Professional Documents
Culture Documents
SECTION
BR
22 23 '" .23 24 25 25 26 27 27 27 27
CONTENTS
PRECAUTIONS Precautions Special Service Tools Tools Commercial Checking Checking Changing AIR Bleeding Removal Inspection Installation Service AND PREPARATION
3
3 4 4
Caliper Rotor
CHECK AND ADJUSTMENT Brake Brake Brake Fluid Level Line Fluid
5
5 5 5
REAR DRUM BRAKE Removal Inspection Inspection Inspection Installation REAR DISC BRAKE Pad Replacement Wheel Cylinder Overhaul Drum Lining Wheel Cylinder
BLEEDING
Procedure LINE
6
6
BRAKE HYDRAULIC
7
8 8 8
29
29
CONTROL VALVE
Proportioning Removal Inspection Adjustment MASTER CYLINDER Removal Disassembly Inspection Assembly Installation BRAKE BOOSTER On-vehicle Removal Inspection Installation VACUUM HOSE and Installation Removal Inspection FRONT DISC BRAKE Pad Replacement.. Removal Disassembly Service Valve BRAKE PEDAL AND BRACKET and Installation
9
9
11
11 11 11
36
36 36 37
12
12 12 13 13 14
38
38 38 38 39 39 .40 .45
15
15 15 16 16 17 17 17
52
52
19
19 22 22
CONTENTS
(Cont'd.)
When you read wiring diagrams: Read GI section, "HOW TO READ WIRING DIAGRAMS" . See El section, "POWER SUPPLY ROUTING" for power distribution circuit. When you perform trouble diagnoses, read GI section, "HOW TO FOllOW FLOW CHART IN TROUBLE DIAGNOSES" and "HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT".
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" (SINGLE AIR BAG SYSTEM)
The Supplemental Restraint System "Air Bag" and used along with a seat belt, helps to reduce the risk or severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: To avoid rendering the SRS inoperative, which could increase the in the event of a collision which would result in air bag inflation, all by an authorized NISSAN dealer. Improper maintenance, including incorrect removal and installation injury caused by unintentional activation of the system. Do not use electrical test equipment on any circuit related to the Service Manual. risk of personal injury or death maintenance must be performed of the SRS, can lead to personal SRS unless instructed to in this
BR-3
BRAKE SYSTEM
Recommended fluid is brake fluid "DOT 3" or "DOT 4". Never reuse drained brake fluid. Do not mix different types of brake fluids (DOT 3, DOT 4). Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. To clean master cylinder parts, disc brake caliper parts or wheel cylinder parts, use clean brake fluid. Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of hydraulic system. Use flare nut wrench when removing and installing brake tubes. Always torque brake lines when installing. WARNING: Clean brakes with a vacuum dust collector to minimize risk of health hazard from powder caused by friction.
a: 10 mm (0.39 in)
NT406
~:
Commercial
Tool name Description
Service Tools
CD
@ Torque wrench
NT360
a: 10 mm (0.39 in)
NT151
BR-4
Min. line OK
Check fluid level in reservoir tank. It should be between Max. and Min. lines on reservoir tank. If fluid level is extremely low, check brake system for leaks. If brake warning lamp comes on, check brake fluid level switch and parking brake switch.
MIN
SBR418C
ABR159
SBR419C
BR-5
SBR995
I I
SBR419C
RHO models
I
front brake-+Right rear brake-+Left
Right rear brake-+Left front brake-+Left rear brake-+Right front brake. 1. Connect a transparent vinyl tube to air bleeder valve. 2. Fully depress brake pedal several times. 3. With brake pedal depressed, open air bleeder valve to release air. 4. Close air bleeder valve. 5. Release brake pedal slowly. 6. Repeat steps 2. through 5. until clear brake fluid comes out of air bleeder valve. 7. Tighten air bleeder valve. ~: 7 - 9 N.m (0.7 - 0.9 kg-m, 61 - 78 in-Ib)
BR-6
ASS actuator
= .Primary
line
SBR086D
L Master cylinder
. Secondary line 0 : Flare nut 15 - 18 (1.5 - 1.8, 11 - 13) : Connecting bolt 17 - 20 (1.7 - 2.0, 12 - 14) ~ : N.m (kg-m. ft-Ib)
BR-7
LINE
SBR419C
CAUTION: Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. All hoses must be free from excessive bending, tWisting and pulling. 1~ Connect a vinyl tube to air bleeder valve~ 2. Drain brake fluid from each air bleeder valve by depressing brake pedal. 3. Remove flare nut securing brake tube to hose, then withdraw lock spring. 4. Cover openings to prevent entrance of dirt whenever disconnecting hydraulic line.
Inspection
Check brake lines (tubes and hoses) for cracks, deterioration other damage. Replace any damaged parts. or
Installation
CAUTION: Refill with new brake fluid "DOT 3" or "DOT 4". Never reuse drained brake fluid. Do not mix different types of brake fluids (DOT 3, DOT 4). 1. Tighten all flare nuts and connecting bolts. Flare nut: . ~: 15 - 18 N'm (1.5 - 1.8 kg-m, 11 - 13 ft-Ib) Connecting bolt: ~: 17 - 20 N'm (1.7 - 2.0 kg-m, 12 - 14 ft-Ib) 2. Refill until new brake fluid comes out of each air bleeder valve. 3. Bleed air. Refer to "Bleeding Procedure", BR-6.
BR-8
With ABS GA16DE' 6.375 (63.7, 65, 924) 3,432 - 3,825 (34.3 - 38.2, 35 - 39, 498 - 555) SR20DE 5,394 (53.9, 55, 782) 2,452 (245 25 356 - 2,844 - 28.4, - 29, - 412)
4.
If output pressure is out of specifications, replace dual proportioning valve (separated type) or master cylinder assembly (built-in type). Bleed air after disconnecting the Tool. Refer to "Bleeding Procedure", BR-5.
BR-9
tDJ:
BR-10
iii : N'm
~
(kg-m, in-Ib)
SBR205D
Inspection
Check brake pedal for following items: Brake pedal bend Clevis pin deformation Crack of any welded portion Crack or deformation of clevis pin stopper
SBR997
Adjustment
Check brake pedal free height from dash reinforcement panel (RHD) and dash lower panel (LHD). Adjust if necessary. H: Free height Refer to 50S (BR-SS). 0: Depressed height Refer to 50S (BR-SS). Under force of 490 N (50 kg, 110 Ib) with engine running 1. Loosen lock nut and adjust pedal free height by turning brake booster input rod. Then tighten lock nut. 2. Check pedal free play. Make sure that stop lamps go off when pedal is released. 3. Check brake pedal's depressed height while engine is running. If lower than specification, check for leaks, air in system or damage to components (master cylinder, wheel cylinder, etc.). Then make necessary repairs.
SBR034D
BR-11
1. Connect a vinyl tube to air bleeder valve. 2. Drain brake fluid from each air bleeder valve, depressing brake pedal to empty fluid from master cylinder. 3. Remove brake pipe flare nuts. 4. Remove master cylinder mounting nuts.
SEC. 460
Reservoir cap
----g
~
___Reservoir tank
o
~
l-~
/'
~
. .-:'J
C'9 --~
Stopper cap ~
Disassembly
1. Bend claws of stopper cap outward.
BR-12
SBR435B
3. Remove piston assemblies. If it is difficult to remove secondary piston assembly, apply compressed air through fluid outlet. 4. Draw out reservoir tank.
gradually
SBR939A
Inspection
Check master cylinder Replace if damaged. inner wall for pin holes or scratches.
Assembly
Secondary piston
1.
Primary piston
Insert secondary piston assembly. Then insert primary piston assembly. Pay attention to direction of piston cups in figure at left. Also, insert pistons squarely to avoid scratches on cylinder bore. Pay attention to alignment of secondary piston slit with valve stopper mounting hole of cylinder body (For models with ABS only).
SBR012A
Primary piston
_-rnIJ
SBR221BA
BR-13
5.
piston
is pushed
into cylinder
SBR435B
Installation
CAUTION: Refill with new brake fluid "DOT 3" or "DOT 4". Never reuse drained brake fluid. Do not mix different types of brake fluids (DOT 3, DOT 4). 1. Place master cylinder onto brake booster and secure mounting nuts lightly. 2. Torque mounting nuts. ~: 11.7 - 14.7 N'm (1.2 - 1.5 kg-m, 8.7 -10.8 ft-Ib) 3. Fill up reservoir tank with new brake fluid. 4. Plug all ports on master cylinder with fingers to prevent air suction while releasing brake pedal. 5. Have driver depress brake pedal slowly several times until no air comes out of master cylinder. 6. Fit brake lines to master cylinder. 7. Tighten flare nuts. ~: 15 - 18 N'm (1.5 - 1.8 kg-m, 11 - 13 ft-Ib) 8. Bleed air from brake system. Refer to "Bleeding Procedure", BR-6."
BR-14
CHECK
Depress brake pedal several times with engine off. After exhausting vacuum, make sure there is no change in pedal stroke. Depress brake pedal, then start engine. If pedal goes down slightly, operation is normal. Start engine, and stop it after one or two minutes. Depress brake pedal several times slowly. Booster is airtight if pedal stroke is less each time. Depress brake pedal while engine is running, and stop engine with pedal depressed. The pedal stroke should not change after holding pedal down for 30 seconds.
AIRTIGHT CHECK
SBR002A
OK
NG
SBR365AA
Removal
CAUTION: Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. Be careful not to deform or bend brake pipes, during removal of booster.
SEC. 465.470
Gasket
SBR223BB
BR-15
Installation
Approx. 125 mm (4.92 In)
CAUTION: Be careful not to deform or bend brake pipes during installation of booster. Replace clevis pin if damaged. Refill with new brake fluid "DOT 3" or "DOT 4". Never reuse drained brake fluid. Do nol mix different types of brake fluids (DOT 3, DOT 4). Due to the angle of installation, thread can be damaged by the dash panel. 1. Before fitting booster, temporarily adjust clevis to dimension shown. (Does not apply to vehicles fitted with ABS.) 2. Fit booster, then secure mounting nuts (brake pedal bracket to booster) lightly. 3. Connect brake pedal and booster input rod with clevis pin. 4. Secure mounting nuts. Specification: ~: 13 - 16 N'm (1.3 - 1.6 kg-m, 9 - 12 ft-Ib) 5. Install master cylinder. Refer to BR-12. 6. Bleed air. Refer to "Bleeding Procedure", BR-6.
BR-16
VACUUM HOSE
----a
Intake manifold
24 mm
; C::::::::'::::~:d
~
...
Brake booster
q
TYPE 2
SBR498A
CAUTION
ENG.
Inspection
HOSES AND CONNECTORS
Check vacuum lines, connections and check valve for airtightness, improper attachment, chafing and deterioration.
BR-17
SBR943A
SBR826B
Continuity Yes
No
more
VACUUM PUMP
1. Install vacuum gauge. 2. Run engine at 1,000 rpm or more. 3. Check vacuum. Specified vacuum: 86.6 kPa (8~6 mbar, 650 mmHg, 25.59 inHg) or more
BR-18
1. 2.
reservoir
cap.
Open cylinder body upward. Then remove pad retainers, return spring (Except AD22VF brake model) and inner/ol,lter shims. Standard pad thickness: CL22VD and CL22VE 11 mm (0.43 in) CL22VF 10 mm (0.39 in) Pad wear limit: 2.0 mm (0.079 in) Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.
3.
tJ
L:{SR020D
BR-19
<D m @ to sliding
portion
t~m@
~
@~@'~I~_\
I
'~
'j/0
~m@
iii:
(OJ :
tOJ
'1r ~ m'8'
\!.o/WLJ\SI
(fJJ;18 ~
~WIlI[LJ;I\OI
-=a 18\
17
fJ@
m@
m@
CD
@ @ @
Main pin Pin boot Torque member fixing bolt Torque member Shim cover Inner shim Inner pad
@
@ @J
@
@ @
@ @
(j)
Pad retainer Outer pad Outer shim Connecting bolt Copper washer Main pin bolt
@ @
@
@ @
@
Bleed valve Cylinder body Piston seal Piston Piston boot Pad return spring
BR-20
Ij] : N.m
-I
@
15 ~
to.J : m@
N. m (kg-m,
Ij] 7
: Rubber : PBC
grease point
f] : Brake
m@
G)
Plug
@
@ @ @ @
@ @ @ @
@ @ @
Inner pad Inner shim Shim cover Connecting Brake Copper hose washer bolt
@ @ @ @
@
Main pin bolt Cylinder Piston Piston boot Piston boot retainer body
Piston seal
@J
(J)
Pad retainer
Air bleeder
BR-21
Remove torque member fixing bolts and connecting bolt. It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose.
AD22VF
Disassembly
1. Remove piston boot retainer with a screwdriver.
SBR776B
WARNING: Do not place your fingers in front of piston. CAUTION: Do not scratch or score cylinder wall. 2. Push out piston with dust seal with compressed 3. Remove piston seal with a suitable tool.
air.
SBR772
Inspection
Caliper
CYLINDER BODY
Check inside surface of cylinder for score, rust, wear, damage or presence of foreign objects. If any of the above conditions are observed, replace cylinder body. Minor damage from rust or foreign objects may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary. CAUTION: Use brake fluid to clean. Never use mineral oil.
BR-22
Inspection RUNOUT
1:
Rotor
SBR936A
Secure rotor to wheel hub with at least two nuts (M12 x 1.25). 2. Check runout using a dial indicator. Make sure that wheel bearing axial end play is within the specifications before measuring. Refer to FA section ("Front Wheel Bearing", "ON-VEHICLE SERVICE"). Maximum runout: 0.07 mm (0.0028 in) 3. If the runout is out of specification, find minimum runout position as follows: a. Remove nuts and rotor from wheel hub. b. Shift the rotor one hole and secure rotor to wheel hub with nuts. c. Measure runout. d. Repeat steps a. to c. so that minimum runout position can be found. 4. If the runout is still out of specification, turn rotor with on-car brake lathe ("MAD, DL-8700", "AMMCO 700 and 705" or equivalent).
THICKNESS
Thickness variation (At least 8 positions): Maximum 0.02 mm (0.0008 in) If thickness variation exceeds the specification, turn rotor with on-car brake lathe. Rotor repair limit: CL22VD and CL22VE 16.0 mm (0.630 in) CL22VF 24.0 mm (0.945 in)
SBR944A
Assembly
1. 2. 3.
Piston
Piston seal
With piston boot fitted to piston, insert piston groove on cylinder body and install piston. Properly secure piston boot. Secure piston boot with retainer. (AD22VF model only)
boot
into
SBR777B
BR-23
BR-24
SEC. 441
Front
m,W . Rubber
~
grease POint
/il.
Cl)
@ @ @ @ @ @ @
@
Wheel cylinder assembly Boot Piston Piston cup Cylinder body Spring
(J)
@ @
@)
@ @
@ @ @
Shoe hold-down spring Toggle lever Washer Retainer ring Shoe hold-down pin Plug
Removal
WARNING: Clean brake lining with a vacuum dust collector to minimize hazard of airborne particles or other materials. CAUTION: Make sure parking brake lever is released completely. the
BR-25
If drum is hard to remove, the following procedures should be carried out. a. Remove plug. Then shorten adjuster to make clearance between brake shoe and drum as shown.
Adjuster
SBR280B
b.
Bolts
(M8
1.25)
SBR020A
SBR785BA
5. Remove retainer ring with a suitable tool. Then separate toggle lever and brake shoe.
Inspection
Wheel Cylinder
Check wheel cylinder for leakage. Check for wear, damage and loose conditions. Replace if any such condition exists.
BR-26
SBR215B
Inspection -
Drum
Maximum inner diameter: 181 mm (7.13 in) Out-of-roundness: 0.03 mm (0.0012 in) or less
SBR022A
Contact surface should be fine finished with No. 120 to 150 emery paper. Using a drum lathe, lathe brake drum if it shows scoring, partial wear or stepped wear. After brake drum has been completely reconditioned or replaced, check drum and shoes for proper contact pattern .
Inspection A
Lining
to
Check lining thickness. Standard lining thickness: 4.0 mm (0.157 in) Lining wear limit (A): 1.5 mm (0.059 in)
SBR021A
Installation
Always perform shoe clearance adjustment. Refer "Adjustment" in "PARKING BRAKE CONTROL", BR.37. 1. Fit toggle lever to brake shoe with retainer ring.
BR-27
SBR216B
~ ~ Vohi'"
'COol
Yes
No
DepreSSi~~
Right
"
/
SBR217B
7. Install brake drum. 8. When installing new wheel cylinder or overhauling wheel cylinder, bleed air. Refer to "Bleeding procedure", BR-6. 9. Adjust parking brake. Refer to BR-37.
SBR279B
BR-28
SBR023D
When installing new pads, push piston into cylinder body by turning piston clockwise. Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston.
8.
SBR868C
BR-29
@m@to
,Ii""
pmli"
J
,,,,,,, ""
m @ to p,d
,-,
"""
@ ~~~:':'~) ~'
m@
(Model CL9HC)
!
d """
<l
~
@(Model
:d~
CL9HC)
. N.m (kg-m,.
@. 'f
pom'
CL7H
B)
'i'i' m'O' in @ U
SBR208D
CD
@ @
@
m@
Pin
@ @
Oo'e"him
Strut O-ring Push rod Key plate Snap ring Seat Spring Spring cover
Cable guide
Cylinder Toggle
@
@
@ (6)
(j)
Pin boot Torque Retainer Inner shim Inner pad Pad retainer Outer pad m ember
@
@
@ @ @ @ @l
Piston seal Snap ring Spacer Wave washer Spacer Bearing Adjuster Cup Piston Piston boot
@
@ @'J @) @
@ @
@ @
@ @ @l
@
Snap ring
BR-30
Disassembly
1. Remove piston by turning it counterclockwise long nose pliers or commercial service tool. with suitable
(
i
(
~i
U
SBR646
SBR868C!
2.
piston
with
suitable
pliers
and
SBR889
3. a. b.
Disassemble cylinder body. Pry off snap ring with suitable pliers, then remove spring cover, spring and seat. Remove snap ring, then remove key plate, push rod, rod and strut.
BR-31
--,II
~//
l
SBR656
4.
SBR026D
Inspection -
Caliper
Never use mineral
oil.
CYLINDER BODY
Check inside surface of cylinder for score, rust, wear, damage or presence of foreign objects. If any of the above conditions are observed, replace cylinder body. Minor damage from rust or foreign objects may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary.
TORQUE MEMBER
Check for wear, cracks or other damage. Replace if necessary.
PISTON
CAUTION: Piston sliding surface ;s plated. Do not polish with emery paper even if rust or foreign objects is stuck to sliding surface. Check piston for score, rust, wear, damage or presence of foreign objects. Replace if any of the above conditions are observed.
BR-32
RUBBING SURFACE
Check rotor for roughness,
RUNOUT
1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25). 2. Check runout using a dial indicator. Make sure that wheel bearing axial end play is within the specifications before measuring. Refer to "Rear Wheel Bearing" of "ON-VEHICLE SERVICE" in RA section. 3. Change relative positions of rotor and wheel hub so that runout is minimized. Maximum runout: 0.07 mm (0.0028 in)
THICKNESS
Rotor repair limit: Minimum thickness CL7HB 6.0 mm (0.236 in) CL9HC 8.0 mm (0.315 in) Thickness variation (At least 8 portions) Maximum 0.02 mm (0.0008 in) Replace rotor if any of the above do not meet the specifications
SBR847
Assembly
1. Insert cam with depression inder. facing towards open end of cyl-
SBR247B
2.
Generously apply rubber grease to strut and push rod to make insertion easy.
BR-33
Match protrusion
in cylinder.
Snap ring
4.
~
Keyplate~
Rod
---{[J
SBR809B
Press
5.
and snap
ring
while
Spring-l Seat--@
SBR810B
6.
7.
Install cup, adjuster, bearing, spacers, washers ring with a suitable tool.
and snap
Cup---@)
P"'o0-e
SBR078D
BR-34
SBR646
SBR868C
Installation
CAUTION: Refill with new brake fluid "DOT 3" or "DOT 4". Never reuse drained brake fluid. Do not mix different types of brake fluids (DOT 3, DOT 4). 1. Install caliper assembly. 2. Install brake hose to caliper securely. 3. Install all parts and secure all bolts. 4. Bleed air. Refer to "Bleeding Procedure", BR-6.
BR-35
ItJ 3.'.'~
\;..,
,Lever
I
assembly ~15.7
..
~
jjf
/,
" Ad' t~ IUS Ing nu ~ t ~'
f
J,
I
(y -
~1iI3.2
Front
e \
~\
<>
"""'...~)\)')'))Jl--'
<~
~
~/
Parking brake ,,~'::\' warning lamp switch
i I
JJ~? iii
~
I' (~./?'
M___
I
~
iii ~ci~3;~'~.44,
28.6 _ 38.2)
II] 3.2
Bracket
Ill: N.m
~: N.m
4.
Remove lock plate and disconnect cable (disc brake only). For drum brake models, refer to BR-25.
Inspection
1. 2. 3. 4. Check control lever for wear or other damage. Replace if necessary. Check wires for discontinuity or deterioration. Replace if necessary. Check warning lamp and switch. Replace if necessary. Check parts at each connecting portion and, if deformed or damaged, replace.
BR-36
Before or after adjustment, pay attention to the following points. a. For rear disc brake be sure that toggle lever returns to stopper when parking brake lever is released. b. There is no drag when parking brake lever is released.
Front
V
SBR029D
1. Adjust clearance between shoe and drum/pad and rotor as follows: a. Release parking brake lever and loosen adjusting nut. b.- Depress brake pedal fully at least 10 times with engine running. 2. Pull control lever 4 - 5 notches. Then adjust control lever by turning adjusting nut.
SBR042D
3.
196 N (20 kg, 44 Ib)
/
SBR073D
Pull control lever with specified amount of force. lever stroke and ensure smooth operation. Number of notches: Drum brake: 7 - 8 Disc brake: 8 - 9
Check
4.
Bend warning lamp switchplate to ensure following. Warning lamp comes on when lever is pulled "A" notches and goes out when fully released. Number of "A" notches: 1 or less
BR-37
tracking performance through steering wheel operation. to be avoided through steering wheel operation. stability by preventing flat spins.
Operation
When the vehicle speed is less than 10 km/h (6 MPH) this system does not work. The Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS warning light for 1 second after turning the ignition switch ON. The system performs another test the first time the vehicle reaches 6 km/h (4 MPH). A mechanical noise may be heard as the ABS performs a selftest. This is a normal part of the self-test feature. If a malfunction is found during this check, the ABS warning light will come on. During ABS operation, a mechanical noise may be heard. This is a normal condition.
)(
SBR918C
G) @ @
@
@ (J) @
@)
@ @)
BR-38
SBR048DB
Control unit
System Description
SENSOR
The sensor unit consists of a gear-shaped sensor rotor and a sensor element. The element contains a bar magnet around which a coil is wound. The sensor is installed on the back side of the brake rotor. Sine-wave current is generated by the sensor as the wheel rotates. The frequency and voltage increase(s) as the rotating speed increases.
Magnetic flux ~
I
s::';o~'~W.
. I
Tooth~ / ~m~f
one tooth
CONTROL UNIT
The control unit computes the wheel rotating speed by the signal current sent from the sensor. Then it supplies a DC current to the actuator solenoid valve. It also controls ON-OFF operation of the valve relay and motor relay. If any electrical malfunction should be detected in the system, the control unit causes the warning lamp to light up. In this condition, the ASS will be deactivated by the control unit, and the vehicle's brake system reverts to normal operation.
SBR049DA
BR-39
~!Ii
~: ~:
\
L Rear wheel sensor
(LH)
~: ~:
BR-40
2.
Suitable drift
SBR873CA
Installation
Install the sensor rotor. For front sensor rotor, use hammer and wooden block. For rear sensor rotor, use suitable drift and press. Always replace sensor rotor with new one .
SBR985C
Pay attention to the dimension of rear sensor rotor as shown in figure. h: 4.5 - 5.5 mm (0.177 - 0.217 in)
Suitable drift
SBR986C
B,.,k"
ABS
.'0"'" ","
CONTROL
UNIT
Location: Passenger side, behind dash side lower finisher. Make sure that the sensor shield ground cable is secured with mounting bolt.
BR-41
RHO
cc:J
, ry side linder prima From master cy ndary side From master cy rInder seco
Front
LHO
To rear
cylinder From m aster'de secondary Sl (LH) To rear Wheel cylinder To rear Wheel cylinder (RH)
r.ii1 ' N.m (kg-m. in-Ib) IX! ' N.m (kg-m. ft-Ib)
cc:J:
SBR033DA
BR-42
4.
Disconnect
all connectors
5. 6. 7.
Remove mounting bolt for relay bracket. Remove ASS relay box with bracket. Remove air conditioner low-pressure tubes. Refer to HA section, ("Refrigerant Lines", "SERVICE PROCEDURES") .
8. Disconnect brake pipes and move away from actuator. It is not necessary to remove these pipes from vehicle.
and
9.
Remove/loosen bracket.
mounting
nuts
between
actuator
BR-43
SBR039D
CAUTION: After installation, pay attention to the following points: Refill brake fluid and bleed air. Refer to "CHECK AND ADJUSTMENT", BR-5 and "AIR BLEEDING", BR.6, respectively. Charge air conditioner refrigerant. Refer to HA section, ("R-134a Service Procedure", "SERVICE PROCEDURES").
ASS actuator
The installation
procedure
_-=--=--=--=--_-_-\,_~ ""'~t"b"ok.,
SBR040D
ABS RELAYS
1. 2. Disconnect battery cable. Remove ASS relay cover.
BR-44
BR-ABS-01
IGNITION SWITCH ON or START FUSE BLOCK
(JIB)
Refer to EL-POWER.
<D:
@:
P!L
~:I
P!L
I~I
Y
rn
PIL
I JUNCTION
BOX
NO.2 (JOINT
~@ LIB @
CONNECTORS)
1!:i=!J~
GY <fill)
LIB
I
LIB ~ To BR-ABS-O?
lelIl
PIL P!L STOP LAMP SW
~~
e<fill)
I-
9F'~
GY
LIB
14-81
ffi
IGN SW
13-0 I
FAIL LAMP ABS CONTROL UNIT
(B111)
Fa~
l..1..@
TI1910 W ~---------------------------------,
B 1112
~~(B115) 5 6
HBR002
BR-45
(Coni' d)
BR-ABS-02
IGNITION SWITCH ON or START FUSE 7 .5A BLOCK Refer to EL-POWER. OrAG L TXD RXD CONTROL UNIT
(!ID1)
ABS
rn
(JIB)
~
ORIB ~
1~61
GY!L GY/L
~
GIB GIB
I$~ ~
ORIB
~ciJ~ - -- ~~I
cr
~ ORIB
GY!L
It
GIB
It
I~
i~MO~o~?ic~g~) ~:<O
JOINT CONNECTOR-5
1*.21~:<ID
GIB
GY/L GY/L
rtl
GIB
I
DATA LINK CONNECTOR FOR CONSULT
(M13)
r1l
----------------------- I
<ID:
@: @:
~f1
*2
~~(~) 56j819101112
~(~24) ~OR
HBR003
BR-46
(Cont'd)
BR-ABS-03
CONTROL SENSOR FR-RH H ~
ABS
UNIT
GN02 GNO 1 GNO
<em>
o
~
B I
t
R R
,.
1 1 1 I I I I
..
l
1
---)
I 1 I 1
1 1 I I I....
Ll-l
.
rn
1
JOINT
CONNECTOR
-7 (B109)
I I
1
(, I I
'] $---$-]1 _.
W@1IDB
----
W @)
-----
I
J
I I
1 1 I 1 1 I I
1
l....
l~t~~8}j~f
W (1Q"n B
1 1
1
-]1
I
(jJ:
r-I
-----
_
1
1 I 1 I....
I
1
l....
B SENSOR FRONT RH
(1llQj) WHEEL SPEED
'J
W B
W
~
rv
M
rv
~(Eli[9)
GY
SENSOR FRONT RH
(E 11)
WHEEL
SPEED
&~(BIT5)
5 6
TII9ID
..In
W
em), @ill)
1112
<..!J.g) GY
IIlIITl.IIillJ
HBR004
BR-47
(Cont'd)
BR-ABS-04
SENSOR FR-LH H ~ L ASS CONTROL UNIT ~
----
t
L L
<D:
@:
-ec
)
I I I I I 1 1 I I I 1 I I
,.
I I I 1--
--
-L
)
I I I I
'] $---$J
---R ~ R
<MID
mJOINT
-7
1
CONNECTOR
(B109)
I 1
I' ---- !
----A@L
(ffi1)
- - --
l--
I I
I$f---J$-J R L
----(,
t
--
I I ,I
I I I
- ---
.
)
1 I I
(eUO)
M
R L rv
-----
M
R L rv
GY
-----
~~(@ 56 iBl91<iu
...IE. @,(~)
12 W
~(B109)
SR
(tig)
SR
illIIIIIIIIIl
HBR005
BR-48
(Conl'd)
BR-ABS-05
A8S
UNIT
~
PU
----( ....
H 3 8 1 1
LG
<illTI)
t
JOINT CONNECTOR-7
@QID
lY;ll
r-:l~!
I I I .
"
-----
~
L
t
I I I I I I I I
---- /)I
(8110)
r
I 1 1 I I I I I I I I I I I I I ,I
)
'I
M
PU LG
----
rv
SENSOR REAR RH
(!W)
WHEEL
SPEED
M
P L
WHEEL
rv
~(8109)
l:TIIillIIIIIJ
GY
HBR006
BR-49
(Coni' d)
BR-ABS-06
ABS CONTROL UNIT ~
FLOUT
13';'
FLIN
FROUT
1261
FRIN
1541
RLOUT
12';'
RLIN
1531
RROUT
1341
RRIN ~ PU/W
GY
IbiJ GY/R
BR
BR/W
LG
LG/R
PU
t
@
18 - -19 --20 21
}Next
page
GY
GY/R
nf4ll
BR ~
BR/W
LG
LG/R
PU
PU/W ~
rTI
wf6n
rrtll Iff7il
MOTOR
ABS ACTUATOR
(fJ103)
r-------------------------,
~
L
~~
~@:
B
I I
HBRDD?
BR-50
(ConI' d)
SR-ASS-07
I BAT.ERY I
Refer to EL-POWER.
13: I
LG/R
~
Y
4=U G/R
t
.
page
Preceding{
~
B
L/B ~ LIB
rg.~~, ~
BR
t
@>
LG/R
t Lt
ffi
n=fo]
rh
@
I:
n=f3n
@
~
)
m
Y
G/R
rrf1iJ
ABS RELAY BOX UQ)
~)
-----<
@)
~ MOTOR RELAY
:.
? I@ ~ @
@>
I@
~----------------------~
I
:
I I
(411'3)
UQ)
GY
~~
~B
~----------------------~
HBRDDa
BR-51
SEF233G
SEF234G
BR-52
SELF-DIAGNOSIS
PROCEDURE
Start engine. Dr.ive vehicle over 15 km/h (9 MPH) for at least one minute .
.=J
MPH
-~s:: ~
Stop vehicle with engine running.
~~
lamp activates.
SBR875CA
Verify the location of the malfunction with the malfunction code chart. Then make necessary repairs following the diagnostic procedures.
After the malfunctions are repaired, erase the self-diagnostic results stored in the control unit.
Disconnect connectors for ASS control unit or the battery negative terminal for at least one minute.
Check warning lamp for deactivation after driving vehicle over 15 km/h (9 MPH) for at least one minute.
BR-53
RESULTS (Malfunction
codes)
lamp flashes on and off.
Determine the code No. by counting the number of times the warning The malfunction code chart is given on the next page.
Example Malfunction code No. 12 and 23
Warning lamp ON a b c 3 seconds (Clearance between code No.) 0.6 second (Ten digits) 0.3 second (One digit)
c
SBR877CA
RESULTS (Malfunction
codes)
Disconnect ASS control unit connectors or battery negative terminal for at least one minute. When using CONSULT, touch "ERASE" on the CONSULT screen with self-diagnostic results mode.
BR-54
CODE/SYMPTOM
CHART
Diagnostic procedure
Malfunctioning part Actuator front left outlet solenoid valve Actuator front left inlet solenoid valve Actuator front right outlet solenoid valve Actuator front right inlet solenoid valve Actuator rear right outlet solenoid valve Actuator rear right inlet solenoid valve Actuator rear left outlet solenoid valve Actuator rear left inlet solenoid valve Front left sensor (open-circuit) Front left sensor (short-circuit) Front right sensor (open-circuit) Front right sensor (short-circuit) Rear left sensor (open-circuit) Rear left sensor (short-circuit) Rear right sensor (open-circuit) Rear right sensor (short-circuit) Sensor rotor Actuator motor or motor relay Solenoid valve relay Power supply (Low voltage) Control unit Control unit power supply circuit Warning lamp bulb circuit
45 46 41 42 51 52 55 56 25 26 21 22 35 36 31 32 18 61 63 57 71
3 3 3 3 3 3
3
3 4 4 4 4 4 4 4 4 4 5
6
7 8
Warning lamp stays on when igniControl unit or control unit connector tion switch is turned on Solenoid valve relay stuck Power supply for solenoid valve relay coil Warning lamp stays on, during self-diagnosis Warning lamp does not come on when ignition switch is turned on Warning lamp does not come on during self-diagnosis Pedal vibration and noise Long stopping distance Unexpected pedal action ABS does not work ABS works frequently Control unit Fuse, warning lamp bulb or warning lamp circuit Control unit Control unit
10 11 12 13
BR-55
(Except Europe)
SELF-DIAGNOSIS
PROCEDURE
Drive vehicle over 30 km/h (20 MPH) for at least one minute.
~
Turn ignition switch "OFF".
L L
Ground terminal "L" of "DATA LINK CONNECTORfor CONSULT" with a suitable harness.
Turn ignition switch "ON" while grounding terminal "L". Do not depress brake pedal.
After 3.6 seconds, the warning lamp starts flashing to indicate the malfunction code No (See NOTE.)
[i
s~'~" \
~Isconne
ct the harness)
Verify the location of the malfunction with the malfunction code chart. Refer to BR-57. Then make the necessary repairs following the diagnostic procedures.
for CONSULT
~/''':~~ ~/\\l---u~
~ / ! /717) ')
L
After the malfunctions are repaired, erase the malfunction codes stored in the control unit. Refer to BR-57.
~
SBR054D
Rerun the self-diagnostic results mode to verify that the malfunction codes have been erased.
Disconnect the check terminal from the ground. The self-diagnostic results mode is now complete.
NOTE: The indication terminates after five minutes. However, when the ignition switch is turned from "OFF" to "ON", the indication starts flashing again.
BR-56
Check warning lamp for deactivation after driving vehicle over 30 km/h (20 MPH) for at least one minute.
After making certain that warning lamp does not come on, test the ASS in a safe area to verify that it functions properly.
RESULTS (Malfunction
codes)
Determine the code No. by counting the number of times the warning lamp flashes on and off. When several malfunctions occur at one time, up to three code numbers can be stored; the latest malfunction will be indicated first. The indication begins with the start code 12. After that a maximum of three code numbers appear in the order of the latest one first. The indication then returns to the start code 12 to repeat (the indication will stay on for five minutes at the most). The malfunction code chart is given on the next page. Example: Code No. 32 REAR SENSOR SHORT-CIRCUIT
Start code: 12 Tens digits Units digits Warning lamp ON OFF 3.6 ON IGN OFF
SBR441C
0.4
1.6
0.4 0.4
0.4
3.6
Unit: Second
Self-diagnosis
completed
"I
~~
RESULTS
::J1IU
10---+1
1
i !
... ...
12.5
see
LJ
Disconnect the check terminal from ground (ASS warning lamp will stay lit). 2. Within 12.5 seconds, ground the check terminal 3 times. Each terminal ground must last more than 1 second. The ASS warning lamp goes out after the erase operation has been completed. 3. Perform self-diagnosis again. Refer to SR-56. Only the start code should appear, no malfunction codes.
ABR256
MALFUNCTION
Refer to SR-55.
CODE/SYMPTOM
CHART
BR-57
TO ASS
SELF-DIAGNOSTIC RESULTS X X X X DATA MONITOR X X X X X X X X X X X X X X ACTIVE TEST
X X X X X X X X X
X X X X X X X .X
-
X X
BR-58
SELF-DIAGNOSIS
PROCEDURE
1) Turn ignition switch OFF. 2) Connect CONSULT to Data Link Connector for CONSULT.
1) Start engine.
Ii)
NISSAN
2) Drive vehicle over 30 km/h (20 MPH) for at least one minute.
CONSULT
EE940.
.
(;)
r
1) Stop vehicle with engine running and touch "START" on CONSULT screen. Program card AE950: For Australia EE940: Except Australia 2) Touch "ASS".
I
@] ~
I,
SEF253Q
(!]
SELECTSYSTEM
3) Touch "SELF-DIAG RESULTS". The screen shows the detected malfunction and the times of ignition switch ON and OFF after it occurred.
lP]
II
After the malfunctions are repaired, erase the self-diagnostic results stored in the control unit by touching "ERASE".
@]
Check warning lamp for deactivation after driving vehicle over 30 km/h (20 MPH) for at least one minute.
II
0
0
Test the ASS in a safe area to verify that it functions properly. Note: "SELF.DlAG RESULTS" screen shows the detected malfunction and the times of ignition switch ON and OFF after it occurred.
TIME
ERASE
II
PRINT
SBR950C
BR-59
RESULTS MODE
Diagnostic item is detected when ... right wheel sensor is open. high input voltage is entered.) left wheel sensor is open. high input voltage is entered.) right sensor is open. high input voltage is entered.) left sensor is open. high input voltage is entered.) right wheel sensor is shorted. low input voltage is entered.) left wheel sensor is shorted. low input voltage is entered.) Diagnostic procedure 4 4 4 4 4 4 4 4 4 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 6 5 7 8
Circuit for rear right sensor is shorted. (An abnormally low input voltage is entered.) Circuit for rear left sensor is shorted. (An abnormally low input voltage is entered.) Teeth damage on sensor rotor or improper installation of wheel sensor. (Abnormal wheel sensor signal is entered.) Circuit for front right inlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for front left inlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for rear right inlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for rear left inlet solenoid valve is open. (An abnormally low output voltage is entered.) Circuit for front right inlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for front left inlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for rear right inlet solenoid valve is shorted. (An abnormally high output voltage is entered.) Circuit for rear (An abnormally Circuit for front (An abnormally Circuit for front (An abnormally Circuit for rear (An abnormally Circuit for rear (An abnormally Circuit for front (An abnormally Circuit for front (An abnormally Circuit for rear (An abnormally Circuit for rear (An abnormally left inlet solenoid valve is shorted. high output voltage is entered.) right outlet solenoid valve is open. low output voltage is entered.) left outlet solenoid valve is open. low output voltage is entered.) right outlet solenoid valve is open. low output voltage is entered.) left outlet solenoid valve is .open. low output voltage is entered.) right outlet solenoid valve is shorted. high output voltage is entered.) left outlet solenoid valve is shorted. high output voltage is entered.) right outlet solenoid valve is shorted. high output voltage is entered.) left outlet solenoid valve is shorted. high output voltage is entered.)
Actuator solenoid valve relay is ON, even control unit sends off signal. Actuator solenoid valve relay is OFF, even control unit sends on signal. Circuit for actuator motor is open or shorted. Actuator motor relay is stuck. Power source voltage supplied to ABS control unit is abnormally low. Function of calculation in ASS control unit has failed.
BR-50
DATA MONITOR
NISSAN
PROCEDURE
CONSULT
EE940 fDU
1) Turn ignition switch OFF. 2) Connect CONSULT to Data Link Connector for CONSULT. 3) Turn ignition switch ON.
I
I
Iil
~
SEF253Q
II
Iil 2) Touch
t!J
m 1) Touch
1
~
SELECT SYSTEM
01
ENGINE
I!l
(I
AfT
AIRBAG ABS IVMS
SBR104D
I!l
1) Touch "SETTING" on "SELECT MONITOR ITEM" screen. 2) Touch "LONG TIME" on "SET RECORDING COND" screen. 3) Touch "START" on "SELECT MONITOR ITEM".
t!J
I
I
01
I I
I!l
I I I I
SST412B
I~
SETTING
II
START
SBR936C
SBR937C
BR-61
Fa
CONSULT
EE940 rBU
When conducting Active test, vehicle must be stationary. When ASS warning lamp stays on, never conduct Active test.
1) Turn
ignition
switch
I
I
m
~
I
SEF253Q
2) Connect 3) Start
CONSULT
engine.
SELECT SYSTEM
m
[!)
Fa
l
1) Touch 2) Touch 3) Touch "START" "ASS". "ACTIVE TEST". on CONSULT screen.
ENGINE
AlT
AIRBAG ASS IVMS
II 2) Touch I
SBR104D
!1
1) Select
active
test item
by touching
screen.
"START".
~
Carry out the active test by touching screen key.
OJ
SST412B
!1
I I
II
ASS MOTOR
SBR976C
SELECT
ITEM
START
SBR934C
BR-62
Engine is running.
Operating conditions for each solenoid valve are indicated. ABS is not operating: OFF
Ignition switch ON (Engine stops): OFF Engine running: ON Ignition switch is ON or engine is running. ABS is not operating: OFF ABS is operating: ON Warning lamp is turned on: ON Warning lamp is turned off: OFF Power supply voltage for control unit
MOTOR RELAY
Engine is running.
ABS MOTOR
Note: Active test will automatically stop ten seconds after the test starts. (LIMIT SIGNAL monitor shows ON.)
BR-63
DABS
warning lamp
Ii Rear right
[i1 Rear
SBR047DA
BR-64
m
Check brake fluid level in reservoir tank. Low fluid level may indicate brake pad wear or leakage from brake line.
Min line OK
SBR418CB
NG
Repair.
Check brake booster for operation and air tightness. Refer to BR-15.
OK
NG
Replace.
NG
Replace.
BR-19,29.
OK
NG
/~
/
/'
/
"
,J
(')
~---
SBR058C
Check warning lamp activation. When ignition switch is turned on, warning lamp turns on.
OK
NG
lamp
Check warning lamp for deactivation. When ignition switch is turned on, warning lamp turns on, then deacti. vates after 1 second.
OK
NG
Go to Self-diagnosis,
BR-56.
\) 003
i
/
-..,J
~"
(-ji=o
~"
..
[--,-SBR051DA
'-,--_
NG
Go to Self-diagnosis,
BR-56.
END
BR-65
on
SBR055D
[(
C/UNIT CONNECTOR
28 . 29 . 39
p~
CONTROL UNIT GROUND Check resistance between the terminals and ground.
Resistance:
15
SBR237D
on
~ABS
EtiD r:tt i5
[ill
ABS RELAY BOX GROUND Check resistance between ASS relay box harness 6-pin connector (body side) terminal @ and ground.
Resistance:
on
SBR931CB
BR-66
Z
W Ul
~ LL
zo.
"'
@
II 0 I<l: :J I<l: (fJ CD <l:
U
H 0 ZW>W><l:
@UJ>a:
@
O<l:W
-l-l-l
~ @
@
"1
l"-
I"l'"J
S)
l'"J
l'"J l'"J
Ul
f.D "1
"
Ul
Ul "1
l'"J Ul
l'"J
"
f.D
"
0. L: <l: .-JI U 0.1OH 1-3: (fJUl
~ co ~ "
f.D f.D
::":
OJ
;:::
:::
co
l'"J
S'l
~
"-"1
>-
II W lICD
W Ul LL
<l:
CO
I U
IH
W Ul
~ LL
1-<:... HO Z C!lZ
HO
HBR001
BR-67
c(
C/UNIT CONNECTOR
30
p~
item)
15
Replace fuse.
NG
Replace bulb.
Ii)
~
c(
C/UNIT CONNECTOR
30 ~
15
I...a1
Iv
SBR239D
l.41
1. Install 10A fuse and bulb. 2. Disconnect connectors from control unit and ASS relay box. 3. Check voltage between control unit connector terminal @ and ground after turning ignition switch "ON". Battery voltage should exist after turning ignition switch "ON".
OK
NG
f~~~_
~i5
Check continuity between ASS relay box 6-pin connector (body side) and control unit terminals.
ASS relay box Control unit
NG
@)
@
Ground
<ID
Continuity should exist. OK
SBR945CB
1. Remove solenoid valve relay. 2. Check continuity between ASS relay box 6-pin connector (ASS relay box side) and ASS relay box terminals.
ASS relay box connector ASS relay box terminals
NG
@)\B
@e
@
<ID
Continuity should exist. Note: Pay attention to tester polarity", OK SOLENOID VALVE RELAY CHECK Refer to SOLENOID VALVE RELAY in Electrical Components Inspection, BR-8S.
OK
NG
Go to Diagnostic Procedure 7, BR-81. ": Specifications may vary depending on the type of tester. Before performing this inspection, refer to the instrucllon manual of the tester.
BR-68
C/UNIT
1
CONNECTOR
SBR240D
OK
~i5
( C/UNIT CONNECTOR
2 . 37 '--v--'
1. Disconnect connector from control unit. 2. Check voltage between control unit connector terminal (i) and ground alter turning ignition switch "ON". Battery voltage should exist.
----.......
NG
E$B
SBR241D
[;]
NG SOLENOID VALVE RELAY COIL POWER ----+ SUPPL Y CIRCUIT 1. Turn ignition switch "OFF". Disconnect ABS relay box 6-pin connector. 2. Check continuity between control unit connector terminals and ABS relay box 6-pin connector (body side) terminals. Control unit @ @ ABS relay box @
~ ~
~i5
CID
[!]
CIRCUIT CHECK
~OK
o DO
!MJ
1. Disconnect solenoid valve relay. 2. Check continuity between ABS relay box 6-pin connector (ABS relay box side) terminals and solenoid valve relay box terminals. ABS relay box connector @ ASS relay box terminals @ @
CID
OK SOLENOID VALVE RELAY CHECK Refer to SOLENOID VALVE RELAY in Electrical Components Inspection, BR-85. .OK NG
@
(Go to next page.)
BR-69
c(
C/UNIT CONNECTOR
30
p~
15
GROUND-SHORT CHECK FOR WARNING LAMP CIRCUIT. 1. Turn ignition switch "OFF". 2. Disconnect connectors from control unit and ABS relay box 6-pin connector. 3. Check continuity between control unit connector terminal @J and body ground. Continuity should not exist.
OK
NG
SBR242D
EIT8 ~i5
SBR971CB
1. Disconnect actuator ground terminal and 6-pin connector. 2. Check continuity between ASS relay box 6-pin connector (ABS relay box side) terminal @ and body ground. Continuity should not exist. Note: Pay attention to tester polarity .
OK
NG
Ii
SOLENOID VALVE CIRCUIT
SBR972CB
NG
1. Disconnect ABS actuator 8-pi n connector. 2. Check continuity between each ABS actuator 8-pin connector (ABS actuator side) terminals and body ground. Continuity should not exist.
OK
Check control unit pin terminals for damage or the connection of control unit harness connector. Reconnect control unit harness connector. Then retest.
. Specifications may vary depending on the type of tester. Before performing this inspection, refer to the instruction manual of the tester.
BR-70
c(
C/UNIT CONNECTOR
1
p~
15
SBR243D
1
Replace 7.5A fuse. Does the fuse blowout when ignition switch is turned "ON"? Yes ~ Inspection end
[!1
CONTROL UNIT POWER SUPPLY CIRCUIT 1. Disconnect control unit connector. 2. Check continuity between control unit connector terminal (D and body ground. Continuity should not exist. OK NG ---... Repair harness and connector.
c(
C/UNIT CONNECTOR
2
p~
15
SBR244D
III
Check continuity between control unit connector terminal @ and body ground. Continuity should not exist. OK Check control unit pin terminals for damage or the connection of control unit harness connector. Reconnect control unit harness connector. Then retest. NG
--+
BR-71
c(
C/UNIT CONNECTOR
5 . 6 25. 26
P ASS
,33 . 34
53
54,
ABS ACTUATOR SOLENOID VALVE (Malfunction code No. 41, 45, 51, 55, 42, 46, 52, 56)
1. Disconnect connectors from control unit, ASS actuator and ASS relay box. Check terminals for damage or loose connections. Then reconnect connectors. 2. Carry out self-diagnosis again. Does warning lamp activate again? Yes ~ Inspection end
SBR245D
(;)
ASS actuator
~i8
m
ABS ACTUATOR SOLENOID VALVE CHECK 1. Disconnect connectors from control unit and ABS relay box. 2. Check resistance between control unit connector terminals and ASS relay box 2-pin connector @ (ABS actuator side) terminal. Code No. 41 45 51 55 42 46 52 56 Control unit @ @ @ @ @
ASS relay OK
SBR246D
CID
@
box @ @ @ @ @ @ @ @ NG
85 -
110n
(;)
1. Disconnect ASS actuator 8-pin connector. 2. Check resistance between ABS actuator 8-pin connector (ABS actuator side) terminals and ASS relay box 2-pin connector @) (ABS actuator side) terminal. Code No. 41 45 51 55 42 46 52 56
ASS
OK
Repair harness and connector between control unit connector terminal and ASS actuator 8-pin connector terminal.
ASS relay
actuator @ @ @ @ @)
CD
(J)
CID
box @ @) @ @ @ @ @ @ NG
85-
11.0n
BR-72
EffB~
SBR058D
1. Disconnect ASS relay box connectors. 2. Check continuity between ASS relay box 2-pin connector @D (ASS relay box side) terminal @ and 6-pin connector <!ill) (ASS relay box side) terminal @. Continuity should exist. NG
OK
Proce-
Uw@
1. Remove solenoid valve relay. 2. Check continuity between ASS relay box 2-pin connector @D (ASS relay side) terminal @ and ASS relay box terminal @. Continuity should exist.
SBR059D
NG
BR-73
E( C/UNITCONNECTOR P
,14.9.11 . 12, ,15.10.38.13,
~i5
SBR247D
m
WHEEL SENSOR ELECTRICAL CHECK 1. Disconnect control unit connector. 2. Check resistance between control unit connector terminals. Code No. 21 or 22 (Front RH wheel) Terminals @ and @ Code No. 25 or 26 (Front LH wheel) Terminals @ and @ Code No. 31 or 32 (Rear RH wheel) Terminals @ and @ Code No. 35 or 36 (Rear LH wheel) Terminals @ and @ Resistance: 0.8 1.2 kD NG Note CHECK WHEEL SENSOR. Refer to WHEEL SENSOR in Electrical Components Inspection, SR-85. OK Note Repair harness and connectors between control unit conn'ector and wheel sensor connector. Note: Wheel position should be distinguished by ~ Note Replace wheel sensor. OK ~@ (See next page.)
BR-74
Note WHEEL SENSOR MECHANICAL CHECK Check for inflation pressure, wear and size of each tire.
OK
OK
\\
Feeler gauge
)6
SBR069C
Sensor
m "Note
Check clearance between sensor and rotor. Clearance: Front 0.1 - 1.1 mm (0.004 . 0.043 in) Rear 0.1 - 1.1 mm (0.004 - 0.043 in)
OK NG
)I
Note
NG
Check control unit pin terminals for damage or the connection of control unit harness connector. Reconnect control unit harness connector. Then retest.
Note: Wheel position should be distinguished by code No. except code No. 18 (sensor rotor).
BR-75
TROUBLE DIAGNOSES
[it ~c:\
DISCONNECT
Diagnostic Procedure 5
MOTOR RELAY OR MOTOR
(Malfunction code No. 61)
NG
rn
";V
MOTOR POWER SUPPLY CIRCUIT Check fusible link @] for ABS relay box. For fusible link layout, refer to POWER SUPPLY ROUTING in EL section.
SBR953CC
@ (Skip page.)
OK
c(
~iv
C/UNIT CONNECTOR
7 19. 2,
~iV
~
1. Disconnect connectors from control unit and ABS actuator. Check terminals for damage or loose connection. Then reconnect connectors. 2. Carry out self-diagnosis again. Does warning lamp activate again? Yes
No
Inspection end
SBR248D
1. Disconnect ABS relay box 2-pin connector@. 2. Check voltage between connector (body side) terminal @ and ground. Battery voltage should exist.
NG
COI
CIRCUIT CHECK 1. Disconnect ABS relay box 6-pin connector and control unit connector. 2. Check continuity between control unit connector terminals and ABS relay box 6-pin connector ~ (body side) terminals.
Control unit ASS relay box
NG
@ @
cID
Continuity should exist.
OK
MOTOR RELAY CHECK Refer to MOTOR RELAY in Electrical Components Inspection, BR-8S.
OK
NG
ACTUATOR MOTOR GROUND CHECK Refer to ACTUATOR MOTOR GROUND in Ground Circuit Check, BR-66.
OK
NG
@
(Go to next page.)
BR-76
[:tI 15
(ASS ~
9 2~~ 11 ~~
@
T
MOTOR RELAY CIRCUIT 1. Remove motor relay. 2. Check continuity between ASS relay box connectors (ASS relay box side) and ASS relay box terminals. ASS relay box connector @ @ @ Connector@ @ Connector@
@
NG
ASS 'relay bO
[ill [ill
f
86 85 87
EJ
WJ
Ii]
Check continuity between ASS relay box 2-pin connector @ (ASS actuator side) terminal @ and actuator motor positive terminal. Continuity should exist.
NG
do
131
MOTOR CHECK 1. Disconnect actuator motor terminals. 2. Apply battery voltage to motor terminals. Motor should operate. Do not connect wire for more than 5 seconds.
OK NG
Go to Diagnostic
Procedure 7, SR-81.
SBR249D
BR-77
1c0, V
DISCONNECT
CID
Replace fusible link. Does the fusible link blowout when ignition switch is turned "ON"? No Inspection end
cD
Ii
MOTOR POWER SUPPL V CIRCUIT
SBR957CC
NG
1. Disconnect battery cable and ASS relay box 2-pin connector @. 2. Check continuity between ASS relay box 2-pin connector @ (body side) terminal @ and ground. Continuity should not exist.
SBR958CB
III @ 0U
@El
\J.tV
9
rrt\
DISCONNECT
1. Disconnect ASS relay box 6-pin connector and control unit connector. 2. Check continUity between ASS relay box 6-pin connector @E) (body side) terminal @ and ground. Continuity should not exist. OK
NG
-';;V
~c;"1
Check continuity between ASS relay box 6-pin connector (ABS relay box side) terminal @ and ground, 2-pin connector @ (ASS relay box side) terminal @ and ground. Continuity should not exist.
SBR065DB
NG
OK
o
Remove motor
L1J.1J
ground.
1. Remove motor ground. 2. Check continuity between ASS relay box 2-pin connector @) (ASS actuator side) terminal @) and ground. Continuity should not exist. OK MOTOR CHECK
NG
SBR250D
n!II
Check control unit pin terminals for damage or the connection of control unit harness connector. Reconnect control unit harness connector. Then retest.
BR-78
TROUBLE DIAGNOSES
Fa
ASS relay box 2-pin connector @ ~ (body side)
DISCONNECT
Diagnostic Procedure 6
I..lI&I ~V
~~
ctD
SOLENOID VALVE POWER SUPPLY CHECK Check fusible link @]. For fusible link layout, refer to POWER SUPPLY ROUTING in EL section.
SBR961CC
OK
~Io
( C/UNIT CONNECTOR
2 . 30 . 37
Efe
SBR251D
1. Disconnect connectors from control unit and ASS actuator. Check terminals for damage or loose connection. .Then reconnect connectors. 2. Carry out self-diagnosis again. Does warning lamp activate again? Yes GROUND CIRCUIT CHECK Refer to CONTROL UNIT GROUND and ACTUATOR GROUND in Ground Circuit Check, SR-66.
OK
No
Inspection end
SOLENOID VALVE POWER SUPPLY CHECK 1. Disconnect connectors from ASS relay box. 2. Check voltage between ASS relay box 2-pin connector @ (body side) terminal @ and ground. Battery voltage should exist.
CIRCUIT CHECK 1. Disconnect control unit connector. 2. Check continuity between control unit connector terminals and ASS relay box connector @ill (body side) terminals.
Control unit
3T
Xi
@
Continuity should exist.
OK
SOLENOID VALVE RELAY CHECK Refer to SOLENOID VALVE RELAY in Electrical Components Inspection,
SR-85. OK
@
(Go to next page.)
BR-79
~i5
LI!ID c:!D ~
,2.4.~.8.18,
SOLENOID VALVE RELAY CIRCUIT CHECK Check continuity between ASS relay terminals and ASS relay box connector (ASS relay box side) terminals.
ABS relay box terminal
NG
~SS
relay box
87a
[]QJ
:~ }
85
87a
85
00
30
I Go to diagnostic
SBR068D
procedure 3, SR-72.
I;]
~i5
[Q]
Replace fusible link. Does the fusible link blowout when Ignition switch is turned "ON"? Yes
No
Inspection end
I;]
RELAY UNIT POWER SUPPLY CIRCUIT 1. Disconnect ASS relay box 2-pin connector@. 2. Check continuity between ASS relay box 2-pin connector @ (body side) terminal @ and ground. Continuity should not exist.
OK
NG
-=SBR964CC
c1!D
ASS relay box 2-pin connector (ASS relay box side) @ED
~i5
Ii
1. Disconnect ASS relay box connectors and control unit connector. 2. Check continuity betwee"ll ASS relay box 2-pin connector @ (ASS relay box side) terminal @ and ground. Continuity should not exist.
SBR069D
NG
-=-
OK
Ii
@[)
~io
Ii
Check continuity between ASS relay box 2-pin connector @ (ASS actuator side) terminal @ and ground. Continuity should not exist.
OK
NG
SBR252D
BR-80
c(
C/UNIT CONNECTOR
1
p~
18
SBR253D
1. Disconnect control unit connectors. Check terminals for damage or loose connections. Then reconnect connectors. 2. Carry out self-diagnosis again. Does warning lamp activate again?
CONTROL UNIT POWER SUPPLY CHECK 1. Disconnect control unit connector. 2. Check voltage between control unit connector terminal G) and ground. Battery voltage should exist when ignition switch is turned ON.
OK
CONTROL UNIT GROUND CHECK Refer to CONTROL UNIT GROUND in Ground Circuit Check, BR-66. OK Check control unit pin terminals for damage or the connection of control unit harness connector. Reconnect control unit harness connector. Then retest. @
NG
NG
Replace fuse.
Check continuity between battery and control unit connector terminal CD. OK Check battery. Refer to BATTERY in EL section.
NG
BR-81
Does warning lamp indicate code No. 71 again? No Inspect the system according to the code No.
Yes
Diagnostic Procedure 9
Brake pedal
SYMPTOM:
1. Apply brake. 2. Start engine. 3. Does the symptom appear only when engine is started? No Does the symptom appear when electrical equipment switches (such as headlamp) are operated? Yes Check wheel sensor shield grou.nd secured with control unit mounting bolt. Refer to BR-41. OK
No
SAT797A
Ii1
Check control unit pin terminals for damage or the connection of control unit harness connector. Reconnect control unit harness connector. Then retest.
Note: ABS may operate and cause vibration under any of the following conditions. Applying brake gradually when shifting or operating clutch. Low friction (slippery) road. High speed cornering. Driving over bumps and pot holes. Engine speed is over 5,000 rpm with vehicle stopped.
BR-82
Disconnect ABS relay box 6-pin connector and check whether stopping distance is still long.
IiJ
Note: Stopping distance may be larger than vehicles without ABS when road condition is slippery.
Diagnostic Procedure 11
SYMPTOM: Unexpected pedal action
Yes Perform Preliminary Check. refer to SR-65.
m
Check brake pedal stroke. Is stroke excessively large? No Disconnect ASS relay box 6-pin connector and check whether brake is effecSBR540A
tive.
Yes Ensure warning lamp remains off while driving. OK CHECK WHEEL SENSOR. 1. Check wheel sensor connector for terminal damage or loose connection. 2. Perform wheel sensor mechanical check. Refer to in Diagnostic Procedure 4, BR-75. Carry out self-diagnosis. Refer to BR-53 (Europe) or SR-56 (Except Europe). Repair.
IiJ
OK Check control unit pin terminals for damage or the connection of control unit harness connector. Reconnect control unit harness connector. Then retest.
BR-83
Note: ABS does not work when vehicle speed is under 10 km/h
(6 MPH).
Diagnostic Procedure 13
SYMPTOM: ASS works frequently.
NG
CHECK BRAKE FLUID PRESSURE. Check brake fluid pressure distribution. Refer to proportioning valve inspection,
BR-9. OK
CHECK WHEEL SENSOR. 1. Check wheel sensor connector for terminal damage or loose connections. 2. Perform wheel sensor mechanical check. Refer to Ii) in Diagnostic Procedure 4, BR-75.
OK
NG
Repair.
Check front and rear axles for excessive looseness. Refer to FA section ("Front Wheel Bearing", "ON-VEHICLE SERVICE") and RA section ("Rear Wheel Bearing", "ON-VEHICLE SERVICE").
OK
NG
Repair.
Check control unit pin terminals for damage or the connection of control unit harness connector. Reconnect control unit harness connector. Then retest.
BR-84
ACTUATOR
MOTOR RELAY
Condition Continuity existence between terminals @ and @ No
Battery voltage not applied between terminals @ and @. Battery voltage applied between terminals @ and @.
Yes
SBR140C
to relay terminals,
insert fuse
Battery voltage not applied between terminals @ and @. Battery voltage applied between terminals @ and @.
Yes
No
No
Yes
SBR329B
to relay terminals,
insert fuse
BR-85
(SOS)
With ABS
CD20
GA14DE
GA16DE Option
I
CL22VE
CD20
180 (7.09)
22.22 (7/8)
Dual proportioning
BR-86
106x39.5x11.0 (417 x 1.555 x 0.433) 232 x 18 (9.13 x 0.71) 247 x 18 (9.72 x 0.71)
LT18C Brake model Cylinder bore diameter mm (in) mm (in) Lining or pad length x width x thickness
15.87 (5/8)
CL7HB
33.96 (1-3/8)
30.23
(1-1/4)
33.96
(1-3/8)
89.1 x 39.5 x 10.0 (3.508 x 1.555 x 0.394) 258 x 9.0 (10.16 x 0.354)
89.1 x 39.5 x 10.0 (3.508 x 1555 x 0.394) 258 x 9.0 (10.16 x 0.354)
Drum inner diameter or rotor outer diameter x thickness mm (in) Master cylinder
20.64
180 (7.09)
(13/16)
22.22 (7/8)
23.81 (15/16)
22.22
(7/8)
23.81 (15/16)
mm (in) Dual proportioning valve built into master cylinder 1.961 (19.6. 20. 284) x 0.2 Dual proportioning valve separated from master cylinder 2.942 (29.4. 30. 427) x 0.2 1.961 (19.6. 20. 284) x 0.2
Brake booster Booster model Diaphragm diameter mm (in) Recommended brake fluid 205 (8.07) Primary: 205 (8.07) Secondary: 180 (7.09) DOT 3
BR-87
(SDS)
DRUM BRAKE
Unit: mm (in)
Pad wear limit Minimum thickness Rotor repair limit Minimum thickness
BRAKE PEDAL
Unit: mm (in) Applied model Free height
MIT AIT
RHD
LHD
Depressed height [under force 01 490 N (50 kg, 110 Ib) with engine running] Clearance between switches and pedal stopper bracket See below.
Depressed Height [Under force of 490 N (50 kg, 110 Ib) with engine running]
Unit: mm (in) Applied model
MIT AIT
LHD
1 or less
BR-88