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    Tham gia ngày:
    17/10/09
    Số km:
    14
    Được đổ xăng:
    23
    Mã lực:
    6
    Xăng dự trữ:
    103 lít xăng
    BRAKESYSTEM

    BR–1

    [​IMG]

    BRAKESYSTEM

    BR–2



    BRAKESYSTEM



    – Precautions


    PRECAUTIONS

    1. Caremustbetakentoreplaceeachpartproperlyasit couldaffect the performance of the brake system and re- sult inadrivinghazard.Replacethepartswithpartsofthe samepartnumberorequivalent.

    2. It isveryimportanttokeeppartsandtheareacleanwhen repairingthebrakesystem.


    TROUBLESHOOTING


    Problem


    Loworspongy




    Linings worn


    Possible cause


    Remedy


    Replacebrakeshoes


    Page


    BR–26

    [​IMG]pedal

    Brake pads worn Leak in brake system Mastercylinderfaulty



    Airinbrakesystem

    Wheelcylinderfaulty

    Replacepads

    Repair leak

    Repairorreplacemastercylinder

    Bleed brake system Repair wheel cylinder Repaircylinder


    Brakecylinderfaulty

    Piston seals worn or damaged

    Repairorreplaceadjuster

    BR–18, 34

    BR–18, 34

    Rearbrakeautomaticadjusterfaulty




    Brakesdrag


    Parkingbrakeoutofadjustment

    Bindingparkingbrakewire


    Adjust parking brake

    Repairasnecessary


    BR–8


    Boosterpushrodoutofadjustment

    Adjust push rod


    BR–16


    Tension or return spring faulty

    Replace spring


    BR–26, 42


    Brake line restricted

    Repairasnecessary



    Lining cracked or distorted

    Replaceshoe



    Pad cracked or distorted

    Replacepad

    BR–26, 42


    Wheelcylinderorcaliperpistonsticking

    Repairasnecessary

    BR–18,34


    Adjuster broken


    BR–18, 26


    Mastercylinderfaulty


    34



    Replace adjuster




    Repair or replace master

    BR–9



    cylinder


    Brakespull

    Tires improperly inflated

    Inflate tires to proper pressure




    Check for cause. Replace shoes



    Oil or grease on shoes or pads

    or pads

    BR–18, 26



    Replacebrakeshoes

    34


    Brakeshoesdistorted,liningswornorglazed


    BR–26, 42


    Brakepadsdistorted,wornorglazed




    Drum or disc out of round

    Replacepads

    BR–18, 34


    Tension or return spring faulty

    Replace drum or disc

    BR–18, 26


    Wheelcylinderfaulty

    Replace spring

    34


    Brakecylinderfaulty

    Repair wheel cylinder

    BR–26, 42


    Pistonfrozeninbrakecylinder

    Repaircylinder

    BR–26


    Brake pad sticking

    Repaircylinder

    BR–18, 34



    Replacepads

    BR–18, 34




    BR–18, 34



    Repair brake cylinder

    BR–18,34



    BR–9



    BR–7

    BR–26

    BR–2



    BRAKESYSTEM



    – Troubleshooting


    PRECAUTIONS

    1. Caremustbetakentoreplaceeachpartproperlyasit couldaffect the performance of the brake system and re- sult inadrivinghazard.Replacethepartswithpartsofthe samepartnumberorequivalent.

    2. It isveryimportanttokeeppartsandtheareacleanwhen repairingthebrakesystem.


    TROUBLESHOOTING


    Problem


    Loworspongy




    Linings worn


    Possible cause


    Remedy


    Replacebrakeshoes


    Page


    BR–26

    [​IMG]pedal

    Brake pads worn Leak in brake system Mastercylinderfaulty



    Airinbrakesystem

    Wheelcylinderfaulty

    Replacepads

    Repair leak

    Repairorreplacemastercylinder

    Bleed brake system Repair wheel cylinder Repaircylinder


    Brakecylinderfaulty

    Piston seals worn or damaged

    Repairorreplaceadjuster

    BR–18, 34

    BR–18, 34

    Rearbrakeautomaticadjusterfaulty




    Brakesdrag


    Parkingbrakeoutofadjustment

    Bindingparkingbrakewire


    Adjust parking brake

    Repairasnecessary


    BR–8


    Boosterpushrodoutofadjustment

    Adjust push rod


    BR–16


    Tension or return spring faulty

    Replace spring


    BR–26, 42


    Brake line restricted

    Repairasnecessary



    Lining cracked or distorted

    Replaceshoe



    Pad cracked or distorted

    Replacepad

    BR–26, 42


    Wheelcylinderorcaliperpistonsticking

    Repairasnecessary

    BR–18,34


    Adjuster broken


    BR–18, 26


    Mastercylinderfaulty


    34



    Replace adjuster




    Repair or replace master

    BR–9



    cylinder


    Brakespull

    Tires improperly inflated

    Inflate tires to proper pressure




    Check for cause. Replace shoes



    Oil or grease on shoes or pads

    or pads

    BR–18, 26



    Replacebrakeshoes

    34


    Brakeshoesdistorted,liningswornorglazed


    BR–26, 42


    Brakepadsdistorted,wornorglazed




    Drum or disc out of round

    Replacepads

    BR–18, 34


    Tension or return spring faulty

    Replace drum or disc

    BR–18, 26


    Wheelcylinderfaulty

    Replace spring

    34


    Brakecylinderfaulty

    Repair wheel cylinder

    BR–26, 42


    Pistonfrozeninbrakecylinder

    Repaircylinder

    BR–26


    Brake pad sticking

    Repaircylinder

    BR–18, 34



    Replacepads

    BR–18, 34




    BR–18, 34



    Repair brake cylinder

    BR–18,34



    BR–9



    BR–7

    BR–26



    BRAKESYSTEM



    – Troubleshooting

    BR–3


    TROUBLESHOOTING(Cont’d)


    Problem


    Hard pedal but brakes

    Possiblecause


    Oil or grease on shoes or pads

    Remedy

    Checkfor cause. Replace shoes

    Page

    BR–18,26

    inefficient


    or pads

    34


    Brakeshoesdistorted,liningswornorglazed,

    Replacebrakeshoes

    BR–26,


    drumsworn




    Brakepadsdistorted,wornorglazed

    Pistonfrozeninbrakecylinder

    Brakeboosterfaulty

    Vacuumleaks

    Replacepads Repaircylinder Repair booster

    Repairasnecessary

    BR–18,34

    BR–18,34

    BR–15


    Brake line restricted

    Repairasnecessary



    Snapping or clicking noise(Drumbrake)

    [​IMG]when brakes are applied

    Brake shoes binding at backing plate ledges

    Backing plate ledges worn

    Loose or missing shoe hold–down spring

    Loose set bolt at backing plate

    (Discbrake)

    Loose or missing pad support plate

    Loose installation bolt


    Replace pad support plate

    Tighten

    Replaceslidebushing

    BR–18,34

    BR–18, 34

    BR–18, 34


    Scraping or grinding noiseWorn brake linings or pads

    Replace or refinish drums or rotors if


    BR–18, 26

    when brakes are applied

    heavilyscored

    34

    Caliper to wheel or rotor interference

    Replace as required

    BR–18, 34

    Dust cover to rotor or backing plate to drum



    interference

    Other brake system components faulty

    Correctorreplace

    BR–18,26

    34


    Repairorreplaceas



    necessary


    Tires rubbing against chassis and/or

    Repairasnecessary


    body





    Wear on slide bushing


    Lubricate



    Replace and lubricate ledges Replaceshoehold–downspring Tighten


    BR–26



    BR–26

    BR–26



    BR–26



    TROUBLESHOOTING(Cont’d)


    Problem


    Possible cause

    I Remedy


    .Page

    Squeaking,squealing groaningorchattering noise when brakes are applied

    Note: Brake friction

    materials inherently

    Brake drums and linings, rotors and pads

    wornorscored

    Dirty, greased, contaminated or glazed linings or pads

    Improperliningsorpadsusing

    Maladjustmentofbrakepedalorbooster

    Inspect, repair or replace

    Clean or replace

    Inspectforcorrectusageor replace

    Inspect and adjust

    BR–18,26,

    34

    BR–18, 26

    34

    generate noise and heat inpushrod ordertodissipateeniergy.(Discbrake)

    BR–6,16

    As a result, occasional squeal is normal and is aggravatedbysevere environmental conditions such as cold,’ heat, wetness, snow,salt,mud,

    Missing or damaged brake pad

    anti–squeal shim

    Pad wear and pad wear indicator making contact with the rotor

    Burredorrustedcalipers

    (Drum brake)


    Replace

    Replace

    Cleanordeburr


    BR–18, 34

    BR–18, 34

    BR–18, 34

    etc. This occasional squealWeak damaged or incorrect shoe

    isnotafunctionalproblemhold–down springs, loose or damaged

    and does not indicate anyshoe hold–down spring pins and springs

    loss of brake effectivenessandgroovedbackingplateledges


    –Inspect,repairorreplace


    BR–26





    Squealingand squeakingnoisewhen

    Maladjustmentof brake pedal or booster push rod


    Inspect and adjust

    Inspect, repair or replace


    BR–6, 16

    brakes are not applied

    Poor return of brake booster or master cylinder or


    BR–9,15


    wheel cylinder

    (Discbrake)


    26


    Rusted or stuck piston

    Inspect and lubricate as

    BR– 18, 34


    Improperpositioningofpadincaliper

    necessary



    Rotor rubbing against caliper housing

    Repairorreplace

    BR–18,34


    Improperinstallationofdiscbrakepadsupport

    Repairorreplace

    BR–18, 34


    plate

    Repairorreplace

    BR–18, 34


    Pad wear and pad wear indicator making contact

    Replace

    BR–18, 34


    withtherotor




    (Drum brake)




    Weak, damaged or incorrect shoe hold–down




    springs


    Replace


    BR–26, 42


    Grooved backing plate ledges


    Repairorreplace


    BR–26, 42


    Bent or warped backing plate causing


    Repairorreplace


    BR–26, 42

    [​IMG]interference with drum

    Impropermachiningofdrumcausinginterference with backing plate or shoe

    Other brake system components: Loose or extra parts in brakes

    Rear drum adjustment too tight causing lining to glaze

    Worn,damagedorinsufficientlylubricatedwheel bearings

    Replace drum





    Inspect,repairorreplaceas necessary

    BR–26, 42



    BRAKESYSTEM



    – Troubleshooting

    BR–5


    TROUBLESHOOTING(Cont’d)


    Problem Groaning,clickingor rattlingnoisewhen brakes are not applied

    Possiblecause Stones or foreign material trapped inside wheelcovers

    Loosewheelnuts

    Remedy Page

    Remove foreign material



    Tighten to correct torque Replace if stud holes are elongated


    Maladjustmentof brake pedal or booster push rod

    worn, damaged or dry wheel bearings

    (Discbrake)

    Looseormissinganti–rattlespringorpad support plate or rimping on outer pad Failure of shim

    Wear on slide bushing

    Loose installation bolt Poor return of piston (Drum brake)

    Looseorextraparts

    Inspect and adjust



    Inspectandlubricateor replace



    Inspect, repair or replace




    Inspect , replace if necessary Inspect , replace if necessary Inspect,tightenifnecessary Inspect, repair or replace


    BR–6,16







    BR–21,37




    BR–21, 37

    BR–21, 37

    BR–21, 37

    BR–21, 37





    [​IMG]Inspect and repair

    BR–26, 42





    StOPlight SwitCh

    PushRod

    CHECKS AND ADJUSTMENTS CHECKANDADJUSTMENTOFBRAKE PEDAL

    1. CHECKTHATPEDALHEIGHTISCORRECT

    Pedalheightfromasphaltsheet:

    177.5–187.5mm(6.988–7.382in.)

    Ifincorrect,adjustthepedalheight.

    2. IFNECESSARY,ADJUSTPEDALHEIGHT

    (a) Ifnecessary,removetheinstrumentlowerfinishpan- elandairduct.

    (b) Loosenthestoplightswitchlocknut. (e) Sufficientlyloosenthestoplightswitch. (d) Loosenthepushrodlocknut.

    (e) Adjustthepedalheightbyturningthepedalpush rod.

    (f) Returnthestoplightswitchuntilitlightlycontactsthe

    -,~


    pedalstopper.

    (g) Tightenthetwolocknuts.

    (h) Checkthatthestoplightslightwhenthebrakepedal depressed.

    (i) Afteradjustingthepedalheight,checkandadjust

    thepedalfreeplay.












    [​IMG]

    PushRod

    3. CHECKTHATPEDALFREEPLAYISCORRECT

    (a) Stoptheengineanddepressthebrakepedalsever- altimesuntilthere is no more vacuum left in the booster.

    (b) Pushinthepedaluntilthebeginningofresistance isfelt.Measurethedistance,asshown.

    Pedalfreeplay:3–6mm(0.12–0.24in.)

    HINT:Thefreeplaytothefirstresistanceisduetotheplay betweentheclevisandpin.Anditis13mm(0.04–

    0.12in.)onthepedal.

    4. IFNECESSARY,ADJUSTPEDALFREEPLAY

    (a) Ifincorrect,adjustthepedalfreeplaybyturningthe pedalpushrod.

    (b) Starttheengineandconfirmthatpedalfreepiayex- ists.

    (e) Afteradjustingthepedalfreeplay,checkthepedal

    height.

    (d) Installtheairductandinstrumentlowerfinishpanel.


    BRAKESYSTEM


    – ChecksandAdjustments






    PtdtlR.,erve Oistanot


    _.'



    ._

    5. CHECKTHATPEDALRESERVEDISTANCEIS CORRECT

    Releasethe parking brake. With engine running, depress

    thepedalandmeasurethepedalreservedistance,as shown.

    Pedalreservedistancefromasphaltsheetat50kg

    (110.21b):Morethan85mm,(3.35in.)

    Ifincorrect,troubleshootthebrakesystem.


















    GOOD









    1St2nd
















    NO~OOD


























    ..."

    OPERATIONALTESTOFBRAKE BOOSTER

    HINT:If there is leakage or lack of vacuum, repair before testing.Ifavailable,useabrakeboostertestertocheckthe boosteroperatingcondition.

    1. OPERATINGCHECK

    (a) Depressthebrakepedalseveraltimeswiththeen- ginestopped,andcheckthatisnochangeintheped- alreservedistance.

    (b) Depressthebrakepedalandstarttheengine.Ifthe pedalgoesdownslightly,operationisnormal.

    2. AIRTIGHTNESSCHECK

    (a) Starttheengineandstopitafterone or two minutes.

    Depressthebrakepedal several times slowly.Ifthe pedalgoesdownfurtherestthefirsttime,butgradual- lyrisesafterthesecondorthirdtime,theboosterisair tight.

    (b) Depressthe brake pedal while the engine is running, andstopitwiththepedaldepressed.Ifthereisno

    [​IMG]









    --

    @~





    ~ --

    changeinpedalreservetravelafterholdingthepedal

    forthirtyseconds,theboosterisairtight.

    BLEEDINGOFBRAKESYSTEM

    HINT:Ifanyworkisdoneonthebrakesystemorifairissus- pectedinthebrakelines,bleedthesystemofair. NOTICE:Do not let brake fluid remain ona painted surface. Washitoffimmediately.

    1. FILLBRAKERESERVOIRWITHBRAKEFLUID

    Checkthefluidlevelinthereservoir.Ifnecessary,add brakefluid.

    2. BLEEDMASTERCYLINDER

    HINT:Ifthemastercylinderwasdisassembledoriftheres- ervoirbecomes empty, bleed the air from the master cylin- der.

    (a) Disconnectthebrake tubes from the master cylinder. (b) Depressthebrakepedalandholdit.



    [​IMG](c) Blockofftheouterholeswithyourfingers,andre- leasethebrakepedal.

    (d) Repeat(b)and(c)threeorfourtimes.








    ""...












    ....




























    ••





    3. BEGINBLEEDINGAIRFROMBRAKEORWHEEL CYLINDERWITHLONGESTHYDRAULICLINE

    (a) Connectthevinyltubetothebrakeorwheelcylinder

    bleederplug,andinserttheotherendoftubeina halffullcontainerofbrakefluid.

    (b) Slowlypumpthebrakepedalseveraltimes.

    (c) Whilehavinganassistantpressonthepedal,loosen thebleederpluguntilfluidstartstorunout.Thenclose thebleederplug.

    (d) Repeat(b)and(c)untiltherearenomoreairbubbles inthefluid.

    (e) Tightenthebleederplug.

    Bleederplugtighteningtorque:

    85kg–cm(74in.–!b,8.3N–m)

    4. REPEATPROCEDUREFOREACHWHEEL





    CHECKANDADJUSTMENTOFPARKING BRAKE

    1. CHECKTHATPARKINGBRAKELEVERTRAVELIS CORRECT

    Pull theparkingbrakeleverallthewayup,andcountthenum- berofclicks.

    Parkingbrakelevertravelat20kg(44.1Ib,196N):

    5–8clicks

    Ifincorrect,adjusttheparkingbrake.

    2. IFNECESSARY,ADJUSTPARKINGBRAKELEVER TRAVEL

    HINT:Before adjusting the parking brake, make sure that the rearbrakeshoeclearancehasbeenadjusted.

    Forshoeclearanceadjustment,seesteps8and9onpage

    BR–32orstep8onpage48. (a) Removetheconsolebox.

    (b) Loosenthelocknutandturntheadjustingnutuntilthe levertraveliscorrect.

    (e) Tightenthelocknut.

    Torque:55kg–cm(48in.–Ib,5.4N–m)

    (d) Installtheconsolebox.



    MASTERCYLINDER

    [​IMG]REMOVALOFMASTERCYLINDER








    .Ga_






    130t9.13.

    t











    t kg·em(ft.lb.N,m. I:Specified (Otque

    •Non-reusable pan:



    1. DISCONNECTLEVELWARNINGSWITCH CONNECTOR

    2. TAKEOUTFLUIDWITHSYRINGE

    NOTICE:Donotletbrakefluidremainonapaintedsurface. Washitoffimmediately.

    3. DISCONNECTBRAKETUBES

    UsingSST, disconnectbraketubesfromthemastercylinder. SST09751–36011














    ..'.,.

    4. REMOVEMASTERCYLINDER

    (a) Removethethreenutsand3–wayunion. (b) Removetheclamp.

    (c) Removethemastercylinderfromthebrakebooster andremovethegasket.



    COMPONENTS



    w/oA.B.S.



    ~c.P




    ~>---Strainef


    ReservoirSetSetew ~

    17.5(1L21n..1b.1.71


    SnapRing




















    w/A8.S.



    ~S~to~ppet~-8-0~,~~!!,

    I l00(7.tot f

    ~.Ga$ket






    Aeser.<Olt SetScrew

    ~c ••

    17.5111•.2...... 1.71 @-Strliner



    Reservoir




    SnapRing








    Grommet--L--_





    .G.....-~~~i'



    ~~tP


    No,2PistonandSpring:



    S¢ng






    IkQ-cm(ft·lb.N-m) I:Spe.eified tOtque

    •Hon·teusable part

    StoppetBolt

    I100(7.101I







    Mm.




    DISASSEMBLYOFMASTER CYLINDER

    1. REMOVERESERVOIR

    (a) Removethesetscrewandpulloutthereservoir. (b) Removethecapandstrainerfromthereservoir.

    2. REMOVETWOGROMMETS

    3. PLACECYLINDERINVISE




    4. REMOVEPISTONSTOPPERBOLT

    Usingascrewdriver,pushthepistonsinallthewayand removethepistonstopperboltandgasket.

    HINT:Tapethescrewdrivertipbeforeuse.










    5. REMOVETWOPISTONSANDSPRINGS

    (a) Pushinthepistonwithascrewdriverandremovethe snapringwithsnapringpliers.

    (b) RemovetheNo.1pistonandspringhand,pulling straightout,notatanangle.

    NOTICE:Ifpulledoutatanangle,thereispossibilityof damagingthecylinderbore.





    (c) Placearagandtwowoodenblocksontheworktable andlightly tap the cylinder flange against the blocks untilthepistondropsoutofthecylinder.

    HINT:Makesurethedistance(A)fromtheragtothetop

    oftheblocksisatleast100mm(3.94in.)



    [​IMG]A

    .....






    INSPECTIONOFMASTERCYLINDER COMPONENTS

    HINT:Cleanthedisassembledparts with compressed air.

    1. INSPECTCYLINDERBOREFORRUSTORSCORING

    2. INSPECTCYLINDERFORWEARORDAMAGE

    Ifnecessary,cleanorreplacethecylinder.





    w/oA.B.S. .













    wi A.S,S.

    ASSEMBLYOFMASTERCYLINDER

    (SeepageBR–10)

    1. APPLYLITHIUMSOAPBASEGLYCOLGREASETO RUBBERPARTSINDICATEDBYARROWS














    2. INSTALLTWOSPRINGSANDPISTONS

    CAUTION:Becarefulnottodamagetherubberlipson thepistons.

    (a) Insertthetwospringsandpistonsstraightin,notat

    anangle.

    NOTICE:Ifinsertatanangle,thereispossibilityofdamag- ingthecylinderbore.

    (b) Pushinthepistonwithascrewdriverandinstallthe snapringwithsnapringpliers.

    HINT:Tapethescrewdrivertipbeforeuse.

    3. INSTALLPISTONSTOPPERBOLT

    Usinga screwdriver,pushthepistoninallthewayand installthe piston stopper bolt over the gasket. Torquethe bolt.

    Torque:100kg–cm(7ft–Ib,10N–m)








    4. INSTALLTWOGROMMETS





    o








    .."..










    --

    5. INSTALLRESERVOIR

    (a) Installthecapandstrainertothereservoir. (b) Pushthereservoirontothecylinder.

    (c) Installthesetscrewwhilepushingonthereservoir.

    Torque:17.5kg–cm(15.2in.–Ib,1.7N–m)








    NOTICE:Because the master cylinder and reservoir tankunionisagrommettype,thesetscrewis de- signedtonotseparatethereservoirfromthecylinder andwillnot tighten down the reservoir. Therefore, thereisaclearanceatpoint A. Do not insert washers oranequivalentwhentightening.

    BR–14



    BRAKESYSTEM



    – MasterCylinder

    [​IMG]


    INSTALLATIONOFMASTERCYLINDER

    (SeepageBR–9)

    1. CLEANOUTGROOVEONLOWERINSTALLATION SURFACEOFMASTERCYLINDER

    2. CONFIRMTHAT”UP”MARKONMASTERCYLINDER

    BOOTISINCORRECTPOSITION






    3. ADJUSTLENGTHOFBRAKEBOOSTERPUSHROD BEFOREINSTALLINGMASTERCYLINDER

    (SeepageBR–16)











    4. INSTALLMASTERCYLINDER

    Setthenewgasketandinstallthemastercylinder,clamp and3–wayuniononthebrakeboosterwiththreenuts.

    Torque:130kg–cm(9ft–Ib,13N¿m)










    5. CONNECTBRAKETUBES

    UsingSST,connect.thebraketubestothemastercylin- der.

    Torquetheunionnuts. SST09751–36011

    Torque:155kg–cm(11ft–ib,15N–m)







    6. CONNECTLEVELWARNINGSWITCHCONNECTOR

    7. FILLBRAKERESERVOIRWITHBRAKEFLUIDAND BLEEDBRAKESYSTEM

    (SeepageBR–7)

    8. CHECKFORFLUIDLEAKAGE

    9. CHECKANDADJUSTBRAKEPEDAL (SeepageBR–6)



    BRAKEBOOSTER

    [​IMG]REMOVALOFBRAKEBOOSTER






    151"1.,.)


    3-W~Union





    .'.

    •GasI<..












    '301••'31









    Ikg-cm(It·lb,.N·m) I:Specffiedtorque

    •Non-reusablepart


    1. REMOVEMASTER¿CYLINDER (SeepageBR–9)

    2. DISCONNECTVACUUMHOSEFROMBRAKE

    BOOSTER

    3. REMOVEPEDALRETURNSPRING

    4. REMOVECLIPANDCLEVISPIN







    5. REMOVEBRAKEBOOSTER,GASKETANDCLEVIS

    (a) Removethefournutsandclevis.

    (b) Pulloutthebrakeboosterandgasket.







    SST

    INSTALLATIONOFBRAKEBOOSTER

    (SeepageBR–15)

    1. ADJUSTLENGTHOFBOOSTERPUSHROD

    (a) SettheSSTonthemastercylinderwiththegasket, andthenlowerthepin until its slightly touches the piston.

    SST09737–00010

    [​IMG]


    (b) Turnthe SST upside down and set it on the booster. SST49737–00010

    (c) Measuretheclearancebetweentheboosterpush

    rodandpinhead(SST).

    Clearance:0mm(0in.)










    (d) Adjusttheboosterpushrodlengthuntilthepushrod lightlytouchesthepinhead.












    2. INSTALLBRAKEBOOSTER,GASKETANDCLEVIS

    (a) Installtheclevislocknutandclevistothebrake booster.

    (b) Installthebrakeboosterandgasket.

    (c) Installandtorquetheboostermountingnuts.

    Torque:130kg–cm(9ft–Ib,13N¿m)







    3. CONNECTCLEVISTOBRAKEPEDAL

    Inserttheclevispinintotheclevisandbrakepedal,and installthecliptotheclevispin.

    4. INSTALLPEDALRETURNSPRING

    5. INSTALLINSTRUMENTLOWERFINISHPANEL



    BRAKESYSTEM



    – BrakeBooster

    BR–17

    [​IMG]

    6. INSTALLMASTERCYLINDER (SeepageBR–14)

    7. CONNECTVACUUMHOSETOBRAKEBOOSTER

    8. FILLBRAKERESERVOIRWITHBRAKEFLUIDAND BLEEDBRAKESYSTEM

    (SeepageBR–7)

    9. CHECKFORFLUIDLEAKAGE

    10. CHECKANDADJUSTBRAKEPEDAL (SeepageBR–6)

    Checkand adjust the brake pedal, then tighten the clevis locknut.

    Torque:260kg–cm(19ft–fb,25N–m)

    11. PERFORMOPERATIONALCHECK (SeepageBR–7)



    FRONT BRAKE

    COMPONENTS





    UnionBolt

    310(22.)1)1
























    B)eederPlug

    I85(74in.-Ib.'.31


















    Ikg-em1ft-lb.N,m) I:SpeeiftedlorQue

    •Non-reusable part











    R_ Disc

    REPLACEMENTOFBRAKEPADS

    HINT:If a squealing noise occurs from the front brakes whiledriving,checkthepadwearindicator. If there are tracesof the indicator contacting the rotor disc, the brake padshouldbereplaced.

    [​IMG]







    1. REMOVEFRONTWHEEL

    Removethewheelandtemporarilyfastentherotordisc withthehubnuts.







    ..,~





    2. INSPECTPADLININGTHICKNESS

    Checkthepadthicknessthroughthecylinderinspection holeandreplacepadsifnotwithinspecification.

    Minimumthickness:1.0mm(0.039in.)










    3. REMOVECYLINDERFROMTORQUEPLATE

    (a) Removetwo installation bolts from the torque plate.












    (b) Removethebrakecylinderandsuspenditsothehose isnotstretched.

    HINT:Donotdisconnectthebrakehose.












    F.. 211Z·FEEngl

    o'wlA,B.s.

    /) ~

    ~


    I(~~rqa

    4. REMOVEFOLLOWINGPARTS:

    (a) Twoanti–squealsprings. (b) Twobrakepads

    (c) Two or four anti–squeal shims (d) Two pad wear indicator plates (e) Fourpadsupportplates

    FOf'2VZ·FE Engine ofwI A.B.S. P3n7



    5. CHECKROTORDISCTHICKNESS (Seestep2onpageBR–23)

    6. CHECKROTORDISCRUNOUT

    (Seestep3onpageBR–23)











    7. INSTALLPADSUPPORTPLATES














    8. INSTALLNEWPADS

    (a) Installnewpadwearindicatorplatetoinnerpad.

    NINT:Besurethearrowonthepadwearindicator plateispointinginthedirectionofthediscrotation.

    (b) (Except2VZ–FEEngineofw/A.B.S.)

    Installtheoneanti–squealshimtotheeachpad. (c) (For2VZ–FEEngineofw/A.B.S.)

    Install the two anti–squeal shims to the each pad. HINT: Apply disc brake grease to both side of the inner anti–squealshimoftheoutsidepad.

    (d) Installthepadsontoeachsupportplate. NOTICE:Donotallowoilorgreasetogetonthe rubbingface.

    (e) Installthetwoanti–squealsprings.










    [​IMG]













    ,-",IUI

    9. INSTALLCYLINDER

    (a) Drawoutasmallamountofbrakefluidfromthereser- voir.

    (b) Pressinpistonwithahammerhandleoranequiva- lent.

    HINT:Alwayschangethepadononewheelatatimeas thereisapossibilityoftheoppositepistonflyingout.

    (c) Insertthebrakecylindercarefully–sothebootis not wedged.




    (d) Installandtorquetwoinstallationbolts.

    Torque:400kg–cm(29ft–Ib,39N¿m)

    10. INSTALLFRONTWHEEL

    11. CHECKTHATFLUIDLEVELISMAXLINE





    ...~












    ......
















    For2VI·FE EIlfPOn

    /)AofwiA-S.s.

    ~

    '(~~Qo_





    REMOVALOFCYLINDER

    (SeepageBR–18)

    1. DISCONNECTBRAKELINE

    Removetheunionboltanddisconnectthebrakeline.Use acontainertocatchthebrakefluid.








    2. REMOVECYLINDERFROMTORQUEPLATE

    Removethetwoinstallationboltsandcylinder.













    3. REMOVEPADS

    (Seestep4onpageBR–19)

    ... ZVZ.fE

    neofwIA..8.S.



    DISASSEMBLYOFCYLINDER

    (SeepageBR–18)

    1. REMOVEFOLLOWINGPARTS:

    (a) Twoslidingbushings

    (b) Fourdustboots


    -

    2. REMOVECYLINDERBOOTSETRINGANDCYLINDER

    BOOT

    Usingascrewdriver,removethecylinderbootsetringand cylinderboot.










    3. REMOVEPISTONFROMCYLINDER

    (a) Putapieceofclothoranequivalentbetweenthepis- tonandcylinder.

    (b) Use compressedairtoremovethepistonfromthecyl- inder.

    CAUTION:Donotplaceyourfingersinfrontofthepiston

    whenusingcompressedair.





    4. REMOVEPISTONSEALFROMBRAKECYLINDER

    Usingascrewdriver,removethepistonseal.









    -



    BRAKESYSTEM



    – FrontBrake

    BR–23

    [​IMG]

    INSPECTIONANDREPAIROFFRONT BRAKECOMPONENTS

    1. MEASUREPADLININGTHICKNESS Standardthickness:10.0mm(0.394in.) Minimumthickness:1.0mm(0.039in.)

    Replacethepadifthethicknessislessthantheminimum

    orifitshowssignofunevenwear.





    2. MEASUREROTORDISCTHICKNESS Standardthickness:25.0mm(4.984in.) Minimumthickness:24.0mm(0.945in.)

    Ifthediscisscoredorworn,orifthicknessislessthanmini-

    mum,repairorreplacethedisc.








    3. MEASUREROTORDISCRUNOUT

    HINT:Beforemeasuringtherunout,confirmthatthefront hubbearingplayiswithinspecification.

    Measuretherotordiscrunoutat10mm(0.39in.)fromthe outeredgeoftherotordisc.

    Maximumdiscrunout:4.07mm(0.0028in.)

    Iftherunoutisgreaterthanthemaximum,inspectandad- justitfollowingtheprocedurebelow:

    Thenreplacethediscifnecessary.

    (a) Removethetorqueplatefromtheknuckle.

    (b) Removethehubnutsofthetemporarilyinstalleddisc andpullofftherotordisc.

    (c) Checkthatthehubbearingplayiswithinspecifica- tion, and replace the bearing if not within specifica- tion.(SeepageFA–7)

    (d) Installtherotordiscandmeasurethediscrunout,

    thenshifttherotordisconefifthofaturnandmeasure thediscrunout.Similarlymeasuretherunoutateach position,andselectthepositionwheretherunout is minimum.

    (e) Inthisposition,iftherunoutiswithinspecification, installthe torque plate and torque the mounting bolts.

    Torque:1,090kg–cm(79ft–Ib,107N–m)

    (f) Ifnotwithinspecification,replacetherotordisc,and repeat(d)and(e).



    ASSEMBLYOFCYLINDER

    (SeepageBR–18)

    1. APPLYLITHIUMSOAPBASEGLYCOLGREASETO PARTSINDICATEDWITHARROWS









    2. INSTALLPISTONSEALANDPISTONINCYLINDER














    3. INSTALLCYLINDERBOOTANDSETRINGIN CYLINDER












    4. INSTALLDUSTBOOTSANDSLIDINGBUSHING

    (a) Installthedustbootsintothebrakecylinder.

    (b) Insurethatthebootissecuredfirmlytothebrakecyl- indergroove.








    _11.1:,


    (c) Installthebushingintotheboots.

    (d) Insurethatthebootissecuredfirmlytothebushing groove.








    .,..,


    BRAKESYSTEM


    – FrontBrake




    FOf2VZ-FEEngine ofwiA.B.·S.

    ~ ~

    ~

    [​IMG]'(gp~Q a

    ForZVl·FEEngine01wiAB.S. .3m

    INSTALLATIONOFCYLINDER

    (SeepageBR–18)

    1. INSTALLPADS

    (SeeSteps7and8onpageBR–20)

    2. INSTALLCYLINDER

    (Seestep9onpageBR–20)







    3. INSTALLFLEXIBLEHOSETOBRAKECYLINDER

    Settheflexiblehoseandnewgasketsinpositionand installtheunionbolt.

    Torque:310kg–em(22ft–Ib,30N¿nn)










    4. FILLBRAKERESERVOIRWITHBRAKEFLUIDAND BLEEDBRAKESYSTEM

    (SeepageBR–7)

    5. CHECKFORLEAKS



    REARBRAKE DrumBrake COMPONENTS

    1.'."1.'.".P.l.u.g...

    10017.lot





    /'

    In'C)eC1lon

    Plug

    o=.;:;_--Wh..,CyI_

    .....


    ,.----,Ad,usdng Shim

    [​IMG]


















    I Itg..em(It·It).Nom)I:SpKifMKI torque

    •Non·ttuatblePlrt



    REMOVALOFREARBRAKE

    1. INSPECTSHOELININGTHICKNESS

    Removetheinspectionholeplug,andchecktheshoelin- ingthethicknessthroughthehole.

    Iflessthanminimum,replacetheshoes.

    Minimumthickness:1.0mm(0.039in.)

    2. REMOVEREARWHEEL





    3. REMOVEBRAKEDRUM

    HINT:Ifthebrakedrumcannotberemovedeasily,per- formthefollowingsteps.

    (a) Insertabentwireoranequivalentthroughthehole in the brake drum, and hold the automatic adjusting leverawayfromtheadjuster.

    (b) Usingascrewdriver,reducethebrakeshoeadjust-

    mentbyturningtheadjuster.




    4. REMOVEFRONTSHOE

    (a) UsingSST,disconnectthereturnspring. SST09703–30010







    ......


    (b) UsingSST,removetheshoehold–downspring,cups andpin.

    SST09718–00010

    (c) Disconnecttheanchorspringfromthefrontshoe andremovethefrontshoe.

    (d) Removetheanchorspringfromtherearshoe.





    M'~


    5. REMOVEREARSHOE

    (a) Using SST, remove the shoe hold–down spring, cupsandpin.

    SST09718–00010

    (b) Usingascrewdriver,disconnecttheparkingbrake. cablefromtheanchorplate.

    (c) Using pliers,disconnecttheparkingbrakecable

    fromtheleverandremovetherearshoetogether withtheadjuster.



    6. REMOVEADJUSTERFROMREARSHOE

    (a) Removetheadjustingleverspring.

    (b) Removethe adjuster together with the return spring.











    7. DISCONNECTBRAKETUBEFROMWHEELCYL- INDER

    UsingSST,disconnectthebrakeline.Useacontainerto

    catchthebrakefluid. SST09751–36011

    [​IMG]


    8. REMOVEWHEELCYLINDER

    Removethetwoboltsandthewheelcylinder.













    9. IFNECESSARY,DISASSEMBLEWHEELCYLINDER

    Removethefollowingpartsfromthewheelcylinder.

    • Twoboots

    • Twopistons

    • Twopistoncups

    • Spring_






    INSPECTIONANDREPAIROFREAR BRAKECOMPONENTS

    1. INSPECTDISASSEMBLEDPARTS

    Inspectthedisassembledpartsforwear,rustordamage.









    2. MEASUREBRAKESHOELININGTHICKNESS Standardthickness:5.0mm(0.197in.) Minimumthickness:1.0mm(0.039in.)

    Iftheshoeliningislessthanminimumorshowssignsof unevenwear,replacethebrakeshoes.

    HINT:Ifanyofthebrakeshoeshavetobereplaced,re- placealloftherearshoesinordertomaintainevenbrak-

    ing.




    3. MEASUREBRAKEDRUMINSIDEDIAMETER Standardinsidediameter:228.6mm(9.000in.) Maximuminsidediameter:230.6mm(9.079in.)

    Ifthedrumisscoredorworn,thebrakedrummaybelathed

    tothemaximuminsidediameter.




    .....



    4. INSPECTREARBRAKELININGANDDRUMFOR PROPERCONTACT

    If thecontactbetweenthebrakelininganddrumisimprop-

    er,repairtheliningwithabrakeshoegrinder,orreplace thebrakeshoeassembly.









    Shim

    5. MEASURECLEARANCEBETWEENBRAKESHOE ANDLEVER

    Usingafeelergauge,measuretheclearance.

    Standardclearance:Lessthan0.35mm(0.0138in.)

    If theclearanceisnotwithinspecification,replacetheshim withoneofthecorrectsize.


    Thickness mm (in.)

    Oeara~ 0.2 (0.008) 0..6 (0..0201

    0..3 (0..0.12) 0..6 (0.02')

    0.' (0.0.16) 0.9 co.005)


    6. IFNECESSARY,REPLACESHIM

    (a) Removetheparkingbrakelever,andinstallthecor- rectsizeshim.










    (b) InstalltheparkingbrakeleverwithanewC–washer. (c) Remeasuretheclearance.



    INSTALLATIONOFREARBRAKE

    (SeepageBR–26)

    HINT: Assemblethepartsinthecorrectdirectionas shown.


    fijght-hand rtw_



    From















    LehWheel





    ~~1(L_Y'~


    .A"""

    RightWheel



    1. ASSEMBLEWHEELCYLINDER

    (a) Applylithiumsoapbaseglycolgreasetothecups andpistonsasshown.

    (b) Assemblethewheelcylinder.

    HINT:Installinproperdirectiononly.

    • Spring

    • Twocups


    Spring Cup

    • Twopistons

    • Twoboots.

    2. INSTALLWHEELCYLINDER

    Installthewheelcylinderonthebackingplatewithtwo bolts.

    Torque:100kg–cm(7ft–Ib,10N–m)











    3. CONNECTBRAKETUBETOWHEELCYLINDER

    UsingSST,connectthebraketube. SST09751–36011

    Torque:155kg–crn(11ft–Ib,15N–m)








    M....



    4. APPLYHIGH TEMPERATURE GREASETO BACKING PLATEANDADJUSTER

    (a) Applyhightemperaturegreasetothebrakeshoe

    contactsurfacesasshown.










    (b) Applyhightemperaturegreasetotheadjusterbolt threadsandends.








    --

    5. INSTALLADJUSTERONTOREARSHOE

    Setthe adjuster and return spring in place and install the adjustingleverspring.











    6. INSTALLREARSHOE

    (a) Usingpliers,connecttheparkingbrakecabletothe lever.

    (b) Passtheparkingbrakecablethroughthenotchinthe anchorplate.

    (c) Settherearshoeinplacewiththeendoftheshoe insertedinthewheelcylinderandtheotherendinthe

    anchorplate.













    ...,.

    (d) UsingSST,installtheshoehold–downspring,cups andpin.

    SST09718–01000

    NOTICE:Donotallowoilorgreasetogetontheru bingface.



    7. INSTALLFRONTSHOE

    (a) Installtheanchorspringbetweenthefrontandrear shoes.

    (b) Setthefrontshoeinplacewiththeendoftheshoe insertedin the wheel cylinder and the adjuster in place.







    (c) UsingSST,installtheshoehold–downspring,cups andpin.

    SST09718–00010

    NOTICE:Donotallowoilorgreasetogetontheru bingface.





    ......


    (d) UsingSST,connectthereturnspring. SST09703–30010






















    ..,..,

    8. CHECKOPERATIONOFAUTOMATICADJUSTING MECHANISM

    (a) Movetheparkingbrakeleveroftherearshoeback

    andforth,asshown.Checkthattheadjusterturns.

    Iftheadjusterdoesnotturn,checkforincorrectinstallation oftherearbrakes.

    (b) Adjusttheadjusterlengthtotheshortestpossible

    amount.


    (c) Aligntheadjustingholeonthebrakedrumandlargest holeontheaxlecarrier,installthebrakedrum.



    (d) Pulltheparkingbrakeleverallthewayupuntilaclick- ingsoundcannolongerbeheard.









    ......




    9. CHECK CLEARANCEBETWEENBRAKESHOESAND DRUM

    (a) Removethebrakedrum.

    (b) Measurethe brake drum inside diameter and diame- terofthebrakeshoes.Checkthatthedifferencebe- tweenthediametersisthecorrectshoeclearance. Shoeclearance:0.6mm(0.024in.)

    Ifincorrect,checktheparkingbrakesystem.





    10. INSTALL BRAKE DRUM

    11. INSTALLREARWHEEL

    12. FILLBRAKERESERVOIRWITHBRAKEFLUIDAND BLEEDBRAKESYSTEM

    (SeepageBR–7)

    13. CHECKFORFLUIDLEAKAGE




    REARBRAKE DiscBrake

    COMPONENTS



































    •Non·'lIulobl. part






    ~


    I' vg(ROto<




    REPLACEMENTOFBRAKEPADS

    HINT:If a squealing noise occurs from the brakes while driving, check the pad wear indicator. If there are traces ofthe indicator contacting the rotor disc, the brake pad shouldbereplaced.

    ) ~ PadW..,

    ~lnd"'tO< I

    Disc





    1. REMOVEREARWHEEL

    Removethewheelandtemporarilyfastentherotordisc withthehubnuts.



    BRAKESYSTEM



    – RearBrake

    BR–35

    [​IMG]


    2. INSPECTPADLININGTHICKNESS

    Checkthepadthicknessthroughthecylinderinspection holeandreplacepadsifnotwithinspecification.

    Minimumthickness:1.0mmI0.039in.)










    3. REMOVECYLINDERFROMTORQUEPLATE

    (a) Removetheinstallationboltfromthetorqueplate.













    (b) Removethebrakecylinderandsuspenditsothe hoseisnotstretched.

    HINT:Donotdisconnectthebrakehose.











    4. REMOVEFOLLOWINGPARTS:

    (a) Twobrakepads

    (b) Fouranti–squealshims

    (c) Fourpadsupportplates

    5. CHECKROTORDISCTHICKNESS (Seestep2onpageBR–39)

    6. CHECKROTORDISCRUNOUT

    (Seestep3onpageBR–39)

    7. INSTALLPADSUPPORTPLATES

    Installthefourpadsupportplates.



    8. INSTALLNEWPADS

    (a) Installthetwoanti–squealshimstotheeachpad. HINT:Applydiscbrakegreasetothebothsideoftheinner

    anti–squealshim.





    [​IMG].


    (b) Installthetwopadssothewearindicatorplateisat thebottomside.

    NOTICE:Donotallowoilorgreasetogetontherub–

    bingface.






    .....





    9. INSTALLCYLINDER

    (a) Draw outa small amount of brake fluid from the res- ervoir.

    (b) Pressin piston with a hammer handle or an equiva- lent.

    HINT:Alwayschangethepadononewheelatatimeas thereisapossibilityoftheoppositepistonflyingout.

    (c) Insertthebrakecylindercarefullysothebootisnot

    wedged.


    (d) Install and.torque the installation bolt.

    Torque:200kg–cm(14ft–Ib,20N–m)











    10. INSTALLREARWHEEL

    11. FILLBRAKEFLUID



    BRAKESYSTEM



    – RearBrake

    BR–37

    [​IMG]


    REMOVALOFCYLINDER

    (SeepageBR–34)

    1. DISCONNECTBRAKEHOSE

    Removetheunionboltanddisconnectthebrakehose. Useacontainertocatchthebrakefluid.








    2. REMOVECYLINDERFROMTORQUEPLATE

    Removetheinstallationboltandcylinder.













    3. REMOVEPADS

    (Seestep4onpageBR–35)




    DISASSEMBLYOFCYLINDER

    (SeepageBR–34)

    1. REMOVESLIDINGBUSHINGANDDUSTBOOTS










    2. REMOVEMAINPINBOOT

    Pulloutthemainpinboot.













    3. REMOVECYLINDERBOOTSETRINGAND CYLINDERBOOT

    Usingascrewdriver,removethecylinderbootsetringand

    cylinderboot.





    ..,.,






    4. REMOVEPISTONFROMCYLINDER

    (a) Putapieceofclothoranequivalentasshown.

    (b) Usecompressedairtoremovethepistonfromthe cylinder.

    CAUTION:Donotplaceyourfingersinfrontofthepiston

    whenusingcompressedair.







    5. REMOVEPISTONSEALFROMBRAKECYLINDER

    Usingascrewdriver,removethepistonseal.










    .1022




    INSPECTIONANDREPAIROFREAR BRAKECOMPONENTS

    1. MEASUREPADLININGTHICKNESS Standardthickness:10.0mm(0.394in.) Minimumthickness:1.0mm(0.039in.)

    Replacethepadifthethicknessislessthantheminimum

    orifitshowssignofunevenwear.




    2. MEASUREROTORDISCTHICKNESS Standardthickness:10.0mm(0.394in.) Minimumthickness:9.0mm(0.354in.)

    Ifthediscisscoredorworn,orifthicknessislessthan

    minimum,repairorreplacethedisc.


















    ..'"

    3. MEASUREROTORDISCRUNOUT

    Measuretherotordiscrunoutat10mm(0.39in.)fromthe outeredgeoftherotordisc.

    Maximum.discrunout:0.15mm(0.0059in.)

    Iftherunoutisgreaterthanthemaximum,replacethe disc.

    HINT:Beforemeasuringtherunout,confirmthatthehub

    bearingplayiswithinspeification.




    4. IFNECESSARY,REPLACEROTORDISC

    (a) Removetheaxlecarriermountingboltandnutofup- perside.

    (b) Removethetorqueplate.

    (e) Removethehubnutsofthetemporarilyinstalleddisc andpullofftherotordisc.

    (d) Installanewrotordiscandlooselyinstallthehub

    nuts.




    (e) Installthetorqueplateandtightenthemountingbolt.

    Torque:475kg–cm(34ft–lb,47N–m)

    (f) Installtheaxlecarriermountingboltandnutofupper side.

    Torque:2,600kg–cm(188ft–lb,255N–m)














    .....

    ASSEMBLYOFCYLINDER

    (SeepageBR–34)

    1. APPLYLITHIUMSOAPBASEGLYCOLGREASETO FOLLOWINGPARTS:

    (a) Mainpinboot

    (b) Slidingbushinganddustboots

    (e) Piston,pistonsealandcylinderboot





    2. INSTALLPISTONSEALANDPISTONINCYLINDER














    3. INSTALLCYLINDERBOOTANDSETRINGIN CYLINDER












    4. INSTALLMAINPINBOOT

    Installthemainpinbootinplace.









    ...'"





    5. INSTALLSLIDINGBUSHINGANDDUSTBOOTS

    (a) Installtheslidingbushinganddustbootsintothe brakecylinder.

    (b) Insurethat the boots are secured firmly to the brake

    cylindergroove.






    .MlII .Mll"




    INSTALLATIONOFCYLINDER

    (SeepageBR–34)

    1. INSTALLPADS

    (Seesteps7and8onpagesBR–35and36)

    2. INSTALLCYLINDER

    (Seestep9onpageBR–36)




    """











    ......



    3. INSTALLFLEXIBLEHOSETOBRAKECYLINDER

    Settheflexiblehoseandnewgasketsinpositionand installtheunionboltandtorqueit.

    Torque:310kg–cm(22ft–ib,30N–m)










    4. FILLBRAKERESERVOIRWITHBRAKEFLUIDAND BLEEDBRAKESYSTEM

    (SeepageBR–7)

    5. CHECKFORLEAKS



    ParkingBrake

    (ForRearDiscBrake)

    COMPONENTS


    2WD(w/oA.B.S.)and4WD




    ShoeStrut















    Han.5hoe------1




    AdJu.$ler









    2WD(w/A.B.S.)



    Shoe StJ'ut


    Spring



















    FrontShoe


    [​IMG]


    Ikp-<:m1f141b,N·ml :SpecifiedIOfQue

    •Non-reusable part

    ShoeHold'-CtownCup


    ......


    ShoeHokt-down SP'W19

    RotOrDisc ... on




    DISASSEMBLYOFPARKINGBRAKE

    1. REMOVEREARDISCBRAKEASSEMBLY

    (a) Removetheaxlecarriermountingboltandnutofup- perside.

    (b) Removethetwomountingboltsandremovethedisc brakeassembly.

    (c) Suspendthediscbrakesothehoseisnotstretched.





    2. REMOVEROTORDISC

    HINT:Iftherotordisccannotberemovedeasily,returnthe shoeadjusteruntilthewheelturnsfreely.








    _,,..











    ..,"

    3. REMOVESHOERETURNSPRINGS

    [2WD(w/oA.B.S.)and4WD]

    UsingSST,removetheshoereturnsprings. SST09717–20010










    [2WD(w/A.B.S.)]

    Usingneedle–nosepliers,removetheshoereturnsprings.













    4. REMOVEFRONTSHOE,ADJUSTERANDTENSION SPRING

    (a) Slideout the front shoe and remove the shoe adjust-

    er.

    (b) Removetheshoestrutwithspring.

    (c) Disconnectthetensionspringandremovethefront shoe.

    [​IMG]


    5. REMOVEREARSHOE

    (a) Slideouttherearshoe.

    (b) Removethetensionspringfromtherearshoe.

    (c) Disconnecttheparkingbrakecablefromtheparking brakeshoelever.

    (d) Removetheshoehold–downspringcups,springs andpins.

    --

    INSPECTIONANDREPAIROF

    PARKINGBRAKECOMPONENTS

    1. INSPECTDISASSEMBLEDPARTS

    Inspectthe disassembled parts for wear, rust or damage.









    2. MEASUREBRAKESHOELININGTHICKNESS Standardthickness:2.0mm(0.079in.) Minimumthickness:1.0mm(0.039in.)

    Iftheshoeliningislessthanminimumorshowssignsof

    unevenwear,replacetheparkingbrakeshoes.








    3. MEASUREBRAKEDISCINSIDEDIAMETER Standard inside diameter: 170 mm (6.69 in.) Maximuminsidediameter:171mm(6.73in.)

    Ifthediscisscoredorworn,thebrakediscmaybelathed tothemaximuminsidediameter.


    \




    4. INSPECTPARKINGBRAKELININGANDDISCFOR PROPERCONTACT

    Ifthecontactbetweenthebrakelininganddiscisimprop-

    er,repairtheliningwithabrakeshoegrinder,orreplace thebrakeshoeassembly.








    5. MEASURECLEARANCEBETWEENPARKINGBRAKE SHOEANDLEVER

    Usingafeelergauge,measuretheclearance.

    Standardclearance:Lessthan0.35rnm(0.0138in.)

    Iftheclearanceisnotwithinspecification,replacethe shimwithoneofthecorrectsize.





    [​IMG]Clearance


    "'I» S1



    6. IFNECESSARY,REPLACESHIM

    (a) Removetheparkingbrakelever,andinstallthecor- rectsizeshim..












    (b) InstalltheparkingbrakeleverwithanewC–washer. (c) Remeasuretheclearance.



    ASSEMBLYOFPARKINGBRAKE

    (SeepageBR–42)

    HINT: Assemblethepartsinthecorrectdirectionas shown.


    2WD(w/oA.B.S.yand4WD






    't.on.t








    Left Wheel

    Right Wheel



    2WD(w/A.B.S.)






    Fr.o.nl










    Left Wheel

    Right Wheel

    [​IMG]



    1. APPLYHIGHTEMPERATUREGREASEONBACKING PLATEASSHOWN

    Applyhightemperaturegreasetotheslidingsurfacesof

    theshoe.



    BRAKESYSTEM



    – RearBrake

    BR–47

    [​IMG]


    2. APPLYHIGHTEMPERATUREGREASETOAD- JUSTERASSHOWN












    3. CONNECTPARKINGBRAKECABLETOPARKING BRAKELEVER

    (a) Installtheshoehold–downsprings,cupsandpins.

    (b) Connecttheparkingbrakecabletotheparkingbrake leveroftherearshoe.








    4. INSTALLREARSHOE

    Slideintherearshoebetweentheshoehold–downspring cupandthebackingplate.

    NOTICE:Donotallowoilorgreasetogetontherubbing

    face.








    5. INSTALLTENSIONSPRING,FRONTSHOEAND ADJUSTER

    (a) Installthetensionspringtotherearshoe.

    (b) Installthefrontshoetothetensionspring.

    (c) Installtheadjusterbetweenthefrontandrearshoes. (d) Installtheshoestrutwithspring.







    (e) Slideinthefrontshoebetweentheshoehold–down springcupandthebackingplate.



    6. INSTALLSHOERETURNSPRINGS

    [2WD(w/oA.B.S.)and4WD]

    UsingSST,installthefrontreturnspringandtheninstall therearreturnspring.

    (SeepageBR–46)

    SST09718–20010







    [2WD(w/oA.B.S.)]

    Usingneedle–nosepliers,installtheshoereturn springs.

    (SeepageBR–46)










    7. INSTALLROTORDISC

    (a) Beforeinstalling,polishthediscandshoesurfaces withsandpaper.

    (b) Aligntheholeontherearaxleshaftflangeandser-

    viceholeonthedisc.












    Contract

    ..'"





    8. ADJUSTPARKINGBRAKESHOECLEARANCE

    (a) Temporarilyinstallthehubnuts. (b) Removetheholeplug.

    (c) Turntheadjusterandexpand the shoes until the ro- tordisclocks.

    (d) Returntheadjustereightnotches. (e) Installtheholeplug.





    9. INSTALLREARDISCBRAKEASSEMBLY

    (a) Installthediscbrakeassemblyandtorquethetwo mountingbolts.

    Torque:475kg–cm(34ft–Ib,47N–rn)

    (b) Installtheaxlecarrierboltandnutofupperside.

    Torque:2,600kg–cm(188ft–Ib,255N–m)

    [​IMG]



    ,



    BRAKESYSTEM



    – RearBrake

    BR–49

    [​IMG]

    10. INSTALLREARWHEEL

    11. SETTLINGPARKINGBRAKESHOESANDDISC

    (a) Drivethevehicleatabout50km/h(31mph)onasafe, levelanddryroad.

    (b) Withthe parking brake release button pushed in, pull ontheleverwith9kg(19.8Ib,88N)offorce.

    (c) Drivethevehicleforabout400meters(0.25mile)in

    thiscondition.

    (d) Repeatthisproceduretwoorthreetimes.

    12. RECHECKANDADJUSTPARKINGBRAKELEVER TRAVEL



    LOADSENSING PROPORTIONING VALVE(LSPV)

    COMPONENTS





    LoadSensing "'.",,0<100109V.....

    Assembly


















































    SST

    CHECKANDADJUSTMENTOFFLUID PRESSURE

    1. SETREARAXLELOAD

    (a) Setthevehicleunladen.

    (b) Measuretherearaxleloadandnotethevalue. (e) Settherearaxleload.

    Rearaxleload:RW+100kg(220Ib) RW:Rearaxleunladenweight

    (Measurementtakeninstep(b))

    2. INSTALLLSPVGAUGE(SST)ANDBLEEDBRAKE SYSTEM

    SST09709–29017

    [​IMG]





    ..,..,





    100Ic.g/em2or80 kg!cm1

    3. RAISEFRONTBRAKEPRESSURETO100kg/cm2 (1,422psi,9,807kPa)OR80kg/eM2(1,138psi,7,845 kPa)ANDCHECKREARBRAKEPRESSURE

    Brakepressure: kg/cm2(psi,kPa)

    --w/-A.-B.S-.-

    Front brake

    pressure

    Rearbrake pressure





    w/oA.B.S.




    21¿¿– FE



    Others

    100 6li.9-,.,.

    (1.422.9.801) 1'931-1.122.1S.4S3-1.131)

    100 &3.1-15.7

    11.422.9.807) t9OI5-1.091,6.241- 7.$221

    eo 41.0-54.0 ".I38.7,845l CS83- 768.4.021- 5.2'96J



    HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Readthevalueofrearpressuretvvo’secondsafterad-

    justingthespecifiedfluidpressure.








    120kg/cm!Of100kg/em!

    4. RAISEFRONTBRAKEPRESSURETO120kg/cm2

    (1,705psi,11,768kPa)OR100kg/cm2(1,422psi,

    9,807kPa)ANDCHECKREARBRAKEPRESSURE Brakepressure:kg/cm2(psi,kPa)

    -w-/A-.6.-S. --




    120 13.3-8$.3

    I

    Frontbrake

    pressure

    Rear brake pressure




    w/oA.B.S.



    2VZ–FE


    Others

    (1.707.11.768) (l.0c3-1.227'.I.8$-a~

    120 71.1-84.1 (1,707.11.7613; f1.o1'-1.1N. 6.973- $.24'71

    100 48..4_61.4

    ,1,422,.9JI(7) t688 - 873.4.746- 6.02:11
















    [​IMG]












    ••s",

    5. IFNECESSARY,ADJUSTFLUIDPRESSURE

    (a) Adjustthefluidpressurebychangingthespring lenght.

    Lowpressure–ShortenA Highpressure–LengthenA

    Initialsetlength:2VZ–FE167.6mm(6.598in.) Others166.9mm(6.571in.)

    HINT:1mm(0.04in.)displacementofthespringlengt changesthefluidpressureabout1.0kg/cm2(14.2psi,98 kPa).



    (b) Tightenthenuts.

    [​IMG]Torque:260kg–cm(19ft–Ib,25N–m)










    .,'"


























    ..,~




    (c) Inthe event pressure cannot be adjusted by the spring length,raiseorlowerthevalvebody.

    Lowpressure–Lower

    Highpressure–Raise

    HINT:1mm(0.04in.)displacementofthevalvebody changesthefluidpressureabout7.2kg/cm2(102.4psi,

    706kPa).

    (d) Torquethenuts.

    Torque:130kg–cm(9ft–lb,13N–m)



    (e) Adjust thefluidpressurebychangingthespring lengthagain.

    Ifitcannotbeadjusted,replacethevalveassembly.

    [​IMG]


    REMOVALOFLSPV

    (SeepageBR–50)

    1. DISCONNECTBRAKETUBES

    UsingSST,disconnectthebraketubesfromthevalve body.

    SST09751–36011






    2. REMOVELSPVASSEMBLY

    (a) Removethe adjusting nut and disconnect the spring fromtherearsuspensionarm.











    (b) Removethethreemountingboltsandremovethe

    LSPVassembly.













    INSTALLATIONOFLSPV

    1. INSTALLLSPVASSEMBLY

    (a) Installthevalveassemblywiththethreemounting bolts.

    Torque:260kg–cm(19ft–Ib,25N–m)








    (b) Installthe adjusting bolt lock nut to the adjusting bolt andtheninstalltheadjusting bolt to the rear suspen-

    sionarmwiththeadjustingnut.






    .,~

    BR–54



    BRAKESYSTEM



    – LSPV

    [​IMG]

    (c) SetspringlengthAtoinitialsetlengthandtempo- rarilytightentheadjustingboltlocknut.

    Initialsetlength:2VZ–FE167.6mm(6.598in.)

    Others166.9mm(6.571in.)










    2. CONNECTBRAKETUBES

    UsingSST,connectthebraketubes. SST09751–36011

    Torque:155kg–cm(11ft–Ib,15N–m)

    3. FILLBRAKERESERVOIRWITHBRAKEFLUIDAND BLEEDBRAKESYSTEM

    (SeepageBR–7)

    4. CHECKFORFLUIDLEAKAGE




    5. CHECKANDADJUSTFLUIDPRESSURE (SeepageBR–50)

    6. REMOVESSTANDBLEEDBRAKESYSTEM

    SST09709–29017

    7. CHECKFORFLUIDLEAKAGE

    [​IMG]



    BRAKE HOSES AND TUBES DISCONNECTANDCONNECTHOSE ANDTUBE

    1. DISCONNECTNOSEANDTUBE

    (a) Disconnecttheclip.

    -


    (b) UsingawrenchtoholdthehoseandSST,toholdthe tube,disconnectthetubeandhose.

    SST09751–36011

    2. CONNECTHOSEANDTUBE

    (a) Connectthehoseandtubebyhand.

    (b) UsingawrenchtoholdthehoseandSSTtoholdthe tube,torquetheconnection.

    SST09751–36011

    Torque:155kg–cm(11ft–Ib,15N–m)

    _.


    (c) Installahoseclip.







    INSPECTIONOFBRAKEHOSESAND TUBES

    1. INSPECTBRAKEHOSES

    (a) Inspectthehosefordamage,cracksorswelling. (b) Inspectthethreadsfordamage.

    _.


    2. INSPECTBRAKETUBES

    (a) Inspectthe tube for damage, cracks, dents or corro- sion.

    (b) Inspectthethreadsfordamage.




    -



    ANTI–LOCK BRAKE SYSTEM (A.B.S.) Description

    • TheA.B.S.isabrakesystemwhichcontrolsthewheelcylinderhydraulicpressureofallfourwheelsduring suddenbraking and braking on slippery road surfaces, preventing the wheels from locking. This A.B.S. providesthefollowingbenefits:

    (1) Enablessteeringroundanobstaclewithagreaterdegreeofcertaintyevenwhenpanicbraking. (2) Enablesstoppinginapanicbrakewhilekeepingtheeffectuponstabilityandsteerabilitytoamini-

    mum,evenoncurves.

    • The function of the A.B.S. is to help maintain directional stability and vehicle steerability on most road conditions.However,thesystemcannotpreventthevehiclefrom skidding if the cornering speed limit is exceeded.

    • The A.B.S. has a longitudinal deceleration sensor to match braking characteristics to the full–time four–

    wheeldrive.(For4WD)

    • Incaseamalfunctionoccurs,adiagnosisfunctionandfail–safesystemhavebeenadoptedfortheA.B.S. toincreaseserviceability.



    2WD(SEDAN)









    Ignition


    Front




    scu





    Fuse

    Stop Fuse


    DOMEFuse



    Brake Light

    Brake Cylindet ,-_;.o.;_--l.@--, ~






    Speed Sensor fF~~~~~





    A.S.S.

    A.8.S.

    Computer



    [​IMG]Fl MAIN



    ToStop










    Front Brake Cylinder Rear

    BrakeCytinder



    RearSpeed Sensor

    [​IMG]



    2WD (WAGON)



    StopFuse





    R••rSpeedSensor

    R..,

    StakeOtIindet












    FlMAIN












    4WD







    GAUGe

    Fu..








    R.














    -



    FUNCTIONOFCOMPONENTS


    Component Function



    FrontSpeedSensor RearSpeedSensor DecelerationSensor(For4WD)


    ANTILOCKWarningLight



    Actuator




    Anti–lockBrakeSystemComputer

    Detectsthewheelspeedofeachoftheleftandrightfront wheels.

    Detectsthewheelspeedofeachoftheleftandrightrearwheels.


    Detectsthedecelerationspeedofthevehicleandsendsasignal’

    accordinglytotheA.6.S.computer.


    Lightsuptoalertthedriverwhentroublehasoccuredinthe

    Anti–lockBrakeSystem.


    Controlsthebrakefluidpressuretoeachdiscbrakecylinder throughsignalsfromthecomputer.

    Fromthewheelspeedsignalsfromeachsensor,itcalculates acceleration,decelerationandslipvaluesandsendssignalsto

    theactuatortocontrolbrakefluidpressure.

    [​IMG]



    LOCATIONOFSYSTEMPARTS


    WAGON











    A.B.S. Computet






    SensorRotOl'

    A.B.S."""'Ato,









    Sensor RotOl




    ReatSpeed5eflSOf



    SenSOfRotOl



    [​IMG]







    ANTILOCK Warning IJ9ttt

    --S.h...f.t.j..



    SYSTEMDIAGRAM(2WDOFSEDAN)






    r-------------,

    I c .r- I

    I ..l!:2nI-t- I

    I "'~j.!'"_!

    II I

    I I I I I

    !













    I

    0-:

















    .."."."!.".

    I


    0:

    1



    I


    .1lEJ I

    :It: I

    I I

    I !






    [​IMG]




    I


    I il

    ~-~------+

    ;;;

    _-g

    -"0:''>':


    .c_


    It .....






    -


    .."..

    [​IMG]


    SYSTEMDIAGRAM(2WDOFWAGON)




    r-----------,

    I

    I

    II I





















































    .....



    SYSTEMDIAGRAM(4WD)





    r-----------,

    I


    I 1


    I


    1 ~~ •

    I j~~ _~

    M 1 ..

    -.l~i

    .....:.. .~

    I II

    I I

    ~U


    '::05

    I ~ 1

    I j~ 1

    8..!~•~

    I •

    •~u

    L M., --.:::>- i0~-:¥>

    I .:

    .•.. I

    a: a-.:.

    51 I

    - "3 ••

    >


    a•:

    I :05

    c I ~~

    ·,t:j 1

    I(.F.~.0

    91 I

    r-f gl ~ :1t.::J I

    . ~ ~I I

    • ~IfI~ 1 •

    "!! •

    ! ~ I

    ! .•..


    ..

    'So ~

    !


    MCI) •

    8-GO.~

    I


    o•


    • I -:-. I ~.~

    i.=:J

    ......

    =:;g::

    1 :05

    I I

    I

    -


    .....~. 1

    I :1!l 1

    I I

    _-.e

    -

    - &~

    MCI)

    ~c~

    ~~

    l .; I

    ~ a:U

    f-

    I * I

    '::05

    [​IMG]'---------

    r-~~

    :,!

    ~.E"

    "10

    <0

    ~"

    _••c


    j~'•O~

    it·~S








    "-'....









    ~.l!~

    WIRINGDIAGRAM(2WD)




    ..


    .0 ",I'

    _..I.l.!.

    ~s ~

    .J:~~ ~...~").

    )l'

    _RJ


    "'...... :rl§


    0: e

    :..r..j§c ..~o§c

    ..."''''0:"''''

    c3i!1.l!~

    "

    ....

    ::E~

    8'"

    ~")<")Wlc-, "

    ~).L


    ~')(")..(ft • .:; s~~.

    s-





    ~


    G

    e

    5..,


    '0".0: ~o

    ...'.i.

    .&

    "le

    =<8

    -







    ~~.~.}{



    ;-.

    -to- •"

    ~ .tV • t ,


    M'" "

    'II """'-

    '" "'QO"


    J

    ~ ~ 5! ~

    .Csi..go: ~

    . :r

    ). .::

    "s_'

    z..

    's_"

    ~


    3'" q



    -


    C u 0: '"

    -



    -Q



    :!



    .u


    .l! ...J ; ~ 0:

    ~<

    ~:.".C.~.o


    "0

    '-_

    ,...---t~•

    "'c '" 11;

    ioili::

    g ~~

    > 0-,

    ,,,,

    s ~~ ~i-- ¥'

    .-':2

    • ...R...

    "',~~:'.¥o:lic '9r-.-J' 0

    ! : ~~

    ,"'''' L •C

    .~.. .•..

    w !2

    ::E '" G

    :>

    :> , --(. i'3

    Z


    < .'.. 0


    .u0:

    'i

    r- " ),

    .;

    ~~


    )

    ,:

    :~ ... I-

    .... !!

    [​IMG]

    C

    !?!


    ct~

    .............


    ;;

    ~


    '0'-"-1 '),

    z "

    ......<:.E



    WIRINGDIAGRAM(4WD)


























    -

























    ,.




    ~


    :,

    L..-<>_>---+---<>->--z--,r----,1>-11t------l41'


    ~~




    CONNECTORS(2WD)



    BrakeActuator

    CONNECTORA



    CONNECTORB



    CONNECTORC


    SR









    w




    CheckConnector


    FrontSpeedSensor(LH) FrontSpeedSensor(RH)



    FR






    W T





    RearSpeedSensor(LH

    )

    RearSpeedSensor(RH

    )








    ~

    RL+ RL- RRT RR-



    Anti–lockBrakeSystemComputer



    I I I


    IG GND RL- STP SFR SFL BAT T RIR- PfB W I

    ."V!

    rdo 19 1~17

    1 15 ;~ 5

    311

    [​IMG]

    30 28 2726 252" 2322 21 12 10 9 8 6




    SRL GNO

    FL-

    FR- R-

    SR

    Fl+

    FR+

    RL+

    RR.

    AST

    MR

    MT

    SRR



    CONNETORS(4WD)


    BrakeActuator

    CONNECTORA



    CONNECTORB CONNECTORC

    ..~SRT


    123





    GNO

    R-




    CheckConnector

    FrontSpeedSensor(LN) FrontSpeedSensor(RH)



    FL.






    w T




    RearSpeedSensor(LH)

    RearSpeedSensor(RH)

    DecelerationSensor



    GS+







    RL+

    Rl-

    RR+

    RR-


    GS-





    Anti–lockBrakeSystemComputer

    Ts Connector



    IG

    GNO

    Rl-

    PKB


    STP


    SFR

    SFl


    BAT

    T RR-



    W




    20191817

    -1615 14

    5 3 2 1

    o

    30 282262524 32221 1211109 8 6




    SRl

    GNO

    Fl-


    FR- R-



    T$


    SR



    FL.


    FR+

    Rt.

    RR+

    AST


    MR


    MT

    SRR









    ~ (ct"")O:.o

    Ol! 10.

    -=

    DiagnosisSystem

    DESCRIPTION

    Ifamalfunctionoccurs,thesystemwillidentifytheprob- lemandthecomputerwillstorethecodesforthetrouble

    items.


    1'-

    <111111111...-

    JANTHDCKI~

    "/1111111\')



    ...'"

    At the same time, the system informs the driver of a mal- functionviathe”ANTILOCK”warninglightinthecombina- tionmeter.

    Byturningontheignitionswitchanddisconnectingthe

    checkconnector,thetroublecanbeidentifiedbythe numberofblinks(diagnosticcode)ofthewarninglight.

    1.IghOtO.2N&1illiruw


    OFF

    Normal Code



    TroubleCod.

    Intheeventoftwocodes,thathavingthesmallestnum- ber(code)willbeidentifiedfirst.

    HINT:Thewarninglightdoesnotshowthediagnostic

    0.55j,,6S (InCaseCode23)

    0.5. 1.5s 4.0&

    llghtON

    codeswhilethevehicleisrunning.


    OfF

    2~1QI

    ..,'"






    INITIALCHECK

    CHECK ACTUATOROPERATIONNOISE

    (a) Starttheengineanddriveataspeedover6km/h

    (4mph).

    (b) Checkthattheactuatoroperationnoiseisheard. HINT:Ainitialcheckiscarriedoutonceeachtimeafterthe enginehasbeenstartedandinitialspeedexceeds6 km/h(4mph).Therespectivefunctions,inorder,ofthe3 position solenoidandpumpmotorintheactuatorare checked.However,ifthebrakepedalisdepressed,theini- tialcheckisnotcarriedout,butisstartedafterthepedal hasbeenreleased.











    INSPECTIONOFDIAGNOSISSYSTEM

    1. INSPECTBATTERYVOLTAGE

    Inspectthatthebatteryvoltageisabout12V.

    2. CHECKTHAT WARNINGLIGHTTURNSON

    (a) Turntheignitionswitchon.

    (b) Checkthat the ”ANTILOCK” warning light turns on for

    3seconds.

    Ifnot, inspect and repair or replace the fuse, bulb and wire harness.



    3. READDIAGNOSTICCODE

    (a) Turntheignitionswitchon.

    (b) Disconnectthecheckconnectorfromtheactuator.














    ,........,

    151Digit 2ndOight

    ~













    0.25seconds



    ON



    OFF



    0.25 second.














    1.11











































    till·••

    (c) Ineventofamalfunction,4secondslaterthewarning lightwillbegintoblink.Readthenumberofblinks. (SeeDIAGNOSTICCODEonpageBR–69)

    HINT:Thefirstnumberofblinkswillequalthefirstdigit ofatwodigitdiagnosticcode.Aftera1.5second pause,the

    2ndnumberofblinkswillequalthe2ndnumberofatwo

    digitcode.Iftherearetwoormorecodes,therewillbe a2.5secondpausebetweeneach,andindicationwill beginafter4.0secondpausefromthesmallervalue andcontinueinordertolarger.

    (d) Ifthe system is operating normally (no malfunction),

    thewarninglightwillblink2timespersecond.











    (e) Repairthesystem.

    (f) Afterthemalfunctioningcomponentshasbeenre- paired,clearthediagnosticcodesstoredinthecom- puter.

    (SeepageBR–70)

    HINT:Ifyoudisconnectthebatterycablewhilerepair- ing,alldiagnosticcodesinthecomputerwillerased.





    (g) Connectthecheckconnector.

    (h) Turntheignitionswitchon,andcheckthatthe

    ”ANTILOCK”warninglightgoesoffafterthewarning lightgoesonfor3seconds.

    Code No.

    Light Pattern

    Diagnosi s


    Trouble Part

    [​IMG][​IMG][​IMG][​IMG]11 ON JLJl..

    Off

    12 .fL.JUl.

    13 ILJlJLfL

    14 .fLJlfUl.Jl_


    21 Jl.JLfl._


    22 ILfl fUL


    23 fLfLJU11L

    24 JlJL11JUUl

    31 JlJ1JLfl.

    32 nnn.nn,


    33 IUlJLfUUl._

    34 Jl..fUL.JlJlJ1f

    36 ..flJlJLJlfUl.J

    3. ~


    31 ~


    41 .fUUlJLJl...


    42 .JlJlI1.fLJ1.J1


    43 JlJLf1JLflf1.fL

    4C .JUlJ1J1......J


    &1 Jl.11..flIULJL





    !Alway.on J



    Opencircuitinsolenoidrelaycircuit


    Short circuit in solenoid relay circuit Open circuit in pump motor relay circuit Short circuit in pump motor relay circuit

    Open or short circuit in3 position solenoid of front right wheel


    Open or short circuit in3 position solenoid of front left wheel Open or short circuit in3 position solenoid of rear right wheel Open or short circuit in3 position solenoid of rear left wheel Front right wheel speed sensor signal malfunction

    Frontleftwheelspeedsensorsignalmalfunction Rear right wheel speed sensor signal malfunction Rear left wheel speed sensor signal malfunction

    Open circuit in front left or rear right wheel speed sensor


    Open circuit in front right or rear left wheel speed sensor

    Wrong both rear axle hubs


    Low battery voltage (9.5V or lower)


    Abnormally high battery voltage0 6.2V or higher) Malfunction in deceleration sensor

    Openorshortcircuitindecelerationsensor



    Pump motor of actuator locked or open circuit in pump motor circuit in actuator



    Malfunctionincomputer

    Actuatorinsidewireharness

    Solenoid relay

    Wire harness and connector of solenoid relay circuit

    Actuatorinsidewireharness

    Pump motor relay

    Wire harness and connector of pump motor relay circuit


    Actuator solenoid

    Wire harness and connector of actuatorsolenoidcircuit








    Speedsensor

    Sensor rotor

    Wire harness and connector of speedsensor





    Rearsensorrotors



    Battery

    Voltageregulator


    Decelerationsensor Deceleration sensor installation Wire harness and connector of deceleration sensor

    Pump motor, relay and battery

    Wire harness, connector and ground bolt or actuator pump motor circuit


    Computer



    CLEARINGOFDIAGNOSTICCODES

    CLEARDIAGNOSTICCODES

    (a) Turntheignitionswitchon.

    (b) Disconnectthecheckconnectorfromactuator. HINT:Keepthevehiclestopped[vehiclespeed0km/h (0mph)].






    (c) Clearthediagnosticcodesstoredincomputerbyde- pressingthebrakepedal8ormoretimeswithin3

    seconds.













    0,26seconds



    ON



    OfF



    0.25seconds

    ..,






    (d) Checkthatthewarninglightshowsthenormalcode.



    (e) Connectthecheckconnector.









    ..,..












    ......






    (f) Checkthatthewarninglightgoesoff.




    Troubleshooting



    Problem

    No.


    Alwayscomesonafterignitionswitchisturnedon. 1



    ”ANTILOCK”warninglight













    Brakeworking

    Doesnotcomeonfor3secondsafterignitionswitchon. 2


    Comesonandoff. 3


    Comesonwhilerunning. 1


    Brakespull. 4


    Brakinginefficient. 4


    A.6.S.operatesatordinarybraking. 4


    A.6.S.operatesjustbeforestoppingatordinarybraking. 4


    BrakepedalpulsatesabnormallywhileA.B.S.isoperating. 4



    SkiddingnoiseoccurswhileA.B.S.working. 5

    (A.B.S. works inefficiently)









    ”ANTIL4CK”warninglightcomeson.




    Disconnectcheckconnector. (SeepageBR–68)






    Doeswarninglightalwayscomeonorshow NO

    thenormalcode?

    (ignitionswitchon)


    Seediagnosticcode. (SeepageBR–69)



    YES


    Continuedonpage

    BR–72.



    Continuedfrompage

    BR–71.




    Isconnectorofcomputerproperlyconnected? NO

    Andareallterminalsintheconnector?


    Faultyconnector.



    YES



    Isthere10–16VbetweenterminalIGon computerwireharnesssideconnectorand

    bodyground?(ignitionswitchon)


    NO Faultypowercircuit.



    YES



    Doeswarninglightgooffwhenboththecom- puterconnectorandcheckconnectorare

    ..disconnected?(Ignitionswitchon)


    YES

    (Goesoff¿

    NO

    (Comeon)

    Shortcircuitinwireharnessbetween computerterminalWandactuatorter- minalW.



    Faultycomputer.





    ”ANTILOCK”warninglightdoesnotcomeonfor3secondsafterignitionswitchon.




    Disconnect check connector from actuator, and ground the terminal W of the wire har- nesssideconnector.

    (Ignitionswitchon)





    Doeswarninglightcomeon?



    YES

    NO Bulbburnedoutoropencircuitinwire harnessbetweenwarninglightandac-

    tuatorterminalW.



    Disconnectconnectorsfromcomputerandac- tuator,andgroundterminalWofcomputerwire harnesssideconnector.

    (Ignitionswitchon)





    Doeswarninglightcomeon?


    I ON

    Opencircuitinwireharnessbetween computerterminalWandwarninglight.


    YES



    Withignitionswitchoff,disconnectactuator connectors,andcheckcontinuitybetweenter-

    minalWandASTonactuatorside.






    Reversetesterleadsandcheckagain.

    Isthereonewaycontinuitybetweenterminals?



    YES Faultycomputer.

    NO Shortcircuitinactuatorinsidediode.



    HINT:Ifthediodeisshort–circuited,amal- functionatcomputerterminalWwilloccur. Wheninspectingtheterminal,connectthe computerconnector,anddisconnectactua- torconnectors.Thenturntheignitionswitch on,andcheckthatthewarningfightgoes on.Ifitdoes,thecomputerterminalisOK.





    ”ANTILOCK”warninglightcomesonandoff.



    • Checkconnectorisdisconnected.

    • OpencircuitinwireharnessbetweencomputerterminalTandactuatorterminalT.

    • ActuatorterminalGNDisimproperlyconnectedoropencircuitinwireharnessbetweenactuator terminalGNDandbodyground.

    • ConnectcircuitinwireharnessbetweencomputerterminalTsandTsconnector.(For4WD)





    • Brakespull.

    • Brakinginefficient.

    4 • A.B.S.operatesatordinarybraking.

    • A.B.S.operatesjustbeforestoppingatordinarybraking.

    • BrakepedalpulsatesabnormallywhileA.B.S.working.





    Disconnectcheckconnector. (SeepageBR–68)






    Doeswarninglightshowthediagnostic normalcode?(Ignitionswitchon)

    NO Seediagnosticcode. (SeepageBR–69)



    YES



    Areeachspeedsensorsinstalledinplace? Andareeachinstallationboltstightenedse-

    curely?


    NO Speedsensorinstallationfaulty.



    YES



    Disconnectconnectorfromcomputer, inspect continuity between each speed sensor termi- nalsonwireharnessside.

    (SeepageBR–103)




    ContinuedonpageBR–75



    ContinuedonpageBR–74





    DoesanyabnormalchangeoccurincontinuityYES

    whentheconnectorsorwireharnessofthe

    (Abnormal

    Faultywireharness.

    speedsensorandintermediateconnectorsarechange) I

    twistedorbent?


    NO

    (Nochange)


    Isthereforeignmaterialorferricchipsonthe sensortip?





    YES





    Cleanchipsfromthespeedsensor.

    ,


    NO



    Tryspeedsensordiagnosissystem. IssensorsignallevelOK?

    (SeepageBR–70)


    NO Inspectspeedsensor,andreplaceif necessary.



    YES



    Tryspeedsensordiagnosissystem. IssensorsignalchangeOK?

    (SeepageBR–70)


    NO Inspectsensorrotor,andreplaceif necessary.



    YES


    (For4WD)

    Trydecelerationsensoroperationdiagno- sissystem.

    IssensoroperationOK?

    (SeepageBR–82)



    NO Faultydecelerationsensoror sensorinstallationfaulty.


    YES



    Inspecttheactuatoroperation. (SeepageBR–84)







    IsactuatoroperationOK?

    I NO


    Faultyactuator.



    YES



    Faultycomputer.





    Anti–lockbrakesystemworksinefficiently.




    Disconnectcheckconnector. (SeepageBR–68)






    Doeswarninglightshowthediagnostic normalcode?(ignitionswitchon)

    NO Seediagnosticcode.

    (SeepageBR–69)



    YES



    Istherebatteryvoltagebetweencomput- erterminalSTPandbodygroundwhen

    depressingbrakepedal?


    NO Opencircuitinstoplightswitchand/or wireharness.



    YES



    Inspectactuator. (SeepageBR–84)




























    ..,...












    ......

    SpeedSensorDiagnosisSystem

    PRECAUTION

    Whilecheckingthespeedsensordiagnosissystem, A.B.S.doesnotworkandbrakesystemworksasnormal brakesystem.

    INSPECTIONOFDIAGNOSISSYSTEM

    1. INSPECTBATTERYVOLTAGE

    Inspectthatthebatteryvoltageisabout12V.

    2. CHECKTHAT WARNINGLIGHTTURNSON

    (a) Turntheignitionswitchon.

    (b) Checkthatthe”ANTILOCK”warninglightturnsonfor

    3seconds.

    Ifnot,inspectandrepairorreplacethefuse,bulbandwire harness.

    (c) Checkthatthe”ANTILOCK”warninglightturnsoff. (d) Turntheignitionswitchoff.





    3. PERFORMFOLLOWINGSTEPS (2WD)

    (a) Disconnectthecheckconnectorfromtheactuator.

    (b) Pullthe parking brake lever up, and start the engine.










    (c) Depressthebrakepedal4to6timeswithin2 seconds.









    [​IMG]







    0,12 seconds

    - I--

    ON nnrn r r-




    OFF -f-

    0.12seconds

    .,,""













    81111166






    (d) Checkthatthewarninglightblinksabout4timesev- ery1secondasshown.



    (4WD)

    (a) RemovetherubbercapfromtheTsconnectorlo- catedinfrontoftheactuator.

    (b) ConnecttheterminalsofTsconnector.










    (c) Pullthe parking brake lever up, and start the engine.

    NOTICE:Donotdepressthebrakepedal.














    o.,2$4)cond$

    (d) Checkthatthewarninglightblinksabout4timesev- ery1secondasshown.


    ON




    OFF


    -j

    0.12seconds





    - 3.7mph)

    §@(r~


    Light Checkcompleted

    ON

    4. INSPECTSENSORSIGNALLEVEL

    Drivethevehiclestraightaheadatabout4–6km/h(2.5

    –3.7mph),andcheckthatthewarninglightturnsonafter a1secondpause.

    Ifthe warning light turns on without blinking when the ve- hiclespeedisnotwithinthespecifiedspeedrangeabove, stopthevehicleandreadthediagnosticcode,and repair themalfunctioningparts.

    (SeestepSonpageBR–79)

    HINT:Ifthewarninglightturnsonwhilethevehiclespeed iswithinspecifiedspeedrangeabove,thecheckiscom- pleted.Andwhenthevehiclespeedexceeds6km/h (3.7mph),thewarninglightwillblinkagain.Inthiscondi- tion,speedsensorsareOK.

    NOTICE:While the warning light is off, do not give any shocksto vehicle such as acceleration, deceleration, brak- ing,shift change, steering or shocks from the roadcondi- tion.





    55kmlh

    - 34.2mP'>:l/o) ..........

    ~[~

    5. INSPECTSENSORSIGNALCHANGE

    [​IMG]Drivethevehiclestraightaheadatabout45–55krn/h (28.0– 34.2 mph), and check that the warning light turns onaftera1secondpause.

    Ifthewarninglightturnsonwithoutblinkingwhentheve- hiclespeedisnotwithinthespecifiedspeedrangeabove, stopthevehicleandreadthediagnosticcode,andrepair themalfunctioning.parts.

    (Seestep6onthispage)

    HINT:Ifthewarninglightturnsonwhilethevehiclespeed is within specified speed range above, the check is com- pleted.Andwhenthevehiclespeedisnotwithinspecified speedrange,thewarninglightwillblinkagain.Inthiscon- dition,sensorrotorsareOK.

    NOTICE:While the warning light is off, do not give any shocks tovehiclesuchasacceleration,deceleration,brak- ing,shiftchange,steeringorshocksfromtheroadcondi-

    tion.




    6. READDIAGNOSTICCODE

    Stopthevehicleanddisconnectthecheckconnector,and warninglight will begin to blink. Read the number of blinks.

    (SeeDIAGNOSTICCODEonpageBR–81)










    ON Nannal <:<>do

    Ugh!

    OfF"n·nn·.n.n·n·nonnin"n2nn"n;n~nni(r2.•

    g~JUUUUlIlf~ 72)


    Ugh! TroubleCode


    .

    III 7 -1-121 I

    0.5s 0.5. 1,5s 2.5or4.0,......

    HINT:Thefirstnumberofblinkswillequalthefirstdigit

    ofatwodigitdiagnosticcode.Aftera1.5secondpause, the2ndnumberofblinkswillequalthe2ndnumberofa twodigitcode.Iftherearetwoormorecodes,therewill bea2.5secondpausebetweeneachcode,andthen indicationwillbeginagainaftera4.0secondpause, continuinginorderfromthesmallervalueuptothelarg- erone.




    7. REPAIRMALFUNCTIONINGPARTS

    Repairorreplacethemalfunctioningparts.

    HINT:Whenrepairingorreplacingparts,turntheignition switchOFF.

    BR–80



    BRAKESYSTEM



    – Anti–lockBrakeSystem(A.B.S.)

    [​IMG]


    8. PERFORMFOLLOWINGSTEPS

    (a) (2WD)

    Turntheignitionswitchon. (4WD)

    Turntheignitionswitchoff.

    (b) Connectthecheckconnector.







    (For4WD)

    (c) RemovetheshortpinorwirefromtheTsconnector andinstalltherubbercaptoit.

    (d) Turntheignitionswitchoff.

    DIAGNOSTICCODE



    CodeNo.

    LightPattern Diagnosis

    MalfunctioningPart





    ON annnnnnnnnnnnnn

    OfF JUUUUUUUUUUUUUUl

    Allspeedsensorsandsensorrotorsarenormal





    71 Jl.fUUUUULlL



    72




    73




    74




    75




    76


    Lowvoltageoffrontrightspeedsensorsignal




    Lowvoltageoffrontleftspeedsensorsignal




    Lowvoltageofrearrightspeedsensorsignal




    Lowvoltageofrearleftspeedsensorsignal





    Abnormal change of front right speed sensor signal




    Abnormal change of front left speed sensor signal

    • Front right speed sensor

    • Sensorinstallation



    • Front left speed sensor

    • Sensorinstallation



    • Rearrightspeedsensor

    • Sensorinstallation



    • Rearleftspeedsensor

    • Sensorinstallation


    • Frontrightsensor rotor



    • Frontleft sensor rotor




    Abnormal change of rear right speed sensor signal

    • Rear rightsensor rotor




    [​IMG][​IMG][​IMG]Abnormal change of rear left speed sensor signal

    • Rearleftsensor rotor






















    t§'~t>.~

    I"if .~~

    AJIll


    1'- <::\1\1111L1C1l1(I/(.I)::

    \;!itl"11I"'); _,_




















    Wam.,g

    Ught Engine Start

    DecelerationSensorOperation DiagnosisSystem(For4WD) PRECAUTION

    Whilecheckingthedecelerationsensordiagnosis system,A.B.S.doesnotworkandbrakesystemworksas normalbrakesystem.

    INSPECTIONOFDIAGNOSISSYSTEM

    1. INSPECTBATTERYVOLTAGE

    Inspectthatthebatteryvoltageisabout12V.

    2. CHECKTHAT WARNINGLIGHTTURNSON

    (a) Turntheignitionswitchon.

    (b) Checkthatthe”ANTILOCK”warninglightturnsonfor

    3seconds.

    Ifnot,inspectandrepairorreplacethefuse,bulbandwire harness.

    (e) Checkthatthe”ANTILOCK”warninglightturnsoff.

    (d) Turntheignitionswitchoff.

    3. PERFORMFOLLOWINGSTEPS

    (a) RemovetherubbercapfromtheTsconnectorlo- catedinfrontoftheactuator.

    (b) ConnecttheterminalsofTsconnector.

    (c) Pull theparkingbrakeleverupanddepressthebrake pedal,andstarttheengine.









    (d) Checkthatthewarninglightblinksabout1timeevery

    1secondasshown.

    If thewarninglightdoesnotblink,inspecttheparkingbrake switch,stoplightswitch,Ts connector, deceleration sensor

    [​IMG]ON OFF-

    nAn n

    1-11-

    3. 0.8850.125


    .,













    ,,

    installationandcomputer.








    4. INSPECTSENSORDETECTIONPOINT

    (a) Jackuptherearsideofthevehicle slowly as shown. HINT: When measuring the height, measure at the center oftherearbumperloweredge.

    (b) Checkthatthewarninglightdoesnotturnon.

    (c) Jackdownthevehicleandcheckthatthewarning lightblinking.




    w/o Spoiler6S == 3em(28.8:t '.2 in.)

    wI Spoiler6S:t 3em425.8:t 1.2inJ

    (d) Jackupthefrontsideofthevehicleslowlyasshown. HINT:When measuring the height, measure at the center ofthelowerbodyorspoileredgeofthevehicle.

    (e) Checkthatthewarninglightdoesnotturnon.

    (f) Jackdownthevehicleandcheckthatthewarning lightblinking.

    Ifthewarninglightturnson,inspectthedecelerationse

    sorinstallation.Andifthesensorinstallationis–OK,r placethedecelerationsensor.







    Wlming

    Ugh!

    ON





    0.12.

    5. INSPECTSENSOROPERATION

    (a) Drivethevehiclestraightaheadatabout10km/hl6.2 mph)ormore,lightlydepressthebrakepedal.

    (b) Checkthatthereisnochangeinthewarninglight

    lightpattern.

    OF_F-!l..-!I_Jl..-lI _










    W.ming Braking

    Ugh!

    ~~Fn n fl i=::jl fl fl











    Warning

    light

    ON




    _,













    _,~













    ,,..







    (c) Drivethevehiclestraightaheadatabout20km/h (12.4mph)ormore,depressthebrakepedala little strong.

    (d) Checkthatthewarninglightturnsonwhilebraking.











    (e) Drivethevehiclestraightaheadatabout20km/h (12.4mph)ormore,depressthebrakepedalstrong– ly.

    (f) Checkthat the warning light light pattern changes af- terbrakingasshown.

    If theoperationisnotasspecified,inspectthedeceleration sensorinstallation.AndifthesensorinstallationisOK,r placethedecelerationsensor.


    6. REMOVESHORTPIN

    (a) Stoptheengine.

    (b) RemovetheshortpinorwirefromtheTsconnector. (c) InstalltherubbercaptotheTsconnector.



    A.B.S.Actuator

    COMPONENTS










    'J..WavUnion


    MotorRttay

    11Ofl2.11l


    116111,15)



    HOld"'~~



    Cushion ~


    BrakeTube




    () ......

    "





    .............

    _-----

    155111.15) "
















    630(3'.52.1




    AcluatorSr.dtet





    WAGON


    [​IMG]: SpecifiedtOfqU.



    INSPECTIONOFA.B.S.ACTUATOR OPERATION

    1. INSPECTBATTERYVOLTAGE

    Batteryvoltage:10–14.5V



    2. DISCONNECTCONNECTORSFROMACTUATOR

    Disconnectthethreeconnectorsfromtheactuatoras shown.





















    ...-_..

    To8Ody-e: :

    '----

    Sub-wire Harness(SST) ••311




    ""1'11T1OY,_O~TA

    ~


    ....:TUIItOll Ct«;I«JIr-=::71

    --_- --.


    r!~]=-@

    0-60

    .... --

    ..




    --"-"S-"E'.-i]

    3. CONNECTACTUATORCHECKER(SST)TO ACTUATOR

    (a) Connecttheactuatorchecker(SST)totheactuator

    andbodysidewireharnessthroughthesub–wire harness(SST)asshown.

    SST09990–00150

    (b) Connecttheredcableofthecheckertothebattery positivei±yterminalandblacktothenegative(–¿ter- minal.Connect the black cable of the sub–wire har- nessto the battery negative (–) terminal or body ground.

    (c) Placethe”SHEETA”(SST)ontheactuatorchecker.

    SST09990–00163

    4. INSPECTBRAKEACTUATOROPERATION

    (a) Starttheengine,andrunitatidle.

    (b) Turntheselectorswitchoftheactuatorcheckerto

    ”FRONTRH”position.

    (c) PushandholdintheMOTORswitchforafewsec- onds.

    (d) Depressthebrakepedalandholdituntilthestep1gf

    iscompleted.

    (e) PushthePOWERSWITCH,andcheckthatthe brakepedaldoesnotgodown.

    NOTICE:DonotkeepthePOWERSWITCHpushingmore than10seconds.

    (f) Releasetheswitch,andcheckthatthepedalgoes

    down.









    ....".."_"'--

    (g) PushandholdintheMOTORswitchforafewsec- onds,andcheckthatthepedalreturns.

    (h) Releasethebrakepedal.

    "--fi!E])

    :.1:.0

    ~-~-~--O-

    -







    -!O-~_

    --!iElij

    o








    ···-1T'.O...'IO_T-A....

    0 -@








    -."

    _A~

    (i) PushandholdintheMOTORswitchforafewsec- onds.

    (j) Depressthebrakepedalandholditforabout15

    seconds.Asyouholdthepedaldown,pushthe MOTORswitchforafewseconds.Checkthatthe brakepedaldoesnotpulsate.







    5. INSPECTFOROTHERWHEELS

    (a) Turntheselectorswitchto”FRONTLH”position.

    (b) Repeating(c)to(j)ofthestep4,checktheactuator operationsimilarly.

    (c) Similarly,inspect”REARRH”and”REARLH”posi-

    tion.

    -•-----



    REAR LHswitchinsteadofthePOWERSWITCH,andyou

    _. -~0

    HINT:Wheninspecting”REARLH”position,pushthe



    caninspectinanytheselectorswitchposition.





    ••'Il'T..oYOTA......




    ac"NftIIoc:aa~

    -0_.-~0


    --@ ~

    ----












    ..",ll

    6. PUSHMOTORSWITCH

    PushandholdintheMOTORswitchforafewseconds.

    [​IMG]

    7. DISCONNECTACTUATORCHECKER(SST)FROM ACTUATOR

    (a) Removethe”SHEETA”(SST)anddisconnecttheac-

    tuatorchecker(SST)andsub–wireharness(SST)

    fromtheactuator.

    SST 09990–00150 and 09990–00163 (b) Connect the actuator connectors. (e) Clearthediagnosticcodes.

    (SeepageBR–70)



    BRAKESYSTEM



    – Anti–lockBrakeSystem(A.B.S.)

    BR–87

    [​IMG]


    REMOVALOFBRAKEACTUATOR

    1. TAKEOUTFLUIDWITHSYRINGEORAN EQUIVALENT

    CAUTION:Donotletbrakefluidremainonapainted

    surface.Washitoffimmediately.








    2. DISCONNECTACTUATORCONNECTORS

    Disconnectthethreeconnectorsfromtheactuator.













    3. REMOVEACTUATOR

    (a) UsingSST,disconnectthesixbraketubesfromthe actuatorasshown.

    SST09751–36011










    (b) Removethe three nuts, wave washers and washers. (c) Removetheactuatorfromtheactuatorbracket.












    4. REMOVETHREEHOLDERSANDCUSHIONS

    Removethethreeholdersandcushions.

    BR–88



    BRAKESYSTEM



    – Anti–lockBrakeSystem(A.B.S.)

    [​IMG]


    6. REMOVECONTROLRELAYS

    (a) Removetheconnectorfromthewireharnessclarnp. (b) Removethescrewandremovethewireharness

    clamp.










    (e) Removetherelaycase.














    (d) Removetherelaycapfromthecontrolrelays.

    (e) Removethetwocontrolrelaysfromtheactuator.













    6. REMOVEBRAKETUBES (w/oLSPV)

    UsingSST,removethefivebraketubesfromtheactuator.

    SST09751–36011

    (w/LSPV)

    UsingSST,removethefourbraketubesfromactuator. SST09751–36011





    7. REMOVEPROPORTIONINGVALVEORTHREE–WAY UNION

    (w/oLSPV)

    (a) Removethetwoboltandremovetheproportioning valvefromtheactuator.

    (b) Removetheboltandremovethevalvebracket.



    BRAKESYSTEM



    – Anti–lockBrakeSystem(A.B.S.)

    BR–89

    [​IMG]

    (w/LSPV)

    Removethetwoboltsandremovethethree–wayunion fromtheactuator.











    8. REMOVETHREE–WAYUNION

    Removetheboltandthree–wayunion.













    INSTALLATIONOFBRAKEACTUATOR

    1. TEMPORARILYINSTALLFOLLOWINGPARTS

    (a) Temporarilyinstallthethree–wayunionwithabolt.










    (w/oLSPV)

    (b) Usingaproportioningvalveinstallationbolt,install thevalvebracketinplaceandtightenthebolt.

    Torque:90kg–cm(78in.–Ib,8.8N–m)

    (c) Removetheproportioningvalveinstallationbolt. (d) Temporarilyinstalltheproportioningvalve.







    (w/LSPV)

    Temporarilyinstallthethree–wayunion.

    BR–90



    BRAKESYSTEM



    – Anti–lockBrakeSystem(A.B.S.)




    w/o LSPV














    wiLSPV

    (e) Temporarilyinstallthefiveorfourbraketubesas shown.

    [​IMG]












    2. TIGHTENFOLLOWINGPARTS

    (a) Tightenthethree–wayunioninstallationbolt.

    Torque:160kg–cm(12ft–lb,16N–m)











    (b) (w/oLSPV)

    Tightenthetwoproportioningvalveinstallationbolts.

    Torque:90kg–cm(78in.–Ib,8.8N–m) (w/LSPV)

    Tightenthetwothree–wayunioninstallationbolts.

    Torque:90kg–cm(78in.–Ib,8.8N–m)







    (c) UsingSST,tightenthefiveorfourbraketubes. SST09751–36011

    Torque:155kg–cm(11ft–Ib,15N–m)



    BRAKESYSTEM



    – Anti–lockBrakeSystem(A.B.S.)

    BR–91

    [​IMG]

    3. INSTALLCONTROLRELAYS

    (a) Installthetwocontrolrelaysinposition.

    (b) Installtherelaycapontothecontrolrelays.











    (c) Installtherelaycase.














    (d) Installthewireharnessclampwithascrew.














    4. INSTALLTHREECUSHIONSANDHOLDERS

    Installthethreecushionstoholdersandinstallthemtothe actuator.











    5. INSTALLCONNECTORTOCLAMP

    Installtheconnectortothewireharnessclamp.

    BR–92



    BRAKESYSTEM



    – Anti–lockBrakeSystem(A.B.S.)

    [​IMG]

    6. INSTALL ACTUATOR

    (a) Installtheactuatortotheactuatorbracketinplace. (b) Installthewashers,wavewashersandnuts.

    (e) Tightenthethreenuts.

    Torque:55kg–cm(48in.–Ib,5.4N¿rn)

    HINT:Beforeinstallingthefrontrightsidenut,installthemotor ground terminal between the plate washer and spring washer.





    (d) UsingSST,connectthesixbraketubestotheactua- tor.

    SST09751–36011

    Torque:155kg–cm(11ft–Ib,15N–m)










    7. CONNECTACTUATORCONNECTORS

    (a) Connectthethreeconnectorstotheactuator. (b) Bendthewireharnessclampasshown.











    8. FILLBRAKERESERVOIRWITHBRAKEFLUIDAND BLEEDBRAKESYSTEM

    9. CHECKFORFLUIDLEAKAGE

    10. CHECK ACTUATOROPERATION (SeepageBR–84)




    ControlRelays

    INSPECTIONOFCONTROLRELAYS

    1. REMOVECONTROLRELAYS

    Removethetwocontrolrelaysfromtheactuator.

    5 •




    (eu,.



    NoContinuity

    =

    o








    "



    2. INSPECTPUMPMOTORRELAYCONTINUITY

    (a) Checkthatthereiscontinuitybetweenterminals1 and2.

    (b) Checkthatthereisnocontinuitybetweenterminals

    3and4.

    (c) Checkthatthereisnocontinuitybetweenterminals

    1and4.

    Ifcontinuityisnotasspecified,replacetherelay.




    3. INSPECTPUMPMOTORRELAYOPERATION

    (a) Applybatteryvoltagetoterminals1and2.

    (b) Checkthatthereiscontinuitybetweenterminals3 and4.

    (c) Checkthatthereisnocontinuitybetweenterminals

    1and4.

    Ifoperationisnotasspecified,replacetherelay.





    4. INSPECTSOLENOIDRELAYCONTINUITY

    (a) Checkthatthereiscontinuitybetweenterminals1 and3.

    (b) Checkthatthereiscontinuitybetweenterminals2 and4.

    (c) Checkthatthereisnocontinuitybetweenterminals4 and5.

    Ifcontinuityisnotasspecified,replacetherelay.


    8(Q01~






    NOContinuity

    5. INSPECTSOLENOIDRELAYOPERATION

    (a) Applybatteryvoltagetoterminals1and3.

    (b) Checkthatthereiscontinuitybetweenterminals4 and5.

    (c) Checkthat there is no continuity between terminals2 and4.

    Ifoperationisnotasspecified,replacetherelay.

    6. INSTALLTWOCONTROLRELAYS






    80_7.

    FrontSpeedSensor


























    LHFront

    S.,ted$tnSOC'



    RHFront

    SpeedSentof'



    INSPECTIONOFFRONTSPEED SENSOR

    1. INSPECTSPEEDSENSOR

    .II2't"IUI

    [​IMG](a) Removetheboltfromthepipeclampofthewirehar–

    ness.

    (b) Disconnectthespeedsensorconnector.

    (e) Measuretheresistancebetweenterminals.

    Resistance:0.85–1.30K

    Ifresistancevalueisnotasspecified,replacethesensor. (d) Checkthatthereisnocontinuitybetweeneachtermi-

    nalandsensorbody.

    Ifthereiscontinuity,replacethesensor.

    (e) Connectthespeedsensorconnector.

    NO (f) Installtheboltofthepipeclamp.





    ••


    2. INSPECTSENSORINSTALLATION

    Checkthatthesensorinstallationboltistightenedprop- erly.Ifnot,tightenthebolt.

    Torque:80kg–cm(69in.–Ib,7.8N–m)





    ...



    3. VISUALLYINSPECTSENSORROTORSERRATIONS

    (a) Removethetwoboltsandremovethetorqueplate withbrakecylinder.

    (b) Removetherotordisc.

    (c) Inspectthesensorrotorserrationsforscratches, cracks,warpingormissingteeth.

    (d) Installtherotordiscandbrakecylinderassembly

    withtwobolts.

    Torque:

    2WD960kg–cm(69ft–ib,94N–m)

    4WD1,090kg–cm(79ft–Ib,107N–m)

    NOTICE:Topreventdamagetotheserrations,donotstrike theaxlehub.
























    0.1.'

    INSPECTIONOF FRONT SPEED SENSOR AND SENSOR ROTOR SERRATIONS (REFERENCE) INSPECTFRONTSPEEDSENSORANDSENSORROTOR

    SERRATIONSBYUSINGANOSCILLOSCOPE

    (a) Connectan oscilloscope to the speed sensor connec- tor.

    (b) Runthevehicleat20km/h(12.4mph),andinspect speedsensoroutputwave.

    (c) CheckthatCis0.5Vormore.

    Ifnotasspecified,replacethespeedsensor. (d) CheckthatBis70%ormoreofA.

    Itnotasspecified,replacethesensorrotor.



    RearSpeedSensor(2WD)




    IOCU~7."














    RearSpeed Sensor ~ Bac:kin9Pratewith

    Parking BrakeA$$embty

    o ·O·Ring







    ~

    RearAxle Hub




    ROfot Disc:


    Ikg.em(h·l.b.N·m)I:Specifiedtorque

    •Non·reu$8ble part





    INSPECTIONOFREARSPEED

    lH Rear

    Speed Sensor

    RHRear

    SpeedSeO$O<

    SENSOR

    1. INSPECTSPEEDSENSOR

    (a) Removetheseatcushion.

    (b) Disconnectthespeedsensorconnector.

    (e) Measuretheresistancebetweenterminals.

    ~~

    RL+










    NoContinuity

    =

    o

    at-RR+ RR-

    Resistance:0.85–1.50k

    Ifresistancevalueisnotasspecified,replacethesensor.



    (d) Checkthatthereisnocontinuitybetweeneach ter- minalandsensorbody.

    Ifthereiscontinuity,replacethesensor.

    (e) Connectthespeedsensorconnector. (f) Installtheseatcushion.

    [​IMG]

    SlI.l'SN



    2. INSPECTSENSORINSTALLATION

    Checkthatthesensorinstallationboltistightenedprop- erly.Ifnot,tightenthebolt.

    Torque:80kg–cm(69in.–lb,7.8N–m)










    3. VISUALLYINSPECTSENSORROTORSERRATIONS

    (a) Removethetwoboltsandremovethetorqueplate withbrakecylinder.

    (b) Removetherotordisc.

    (c) Inspect thesensorrotorserrationsforscratches, cracks,warpingormissingteeth.

    (d) Installtherotordiscandbrakecylinderassemblywith

    twobolts.

    Torque:475kg–cm134ft–lb,47N–m)

    NOTICE:Topreventdamagetotheserrations,donotstrike theaxlehub.



























    "'"

    INSPECTIONOFREARSPEEDSENSORANDSENSOR ROTORSERRATIONS(REFERANCE)

    INSPECTREARSPEEDSENSORANDSENSOR

    ROTORSERRATIONSBYUSINGANOSCILLOSCOPE

    (a) Connectanoscilloscopetothespeedsensorconnec- tor.

    (b) Runthevehicleat20km/h(12.4mph),andinspect

    speedsensoroutputwave.

    (c) CheckthatCis0.5Vormore.

    Ifnotasspecified,replacethespeedsensor. (d) CheckthatBis70%ormoreofA.

    Ifnotasspecified,replacetherearaxlehub.

    [​IMG]


    REMOVALOFREARSPEEDSENSOR

    1. DISCONNECTSPEEDSENSORCONNECTOR

    (a) Removetheseatcushion.

    (b) Disconnectthesensorconnector,andpulloutthe sensorwireharness.

    (e) Removethetwoclampboltsholdingthesensorwire harnesstothebodyandsuspensionarm.





    2. REMOVEREARBRAKEASSEMBLY

    (a) Removetheaxlecarriermountingboltandnutofup- perside.

    (b) Removethetwoboltsandremovethediscbrakeas- sembly.

    (c) Suspendthediscbrakesothehoseisnotstretched.

    3. REMOVEROTORDISC






    4. REMOVEREARAXLEHUB

    (a) Removethefouraxlehubmountingbolts. (b) Removetherearaxlehub.

    (c) Removethebackingplatewithparkingbrakeas- semblyandO–ring.








    5. REMOVESPEEDSENSOR

    Removetheboltsandremovethespeedsensorfromthe backingplate.







    ......



    BRAKESYSTEM



    – Anti–lockBrakeSystem(A.B.S.)

    BR–99

    [​IMG]


    INSTALLATIONOFREARSPEED SENSOR

    1. INSTALLSPEEDSENSOR

    Installthespeedsensortothebackingplatewithabolt.

    Torque:80kg–cm(69in.–Ib,7.8N–m)







    2. INSTALLREARAXLEHUB

    (a) Installthebackingplatewithparkingbrakeassem- blyinplace.

    (b) InstallanewO–ringtotheaxlecarrier.

    (c) Installtherearaxlehubwiththefourbolts.

    Torque:820kg–cm(59ft–Ib,80N–m)







    3. INSTALLROTORDISC

    Aligntheholeontheaxlehubandserviceholeonthe disc,andinstalltherotordisc.











    4. INSTALLREARBRAKEASSEMBLY

    (a) Installthediscbrakeassemblyandtorquethetwo mountingbolts.

    Torque:475kg–cm(34ft–Ib,47N–m)

    (b) Installtheaxlecarriermountingboltandnutofupper side.

    Torque:.2,100kg–cm(152ft–lb,206N–m)





    5. CONNECTSPEEDSENSORCONNECTOR

    (a) Installthewireharnesswithclampsandboltsin place.

    (b) Insertthewireharnessconnectortoinsideoftheve- hicle,andconnecttheconnector.

    (c) Installtheseatcushion.




    RearSpeedSensor(4WD)





















    Rea,'s'oe<ldS..,..,..

    StMOrRotor

    (DriveShaftl


    1'I~k9---cm-'(f"'t-""b-."N--m"'l: Specified tOC'qu.



    LHRear

    SpeedSensor







    ~~


    RHRe8r

    Speed5.n$Or

    INSPECTIONOFREARSPEED SENSOR

    1. INSPECTSPEEDSENSOR

    (a) Removetherearseatcushion.

    (b) Disconnectthespeedsensorconnector.

    (c) Measuretheresistancebetweenterminals.

    Resistance:0.85–1.50k

    RL+ RL- RR+ RR-











    NoContinuity

    =

    o


    If resistancevalueisnotasspecified,replacethesensor.



    (d) Checkthat there is no continuity between each ter- minalandsensorbody.

    Ifthereiscontinuity,replacethesensor:

    (e) Connectthespeedsensorconnector. (f) Installtherearseatcushion.




    2. INSPECTSENSORINSTALLATION

    (a) Checkthatthesensorinstallationboltistightened properly.Ifnot,tightenthebolt.

    Torque:195kg–cm(14ft–Ib,19N–m)

    (b) Checkthatthereisnoclearancebetweenthesen- sorandrearaxlecarrierasshown.

    Ifthereisclearance,replacethesensor.



    ""1,,7.



    3. VISUALLYINSPECTSENSORROTORSERRATIONS

    (a) Removethedriveshaft. (SeepageRA–21)

    (b) Inspect thesensorrotorserrationsforscratches, cracks,warpingormissingteeth.

    (c) Installthedriveshaft. (SeepageRA–26)

    NOTICE:Topreventdamagetotheserrations,donotstrike

    thedriveshaft.






    I" '\ :,

    r-:~



    .

    if II

    INSPECTIONOF REAR SPEED SENSOR AND SENSOR ROTOR SERRATIONS (REFERENCE) INSPECTREARSPEEDSENSORANDSENSORROTOR SERRATIONSBYUSINGANOSCILLOSCOPE

    (a) Connectanoscilloscopetothespeedsensorconnec-

    tor.

    (b) Runthevehicleat20km/h(12.4mph),andinspect speedsensoroutputwave.

    O~ (e) CheckthatCis0.5Vormore.

    Ifnotasspecified,replacethespeedsensor. (d) CheckthatBis60%ormoreofA.

    Ifnotasspecified,replacethereardriveshaft.




    Anti–lockBrakeSystemCircuit

    INSPECTIONOFSYSTEMCIRCUIT

    1. INSPECTSYSTEMCIRCUITWITHCONNECTOR CONNECTED

    (a) RemovetheA.B.S.computer.

    (b) Usingavoltmeterwithhighimpedance(10K /V minimum), measurethevoltageateachterminaland bodyground.





    ."V ~ ~

    I[SR

    IG SAT"NO T Al-RR- PKS $TP W SFR

    (.':d


    SRL GNO 1L+ R- FR+ FR...,~L; R- RR; AST

    T. MR SRMT pR

    '--''--' '--






    TesterConnection



    SFL – Body ground



    Ignitionswitchon

    Condition Voltage


    Batteryvoltage

    TroublePart




    SFR – Body ground




    SRl – Body ground

    Ignitionswitchonand”ANTILOCK”warninglightgoeson


    Ignitionswitchon


    Ignitionswitchonand”ANTILOCK”warninglightgoeson


    Ignitionswitchon


    Ignitionswitchonand”ANTILOCK”warninglightgoeson

    About0V


    Batteryvoltage About0V Batteryvoltage

    About0V






    Actuator,control relays



    SRR – Body ground AST – Body ground W – Body ground

    T – Body ground


    Ignitionswitchon


    Ignitionswitchonand”ANTILOCK”warninglightgoeson


    Ignitionswitchon


    Ignitionswitchonand”ANTILOCK”warninglightgoeson


    Ignitionswitchon


    Ignitionswitchonand”ANTILOCK”warninglightgoeson


    Checkconnectordisconnected


    Checkconnectorconnected


    Batteryvoltage About0V Batteryvoitage About0V Batteryvoltage About0V Batteryvoltage

    About0V









    ”ANTILOCK”

    warninglightbulb


    Checkconnector, computer


    Ifthecircuitisnotasspecified,checkandrepairorre- placethetroublepartshowninthetableabove.



    2. INSPECTSYSTEMCIRCUITWITHCONNECTOR DISCONNECTED

    (a) Disconnecttheconnectorsfromthecomputer,in-

    spectatthewireharnesssideconnector.











    TesterConnection


    ~ -A$T


    ChrakItem


    Resistance




    Ignition switch off


    Condition

    Voltage or

    Resistance Value

    About 6


    TroublePart


    Actuator


    Voltage


    Ignitionswitch off and brake pedal depressed


    Batteryvoltage


    Stop light switch,














    T. .. Body QtOI.Irct

    (For4WO)


    AST - Sody "round



    Continuity


    Resistance

    -

    Ts connector shorted


    Ignition switch off


    STP..~ Qf'ouncI Continuity



    PIC8 - Bodyground Voltage

    Ignitionswitchoffandbrakepedalreturned


    IgnitionswitchonandPKBleverpulled

    Continuity


    About 0 v

    stop light


    Parking broke switch,

    Engine running and PKB lever returned

    Batteryvoltage

    levelwarningswitch

    .... -AST

    Resistance

    Ignition switch off

    About 6 0


    MT..Body around

    Continuity

    Ignition switch off

    Continuity


    SO-Me


    MR-RS

    Resistance


    Resistance

    Ignition switch off


    Ignition switch off

    65–100


    50–80

    Actuator


    No continuity


    Continuity


    About 5


    Tsconnector, wiring harness

    Wiringharness

    ..e.-_.......Continuity


    Ignition switch off


    No continuity

    Rear RH speed sensor

    Noe-BodyQI'OUnd


    T-likldy QtOUfId GHD .. Bodyorourct SAT - Bodygtour.:I

    IG- 80dyOround


    SA.- A$T


    ""$-RRe

    "e-_ .......


    "L$-Rle

    Continuity


    Continuity


    Continuity Vortege Voltage Resistance

    Resistance


    Continuity


    Resistance

    Ignition switch off


    Ignition switch off


    Ignition switch off

    -

    Ignitionswitchon


    Ignition switch off

    -

    Ignition switch off

    -

    No continuity


    Continuity


    Continuity Batteryvoltage Batteryvoltage About 6

    0.85 – 1.50 k


    No continuity


    0.85 – 1.50 k

    Rear LH speed sensor

    Checkconnector, wiring harness

    Wiringharness FOGfuse ECU–IGfuse Actuator

    Rear RH speed

    sensor

    Wiringharness

    Rear LH speed sensor

    ..9-_


    fR~-FRe

    .......Continuity -

    Resistance -

    No continuity


    0.85– 1.30k fl

    Front RH speed sensor

    Fle-80dy "toWd

    R.$-FLe


    SAL - ASY


    Continuity


    Resistance


    Resistance

    -

    -

    Ignition switch off


    No continuity


    0.85– 1.30k


    About 6


    FrontrH speed sensor

    Actuator


    Ifthecircuitisnotasspecified,checkandrepairorre- placethetroublepartshowninthetableabove.

    (b) Connecttheconnectors,andinstallthecomput-

    ercover.



    REMOVALANDINSTALLATIONOFA.B.S. COMPUTERANDDECELERATIONSENSOR (For4WD)



    Co,,,,,,_Bolek.'











    ---_

    A.B.S.Ccmpuw





















    1. REMOVEA.B.S.COMPUTER

    (a) Removethecomputercover.

    (b) Removethefivescrewsholdingthecomputertothe computerbracket.

    (e) Pulloutthewireharnessfromtheclamponthe bracket,andpullouttheconnector from the clamp onthebracket.

    (d) Disconnectthethreeconnectors,andremovethe

    A.B.S.computer.



    2. REMOVEDECELERATIONSENSOR

    Removethetwoscrews,andremovethedeceleration sensor.

    NOTICE:Donotdrivewithoutnormalinstallationofdecel- erationsensorandcomputerassembly.



    BRAKESYSTEM



    – Anti–lockBrakeSystem(A.B.S.)

    BR–105

    [​IMG]

    3. INSTALLDECELERATIONSENSOR

    (a) Installthedecelerationsensortothebracketwiththe twoscrews.

    Torque:32.5kg–cm(28in.–Ib,3.2N–m)

    (b) Installtheconnectortotheclamponthebracket.

    (c) Checkthatthedecelerationsensorisinstalledprop- erly.





    4. INSTALLA.B.S.COMPUTER

    (a) Connectthethreeconnectorsandinsertthewirehar- nesstotheclamp.

    (b) Setthecomputerinplace,andinstallitwiththefive screws.

    Torque:32.5kg–cm(28in.–Ib,3.2N–m)

    (c) Installthecomputercover.
     

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