manual pajero 4x4 service brakes.docx

8/11/2019 manual pajero 4x4 service brakes.docx

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35A-1

SERVICE

BRAKESCONTENTS 35109000487

BASICBRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A

ANTI-SKIDBRAKING SYSTEM(ABS) . . . . . . . . . . . . . . . . . . . . . . 35B


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35A-2

BASIC

BRAKE

SYSTEM

CONTENTS 35109000494

GENERAL

INFORMATION . . . . . . . . . . . . . . . . . .

3 Load

Sensing

Proportioning

Valve

FunctionTest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . .5 Disc Brake Pad Check and Replacement . . . . . 15

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Disc Brake Rotor Check . . . . . . . . . . . . . . . . . . . . . 17

Thickness

check . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Brake Lining Thickness C h e c k . . . . . . . . . . . . . . . 20

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Brake Disk Inside Diameter C h e c k . . . . . . . . . . . 21

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . .7

Brake Lining and Brake Disc ConnectionCheck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

ON-VEHICLE

SERVICE . . . . . . . . . . . . . . . . . . . . .

9 BRAKE

PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . .

22Brake Pedal Check andAdjustment . . . . . . . . . . . 9 MASTER CYLINDERAND BRAKEStop Lamp Switch Check . . . . . . . . . . . . . . . . . . . . 11 BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Brake Booster Operating Test . . . . . . . . . . . . . . . . 11

Check Valve Operation Check. . . . . . . . . . . . . . . . 12

Brake Booster Vacuum Switch Check

Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

LOAD SENSING PROPORTIONINGVALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 FRONT DISC BRAKE . . . . . . . . . . . . . . . . . . . . 27

Brake Fluid Level Sensor Check . . . . . . . . . . . . . 14REAR DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . 33

Load Sensing Spring Length Check and

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14


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BASIC BRAKE SYSTEM General Information 35A-3

GENERAL INFORMATION 35100010304

Thebrakesystemhashighreliabilityanddurabilitywhichmaintainsexcellentbrakingperformanceandbraking feeling.Themain featuresareasfollows. A dual type mastercylinder isequipped inall

models. A tandem type brake booster has been

adopted.

Thefollowingtypeofbrakehavebeenadopted.Front:Floatingcaliper,2-piston,ventilateddiscbrakes (V5-W43, V6-W43)Rear: Floating caliper, 1-piston, solid discbrakes (S5-S43P)

Items 6G7 4D5

4D5

MastercylinderI.D.mm 23.8

Brake

booster

effective

dia.

of

power

cylinder

mm

205

+

230

180

+

205

Brakeboosterboostingratio 5.0 6.0 5.0

Frontbrakedisceffectivedia.mm 265 227 265

Front

brake

wheel

cylinder

I.D.

mm

42.86

Rearbrakedisceffectivedia.mm 272

RearbrakewheelcylinderI.D.mm 42.85


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35A-4 BASIC BRAKE SYSTEM General Information

CONFIGURATION DIAGRAM

Brake booster

Loadsensingproportioning valve

Mastercylinder

Rearbrake

Frontbrake

Load sensingproportioning valve

Brake booster

Master

cylinder

Rearbrake

Frontbrake


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BASIC BRAKE SYSTEM Service Specifications 35A-5

SERVICE SPECIFICATIONS 35100030386

Items Standardvalue Limit

Brakepedalheightmm 176181

Brakepedalfreeplaymm 38

Brakepedaltofloorboardclearancemm 95ormore

Loadsensingspringlengthmm 164168

LoadsensingproportioningvalveoutputpressurekPa(InputpressurekPa)

When load sensingspring length is 144mm(whenunladen)

3,633(5,884)

5,610(13,730)

When load sensingspring length is 208mm(whenladen)

11,160(13,730)

Disc

brake

pad

thickness

mm

10

2.0

Brakediscrun-outmm Front 0.06

Rear 0.08

Fronthubendplaymm 0.05

Rearaxleshaftendplaymm 00.25

Brakediscthicknessmm Front 24 22.4

Rear 18 16.4

Brakeliningthicknessmm 4.5

Brakedruminsidediametermm 197.0 198.0

Booster

push

rod

to

master

cylinder

piston

clearance

mmVehicle

which

brake

booster of powercylinder is 180 mmand 205 mm ineffectivediameter

0.90

1.30

Vehiclewhichbrakebooster of powercylinder is 205 mmand 230 mm ineffectivediameter

0.701.10

Discbrakedragforce(tangentialforceofwheelmountingbolts)N

Front 106orless

Rear

56

or

less


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35A-6 BASIC BRAKE SYSTEM Lubricants/Sealant/Special Tool

LUBRICANTS 35100040174

Items Specifiedlubricant

Brake

fluid

DOT3

or

DOT4

Brakepistonseal Repairkitgrease

Guide

pin

boot

inner

surface

Lockpinbootinnersurface

Pistonbootmountinggrooves

Sleeveinnersurface

Bushinginnersurface

Pinbootinnersurface

SEALANT 35100050214

Item

Specified

sealant

Remark

Vacuumswitch 3MATDPartNo.8661orequivalent Semi-dryingsealant

Fitting

SPECIAL TOOL 35100060194

Tool Number Name Use

A

B

MB990964

A:MB990520

B:

MB990623

Braketoolset Pushing-inofthediscbrakepiston

Installationofdrumbrakewheelcylinderpistoncup


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BASIC BRAKE SYSTEM Troubleshooting 35A-7

TROUBLESHOOTING 35100070128

Symptom Probablecause Remedy

Vehicle pulls to one sidewhenbrakesareapplied

Greaseoroilonpadorliningsurface Replace

Inadequatecontactofpadorlining Correct

Insufficientbrakingpower Lowordeterioratedbrakefluid Refillorchange

Airinbrakesystem Bleedair

Overheatedbrakerotorduetodraggingofpadorlining

Correct

Inadequatecontactofpad

Brakeboostermalfunction

Cloggedbrakeline

Greaseoroilonpadsurface Replace

Load

sensing

proportioning

valve

malfunction

Increasedpedalstroke(Reduced pedal to floorboardclearance)

Airinbrakesystem Bleedair

Wornpad Replace

Brokenvacuumhose

Faultymastercylinder

Brakefluidleaks Correct

Excessive push rod to master cylinderclearance

Adjust

Brake

drag

Incomplete

release

of

parking

brake

Correct

Cloggedmastercylinderreturnport

Incorrectparkingbrakeadjustment Adjust

Improper push rod to master cylinderclearance

Faultymastercylinderpistonreturnspring Replace

Wornbrakepedalreturnspring

Lackoflubricationinslidingparts Lubricate


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35A-8 BASIC BRAKE SYSTEM Troubleshooting


Insufficientparkingbrakefunction Wornbrakeliningorpad Replace

Greaseoroilonliningorpadsurface

Parkingbrakecablesticking

Stuckwheelcylinderorcaliperpiston

Excessiveparkingbrakeleverstroke Adjusttheparkingbrakeleverstrokeorchecktheparkingbrakecablerouting

Autoadjustermalfunction Adjust

Scrapingorgrindingnoisewhenbrakesareapplied

Wornbrakepad Replace

Calipertowheelinterference Correctorreplace

Dustcovertodiscinterference

Bentbrakebackingplate

Cracked

brake

disc

Squealing,groaningorchatteringnoisewhenbrakesareapplied

Missing or damaged brake pad anti-squeakshim

Replace

Brakediscsandpadswornorscored Correctorreplace

Burredorrustedcalipers Correctordeburr

Dirty,greased,contaminatedorglazedpad

Cleanorreplace

Incorrectbrakepedalorboosterpushrod Adjust

Squealingnoisewhen

brakes

are

notapplied

Bent or warped backing plate causinginterference

with

drum

Replace

Poor return of brake booster, mastercylinder

Looseorextrapartsinbrakes Retighten

Improperpositioningofpadsincaliper Correct

Improper installationofsupportmount-ingtocaliperbody

Worn, damaged or insufficiently lubri-catedwheelbearings

Lubricateorreplace

Incorrect brake pedal or booster pushrod

Adjust


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BASIC BRAKE SYSTEM Troubleshooting/On-vehicle Service 35A-9


Groaning,clickingorrattlingnoisewhenbrakesarenotapplied

Loosewheelnuts Retighten

Looseinstallationbolts

Worn,damagedordrywheelbearings Lubricateorreplace

Failureofshim Replace

Wearonsleeve

Incorrectbrakepedalorboosterpushrod Adjust

Operatingrod

Operatingrod locknut

Pedaldown

Pedalup

Locknut

Stoplampswitch

Stop lampswitch locknut

Outercase

Locknut

ON-VEHICLE SERVICE 35100090292

BRAKE PEDAL CHECKANDADJUSTMENT

BRAKE PEDAL HEIGHT

1. Turn back the carpet etc. under the brake pedal.2. Measure thebrakepedalheightas illustrated. If it isnot

within the standard value, adjust as follows.

Standard value: 176 181 mm (From the surface of

melting

seat

to

the

face

of

pedal

pad)

(1) Disconnect the stop lamp switch connector, loosenthe lock nut, and move the stop lamp switch to aposition where it does not contact the brake pedalarm.

(2) Adjustthebrakepedalheightbyturningtheoperatingrod with pliers (with the operating rod lock nutloosened).

(3) Screw in the stop lamp switch until it contacts thebrakepedalstopper(justbeforebrakepedaliscausedto move), return the stop lamp switch 1/2 to 1 turn

and

secure

with

the

lock

nut.

(4) Connect the connector of the stop lamp switch.(5) Checktobesurethatthestop lamp isnotilluminated

with the brake pedal released.3. Return the carpet etc.

1.0mm


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35A-10 BASIC BRAKE SYSTEM On-vehicle Service

BRAKE PEDAL FREE PLAY

With the engine stopped, depress the brake pedal two orthreetimes.Aftereliminatingthevacuuminthebrakebooster,press thepedaldownbyhand,andconfirm that theamountof movement before resistance is met (free play) is withinthe standard value range.

Standard value: 3 8 mm

If

the

free

play

exceeds

the

standard

value,

it

is

probablyduetoexcessiveplaybetweentheclevispinandbrakepedal

arm.Check for excessive clearance and replace faulty parts asrequired.

CREARANCE BETWEEN BRAKE PEDALAND FLOORBOARD

1. Turn back the carpet etc. under the brake pedal.2. Start the engine, depress the brake pedal with

approximately490Nofforce,andmeasuretheclearancebetween the brake pedal and the floorboard.

Standard value:95mm or more (From the surface of meltingseatto the face of pedal pad)

3. If theclearance isoutside thestandardvalue,checkforairtrappedinthebrakeline,clearancebetweentheliningand the drum and dragging in the parking brake.

Adjust and replace defective parts as required.4. Return the carpet etc.


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BASIC BRAKE SYSTEM On-vehicle Service 35A-11

Nocontinuity

Continuity

Plunger

a

b

STOP LAMP SWITCH CHECK 35100890168

Connect a circuit tester to the stop lamp switch, and checkwhether or not there is continuity when the plunger of thestop lamp switch is pushed in and when it is released. Thestop lampswitch is ingoodcondition if there isnocontinuitywhen the plunger is pushed in to a depth of within 4 mmfrom the outer case edge surface, and if there is continuitywhen it is released.For

vehicles

with

auto-cruise

control

system,

check

the

continuitybetween the terminals aand bofthestop lampswitch.

Good No goodBRAKE BOOSTER OPERATING TEST 35100100162

For simple checking of the brake booster operation, carryout the following tests:1. Run the engine for one or two minutes, and then stop

it.If the pedal depresses fully the first time but graduallybecomes higher when depressed succeeding times, thebooster isoperatingproperly, if thepedalheight remains

unchanged,

the

booster

is

defective.

When engine isstopped

When engine isstarted

2. Withtheenginestopped,steponthebrakepedalseveraltimes.Then step on the brake pedal and start the engine.If the pedal moves downward slightly, the booster is ingood condition. If there is no change, the booster isdefective.

No good Good3. With the engine running, step on the brake pedal and

then stop the engine.Hold the pedal depressed for 30 seconds. If the pedalheightdoesnotchange,theboosterisingoodcondition,if the pedal rises, the booster is defective.Iftheabovethreetestsareokay,theboosterperformancecan be determined as good.If one of the above three tests is not okay at last, thecheck valve,vacuum hose,or boosterwill bedefective.


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Vacuumpumpconnection Accept/rejectcriteria

Connectionatthebrakeboosterside(A)

Anegativepressure(vacuum)iscreatedandheld.

Connection at the intakemanifoldside(B)

Anegativepressure(vacuum)isnotcreated.


CHECK VALVE OPERATION CHECK 35100900243

1. Remove the vacuum hose. (Refer to P.35A-23.)

CautionThe check valve should not be removed from thevacuum hose.

Boosterside

Valve Spring

A B

Intakemanifoldside

2. Checktheoperationofthecheckvalvebyusingavacuumpump.

Body

earth

CautionIf the check valve is defective, replace it as anassembly unit together with the vacuum hose.

BRAKE BOOSTER VACUUM SWITCH CHECK 35100920041

1. Connect an ohmmeter to the connector of the vacuumswitch.

2. Starttheengineandcheckforcontinuitywhenthevacuumhose is connected, and when it is disconnected.The vacuum switch is in good condition if there is nocontinuity when the vacuum hose is connected, and ifthere is continuity when it is disconnected.


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BLEEDING 35100140201

CautionUse the specified brake fluid. Avoid using a mixtureofthe specified brake fluid and other fluid.

Specified brake fluid: DOT3 or DOT4

MASTER CYLINDER BLEEDING

Themastercylinderusedhasnocheckvalve,so ifbleedingiscarriedoutbythefollowingprocedure,bleedingofairfromthe brake pipeline will become easier. (When brake fluid isnot contained in the master cylinder.)1. Fill the reserve tank with brake fluid.2. Keep the brake pedal depressed.3. Have another person cover the master cylinder outlet

with

a

finger.4. With

the

outlet

still

closed,

release

the

brake

pedal.5. Repeat steps 2 4 three or four times to fill the inside

of the master cylinder with brake fluid.

Vehicles

withoutABS BRAKE PIPE LINE BLEEDING

Start the engine and bleed the air in the sequence shownin the figure.

Load sensingproportioningvalve

Vehicles with ABS



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ressure au es


BRAKE FLUID LEVEL SENSOR CHECK35100910086

The brake fluid level sensor is in good condition if there isnocontinuitywhen the floatsurface isabove Aand ifthereis continuity when the float surface is below A.

A

LOAD SENSING SPRING LENGTH CHECKANDADJUSTMENT 35100120045

1. Park the vehicle on a level ground. The vehicle shouldbe unloaded and supported only by wheels.

CautionNever supportthe vehicle withjacks or other similarmeans.

Lever

Stopperbolt

A

2. While the lever of the load sensing proportioning valveis touching the stopper bolt, install the spring supportso that the distance (A) is at the standard value.

Standard value (A): 164 168 mm

3. Ifthespringlengthisnotwithinthestandardvalue,loosenthe bolt attaching the spring support and adjust thedistance by moving the spring support.

Spring

support

LOAD SENSING PROPORTIONINGVALVEFUNCTION TEST 35100130055

1. Connect pressure gauges to the inputand output portsof the load sensing proportioning valve.

2. Bleed the system. (Refer to P.35-13.)

Stopper bolt

10mm

H

Stopper boltcontactposition

3. Disconnect the spring at the support side.4. Place the spring so that it is in parallel with the load

sensing proportioning valve, and pull in the directionindicatedby thearrowso that its lengthHshown in thefigure (the length between its ends) is as noted below.

NOTEAt this time the lever ispressed all the way to the loadsensing proportioning valve.


15/70


Standard value:

SpringlengthHmm

InputfluidpressurekPa

OutputfluidpressurekPa

144*1 5,884 3,633

13,730 5,610

208*2 13,730 11,160

NOTE*1 and*2 indicatetheapplicable lengthsforunladenandladen vehicles respectively.

5. After making the check, install the spring. Disconnectthepressuregaugesfrom the loadsensingproportioningvalve and bleed the air. (Refer to P.35A-13.)

Pad

When new When worn

Brake

DISC BRAKE PAD CHECKANDREPLACEMENT 35100150242

NOTEThe brake pads have indicators that contact the brakediscwhen the brake pad thickness becomes 2 mm, and emita squealing sound to warn the driver.

Wear indicatordisc

1. Check thebrakepad thickness throughthecaliperbodycheck port.

Standard value: 10 mmLimit: 2.0 mm

Caution(1) When the limit is exceeded, replace the pads at

both sides, andalso thebrake pads for thewheelson the opposite side at the same time.

(2) If

there

is

a

significant

difference

in

the

thicknessesof thepads on the leftand right sides,check the sliding condition of the piston, lockpin and guide pin.


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2. Removethe lockpin.Liftthecaliperassemblyandretainwith wire.

CautionDo not wipe the special grease from the lock pin.Do not contaminate the lock pin.

3

2

4 1

3

Padpin

3. Remove the following parts from caliper support.(1) Pad and wear indicator assembly(2) Pad assembly(3) Clip(4) Outer shim

4. Measurethehubtorquewiththepadremovedtomeasurethe brake drag force after pad installation. (Refer toP.35A-28.)

5. Installthepadandcaliperassembly,andcheckthebrake

drag

force.

(Refer

to

P.35A-28.)

1. Check thebrake pad thickness through the caliperbodycheck port.

Standard Value: 10 mmLimit: 2.0 mm

Caution(1) When the limit is exceeded, replace the pads at

both sides, and also the brake pads for the wheels

on

the

opposite

side

at

the

same

time.(2) If there is a significant difference in the

thicknessesofthepadsonthe leftandright sides,check the slidingconditionof the pistonand padpin.

2. Remove the clip and pad pin.


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3. Removethepadandshimwitha flat-tippedscrewdriver.(1) Pad and wear indicator assembly(2) Pad assembly(3) Inner shim(4) Outer shim

4. Measurethehubtorquewiththepadsremovedtomeasurethe brake drag force. (Refer to P.35A-33.)

5. Installthepadandcaliperassembly,andcheckthebrake

drag

force.

(Refer

to

P.35A-33.)

3 12

4

DISC BRAKE ROTOR CHECK 35100270092

CAUTIONWhen servicing disc brakes, it is necessary to exercise caution to keep the disc brakes withinthe allowable service values in order to maintain normal brake operation.

Before re-finishing or re-processing the brake disc surface, the following conditionsshould be checked.

Inspectionitems Remarks

Scratches,rust,saturatedliningmaterials

and

wear

If the vehicle is not driven for a certain period, the sections of

the

discs

that

are

not

in

contact

with

lining

will

become

rusty,

causingnoise and shuddering.

If grooves resulting from excessive disc wear and scratches arenot removed prior to installing a new pad assembly, there willmomentarily be inappropriate contact between the disc and thelining (pad).

Run-outordrift Excessiverun-outordriftofthediscswillincreasethepedaldepressionresistanceduetopistonknock-back.

Changeinthickness(parallelism) If the thickness of the disc changes, this will cause pedal pulsation,shudderingandsurging.

Insetorwarping(flatness) Overheatingand improperhandlingwhileservicing willcause insetorwarping.


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FRONT DISC BRAKE RUN-OUT CHECKANDCORRECTION 35100940078

1. Remove the caliper support; then raise the caliperassembly upward and secure by using wire.

2. Inspect the disc surface for grooves, cracks and rust.Clean the disc thoroughly and remove all rust.

3. Place a dial gauge approximately 5 mm from the outercircumferenceofthebrakedisc,andmeasuretherun-out

of

the

disc.

Limit: 0.06 mm

Chalkmark4. Iftherun-outofthebrakediscisequivalenttoorexceeds

the limitspecification, change the phase of the discandhub, and then measure the run-out again.(1) Before removing the brake disc, chalk both sides

of the wheel stud on the side at which run-out isgreatest.

(2) Place a dial gauge as show in the illustration, andthenmovethehub intheaxialdirectionandmeasurethe play.

Standard value: 0.05 mm

Iftheplay isequaltoorexceedsthestandardvalue,adjust the wheel bearing preload. (Refer to GROUP26 Front HubAssembly.)

(3) If the play does not exceed the standard valuespecification, install thebrakediscataposition180awayfromthechalkmark,andthenchecktherun-outof the brake disc one again.

5. Iftherun-outcannotbecorrectedbychangingthephaseof the brake disc, replace the disc or turn rotor with onthe car type brake lathe (MAD, DL-8700PF orequivalent).


19/70


REAR DISC BRAKE RUN-OUT CHECKANDCORRECTION 35100210100

1. Remove the caliper support; then raise the caliperassembly upward and secure with a wire.

2. Checkthediscsurfaceforgrooves,cracksandrust.Cleanthe disc thoroughly and remove all rust.

3. Place a dial gauge approximately 5 mm from the outercircumferenceofthebrakedisc,andmeasuretherun-out

of

the

disc.

Limit: 0.08 mm

4. If the runoutof the brake disc is the limit valueormore,changethephaseofthediscandhub,andthenmeasurethe run-out again.(1) Beforeremovingthebrakedisc,placeamatingmark

on both the wheel stud and disc with chalk on thepoint at which the run-out is greatest.

(2) Place a dial gauge as shown in the illustration, andthenmovethehub intheaxialdirectionandmeasurethe play.

Standard

value:

0

0.25

mm

(3) Iftheplaydoesnotexceed thestandardvalue installthe brake discata different phase,and then checkthe run-out of the brake disc again.

5. If therun-outcannotbecorrectedbychangingthephaseof the brake disc, replace the disc.


20/70


THICKNESS CHECK 35100160221

1. Using a micrometer, measure disc thickness at eightpositions, approximately 45 apart and 10 mm in fromthe outer edge of the disc.

Brake disc thicknessStandard value: 24 mm

Limit:

22.4

mm

Thickness variation (at least 8 positions)The difference between any thickness measurementsshould not be more than 0.015 mm.

2. If the disc is beyond the limits for thickness, remove itand installanewone.If thicknessvariationexceedsthespecification, replace the brake disc or turn rotor withon the car type brake lathe (MAD, DL-8700PF orequivalent).

1. Remove dirt and rust from the brake disc surface.2. Measure the disc thickness at four locations or more.


Replace the discs and pad assembly for both left andright sides of the vehicle if they are worn beyond thespecified limit.

BRAKE LINING THICKNESS CHECK 35100300272

1. Remove the rear brake assembly, raise the rear brakeassembly and secure it by using a wire, etc.

2. Remove the brake disc.3. Measure the wear of the brake lining at the place worn

the most.

Limit: 4.5 mm

4. Replace the shoe and lining assembly if brake liningthickness is less than the limit if it is not worn evenly.

Caution

Whenever the shoe and lining assembly is replaced,replace bothR.H. andL.H. assembliesas a set topreventcar from pulling to one side when braking.


21/70


BRAKE DISC INSIDE DIAMETER CHECK35100320216

1. Remove the rear brake assembly, raise the rear brakeassembly and secure it by using a wire, etc.

2. Remove the brake disc.3. Measure the inside diameter of the brake disc at two

or more locations.

Standard value: 197.0 mm

Limit:

198.0

mm

Replacebrakedisc,shoeandliningassemblywhenwearexceeds the limit value or is badly imbalanced.

BRAKE LININGAND BRAKE DISCCONNECTION CHECK 351003102751. Remove the rear brake assembly, raise the rear brake

assembly and secure it by using a wire, etc.2. Remove the brake disc.3. Remove the shoe and lining assembly.4. Chalk innersurfaceofbrakediscand rubwithshoeand

lining assembly.

5. Replace

shoe

and

lining

assembly

or

brake

disc

if

very

irregular

contact

area.

NOTEClean off chalk after check.


22/70

35A-22 BASIC BRAKE SYSTEM Brake Pedal

BRAKE PEDAL 35100340403

REMOVALAND INSTALLATION

Post-installation Operation

Brake PedalAdjustment (Refer to P.35A-9.)

29

Nm

22 Nm

8

1

7 6

13 Nm

64

3 2

5

Removal steps

1. Stop lamp switch}A] 2. Brake pedal return spring

3. Snap pin4. Pin assembly

5. Brake pedal6. Bushing7. Spacer8. Pedal support member

INSTALLATION SERVICE POINT

}A]BRAKE PEDAL RETURN SPRING INSTALLATION

For L.H. drive vehicles, face the coil of brake pedal returnspring toward the steering column side.ForR.H.drivevehicles, face it toward thebrakepedalside.


23/70

BASIC BRAKE SYSTEM Master Cylinder and Brake Booster 35A-23

MASTER CYLINDERAND BRAKE BOOSTER 35100370419


Pre-removal Operation Brake Fluid Draining


Brake Fluid Supplying Brake Line Bleeding (Refer to P.35A-13.)

Brake PedalAdjustment (Refer to P.35A-9.)

8

8 8

67

8

1

2

29 Nm

9

15

18

Nm 1120

25

Nm

15 Nm 3 135 14

15 Nm 2 1

4

1 15 Nm

12

914

13 Nm

10

Sealant: 3MATD Part No.8661 or equivalent

Removal steps

1. Brake

tube

connection2. Connector3. Brake fluid level sensor connector4. Master

cylinder

assembly}B] Adjustment of clearance between

brake booster push rod and primarypiston

5. Vacuum switch connector Caution

9. Fitting10. Snap pin11. Pin assembly12. Brake booster13. Sealer14. Vacuum switch

6. Vacuum hose7. Vacuum pipe

}A] 8. Vacuum hose (with built-in checkvalve)

Do not remove the check valve from the vacuumhose. If the check valve is defective, replace it

together with the vacuum hose.


24/70

Brake

booster

size Clearance

A

standardvalvemm

Vehicle

which

brake

boosterofpowercylinderis180mmand205mmineffective

diameter

0.90

1.30

Vehiclewhichbrakeboosterof

power

cylinder

is

205

mm

and

230

mm

in

effectivediameter

0.701.10

35A-24 BASIC BRAKE SYSTEM Master Cylinder and Brake Booster

INSTALLATION SERVICE POINTS

}A]VACUUM HOSE CONNECTION

Insert securely and completely until the vacuumhose at theengine side contacts the edge of the hexagonal part of thefitting, and then secure by using the hose clip.

C}B]CLEARANCE ADJUSTMENT BETWEEN BRAKE

BOOSTER PUSH RODAND PRIMARY PISTON

Calculate clearanceA from the B, C and Dmeasurements.A = B C D

D Standard value:

A B

Measuringdistance

BMeasuringdistance D

NOTEWhenbrakeboosternegativepressure(6G7:66.7kPa,4D5:93.3kPa) is applied, clearance value will become 0.10 0.50 mm.

Blockgauge

Iftheclearance isnotwithinthestandardvaluerange,adjustby changing the push rod length by turning the screw ofthe push rod.


25/70

BASIC BRAKE SYSTEM Master Cylinder and Brake Booster 35A-25

MASTER CYLINDER 35100420206

DISASSEMBLYAND REASSEMBLY

2

1

3

4

5

7

6 8 8

10

Master cylinder kit11

12

11

13

14

2.5 Nm

101213

14

2.5 Nm 9

13

12

Brake

fluid: DOT3

or

DOT4

Disassembly steps

1. Reservoir cap assembly2. Reservoir cap3. Diaphragm4. Brake fluid level sensor5. Float6. Reservoir stopper bolt7. Reservoir tank

8. Reservoir

seal]A}

9.

Piston

stopper

bolt

Piston stopper ring

10. Gasket]A} 11. Piston stopper ring

12. Primary piston assembly13. Secondary piston assembly14. Master cylinder body

Caution

Do

not

disassemble

the

primary

piston

andsecondary

piston

assembly.

DISASSEMBLY SERVICE POINT

]A}PISTON STOPPER BOLT/PISTON STOPPER RINGDISASSEMBLY

Removethepistonstopperboltandpistonstopperringwhiledepressing the piston.

Pistonstopper bolt

INSPECTION 35100430056

Check the innersurfaceofmastercylinderbody forrustor pitting.

Checktheprimaryandsecondarypistonsforrust,scoring,wear or damage.

Check the diaphragm for cracks and wear.


26/70

35A-26 BASIC BRAKE SYSTEM Load Sensing Proportioning Valve

LOAD SENSING PROPORTIONING VALVE 35100540032


CautionDo not disassemble the load sensing proportioning valve.

Pre-removal

Operation

Brake Fluid DrainingPost-installation

Operation

Brake Fluid Supplying

Brake

Line

Bleeding

(Refer

to

P.35A-12.)

15

Nm

2

4

13

Removal steps

}A] 1. Spring support2. Brake tube connection

Lever

Stopperbolt

A

3. Load sensing spring4. Load sensing proportioning valve


}A]SPRING SUPPORT INSTALLATION

While the lever of the load sensing proportioning valve istouching the stopper bolt, install the spring support so thatthe distance (A) is within the standard value.

Standard value (A): 164 168 mm

Springsupport


27/70

BASIC BRAKE SYSTEM Front Disc Brake 35A-27

FRONT DISC BRAKE 35100600259





88 Nm

23

1

15 Nm

5

4

88 Nm

Removal

steps

1. Brake tube

2. Clip3. Brake

hose

bracket}A] 4. Front brake assembly

5. Brake disc (Refer to GROUP 26 Front HubAssembly)


28/70

35A-28 BASIC BRAKE SYSTEM Front Disc Brake


}A]FRONT BRAKE ASSEMBLY INSTALLATION

1. Measurehubtorque(A)withthepadremovedtomeasurethe brake drag force after pad installation.

CautionEngage 2WD before measurement.

2. Securely

attach

the

pad

clip

to

the

caliper

support.

MB990520

3. Cleanthepistonandinsertintocylinderwithspecialtool.4. Becareful that thepistonbootdoesnotbecomecaught,

when lowering the caliper assembly and installing thelock pin.

5. Check the brake drag force as follows.(1) Start the engineand hold the brakepedaldown for

5seconds. (Pedaldepression force:approx.196N)(2) Stop the engine.(3) Turn the brake disc forward 10 times.

(4) Check the hub torque (B) with a spring balance.(5) Calculatethedragforceofthediscbrake[difference

between hub torque (B) and hub torque (A)].

Standard value: 106 N or less

6. If the brake drag force exceeds the standard value,disassemble and clean the piston. Check for corrosionor worn piston seal, and check the sliding condition ofthe lock pin and guide pin.


29/70

15

16

Shim set Clip set


DISASSEMBLYAND REASSEMBLY 35100620293

212 8 Nm

74 Nm

6

109

8

75

1 4

3 1613

11 1415

610 9

87

2 12

13

116 10

9

6

109

87

87

5

108

Grease

16

10

8

7

6

7

36

14

1313 14

Brake caliper kit Seal and boots kit Pad set

Caliper assembly disassembly

steps}A]

1.

Lock

pin}A] 2. Guide pin

3. Bushing4. Caliper support, pad, clip and shim

assembly5. Caliper support6. Pin boot7. Boot ring

]A} 8. Piston boot]A} 9. Piston]B} 10. Piston seal

11. Caliper body12. Bleeder screw

Pad assembly disassembly steps

}A]

1.

Lock

pin}A] 2. Guide pin

3. Bushing4. Caliper support, pad, clip and shim

assembly13. Pad and wear indicator assembly14. Pad assembly15. Outer shim16. Clip


30/70


LUBRICATION POINTS

10

Grease: Repair kit grease

9

CautionThe

piston

seal

inside

the

seal

andboot

kit is

coated

with a specialgrease, so do not wipe this greaseoff.

Brake fluid: DOT3 or DOT4

Grease: Repair kit greaseGrease: Repair kit grease


31/70


DISASSEMBLY SERVICE POINTS

Whendisassemblingthefrontdiscbrakes,disassemblebothsides (left and right) as a set.

]A}PISTON BOOT/PISTON REMOVAL

Protectcaliperbodywithcloth.Blowcompressedairthroughbrake hose to remove piston boot and piston.

CautionWhen removing the pistons, be sure to use the handleof a plastic hammer and adjust the height of the twopistons

while pumping in air slowly so that the pistonsprotrude evenly.

Do

not

remove

one

piston

completely

before

trying

toremove the other piston, because it will become

impossible to remove the second piston.

]B}PISTON SEAL REMOVAL

(1) Remove piston seal with finger tip.

CautionDo not use a flat-tippedscrewdriver or other tool toprevent damage to inner cylinder.

(2) Clean piston surface and inner cylinder withtrichloroethylene, alcohol or specified brake fluid.

Specified brake fluid: DOT3 or DOT4

GuidepinREASSEMBLY SERVICE POINT

}A]LOCK PIN/GUIDE PIN INSTALLATION

Installthelockpinandguidepintothecaliperbodyasshownin the illustration.

Lockpin


32/70



Check cylinder for wear, damage or rust. Check piston surface for wear, damage or rust. Check caliper body or sleeve for wear. Check pad for damage or adhesion of grease, check

backing metal for damage.

PAD WEAR CHECK

Measure the thicknessat the thinnestandwornarea of thepad.Replace the pad assembly if pad thickness is less than thelimit value.


Caution1. Replace

the

pads

always

at

both

sides,

and

also

the

brake pads for the wheels on the opposite side atthe same time.

2. If there is significant difference in the thicknessesof the pads on the left and right sides, check thesliding condition of the piston, lock pin and guidepin.


33/70

BASIC BRAKE SYSTEM Rear Disc Brake 35A-33

REAR DISC BRAKE 35100700140





88 Nm

115 Nm

15 Nm

88 Nm

2

3

Removal steps

1.

Brake

hose

connection}A] 2. Rear brake assembly

3. Brake disc


}A]REAR BRAKE ASSEMBLY INSTALLATION

1. Measurehubtorque(1)withthepadremovedtomeasurethe brake drag force after pad installation.


34/70

35A-34 BASIC BRAKE SYSTEM Rear Disc Brake

MB990520

2. Clean the piston and insert into the cylinderwith specialtool.

3. Install the pad assembly to the caliper.4. Start the engine. Depress the brake pedal fully a few

times, and then stop the engine.5. Turn the brake disc forward 10 times.

6. Check the hub torque (6) with a spring balance.7. Calculate the drag force of the disc brake [difference

between hub torque (1) and hub torque (6)].

Standard value: 56 N

8. If the brake drag torque exceeds the standard value,disassemble and clean the piston. Check for corrosionor worn piston seal, and check the sliding condition ofthe lock pin and guide pin.


35/70

13

14 19

1518

1316

15 17

1211

10 169

14

9

12

1610

16

Brake caliper kit Seal and boot kit


DISASSEMBLYAND REASSEMBLY 35100720184

44 Nm

13

14 198 Nm 5

6

15 7 2

18 8 41

13

16

15

3 67

12

11

10

916

17Pad

set

58

Shim set

24

1

Clip set

Caliper assembly disassembly steps

1. Clip2. K-spring3. Pad pin4. Spring5. Inner shim

]A} 6. Pad and wear indicator assembly]A} 7. Pad assembly

8. Outer shim9. Retaining ring

]B} 10. Piston boot]B} 11. Piston]C} 12. Piston seal

13. Sleeve bolt14. Bushing15. Sleeve

16. Pin

boot17. Inner caliper18. Torque plate19. Bleeder screw

Pad assembly disassembly steps

1. Clip2. K-spring3. Pad pin4. Spring5. Inner shim6. Pad and wear indicator assembly7. Pad assembly8. Outer shim


36/70

35A-36 BASIC BRAKE SYSTEM Rear Disc Brake

LUBRICATION POINTS

CautionThe piston seal inside the seal and bootkit is coatedwith special grease,so donot wipe this

grease

off.

Brake fluid: DOT3 or DOT4




DISASSEMBLY SERVICE POINTS

Whendisassembling thereardiscbrakes,disassemblebothsides (left and right) as a set.


37/70


]A}PADAND WEAR INDICATORASSEMBLY/PADASSEMBLY REMOVAL

Use a flat-tipped screwdriver to remove the pad and wearindicator assembly and the pad assembly.

]B}PISTON BOOT/PISTON REMOVAL

Protectthecaliperbodywithashoptowel.Blowcompressedair through the brake hose to remove the piston boot andpiston.

CautionBlow compressed air gently.

]C}PISTON SEAL REMOVAL

1. Remove the piston seal with your finger tip.

CautionDo not use a flat-tippedscrewdriver or other tool toprevent damage to inner cylinder.

2. Clean the piston surface and inner cylinder withtrichloroethylene, alcohol or specified brake fluid.

Specified break fluid: DOT3 or DOT4


PAD WEAR CHECK

Measure the thicknessat the thinnestandwornarea of thepad.Replace the pad assembly ifpad thickness is less than thelimit value.


Caution1. Always replace both pads on each wheel as a set

(both front wheels or both rear wheels). Failure todoso will result in un-even brakingwhich maycausean unpredictable vehicle condition.

2. If there is significant difference in the thicknessesof the pads on the left and right sides, check thesliding condition of the piston, lock pin and guidepin.


38/70

NOTES


39/70

ANTI-SKID

BRAKING

SYSTEM

(ABS)

35B-1

CONTENTS 35209000282

GENERAL INFORMATION . . . . . . . . . . . . . . . . . .2 Brake Drum Inside Diameter Check

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

Refer

to

GROUP

35ASERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . .3 Brake Lining and Brake Drum Connection Check

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35ALUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Wheel Speed Sensor Output Voltage

Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . .3

Hydraulic Unit Check . . . . . . . . . . . . . . . . . . . . . . . . 24

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . .4 ABS Warning Lamp Relay ContinuityCheck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 22 Remedy for a Flat Battery . . . . . . . . . . . . . . . . . . . 25

Brake Pedal Check andAdjustment. . . . . . . . . . . . . . . . . . . . . . . . . .

Refer

to

GROUP

35A

Stop

Lamp

Switch

Check

BRAKE PEDAL . . . . . . . . Refer to GROUP 35A

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A MASTER CYLINDERAND BRAKE

Brake Booster Operating TestBOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A

Check Valve Operation Check. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A

Proportioning Valve Function Test

Master

Cylinder

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

27

LOAD SENSING PROPORTIONING VALVE. . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A

Bleeding. . . . . . . . . . . . . . . . . . Refer to GROUP 35A

FRONT DISC BRAKE . . Refer to GROUP 35A

Brake

Fluid

Level

Sensor

Check. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A

REAR DISC BRAKE . . . . Refer to GROUP 35A

Disc

Brake

Pad

Check

and

Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A

Disc Brake Rotor Check

HYDRAULIC UNIT . . . . . . . . . . . . . . . . . . . . . . . . 28

WHEEL SPEED SENSOR. . . . . . . . . . . . . . . . . 30

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A

Thickness Check . . . . . . . . . . Refer to GROUP 35A

Brake Lining Thickness Check. . . . . . . . . . . . . . . . . . . . . . . . . .

Refer

to

GROUP

35A

G-SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32


40/70

8

35B-2 ABS General Information

GENERAL INFORMATION 35200010307

TheABSconsistsofcomponentssuchasthewheelspeed sensors, stop lamp switch, hydraulic unitassembly (integrated inABS-ECU) and theABSwarning lamp. If a problem occurs in the system,the malfunctioning components can be identifiedand the trouble symptoms will be memorized by

the

diagnosis

function.

Inaddition,readingofdiagnosiscodesandservicedata and actuator testing are possible by usingthe MUT-II.

Items Specifications

ABStype 4-sensor,3-channeltype

Speedsensor Magnetcoiltypeon4-wheels

FrontABSrotorteeth 47

RearABSrotorteeth 47

CONSTRUCTION DIAGRAM

34

91

7 56

10 26

5

1. ABS Warning lamp relay2. Hydraulic

unit

assembly

(integratedinABS-ECU)

3. Diagnosis connector4. Stop lamp switch5. ABS rotor

6. Wheel speed sensor7. 4WD

detection

switch8. ABS warning lamp9. G-Sensor

10. Freewheel engage switch


41/70

ABS Service Specifications/Lubricant/Special Tools 35B-3

SERVICE SPECIFICATIONS 35200030327

Items Standardvalue

Wheelspeedsensorinternalresistancekfi 1.31.5

Wheelspeedsensorinsulationresistancekfi 100ormore

G-sensoroutputvoltageV Stationaryvehicle 2.42.6

Arrowfacingdownward 3.43.6

LUBRICANT 35200040061

Item

Specified

lubricant

Brakefluid DOT3orDOT4

SPECIAL TOOLS 35200060296

Tool

Number

Name

Use

MB991502 MUT-II subassembly

ForcheckingofABS(DiagnosiscodedisplaywhenusingtheMUT-II)

MB991529 Diagnosiscodecheckharness

ForcheckingofABS(DiagnosiscodedisplaywhenusingtheABSwarninglamp)


42/70

35B-4 ABS Troubleshooting

TROUBLESHOOTING 35201110501

STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING

Refer to GROUP 00 How to Use Troubleshooting/Inspection Service Points.

NOTES WITH REGARD TO DIAGNOSIS

The phenomena listed in the following table are not abnormal.

Phenomenon

Explanationofphenomenon

Systemchecksound Whenstartingtheengine,athuddingsoundcansometimesbeheardcoming from insidethe engine compartment, but this is because the system operation check is beingperformed,andisnotanabnormality.

ABSoperationsound 1. Sound of the motor inside theABS hydraulic unit operation (whine).2. Sound is generated along with vibration of the brake pedal (scraping).3. WhenABSoperates, sound is generated from thevehicle chassisdue to repeated

brake

application

and

release.(Thump: suspension: squeak: tyres)

ABSoperation(Longbrakingdistance)

Forroadsurfacessuchassnow-coveredroadsandgravelroads,thebrakingdistanceforvehicleswithABScansometimesbelongerthanthatforothervehicles.Accordingly,advisethe

customer

to

drive

safely

on

such

roads

by

lowering

the

vehicle

speed

and

not

being

too

overconfident.

Diagnosis detection condition can vary depending on the diagnosis code.Make sure that checking requirements listed in the Comment are satisfied when checking the troublesymptom again.

DIAGNOSIS

FUNCTION 35201120351

DIAGNOSIS CODES CHECK

Read adiagnosiscodeby the MUT-IIorABS warning lamp.(RefertoGROUP00HowtoUseTroubleshooting/InspectionService Points.)

ERASING DIAGNOSIS CODES

With the MUT-II

RefertoGROUP00HowtoUseTroubleshooting/InspectionService Points.


43/70

ABS Troubleshooting 35B-5

Without the MUT-II

1. Use the special tool to earth terminal (1) (diagnosis control terminal) of the diagnosis connector.(Refer to GROUP 00 How to Use Troubleshooting/Inspection Service Points.)

2. Stop the engine.3. Turn on the stop lamp switch. (Depress the brake.)4. After carrying out steps 1. to 3., turn the ignition switch to ON. Within 3 seconds after turning the

ignition switch to ON, turn off the stop lamp switch (release the brake). Then, turn the stop lampswitch on and off a total of 10 times.

NOTEIf theABS-ECU function has been stopped because of fail-safe operation, it will not be possibleto erase the diagnosis codes.

Ignition switchON

OFF

Stop lamp switch ON

OFF

ABSwarning lampON

OFF

ABS-ECU memoryWithin 3 Within Within Within Within Within Within Within Within Within Within 1se-1

1

1

1

1 1

1

1

1

1

seconds secondsecond second second second second second secondsecond secondcond

1st

2nd

3rd

4th

5th

6th

7th

8th

9th

10th Erasing

of

ABS-ECUdiagnosiscodescomplete.


44/70


INSPECTION CHART FOR DIAGNOSIS CODES 35201130576

Inspect according to the inspection chart that is appropriate for the malfunction code.

DiagnosiscodeNo.

Inspectionitem Diagnosiscontent Referencepage

11 Frontrightwheelspeedsensor Openorshortcircuit 35B-7

12

Front

left

wheel

speed

sensor

13 Rearrightwheelspeedsensor

14 Rearleftwheelspeedsensor

15 Wheelspeedsensor Abnormaloutputsignal 35B-8

16 Powersupplysystem 35B-8

21 Frontrightwheelspeedsensor Abnormal 35B-7

22 Frontleftwheelspeedsensor

23

Rear

right

wheel

speed

sensor

24 Rearleftwheelspeedsensor

25 4WDpositiondetectionswitch 35B-9

26 Freewheelengageswitch 35B-10

32 G-sensorsystem 35B-11

33 Stoplampswitchsystem 35B-11

41 Frontrightsolenoidvalve 35B-12

42 Frontleftsolenoidvalve

43 Rearsolenoidvalve

51 Valverelay

53 Motorrelay,motor

63 ABS-ECU RefertoP.35B-28(Replacethehydraulicunitassembly)


45/70


INSPECTION PROCEDURE FOR DIAGNOSIS CODES

Code No.11,12,13,14Wheel speed sensor open circuitor short circuit

Probable cause

Code No.21,22,23,24Wheelspeed sensor abnormal

The

ABS-ECU

determines

that

an

open

circuit

or

short

circuit

occurs

in

more

than

one

line

of

wheel

speed

sensors.

Malfunction of wheel speed sensor Malfunction of wiring harness or connector Malfunction of hydraulic unit assembly

These

codes

are

output

at

the

following

times: Whenan opencircuitcannotbe found,but more than onewheel speedsensor

does

not

output

any

signal

during

driving

at

8

km/h

or

higher. When a chipped or plugged-up rotor tooth, etc. is detected. When the sensor output drops and anti-lock control is continuously carriedout

due

to

a

defective

sensor

or

a

warped

rotor.

Malfunction

of

wheel

speed

sensor Malfunction ofABS rotor Malfunction of wheel bearing Malfunction of wiring harness or connector Malfunction of hydraulic unit assembly

NG

Wheel

speed

sensor

installation

check.

OK

NG

Measure at theABS-ECU connectorsA-01. Disconnect the connector and

measure

from

the

harness

side. Resistancevalues between1 2,

Repair

NGCheck

the

following

connectors:A-01,

A-87,

A-103,

C-18,

E-23,

E-26,E-42

OK

Repair

3

4,

18

19

and

20

21.OK: 1.3

1.5

kfi

OKNG

NGCheck

trouble

symptoms.

Check

the

harness

wire

between

eachwheel

speed

sensor

andABS-ECU,and

repair

if

necessary.

NGWheel

speed

sensor

output

voltagecheck.

(Refer

to

P.35B-22.)

OK

NGCheck

the

following

connector:A-01

OK

Check

trouble

symptoms.

NG

Wheel

speed

sensor

check.

(Refer

toP.35B-31.)

OK

NG

ABS

Rotor

check.

(Refer

to

P.35B-31.)

Repair OK

Wheel

bearing

check.

(Refer

to

GROUP26

and

27

On-vehicle

Service.)

Replace

the

wheel

speed

sensor.

Replace

the

ABS

rotor.

Replace

the

hydraulic

unit

assembly.


46/70


CodeNo.15Wheelspeedsensor (Abnormaloutputsignal) Probable cause

A

wheel

speed

sensor

outputs

an

abnormal

signal

(other

than

an

open

or

short-circuit). Improper installation of wheel speed sensor

Malfunction of wheel speed sensor Malfunction ofABS rotor Malfunction of wheel bearing Malfunction of wiring harness or connector Malfunction of hydraulic unit assembly

NG

Wheel

speed

sensor

installation

check.

OK

NG

Wheel

speed

sensor

output

voltagecheck

(Refer

to

P.35B-22.)

OK

NGCheck

the following connector:

A-01

OK

Check

trouble

symptoms.

NG

Repair

Repair

NG

Wheel

speed

sensor

check.

(Refer

toP.35B-31.)

OK

NG

ABS

Rotor

check.

(Refer

to

P.35B-31.)

OK

OK

Wheel

bearing

check.

(Refer

to

GROUP26

and

27

On-vehicle

Service.)

Replace

the

wheel

speed

sensor.

Replace

the

ABS

rotor.

Check

the

harness

wire

between

each

wheelspeedsensorandABS-ECU,

andrepair

if

necessary.

Replace

the

hydraulic

unit

assembly.

Code No.16Power supplysystem Probable cause

The

voltage

of

the

ABS-ECU

power

supply

drops

lower

or

rises

higher

than

the

specified

value.

If

the

voltage

returns

to

the

specified

value,

this

code

is

no

longer

output.

Malfunction of wiring harness or connector. Malfunction of hydraulic unit assembly

CautionIf battery voltage drops or rises during inspection, this code will be outputas well. If the voltagereturns

to standard value, this code is no longer output.Before carrying out the following inspection, check the battery level, and refill distilled water ifnecessary.

NG

Measure

at

the

ABS-ECU

connector

A-01. Disconnect the connector and

measure

at

the

harness

side. Start the engine. Voltage between

9

Body

earthOK:

System

voltage

OK

NGCheck

the

following connector:A-01

NGCheck

the

following

connectors:

A-01,

C-11,

C-18,

D-26,

D-28

OK

NG

Check

trouble

symptoms.

OK

Check

the

battery.

Repair

Repair

Check

the

harnes

wire

between

the

igni-

tion

switch

and

the

ABS-ECU,

and

repair

if necessary.

OK

Check

trouble

symptoms.NG

Replace

the

hydraulic

unit

assembly


47/70


Code No.254WDpositiondetectionswitch Probable cause

ABS-ECU

determines

that

an

open

circuit

exists

in

the

4WD

position

detection

switch

system.

Malfunction of wiring harness or connector Malfunction of 4WD indicator-ECU Malfunction of 4WD position detection switch Malfunction of hydraulic unit assembly

No

Does

the

4WD

indicator

lamp

operatenormally?

Yes

NG

Measure

at

ABS-ECU

connector


measure

at

the

harness

side. Ignition switch ON

NG4WD

indicator-ECU

check.

(Refer

toGROUP

22

4WD

indicator-ECU.)

NGCheck the following connectors:

A-01,

B-05,

C-12,

C-18,

C-30

OK

Replace the 4WD indicator-ECU.

Repair

Voltagebetween12andbodyearthOK:

System

voltage

or

0

V

OK

NGCheck

the following connector:

A-01

NGCheck trouble symptom. Checktheharnessbetween4WDposi-

tion

detection

switch

and

the

ABS-ECU,and

repair

if

necessary.

Repair

OK

Check

trouble

symptom.NG

Replace

the

hydraulic

unit

assembly


48/70


Code No.26Freewheel engage switch Probable cause

This

code

is

output

at

the

following

times: ABS-ECUdetermines that an opencircuit exists in the freewheel engageswitch

system. When the 4WD detection switch is off and the freewheel engage switch is on,

the vehicle will continue running at 20 km/h or more for approximately 5 min.or

more

and

then

will

continue

running

until

a

speed

of

0

km/h

is

reached.

(Code

Nos.

25

and

26

are

output.)

Malfunction of wiring harness or connector Malfunction of freewheel engage switch Malfunction of 4WD indicator-ECU Malfunction of 4WD position detection switch Malfunction of hydraulic unit assembly

Does

the

4WD

indicator

lamp

operate

normally?

No

Yes

NG

Measure

at

ABS-ECU

connec-tor

A-01. Disconnect the connector

andmeasureattheharness

side. Ignition switch ON Transfer lever:2H Voltage between 11 and

body

earth

OKOK:

System

voltage

NGCheck

the

following connectors:A-01,

A-57,

C-71

OK

NG

Check

trouble

symptom.

NGCheck the following connector:

A-01

Repair

Check

the

harnesses

between

free-

wheelengageswitchandtheABS-ECU,and

repair

if

necessary.

Repair

OK

Check

trouble

symptom.NG

Replace

the

hydraulic

unit

assembly.

Troublesymptom Maincause Remedy

Evenwhenthetransfershift leverisin the 4H position, the 4WDindicatorlampdoesnotilluminate.

Broken

harness

wire

between

the

4WD

indicator-ECU and the freewheel en-gageswitch,orbrokenearthwire fromthefreewheelengageswitch

Repairtheharness.

Freewheel engage switch or 4WDpositiondetectionswitchisdefective.

Replacetheswitch.

Brokenharnesswirebetweenthe4WDindicator-ECU and the 4WD positiondetection

switch

Repairtheharness.

Brokenwireinthe4WDindicator-ECUcircuit

4WDindicator-ECUinspection(RefertoGROUP224WDindicator-ECU.)

4WD indicator lamp illuminatesregardless of the position of thetransfershiftlever.

Short in theharness wire in the4WDpositiondetectionswitchcircuit

Repairtheharness.

4WD position detection switch isdefective.

Replacetheswitch.

ShortintheABS-ECUcircuit ReplacetheABS-ECU.

Shortinthe4WDindicator-ECUcircuit 4WD

indicator-ECU

inspection

(Re-

fer

to

GROUP

22

4WD

indicator-

ECU.)

Noindicatorisilluminated Powercircuitinthe4WDindicator-ECUisdefective.

Repairtheharness.

4WDindicator-ECUisdefective. 4WD indicator-ECU inspection (Re-fer to GROUP 22 4WD indicator-ECU.)

NOTEWhen checking a short in theABS-ECU circuit, remove theABS-ECU connector and check if the 4WDindicatorreturnstonormal.Ifitreturnstonormal,theABS-ECUisdefective.Furthermore,iftheABS-ECUis normal, then the 4WD indicator-ECU will be defective.


49/70


Code No.32G-sensor system Probable cause

This

code

is

output

at

the

following

times: The G-sensor output is less than 0.5 V or more than 4.5 V. An open or short circuit is present in the G-sensor system.

Malfunction of G-sensor Malfunction of wiring harness or connector Malfunction of hydraulic unit assembly

NG

G-sensor

check

(Refer

to

P.

35B-32.)

OK

NG

Measure

at

ABS-ECU

connector


measure

at

the

harness

side. Ignition switch ON

Replace

the

G-sensor.

NGCheck

the

following

connectors:A-01,

C-18,

C-26

OK

Repair

Voltage between 7 and 14OK:

2.4

2.6

V

OK

NGCheck

the

following

connector:A-01

NGCheck

trouble

symptom.

Check

the

harness

between

the

G-sen-sor

and

the

ABS-ECU,

and

repair

if

nec-essary.

Repair

OK

Check

trouble

symptom.

NG

Replace

the

hydraulic

unit

assembly.

Code No.33Stop lamp switchsystem Probable cause

These

codes

are

output

at

the

following

times: Whenthestoplampswitchisnotbeturnedoff(whenthestoplampswitchstays

on

for

15

minutes

or

more

although

the

ABS

is

not

operating) When theABS-ECU determines that there is an open circuit in harness of the

stop

lamp

switch

system.

Malfunction of stop lamp switch Malfunction of harness or connector Malfunction of hydraulic unit assembly

No

Doesthestoplampilluminateandswitchoff

normally?

Yes

NG

Stop

lamp

switch

installation

check.

OK

NG

Stop

lamp

switch

check.

(Refer

to

GROUP

35A

On-vehicle

Service.)OK

Repair

Replace

the

stop

lamp

switch.

Check

the

harness

between

dedicated

fuse

No. 8

and

the

ABS-ECU,

and

repair

if

necessary.

NG

Measure

at

ABS-ECU

connector


measure

at

the

harness

side. Stop lamp switch ON. Voltagebetween13andbodyearth

OK:

Systemvoltage

OK

NGCheck the following connectors:

A-01,

C-12,

C-18,

C-59

,

C-60

OK

Check

trouble

symptom.

NG

Repair

NGCheck

the

following connector:A01

Check

the

harness

between

dedicated

fuseNo. 8andtheABS-ECU,andrepairif

necessary.

Repair

OK

Check

trouble

symptom.NG

Replace

the

hydraulic

unit

assembly.


50/70


Code No.41,42,43 Solenoidvalve system Probable cause

Code No.51Valve relay system

Code No.53Motor relay, Motor system

These

codes

are

output

in

the

following

cases: If there is an open or short circuit in theABS-ECU power circuit (solenoid

valve,

motor). If there is a malfunction in the hydraulic unit inner circuit.

Malfunction of harness or connector Malfunction of hydraulic unit assembly

NGMeasure

at

ABS-ECU

connector


measure

at

the

harness

side. Voltage between 31, 33 and body

earthOK:

System

voltage

OK

Check

and

repair

the

harness

between

the

multipurpose

fuse

No.11

and

ABS-ECU.

NGCheck

the

following

connector:A-02

Repair

OK

Check

trouble

symptom.NG

Replace

the

hydraulic

unit

assembly.

ABSwarninglamp

ABS

warning

lamp

Approx. 3s Approx. 3s

Illuminated

Notilluminated

ABS WARNING LAMP INSPECTION 35201200161

Check that theABS warning lamp illuminates asfollows.

1. Whenthe ignitionkey isturnedtoON,theABSwarninglamp illuminates for approximately 3 seconds and thenswitches off.

2. When the ignition key is turned to START, theABSwarning lamp remains illuminated.

3. When the ignition key is turned from START back to

ON,

the

ABS

warning

lamp

illuminates

for

approximately3 seconds and then switches off.

NOTETheABS warning lampmay remain onuntil thevehiclereachesaspeedofseveralkm/h.This is limited tocaseswhere diagnosis code Nos.21 24 and 55 have beenrecorded because of a previous problem occurring. Inthis case, the ABS-ECU keeps the warning lamp

Ignition START illuminated until the problem corresponding to thatswitch ON

ACC,LOCK

diagnosis code can be detected.

4. If the illumination is other than the above, check thediagnosis codes.


51/70


INSPECTION CHART FOR TROUBLE SYMPTOMS 35201140555

Get an understanding of the trouble symptoms and check according to the inspection procedure chart.

Troublesymptoms InspectionprocedureNo.

Referencepage

CommunicationwithMUT-IIisnotpossible.

Communicationwithallsystemsisnotpossible. 1 35B-14

Communication

with

ABS

only

is

not

possible.

2

35B-14

WhentheignitionkeyisturnedtoON(enginestopped),theABSwarninglampdoesnotilluminate.

3 35B-15

The

ABS

warning

lamp

remains

illuminated

after

the

engine

is

started.

4

35B-16

FaultyABSoperation Unequalbrakingpoweronbothsides 5 35B-17

Insufficientbrakingpower

ABSoperatesundernormalbrakingconditions

ABS operates before vehicle stops under normal

braking

conditions

Largebrakepedalvibration(Caution2.)

Caution1. If steering movementsare made when driving at high speed, or when driving on road surfaces

with low frictional resistance,or when passingover bumps, theABS may operate even thoughsudden brakingisnotbeing applied. Because ofthis, whengettinginformationfrom thecustomer,check if the problem occurred while driving under such conditions as these.

2. During ABS operation, the brake pedal may vibrate or may not be able to be depressed.Suchphenomenaaredue to intermittentchanges inhydraulicpressureinside thebrake line topreventthe wheels from locking and is not an abnormality.


52/70


INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

Inspection Procedure 1

Communicationwith MUT-IIis not possible.(Communicationwith all systemsis not possible.)

Probable cause

The reason is probably a defect in the power supply system (including earth) forthe

diagnosis

line.

Malfunction of connector Malfunction of harness

Refer

to

GROUP

13A

Troubleshooting.


Communicationwith MUT-IIis not possible.(CommunicationwithABSonly is not possible.)

Probable cause

When

communication

with

the

MUT-II

is

not

possible,

the

cause

is

probably

an

open

circuit

in

the

ABS-ECU

power

circuit

or

an

open

circuit

in

the

diagnosis

output

circuit.

Blown fuse Malfunction of wiring harness or connecter Malfunction of hydraulic unit assembly

NGMeasure

at

diagnosis

connector

C-63and

ABS-ECU

connector


measure

at

the

harness

side. Continuity between the following

terminalsOK:

Continuity

NGCheck

the


C12,

C-18,

C-63

OK

NG

Check

trouble

symptoms.

Repair

Check

the

harness

between

the

ABS-

ECU

and

diagnosis

connector,

and

re-

pair

if

necessary.ABS-ECU

side 2423

Diagnosis

connector

side

1

7

OKNG

NGMeasure

at

ABS-ECU

connector


measure

at

the

harness

side. Ignition switch: ON Voltage between 9 body earth

OK: System voltage

OK

NG

Measure

at

ABS-ECU

connectors


measure

at

the

harness

side. Continuity between 32, 34 body

earthOK:

Continuity

Check

the


C-11,

C-18,

D26,

D-28

OK

NG

Check

trouble

symptoms.

Repair

Repair

Check

the

harness

wire

between

the

ignition

switch

and

the

ABS-ECU,

and

repair

if

necessary.

OK

NGCheck

the

following

connector:A-02

Repair

OK

Check

trouble

symptoms.NG

Replace

the

hydraulic

unit

assembly.


53/70

Check

the following conn

A-55,

C04,

C-05,

C-18,

D

19,

D-28



When ignition key is turned to ON (engine stopped),ABS warninglamp does not illuminate.

Probable cause

Lamp

power

supply

circuit

disconnections,

lamp

bulb

burnouts,

ABS

warning

lamp

relay faults, or circuit breaks between theABS warning lamp and the ground arepossible

causes.

Blown fuse Burnt outABS warning lamp bulb Malfunction of theABS warning lamp relay Malfunction of wiring harness or connector Malfunction of hydraulic unit assembly

NG

Fuse

inspection,

Multi-purpose

fuseNo.

11.

OK

Measure

at

ABS

warning

lamp

relay

NG

connector


measure

at

harness

side. Ignition switch: ON Does the ABS warning lamp

illuminate

when

terminal

(3)

is

earthed?OK:

Illuminates

OK

NG

ABS warning lamp relay inspection(Refer

to

P.35B-25.)

OK

NG

Measure

at

ABS

warning

lamp

relayconnector


measure

at

harness

side. Ignition switch: ON Voltage between 4 and the body

earth.OK:

Continuity

Refer

to

GROUP

00

Inspection

Service

Points

for

a

Blown

Fuse.

NG

Check

whether

the

ABS

warninglamp

bulb

is

burnt

out.

OKNG

ectors:

OKNG

Check

trouble

symptoms.

Replace

the

ABS

warning

lamp

relay.

NGCheck

the

following

connectors:A-55,

C-71

OK

NG

Check

trouble

symptoms.

Replace

the

ABS

warning

lamp

bulb.

Repair

Check

the

harness

wire

between

the

ignition

switch

IG1

and

the

ABS

warning

lamp

relay,

and

repair

if

necessary.

Repair

Check the harness wire between theABS

warning

lamp

relay

and

the

earth,

and

repair

if

necessary.

OK

Replace

the

hydraulic

unit

assembly.


54/70



The ABS warning lamp remains illuminated after theengine is started.

Probable cause

It

is

probably

a

short

circuit

in

the

ABS

warning

lamp

circuit. Defective combinationmeter

DefectiveABS warning lamp relay Malfunction of wiring or connector Defective hydraulic unit assembly

NOTE

This trouble symptom is limited to cases where communication with the MUT-II is possible (ABS-ECUpower supply is normal) and the diagnosis code is a normal diagnosis code.

YESWhen

the

combination

meter

connectorC-05

is

disconnected

and

the

ignition

switchison,doestheABSwarninglampremain

on?

Replace

the

combination

meter

NO

NG

Check

the

ABS

warning

lamp

relay(Refer

to

P.35B-25.)

OK

Replace

the

ABS

warning

lamp

relay

When

the

ABS

warning

lamp

relay

connector

A-55

is

disconnected

and

the

ignition

switch

is

on,

does

the

ABS

warning

lamp

remain

on?

OK

Measure

at

ABS

warning

lamp

relay

connector

A-55.

YES

NGCheck

the

following

connectors:A-55,

C05,

C-18

OK

NG

Check

trouble

symptoms.

NG

Repair

Check

the

harness

wire

between

the

Combination

meter

and

the

ABS

warning

lamp

relay,

and

repair

if

necessary.

Disconnect the connector andmeasure

at

harness

side. Ignition switch: ON Voltage between terminal 2 and

body

earth.OK:

System

voltage

OK

NG

Measure

at

ABSECU

connectorA-01. Disconnect the connector and

measure

at

harness

side. Ignition switch: ON Voltage between terminal 16 and

the

body

earth.OK:

System

voltage

OK

Check

the

following

connector:

NGA-55.

OK

NG

Check

trouble

symptoms.

Chek

the

following

connectors:

NG

A-01,

A-55

OK

NG

Check

trouble

symptoms.

Repair

Check

the

harness

wire

between

the

ignitionswitchIG2andtheABSwarninglamp

relay,

and

repair

if

necessary.

Repair

Check

the

harness

wire

between

the

ABS

warning

lamp

relay

and

the

ABSECU,

and

repair

if

necessary.

Replace

the

hydraulic

unit

assembly.


55/70



Brake operationis abnormal. Probable cause

This

varies

depending

on

the

driving

conditions

and

the

road

surface

conditions,

so

problem

diagnosis

is

difficult.

However,

if

a

normal

diagnosis

code

is

displayed,

carry

out

the

following

inspection.

Improper installation of wheel speed sensor Incorrectsensor harness contact Foreign material adhering to wheel speed sensor Malfunction of wheel speed sensor Malfunction ofABS rotor Malfunction of wheel bearing Malfunction of hydraulic unit assembly

NG

Wheel

speed

sensor

installation

check.

OK

Wheel

speed

sensor

output

voltage

OK

check.

(Refer

to

P.35B-22.)

NG

NG

Wheel

speed

sensor

check.

(Refer

toP.35B-31.)

Repair

Hydraulic

unit

assembly

check.

(Refer

to

P.35B-24.)

Replace

the

wheel

speed

sensor.

OK

NG

ABS

rotor

check.

(Refer

to

P.35B-31.)

OKNG

Wheel

bearing

check.

(Refer

to

GROUP26 and 27 On-vehicle Service.)

OKNG

Check

the

following

connectors:A-01,

A-87,

A-103,

C-18,

E-23,

E26,E-42

Replace

the

ABS

rotor.

Repair

Repair

OK

Check

trouble

symptom.

NGNG

Measure

at

ABS-ECU

connector

A01. Disconnect the connector and

measure

at

the

harness

side.

Resistance

value

between

terminals1

2,

3

4,

18

19

and

20

21OK:

1.3

1.5

kfi(The

sensor

harness

and

connectorshould

be

moved

while

these

inspections

are

carried

out.)

OKNG

Check the following connector:A-01

Repair

Repair

OK

Check

trouble

symptom.NG

Replace the hydraulic unit assembly.


56/70


DATA LIST REFERENCE TABLE 35201150299

The following items can be read by the MUT-II from theABS-ECU input data.1. When the system is normal

ItemNo. Checkitem Checkingrequirements Normalvalue

11 Front-rightwheelspeedsensor Performatestrun Vehicle speedsdisplayedonthe

speedometer

and MUT-II areidentical.

12

Front-left

wheel

speed

sensor

13 Rear-rightwheelspeedsensor

14 Rear-left

wheel

speed

sensor

16 ABS-ECUpowersupplyvoltage

Ignition switch power supply voltage and valvemonitorvoltage

916V

25 4WDpositiondetectionswitch Placethetransferleverat4H. ON

Placethetransferleverat2H. OFF

26 Freewheelengageswitch Engage4WD ON

Engage

2WD

OFF

32 G-sensor

output

voltage Stop

the

vehicle. 2.4

2.6

V

Performatestrun. Display valuefluctuates with amean value of2.5V.

33 Stoplampswitch Depressthebrakepedal. ON

Releasethebrakepedal. OFF

2. When theABS-ECU shut off ABS operation.

When the diagnosis system stops theABS-ECU, the MUT-II display data will be unreliable.

ACTUATOR TEST REFERENCE TABLE 35201160209

The MUT-II activates the following actuators for testing.

NOTE1. If theABS-ECU runs down, actuator testing cannot be carried out.2. Actuator testing is only possible when the vehicle is stationary. If the vehicle speed during actuator

testing exceeds 10 km/h, forced actuation will be cancelled.3. Duringtheactuatortest,theABSwarninglampwillilluminateandtheanti-skidcontrolwillbecancelled.


57/70

1s

No. Item

01 Solenoidvalveforfront-leftwheel

Solenoid valves and pumpmotors in thehydraulic unit(simpleinspectionmode)

02 Solenoidvalveforfront-rightwheel

03

Solenoid valve for rearwheel


Activation pattern

A

Startofforcedaction

End offorcedaction

ACTUATOR TEST SPECIFICATIONS

Solenoidvalve

Pumpmotor

B

C

48ms

ON

OFF

3

s

8ms

NOTEA:Hydraulic pressure increasesB:Hydraulic pressure holdsC:Hydraulic pressure decreases

CHECKATABS-ECU 35201180359

TERMINAL VOLTAGE CHECK CHART

1. Measurethevoltagesbetweenterminals(32)and(34)(groundterminals)andeachrespectiveterminal.

NOTEDo not measure terminal voltage for approximately three seconds after the ignition switch is turnedon. TheABS-ECU performs the initial check during that period.

2. The terminal layouts are shown in the illustrations below.

ConnectorterminalNo.

Signal Checkingrequirement Normalcondition

6 Enginecontrolmodule

Ignitionswitch:ON

(Themotorisonapprox.1secondafterengineisstarted)

2Vorless

7 G-sensorsignal Ignitionswitch:ON 2.382.62V

9 ABS-ECUpowersupply

Ignitionswitch:ON Systemvoltage

Ignitionswitch:START 0V

11 Input

from

freewheelengageswitch

Ignition

switch:

ON Transfer

lever

position:

2H System

voltage

Transferleverposition:4H 0V


58/70


ConnectorterminalNo.

Signal Checkingrequirement Normalcondition

12 Inputfrom4WDdetectionswitch

Ignitionswitch:ON Transferleverposition:2H Systemvoltage

Transferleverposition:4H 0V

13 Inputfromstoplampswitch

Ignitionswitch:ON Stoplampswitch:ON Systemvoltage

Stop

lamp

switch:

OFF

0

V

14 G-sensor Always 0V

16 ControloutputtoABSwarninglamprelay.

Ignitionswitch:ON Thelampisswitchoff. 2Vorless

Thelampisilluminated. Systemvoltage

23 MUT-II ConnecttheMUT-II SerialcommunicationwithMUT-II

DonotconnecttheMUT-II 1Vorless

24 Inputfrom

diagnosisindication

selection

ConnecttheMUT-II 0V

Do

not

connect

the

MUT-II Approximately

12

V

31 Solenoidvalvepowersupply

Always Systemvoltage

33 Motorpowersupply


59/70


RESISTANCEAND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS

1. Turn the ignitionswitchoffanddisconnect theABS-ECUconnectorsbeforechecking resistanceandcontinuity.

2. Check between the terminals indicated in the table below.3. The terminal layouts are shown in the illustration below.

ConnectorteminalNo. Signal Normalcondition

2021 Front-leftwheelspeedsensor 1.31.5kfi

12 Rear-rightwheelspeedsensor 1.31.5kfi

18

19 Front-right

wheel

speed

sensor 1.3

1.5

kfi

3

4

Rear-left

wheel

speed

sensor

1.3

1.5

kfi

32bodyearth Solenoidvalveearth Continuity

34bodyearth Motorearth Continuity


60/70

35B-22 ABS On-vehicle Service

ON-VEHICLE SERVICE 35200160316

WHEEL SPEED SENSOR OUTPUT VOLTAGECHECK

1. Lift up the vehicle and release the parking brake.2. Disconnect theABS-ECU connector, and then use the

specialtool(inspectionharnessforconnectorpincontactpressure) to measure the output voltage at theharness-side

connector.

3. Rotatethewheeltobemeasuredatapproximately1/21rotation persecond, and check the output voltage usinga circuit tester or an oscilloscope.

Wheelspeedsensor

Frontleft Frontright

Rearleft Rearright

TerminalNo.

20 18 3 1

21

19

4

2

Output voltage

When measuring with a circuit tester:70 mV or more

When measuring with an oscilloscope:200 mV p-p or more

4. If theoutputvoltage is lowerthan theabovevalues,thereason could be as follow: Faulty wheel speed sensor.So replace the wheel speed sensor.

When turning byhand

When

idling

(56

km/h),

1st

gear

(manual

trans-

mission)orDrange (auto-matic transmission)

Inspecting Waveforms With An Oscilloscope

Use the following method to observe the output voltagewaveform from each wheel sensor with an oscilloscope. Start theengine,androtatetherearwheelsbyengaging

1stgear (vehicles with manual transmission)or D range(vehicles with automatic transmission). Turn the frontwheelsmanuallysothattheyrotateataconstantspeed.

NOTE1. Check the connection of the sensor harness and

connector

before

using

the

oscilloscope.2. The

waveform

measurements

can

also

be

taken

whilethe vehicle is actually moving.

3. The output voltage will be small when the wheel speedis low,andsimilarly itwillbe largewhenthewheelspeedis high.

10.0ms/DIV 1V/DIV


61/70

ABS On-vehicle Service 35B-23

Points In Waveform Measurement

Symptom Probablecauses Remedy

Toosmallorzerowaveformamplitude

Faultywheelspeedsensor Replacesensor

Wa

Documents

manual pajero 4x4 service brakes.docx