hệ thống phanh trên xe camry

[dotrungtruc]

BRAKESYSTEM –

BR–1

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

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

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)

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

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

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.

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

--

@~





~ --

changeinpedalreservetravelafterholdingthepedal

forthirtyseconds,theboosterisairtight.

BLEEDINGOFBRAKESYSTEM

HINT:Ifanyworkisdoneonthebrakesystemorifairissus- pectedinthebrakelines,bleedthesystemofair. NOTICEo 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.

(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

REMOVALOFMASTERCYLINDER








.Ga_






130t9.13.

t











t kg·em(ft.lb.N,m. I:Specified (Otque

•Non-reusable pan:



1. DISCONNECTLEVELWARNINGSWITCH CONNECTOR

2. TAKEOUTFLUIDWITHSYRINGE

NOTICEonotletbrakefluidremainonapaintedsurface. 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.)

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

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

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

(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

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.

•




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.

HINTonotdisconnectthebrakehose.












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. NOTICEonotallowoilorgreasetogetonthe rubbingface.

(e) Installthetwoanti–squealsprings.

,-",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.

~

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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.

CAUTIONonotplaceyourfingersinfrontofthepiston

whenusingcompressedair.





4. REMOVEPISTONSEALFROMBRAKECYLINDER

Usingascrewdriver,removethepistonseal.









-



BRAKESYSTEM



– FrontBrake

BR–23

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.

~ ~

~

'(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

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

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

NOTICEonotallowoilorgreasetogetontheru 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

NOTICEonotallowoilorgreasetogetontheru 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

2. INSPECTPADLININGTHICKNESS

Checkthepadthicknessthroughthecylinderinspection holeandreplacepadsifnotwithinspecification.

Minimumthickness:1.0mmI0.039in.)










3. REMOVECYLINDERFROMTORQUEPLATE

(a) Removetheinstallationboltfromthetorqueplate.













(b) Removethebrakecylinderandsuspenditsothe hoseisnotstretched.

HINTonotdisconnectthebrakehose.











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.

.


(b) Installthetwopadssothewearindicatorplateisat thebottomside.

NOTICEonotallowoilorgreasetogetontherub–

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

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.

CAUTIONonotplaceyourfingersinfrontofthepiston

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

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.

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.

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

1. APPLYHIGHTEMPERATUREGREASEONBACKING PLATEASSHOWN

Applyhightemperaturegreasetotheslidingsurfacesof

theshoe.



BRAKESYSTEM



– RearBrake

BR–47

2. APPLYHIGHTEMPERATUREGREASETOAD- JUSTERASSHOWN












3. CONNECTPARKINGBRAKECABLETOPARKING BRAKELEVER

(a) Installtheshoehold–downsprings,cupsandpins.

(b) Connecttheparkingbrakecabletotheparkingbrake leveroftherearshoe.








4. INSTALLREARSHOE

Slideintherearshoebetweentheshoehold–downspring cupandthebackingplate.

NOTICEonotallowoilorgreasetogetontherubbing

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)

,



BRAKESYSTEM



– RearBrake

BR–49

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

..,..,





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

••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.

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.

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

(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

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

Fl MAIN



ToStop










Front Brake Cylinder Rear

BrakeCytinder



RearSpeed Sensor

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.

LOCATIONOFSYSTEMPARTS


WAGON











A.B.S. Computet






SensorRotOl'

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









Sensor RotOl




ReatSpeed5eflSOf



SenSOfRotOl

ANTILOCK Warning IJ9ttt

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



SYSTEMDIAGRAM(2WDOFSEDAN)






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SYSTEMDIAGRAM(2WDOFWAGON)




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.....



SYSTEMDIAGRAM(4WD)





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"-'....









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WIRINGDIAGRAM(2WD)




..


.0 ",I'

_..I.l.!.

~s ~

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

)l'

_RJ


"'...... :rl§


0: e

:..r..j§c ..~o§c

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e

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......<:.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

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

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.

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.

NOTICEonotdepressthebrakepedal.














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

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.)

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

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

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

: 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.

NOTICEonotkeepthePOWERSWITCHpushingmore 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.

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

REMOVALOFBRAKEACTUATOR

1. TAKEOUTFLUIDWITHSYRINGEORAN EQUIVALENT

CAUTIONonotletbrakefluidremainonapainted

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.)

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

(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.

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

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.)

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

(a) Removetheboltfromthepipeclampofthewirehar–

ness.

(b) Disconnectthespeedsensorconnector.

(e) Measuretheresistancebetweenterminals.

Resistance:0.85–1.30KΩ

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.

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.

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

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.

NOTICEonotdrivewithoutnormalinstallationofdecel- erationsensorandcomputerassembly.



BRAKESYSTEM



– Anti–lockBrakeSystem(A.B.S.)

BR–105

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.