:
Use a disc brake piston tool to easily press piston.
4. Install brake pads.
5. Depress the brake pedal several times.
6. Check a drag of rear disc brake again. If any drag is found, disassemble the cylinder body. Refer to BR-
42, "BRAKE CALIPER ASSEMBLY : Disassembly and Assembly".
7. Burnish contact surfaces after refinishing or replacing disc rotors, or if a soft pedal occurs at very low mile-
age. Refer to BR-15, "
DISC ROTOR : Inspection and Adjustment".
JPFIA0041ZZ
Page 941 of 5121

SERVICE DATA AND SPECIFICATIONS (SDS)
BR-45
< SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
General SpecificationsINFOID:0000000003811218
Unit: mm (in)
Brake PedalINFOID:0000000003811219
Unit: mm (in)
Brake BoosterINFOID:0000000003811220
Unit: mm (in)
Front Disc BrakeINFOID:0000000003811221
Unit: mm (in)
Rear Disc BrakeINFOID:0000000003811222
Unit: mm (in)
Front brakeCylinder bore diameter 57.2 (2.252)
Pad length × width × thickness 126.0 × 46.0 × 11.0 (4.96 × 1.811 × 0.433)
Rotor outer diameter × thickness 296 × 26.0 (11.65 × 1.024)
Rear brake Cylinder bore diameter 34.93 (1.3752)
Pad length × width × thickness 83.0 × 31.9 × 8.5 (3.268 × 1.256 × 0.335)
Rotor outer diameter × thickness 292 × 9.0 (11.50 × 0.354)
Master cylinder Cylinder bore diameter 23.8 (15/16)
Control valve Valve type Electric brake force distribution
Brake booster Diaphragm diameter 278 (10.94)
Recommended brake fluid DOT 3 or DOT 4
Item Standard
Brake pedal height 191.7 – 201.7 (7.55 – 7.94)
Clearance between stopper rubber and stop lamp switch and ASCD brake switch threaded end 0.74 – 1.96 (0.0291 – 0.0772)
Brake pedal play3.0 – 11.0 (0.118 – 0.433)
Depressed brake pedal height
[Depressing 490 N (50 kg, 110 lb) while turning the engine ON]103 (4.06) or more
Item Standard
Output rod length 30.4 – 30.6 (11.97 – 12.05)
Input rod length126.5 (4.98)
Item Limit
Brake pad Wear thickness 2.0 (0.079)
Disc rotorWear thickness 24.0 (0.945)
Runout (with it attached to the vehicle) 0.040 (0.0016) or less
Item Limit
Brake pad Wear thickness 2.0 (0.079)
Disc rotorWear thickness 8.0 (0.315)
Runout (with it attached to the vehicle) 0.050 (0.0020) or less
Page 942 of 5121

BRC-1
BRAKES
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SECTION 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
Page 943 of 5121

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
Page 944 of 5121

BRC-3
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68
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