FRONT DISC BRAKEBR-37
< REMOVAL AND INSTALLATION >
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BRAKE CALIPER ASSEMBLY : Removal and InstallationINFOID:0000000006222492
REMOVAL
WARNING:
Clean any dust from the brake caliper assembly an d brake pads with a vacuum dust collector. Never
blow with compressed air.
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with wate r if it gets on a painted surface.
Never depress the brake pedal. Brake fluid m ay splash while removing the brake hose.
If the brake fluid or grease adheres to the brake cal iper assembly and disc rotor, quickly wipe it off.
1. Remove tires with power tool.
2. Fix the disc rotor using wheel nuts.
3. Drain brake fluid. Refer to BR-10, "
Draining".
4. Separate brake hose from brake caliper assembly. Refer to BR-23, "
FRONT : Removal and Installation".
5. Remove torque member mounting bolts, and remove brake caliper assembly. CAUTION:
Never drop brake pad and brake caliper assembly.
6. Remove disc rotor. Refer to FA X - 8 , "
Removal and Installation" (2WD), FAX-18, "Removal and Installation"
(AWD).
INSTALLATION
WARNING:
Clean any dust from the brake caliper assembly an d brake pads with a vacuum dust collector. Never
blow with compressed air.
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with wate r if it gets on a painted surface.
Never depress the brake pedal. Brake fluid m ay splash while removing the brake hose.
If the brake fluid or grease adheres to the brake cal iper assembly and disc rotor, quickly wipe it off.
1. Torque member 2. Sliding pin boot 3. Sliding pin
4. Piston boot 5. Piston 6. Piston seal
7. Cylinder body 8. Bleeder valve 9. Cap
: Apply rubber grease.
: Apply brake fluid.
Refer to GI-4, "
Components" for symbols not described on the above.
JPFIA0800GB
Revision: 2010 May2011 QX56
BR-38
< REMOVAL AND INSTALLATION >
FRONT DISC BRAKE
1. Install disc rotor. Refer to FA X - 8 , "Removal and Installation" (2WD), FAX-18, "Removal and Installation"
(AWD).
2. Install the brake caliper assembly to the steeri ng knuckle and tighten the torque member mounting bolts to
the specified torque.
CAUTION:
Never spill or splash any grease and moisture on the torque member mounting face, threads,
mounting bolts. Wipe out any grease and moisture.
3. Install brake hose to brake caliper assembly. Refer to BR-23, "
FRONT : Removal and Installation".
4. Perform the air bleeding. Refer to BR-11, "
Bleeding Brake System".
5. Check a drag of front disc brake. If any drag is found, refer to BR-39, "
BRAKE CALIPER ASSEMBLY :
Inspection".
6. Install tires with power tool. Refer to WT-64, "
Exploded View".
BRAKE CALIPER ASSEMBLY : Disassembly and AssemblyINFOID:0000000006222493
DISASSEMBLY
NOTE:
Never remove the torque member, brake pads and pad retainers when disassembling and assembling the cyl-
inder body.
1. Remove the sliding pin bolt, and remove the cylinder body from the torque member.
CAUTION:
Fix the brake pad at suitable tape so that the brake pad will not drop.
2. Remove sliding pin boots from torque member.
3. Place a wooden block as shown in the figure, and blow air from brake hose mounting hole to remove pistons and piston boots.
CAUTION:
Never get fingers caught in the pistons.
4. Remove piston seals from cylinder body using suitable tool. CAUTION:
Be careful not to damage a cylinder inner wall.
5. Remove bleeder valve and cap.
6. Perform inspection after disassembly. Refer to BR-39, "
BRAKE
CALIPER ASSEMBLY : Inspection".
ASSEMBLY
1. Install bleeder valve and cap.
BRB0032D
JPFIA0781ZZ
Revision: 2010 May2011 QX56
REAR DISC BRAKEBR-41
< REMOVAL AND INSTALLATION >
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REAR DISC BRAKE
BRAKE PAD
BRAKE PAD : Exploded ViewINFOID:0000000006222495
BRAKE PAD : Removal and InstallationINFOID:0000000006222496
REMOVAL
WARNING:
Clean any dust from the brake caliper assembly an d brake pads with a vacuum dust collector. Never
blow with compressed air.
CAUTION:
Never depress the brake pedal while removing th e brake pads because the piston may pop out.
If the brake fluid or grease adheres to the brake cal iper assembly and disc rotor, quickly wipe it off.
1. Remove tires with power tool.
2. Remove upper sliding pin bolt.
3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch. Then remove the
brake pads from the torque member.
CAUTION:
Never deform the pad retainer when removing the pad retainer from the torque member.
Never damage the piston boot.
Never drop the brake pads and shims.
Remember each position of the removed brake pads.
4. Perform inspection after removal. Refer to BR-42, "
BRAKE PAD : Inspection".
INSTALLATION
WARNING:
Clean any dust from the brake caliper assembly an d brake pads with a vacuum dust collector. Never
blow with compressed air.
CAUTION:
Never depress the brake pedal while removing th e brake pads because the piston may pop out.
If the brake fluid or grease adheres to the brake cal iper assembly and disc rotor, quickly wipe it off.
1. Cylinder body 2. Inner shim 3. Inner pad (with pad wear sensor)
4. Pad retaining 5. Torque member 6. Outer pad
7. Outer shim
: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
Refer to GI-4, "
Components" for symbols not described on the above.
JPFIA0734GB
Revision: 2010 May2011 QX56
BR-42
< REMOVAL AND INSTALLATION >
REAR DISC BRAKE
1. Install the torque member if the pad retainers has been removed.CAUTION:
Securely assemble the pad retainers so that it wi ll not be lifted up from the torque member.
Never deform the pad retainers.
2. Apply PCB (Poly Butyl Cuprysil) grease or silicone-based grease to the matching faces (A) between the brake pad and
shim, and install the shims to brake pads.
CAUTION:
Always replace the shims when replacing the brake pad.
3. Apply PCB (Poly Butyl Cuprysil) grease or silicone-based grease to the matching faces (B) between the brake pad and
torque member.
4. Install cylinder body to the torque member. CAUTION:
Never damage the piston boot.
When replacing brake pad with new one, check a brakefluid level in the reservoir tank because brake flui d returns to reservoir tank when pressing pis-
ton in.
NOTE:
Use a disc brake piston tool to easily press piston.
5. Install the upper sliding pin bolt and tighten it to the specified torque.
6. Depress the brake pedal several times to check that no drag feel is present for the front disc brake. Refer
to BR-42, "
BRAKE PAD : Inspection".
7. Install tires with power tool. Refer to WT-64, "
Exploded View".
BRAKE PAD : InspectionINFOID:0000000006222497
INSPECTION AFTER REMOVAL
Replace the shims if rust is excessively attached.
Eliminate rust on the pad retainers and the torque mem ber. Replace them if rust is excessively attached.
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. Refer to BR-41, "
BRAKE PAD : Removal and Installation".
3. Press the piston. Refer to BR-41, "
BRAKE PAD : Removal and Installation".
4. Install brake pads. Refer to BR-41, "
BRAKE PAD : Removal and Installation".
5. Depress the brake pedal several times.
6. Check a drag of rear disc brake again. If any drag is found, disassemble the caliper. Refer to BR-44,
"BRAKE CALIPER ASSEMBLY : Disassembly and Assembly".
7. Burnish contact surfaces brake pads and disc rotor after refinishing or replacing brake pads, or if a soft pedal occurs at very low mileage. Refer to BR-18, "
BRAKE PAD : Inspection and Adjustment".
BRAKE CALIPER ASSEMBLY
BRAKE CALIPER ASSEMBLY : Exploded ViewINFOID:0000000006222498
REMOVAL
JPFIA0741ZZ
Revision: 2010 May2011 QX56
BR-44
< REMOVAL AND INSTALLATION >
REAR DISC BRAKE
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with wate r if it gets on a painted surface.
Never depress the brake pedal. Brake fluid may splash while removing the brake hose.
If the brake fluid or grease adheres to the brake calip er assembly and disc rotor, quickly wipe it off.
1. Remove tires with power tool.
2. Fix the disc rotor using wheel nuts.
3. Drain brake fluid. Refer to BR-10, "
Draining".
4. Separate brake hose from brake caliper assembly. Refer to BR-26, "
REAR : Removal and Installation".
5. Remove torque member mounting bolts, and remove brake caliper assembly. CAUTION:
Never drop brake pad and caliper assembly.
6. Remove disc rotor. Refer to RAX-7, "
Removal and Installation".
INSTALLATION
WARNING:
Clean any dust from the brake caliper assembly an d brake pads with a vacuum dust collector. Never
blow with compressed air.
CAUTION:
Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with wate r if it gets on a painted surface.
Never depress the brake pedal. Brake fluid may splash while removing the brake hose.
If the brake fluid or grease adheres to the brake calip er assembly and disc rotor, quickly wipe it off.
1. Install disc rotor. Refer to RAX-7, "
Removal and Installation".
2. Install the brake caliper assembly to the axle hous ing 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. Wipe out any grease and moisture.
3. Install brake hose to brake caliper assembly. Refer to BR-26, "
REAR : Removal and Installation".
4. Perform the air bleeding. Refer to BR-11, "
Bleeding Brake System".
5. Check a drag of rear disc brake. If any drag is found, refer to BR-45, "
BRAKE CALIPER ASSEMBLY :
Inspection".
6. Install tires with power tool. Refer to WT-64, "
Exploded View".
BRAKE CALIPER ASSEMBLY : Disassembly and AssemblyINFOID:0000000006222500
DISASSEMBLY
NOTE:
Never remove the torque member, brake pads and pad retainers when disassembling and assembling the cyl-
inder body.
1. Remove the sliding pin bolt, and remove the cylinder body from the torque member.
CAUTION:
Fix the brake pad at suitable tape so that the brake pad will not drop.
2. Remove sliding pin boots from torque member.
3. Remove bushing from sliding pin bolt.
4. Place a wooden block as shown in the figure, and blow air from brake hose mounting hole to remove piston and piston boot.
CAUTION:
Never get fingers caught in the piston.
MAA0272D
Revision: 2010 May2011 QX56
PRECAUTIONSBRC-7
< PRECAUTION > [WITH VDC]
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and tires installed on the vehicle are the specified si ze and parts. Brake performance and controllability may
be negatively affected when other parts than the specified are installed.
Brake stopping distance may become longer and steering stability may be negatively affected, when tires in
different size and combination or other parts than the specified are used.
When a radio (including wiring), antenna and antenna lead line are located near ABS actuator and electric
unit (control unit), a malfunction or improper operation ma y occur for the control of VDC function, TCS func-
tion, ABS function, EBD function, hill start assist func tion or brake limited slip differential (BLSD) function.
When the following items are replaced by other parts than genuine parts or modified, ABS warning lamp, brake warning lamp and VDC warning lamp may turn ON, and the control may not operate normally for VDC
function, TCS function, ABS function, EB D function, hill start assist function or brake limited slip differential
(BLSD) function.
- Suspension component parts (shock absorber, spring, bushing and others)
- Tire and wheel (other than the specified size)
- Brake component parts (brake pad, disc rotor, brake caliper and others)
- Engine component parts (ECM, muffler and others)
- Body reinforcement component parts (rollover bar, tower bar and others)
When suspension, tire and brake component parts are excessively worn or deteriorated and the vehicle is
driven, ABS warning lamp, brake warning lamp and VDC warning lamp may tu\
rn ON, and the control may
not operate normally for VDC function, TCS function, ABS function, EBD function, hill start assist function or
brake limited slip differential (BLSD) function.
ABS warning lamp, brake warning lamp and VDC warning lamp may turn ON, when only front wheel or rear wheel is rotated using a free roller. This is not a ma lfunction, because it is caused by wheel speed difference
between wheel that is rotated and wheel that is not rota ted. In this case, perform self-diagnosis, check self-
diagnosis results, and erase memory.
When power supply voltage is not normal, ABS warning lamp, brake warning lamp and VDC warning lamp
turn ON. ABS actuator and electric unit (control unit) st ops control for VDC function, TCS function, ABS func-
tion, EBD function, hill start assist function or brake limited slip differential (BLSD) function. Ordinary brake
operates. After power supply returns to normal, ABS warning lamp, brake warning lamp and VDC warning
lamp turn OFF. The control becomes operative for VD C function, TCS function, ABS function, EBD function,
hill start assist function or brake li mited slip differential (BLSD) function.
VDC warning lamp may turn ON and VDC function or TCS function may not normally operate, when driving
on a special road the is extremely slanted (bank in a circ uit course). This is not a malfunction if the status
returns to normal for VDC function or TCS function after the engine is started again. In this case, perform
self-diagnosis, check self-diagnosis results, and erase memory.
A malfunction in yaw rate/side/decel G sensor syste m may be detected when the vehicle sharply turns dur-
ing a spin turn, acceleration turn or drift driving while VDC function or TCS function are OFF (VDC OFF
switch is pressed and VDC OFF indicator lamp is in ON st atus). This is not a malfunction if the status returns
to normal for VDC function or TCS function after the engine is started again. In this case, perform self-diag-
nosis, check self-diagnosis results, and erase memory
Precaution for Harness RepairINFOID:0000000006222558
Solder the repair part, and wrap it with tape. [Twisted wire fray must be 110 mm (4.33 in) or less.]
SKIB8766E
Revision: 2010 May2011 QX56
BRC-26
< SYSTEM DESCRIPTION >[WITH VDC]
SYSTEM
ABS FUNCTION
ABS warning lamp and VDC warning lamp in combinati
on meter turn ON when a malfunction occurs in system
[ABS actuator and electric unit (control unit)]. The c ontrol is suspended for VDC function, TCS function, ABS
function, hill start assist function and brake limited sl ip differential (BLSD) function. The vehicle status
becomes the same as models without VDC function, TCS f unction, ABS function, hill start assist function and
brake limited slip differential (BLSD) function. However, EBD function is operated normally.
NOTE:
ABS self-diagnosis sound may be heard the same as in the normal condition, because self-diagnosis is per-
formed when ignition switch turns ON and when vehicle initially starts.
EBD FUNCTION
ABS warning lamp, brake warning lamp and VDC warning lamp in combination meter turn ON when a mal-
function occurs in system [ABS actuator and electric unit (control unit)]. The control is suspended for VDC
function, TCS function, ABS function, EBD function, hill start assist function and brake limited slip differential
(BLSD) function. The vehicle status becomes the sa me as models without VDC function, TCS function, ABS
function, EBD function, hill star t assist function and brake limited slip differential (BLSD) function.
DTC Malfunction detected condition Fail-safe condition
C1101 When an open circuit is detected in rear RH wheel sensor circuit.
The following functions are sus-
pended.
VDC function
TCS function
ABS function
EBD function (only when both 2 rear wheels are malfunctioning)
hill start assist function
Brake limited slip differential
(BLSD) function
C1102 When an open circuit is detected in rear LH wheel sensor circuit.
C1103 When an open circuit is detected in front RH wheel sensor circuit.
C1104 When an open circuit is detected in front LH wheel sensor circuit.
C1105
When power supply voltage of rear RH wheel sensor is low.
When distance between rear RH wheel sensor and rear RH wheel sensor rotor is
large.
When installation of rear RH wheel sensor or rear RH wheel sensor rotor is not
normal.
C1106 When power supply voltage of rear LH wheel sensor is low.
When distance between rear LH wheel sensor and rear LH wheel sensor rotor is
large.
When installation of rear LH wheel sensor or rear LH wheel sensor rotor is not nor- mal.
C1107 When power supply voltage of front RH wheel sensor is low.
When distance between front RH wheel sensor and front RH wheel sensor rotor
is large.
When installation of front RH wheel sensor or front RH wheel sensor rotor is not normal.
C1108 When power supply voltage of front LH wheel sensor is low.
When distance between front LH wheel sensor and front LH wheel sensor rotor is
large.
When installation of front LH wheel sensor or front LH wheel sensor rotor is not normal.
C1109 When ignition voltage is 10 V or less.
When ignition voltage is 16 V or more. The following functions are sus-
pended.
VDC function
TCS function
ABS function
EBD function
hill start assist function
Brake limited slip differential
(BLSD) function
C 1111
When a malfunction is detected in motor or motor relay.
When a low pressure malfunction is detected in accumulator.
When a malfunction is detected in accumulator pressure sensor.
C 111 5 When difference in wheel speed between any wheel and others is detected during
the vehicle is driven, because of installation of other tires than specified. The following functions are sus-
pended.
VDC function
TCS function
ABS function
hill start assist function
Brake limited slip differential
(BLSD) function
C 111 6
When stop lamp switch signal is not input when brake pedal depress.
When stop lamp switch signal is not input when stop lamp relay operates.
C 111 8
*1When a malfunction is detected in transfer control unit system.
Revision: 2010 May2011 QX56
ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)BRC-49
< ECU DIAGNOSIS INFORMATION > [WITH VDC]
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C 111 5 When difference in wheel speed between any wheel and others is detected during
the vehicle is driven, because of installation of other tires than specified. The following functions are sus-
pended.
VDC function
TCS function
ABS function
hill start assist function
Brake limited slip differential
(BLSD) function
C 111 6
When stop lamp switch signal is not input when brake pedal depress.
When stop lamp switch signal is not input when stop lamp relay operates.
C 111 8
*1When a malfunction is detected in transfer control unit system.
C1120 When a malfunction is detec ted in front LH ABS IN valve.
The following functions are sus-
pended.
VDC function
TCS function
ABS function
EBD function
hill start assist function
Brake limited slip differential (BLSD) function
C1121 When a malfunction is detec
ted in front LH ABS OUT valve.
C1122 When a malfunction is detected in front RH ABS IN valve.
C1123 When a malfunction is det ected in front RH ABS OUT valve.
C1124 When a malfunction is detected in rear LH ABS IN valve.
C1125 When a malfunction is detected in rear LH ABS OUT valve.
C1126 When a malfunction is det ected in rear RH ABS IN valve.
C1127 When a malfunction is detected in rear RH ABS OUT valve.
C1130 When a malfunction is detected in ECM system. The following functions are sus-
pended.
VDC function
TCS function
hill start assist function
Brake limited slip differential
(BLSD) function
C1140 When a malfunction is detected in actuator relay. The following functions are sus-
pended.
VDC function
TCS function
ABS function
EBD function
hill start assist function
Brake limited slip differential
(BLSD) function
C1142
*2When a malfunction is detected in master cylinder pressure sensor or control pres-
sure sensor. The following functions are sus-
pended.
VDC function
TCS function
hill start assist function
Brake limited slip differential
(BLSD) function
C1143 When a malfunction is detected in steering angle sensor.
C1144 When neutral position adjustment of steering angle sensor is not complete.
C1145
When a malfunction is detected in yaw rate signal.
When yaw rate signal is not continuously received for 2 seconds or more.
When side G signal is not continuously received for 2 seconds or more.
When decel G signal is not continuously received for 2 seconds or more.
The following functions are sus-
pended.
VDC function
TCS function
ABS function
hill start assist function
Brake limited slip differential
(BLSD) function
C1146 When a malfunction is detected in side/decel G signal.
C1155
When brake fluid level low signal is detected.
When an open circuit is detected in brake fluid level switch circuit.
C1160 When calibration of yaw rate/side/decal G sensor is not complete.
C1164 When a malfunction is detected in cut valve 1. The following functions are sus- pended.
VDC function
TCS function
ABS function
EBD function
hill start assist function
Brake limited slip differential (BLSD) function
C1165 When a malfunction is detected in cut valve 2.
C1166 When a malfunction is detected in suction valve 1.
C1167 When a malfunction is detected in suction valve 2. DTC Malfunction detected condition Fail-safe condition
Revision: 2010 May2011 QX56