Brake System GENERAL cscs stseentnenetntnesene BR-2 BRAKE SYSTEM... -BR- 9 LSPV (LOAD SENSING PROPORTIONING VALVE) ......:s.essss BR 26 PARKING BRAKE SYSTEM BR-28 [ABS (ANTI-LOCK BRAKE SYSTEM) . BR-30BR2 GENERAL SPECIFICATIONS exes Masi finder Te 1D. mm tn) Becstng rato Front brake 8 Dee 00. ise tckness| Oxtnde 1.0. rake 18 Etectve da, oxtngr 1.0. Cearanco adjustment Paring brake ecuston Pe 00. = Outer dameter 10, = tar ameter Mechanical brake acing BRAKE SYSTEM Spoateaton| Tandem type 254 (19) Provided \acaum type with tandem beoter 70:1 Disc pe 2545 (1002 in): 20.2765 men (1088) : 4D 24 rem (0965 in} 10 mem (0304 in) 429 mm (1.69 mn) 0) Leading wrling rum 270 mim (1.63 in} 2223 me (088 In}GENERAL BR SERVICE STANDARD cn Service it Slanded aloe ‘rake posal height 170 mm (65916) Clearance beeen sop lamp sch outer 080 and pedal stesper Brake pods! roe pay Clearance between brake pel and aor boars Peking brake lower sroko (non oor ascomby | puted wah 196N 20k, 4) ore Front ese brake pa hikes Front thickness (minimum) Front ie runout Fear cram 1D. esr broke ning teks TIGHTENING TORQUE. eon 05:1.0mm(0020-0.028in) 38mm (01203in) 70 rm (273) 79 ke 20mm (07s n) 10mm (0304 ny 24 mm (088in) 26 mm (0845 n) 0.05 mem (0.002 n) (2.005 mm (0.0082 in) 272mm (1071) 270ne (10850 in) 1.5 mm (0059in) 4.7mm (185 in) ro Koon ‘aster cylinder to booster mounting nut B12 ‘80-120 rake booster mounting nut 136 120-160 oats ‘Brake toosor vacuum hos ting fo surge tank 1518 150-180 m9 Front teed scr 79 70-90 566 Brake fare mit, brake hose sa7 10-170 eae Fear bleed sew on 7-130 594 Caliper guide rad tot zoe 220-220 1628 Calpe assem to knee eo100 | e00-r000 5073, ‘rake hoes to font caliper 25.20 zsosuo | 1e5222 Wee! eynder mounting bot re18 120-180 sa13 Parking take mounting tat wr28 170-280 219 Wes! speed sensor meuntng bot Frontost) e207 297 5768 Hysraue & etetonie cont unt mounting bot 2510 5-100 67 Hygraue &olcroni canto! unt mounting bracket bal 25-0 85-100 67 ‘Sx brake tubs on the Hyaue Unit [tsar 120-170 oe G cauTion ‘Replace te soltlocking nuts with new ones aterBRA BRAKE SYSTEM LUBRICANTS: sane ne Recomended Wicd ‘ausnity | [rae 2OT8 e Dore soo ‘rake peal buting anda pdalbok | Gases aso SAE J10, NGI HOO fees [ies in Whee beste see SAE INO, NLGINE® [A eed raking brake sa and basing plate | Beang grease, NLGI No 7e equ SPECIAL TOOLS. esas “oo! (Wurber and Name) ee ‘ase - 17000 Pushing back of he Font dis and veer Piston expander fase wake ison TROUBLESHOOTING esse Todo ym Probate caus ened ] fig oc viaton when caper imoropery mouried onteet Looe caliper mounting tote thon Uneven worn orcrachod baka drum ortrakedise | Replace Foign material a brake darn ean ‘Seued pad or ning contact sutaco pace pase dose ean pat as coed Uneven pad contact onset Lack of Wexieaton in sng parts ubicate Loose suspension pars atighon Excneshe se runout epace diss ‘orci pal To ane ade | Dilerence in and right re nfatonprossuwe | Ads when brakes ae apples | magequate contacto pa er ning ‘coneet ‘Grease or lon pad o ring srace pace ‘rum warpod or uneven wear piace Incooet wheel clndsrnsallaton ‘conet ‘Auto adie maluncion ConectRs GENERAL Toube syrpiom Probabe enue Femedy Trefcon raking power | Low or detovoraed brake id ello change Ain tho bra syste Blood He syst Brake booster matuncton Conact Insdauate contact of pad ing Comoct {roase o ol on pad ining sutaco Replace Auto acuster matinetion Corot vemested brako oor cu to craging of padetning | Cvect Festictod baka Ine epace Proprtoning vale maltincton Ferlace Trereasod pedal soke [Arn the syst Blea he satan vagus rake Hid oaks Comost (Redveed clearance Dotween peda and Exoossivo push edt masta eyindertosranse | Ast ocr) rake crag Tnsamplie eaasa of paring baka or Incorrect parking brake ecjstment Adjust Worn brake pea! rtun spring Replace Festictod mastor cylinder rtun pct Comat {rokan rear cru bake shoe turn spring Replace Lack of ubeaton i ling parts Luareate Detective mastor clade check vave of Replace pon voir serng Insufcont push red master oynder cleanse | Acust {seen park brs | Worn kenge a lace Grease rollon tng orp suriace Replace Parking brake eae stcking Replace ‘te acjstr matunston ‘coret Excessive paring bake lever soko Aust he pang ra oer Soke of chook the pang brake eatie routing ‘SERVICE ADJUSTMENT PROCEDURES xem INSPECTION AND ADJUSTH prot oasur th baka pada eight the height ent win he standard vee, aust a tons ‘Standard value 170 nen (668m) . explerponn =aRs 1) Disconet te sip lamp swtehconnactor and Teceen the stop lamp sen lock mat Move hows core he bake pod arm, 2) Loosen he operating rod ick rut and asthe Trane pec! height by turing the aperang rod ‘ith ples uni bs connect rake pedal aight aio 3) Tumthestoplam smc unt ip just ouchas the lab onthe Bake peaal Then trn back 12 to revolution and excrete lk nt 4) Connect ne stop lamp swich connor, 5) Chackthatne stop amp doesn’ Burnt whon tho brake po st dopressed. 2. Winthe onghe stopped, dopress te brake ped two ‘rv tes to eleate the vacuum in the power brake booster Then, press the pods dow by hand {o very thatthe oar of movement before ary ‘Stance (ree pay) switin spoceaton, ‘Standard vue 8 me (072052 1) 1 me tee pay Below the standard value, chee {hatin clearance bot he eur ease ofthe sop lamp svc andthe eke pada within the standard ‘alve, Ife fe plays atove the standard value he clear: ance betwoon te cles pn andthe rake peda ar ‘rosede te standard value necessary, check and rooice. 8. When te engine start! a the bre podal s ‘opressed wth about for, heck oo ak he ‘master oyncer, rake ne and connasons Titer ie oak eps STOP LAMP SWITCH INSPECTION Connect circu str'o the stop amp sich, Wan the ‘sith planers aushed check at eof carina. ter isn cont to stop lamp sch is goo. Nace catty ek pe BRAKE BOOSTER OPERATION TEST Forasimpechoccot bake booster operation, prerm the 1. Rune angie fo one ortwo minutes andthen shut Ct Depress the ako pedal seal mes anormal ‘cot pease. hore podal goes own compet {he rr ima, but ses gradual, ho brake book funstoning propery he haga he peda ost ‘change, he hoeste may be damaped 008 Not good LeGENERAL 22, Afar hesling that the halght ofthe peda changes ‘when doprossng to rako pod! soeraltnos wih the engine stopp, sat keeping the bra pedal Cepresens At he tine, ## ge donn eighty, he oostore good but the night a doesn change, ‘i camegne ‘When engines stopped | When engines stared 5. Whe engine running, depces the brake peal and then sop the engine Ho the pedal Copreesed or ‘0 second. ta pda eight dows nat range, he Soostr sm god cndton he ped ies os carsaged Wane oth above te tse fe not OK, check he ‘acuienhoeas, he ehesk av and brake bose Mane any necessrycorrectons. Hal tests ee OX ‘he unt in good eonston (CHECK VALVE OPERATION CHECK ‘non choskng the check vane brine vacuum hoe, 2p the check va tt 1 Remove th vacuum hoes, Wrote Tho chock vahe i pressed ise the vacuum hose athe poston othe marking. 2. Check ho aeration ofthe chock vale by using a vacuum pure. Vacuum sump | AcceptRojct erloria ‘connection ‘Connacton ee brake | A pogaive proseue booster ce (8) (vacuum) cates and ha ‘onnacon at fake | A nagatve presbure manta i 3) (acca) nat rested GS caumion Ihe check valve is defective, replace it fan a6- ‘sembly unt together wit the vacuum hose. ie Sea Se ( LN AeBR. BRAKE SYSTEM BLEEDING THE BRAKE SYSTEM. cicnw 1. Removo th reservoir cap adil he brake reservir wih bra AS cauTion Bo not allow brake Mud to remain on a painted Surface. Wash Hof immediately. 2 Connect vinyl tbe to he whee! cylinder Howser Puganainsortthe othr endothe be nacontain rae sd wh a 9. Str he engine 4. Stow depose he brake padal several as, 5. Whe dopressing the brake pedal tly, oosen the ‘ood plug un id rune out ‘Then loss the boda sero and release ne brake pods ») 8. ‘Ropoa! step a8 uti hve ar na mee Bubbles ine 7. Tien te bode’ plug soem, "Bleeder screw lightning torque: 7..Nm (0-90 kgem, 566 bt) 8. Repeat the above prccseura foreach whee! in he soquce ston Inthe lust,BRAKE SYSTEM BR-2 BRAKE SYSTEM BRAKE BOOSTER COMPONENTS so 5, Vacuum nose (in bun ek vate) | exzaoia0.e5) Removal stops 1 Brake tube connection 8 Spitpin 2 Brae ud inv eencor connector 7. Washer 3. Chitchhoteconsacion 8 Clevispin 4 Master naar assombly 3. Brake Doster | ‘ndstrant ot stance beeen bake booster 10. Sealer pushrod and primary piston Spacer ccaTUION. = The cheok valve should not be removed from the vacuum hose. the cheek ve Is defective replace It togethor with the vacuur hose.BR-10 BRAKE SYSTEM BOOSTER PUSH ROD esc ‘Adjust th clerance) the brake Boos push oa ‘Standard value: 0.1258575 rim (00050-5915), 12. clearance i not win the stand value range, a [usb enanging te push od lenge ty tuning the scr ‘tbe push rodBRAKE SYSTEM BR-t MASTER CYLINDER DISASSEMBLY AND REASSEMBLY sxsw i Disassembly stops 1, Reeonoiteap 6 Piston topper ring 2. Reser sopper bls 7. Primary paton assomy { 3. Recent 8. Maser ender boay 4 Reser eos! 8. Secondary pston assertly 5. Fer ‘caution Do not cisassomble the primary and secondary plston assemblyBRA2 DISASSEMBLY SERVICE POINTS amv: PISTON STOPPER PIN DISASSEMBLY Remove the piston soper pin, hile cepresing th ps- PISTON STOPPER RING DISASSEMBLY Remove he pton stopper ing, whe sprosing he pis: insPEcrion 1. Check te ine suas of master yinder boy for ster ping 2 Chosk he pimary and secondary pistons for us, Scorng wea, cage or Woe. 8. Chack he salto damage and wear [BRAKE FLUID LEVEL SENSOR CHECK 1 Connect rout tester to brake uae soso, 2. Sensors in good conton heros no eet cont uty wan uingeearoioverandcreut cont ‘hon retuned fo egal poston, BRAKE SYSTEM Gs 1. Apply gone brako fd tothe rubber pat ofthe binder ana rors oxo 2. Carty inset he springs and pistons inthe proper Sireston 3. Press agai he pistons with a srewerivr and she rtsnee tg. 4. Wn the pon pushod completly by a stems, Insta he cxinder pn, 5. Mount wo grommets 6. Install he reer on the eyinderBRAKE SYSTEM BRAKE PEDAL COMPONENTS: xin Removal steps 4. Stop lang ante connector 2. Chach cabo connection (Cable typo chch) 5. Chen tum aping (Cable type cach and hyraue cic in ptol his) 4 Spitpn 5 Washer & Cevapn 7, Caden master cnr mounting nuts Pyare eh) Brake bocetarmovrting nas 29, Pada suport mambo’ mounting bots $0 Brake and aah mb ‘TORQUE : im (kgem, 1)BRa4 COMPONENTS cases Removal steps ated (Ree fe @ROUP1 - Cha ea 12. Stap rg 18. Washer 14, Bake pedal 418. Retum sprog 38, Bush $7, Bee pa 18. Stop amp sien 18, Support member (LH) 25, Support member FH) ‘TORQUE : Nm (kgm, bt) BRAKE SYSTEMBRAKE SYSTEM FRONT DISC BRAKE REMOVAL AND INSTALLATION. ex:ae 100 (000000, 5:75) 100 (001000, 58.26 Removal steps 1 Bela ue 2. Front bake ssterty & Brakenoee brace, 4 Brake ase TORQUE : Nm (kom, ot) = Gi seine, 1039) £6 Fy eonBRAKE SYSTEM.|AKE SYSTEM, INSPECTION AND REPLACEMENT. =. GQuore ns bapa hve wear nscale hat conta! he inte ac wre ne take pad oscknss eco ‘rim, arsemt a saveeing sede war hae 1. Choc the brake pad tikrass though ho caliper booy mspecton nl “Pad lining thickness mm dn) rn (0.368 in) Standard valve Servo uit: 2.0 mm (0.079) CAUTION {tthe pad tng thickness Is out of speciie- ton, fet ana right pads must be replaced as ‘complete set 2. When the thickness diference between the lettpad and right padi large, cheek the sic Ing eoniion of the piston, the fek pn and the gulge in. 2. Renveteguse pn me caiperasendy wand &) caurion 'Be careful not to contaminate the lock pin and ‘ulae pin with grease. ‘3. Remove he ‘lowing parts om the caper super. 1) Pac endear sestor assay 2) Pas assonbly 3) ip 4) Outer stim INSPECTION cscs FRONT BRAKE DISC RUNOUT CHECK 1. Remove te cate: super then ase te cape a8 emely upward and suspend wih a we 2. Chack ne uae of tha dc for eracks and at ane {8 Paco a dal gaugo about Sm (0.2 in}. tom the the rurodt othe oe. Umit 608 mm (0524 in) o ess [FRONT BRAKE DISC RUN OUT CORRECTION 1. tthe runt tho rake ssc ouhalant to o ex ead than specteaton, ‘elace Ne dc arab. Srl then meesore te runout again, 1) Before removing the brake dc, hak both sito 's greatestBR-19 FRONT BRAKE DISC THICKNESS CHECK 1. Using cap, measure se tings at ight po- sions apprsnatey £5" apart and 10mm 0.39) ‘rom he oer eape ofthe de Brake dee Bid Standard value: 24 mm (0985 in} Umit: 22.4 mn (0882 in) cosas Thickness vartion (at last @ positions) 2) Remove the brake ds, ad then place a dal___Thedlerence between any boknees masses geugeas hommes, enmove he Shou ot te moe han 001mm (9008 4) the excuod the fit specication instal the 2. ‘tho disc tikes is beyond the it, apace with brake dsc ater turing't 160" tam th chalk 8 NEW On. ‘mark and then check to rn ou ofthe brake sc agan, DISASSEMBLY cme Front disc brakes should be csassombled seperate Dont mx nght-nan ane han parts. 1. Remove te gistonbootpeton tow compressa sr into th brake hose seating ole. Remove he piston Sand piston box 2 ttherunou cannot be caress by changing he po ‘ston ofthe baked, place he bre di.R20 2. Remove the piston so +) Ramave the piston ssl wa your tinge. caurion Don't use a screwuriver or another too! cause may damage the cylinder. 2). Clan he piston surtace and eynder using the ected bake Ho or leo Brake aia = BOT Ser DOT 4 INSPECTION exc 4. Check the ylnder for moar, damage and rus 2. Check he piston sutace fr woar, damage ad us. ‘Cheek ne calor boy and seo for wer BRAKE SYSTEM 4 Chacktha easois ppl, anathepasandtarking 5. Check the pd wear, Chock the pad icknest and Feplace tits Ine han he spectod vas ad thickness Speciation : 100 mm (0391) Servos eit: 20 mm (0.08) REASSEMBLY cnew 1. Clash all comsonens wah soap! aeote excopt for pad ana shim. 2. ntl ne piston sea 3. After spnyng the speci brake fd othe piston ‘outer aura, intl piston eto ha cy 4 natal ne ton boot and bot ng. 5, Insta he gue pn boots and guide pi.BRAKE SYSTEM INSTALLATION. ses 1. sate pads and bake oyincer. 2. In th brake hose tthe caper Tighioning torque Blosser soe “7-9 No (70-80 kp em, 8.6.6 Br) 2 Filthe brake reser wh rake fi 4. Bled tn ete, wyR22 BRAKE SYSTEM REAR DRUM BRAKE REMOVAL AND INSTALLATION. 40VABS (ANTLLOCK BRAKE SYSTEM) BR 35 DIAGRAM OF INPUT/OUTPUT FOR HECU cision ECUBR 38 BRAKE SYSTEM ‘STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING cnc CGatecng miormaton fom easemer Reoceus [Does nat eocou (Check agnosie code (heck lagrest cone No trouble code Pieces cnte dines “Trouble coda [No trouble dspayed check veuble codes) han ease Basi bake system snort ‘Aono ‘Rechocoubl symptan Foto basic brako sion “ube ede depayed Irepecion chart for agnosie Woe Tremont maturation | coces [ermitnt matuncton * Using the customer problem analysis check sheet for reference, sok the customer ae much deal as bout the probe NOTES WITH REGARD TO DIAGNOSIS. «seo ‘The conltons ltd nthe folowing abe are not abnor conatons Biplanation Sysion cece sound ‘Winer slang tha angio, a hosing sound can sonic bo heard coming trom nsido tho ongre compartment. This & because the ‘Spolam opoation check a bang prtarmes. "285 operation sound 1. Sound of he motor nis ho ABS you aparain Whig). 2. Sounds gonad along wih bree of tho brake pec (Sap) ‘3 Won ABS opoates, sound gonoraod from to voNck chassis ‘oo repeated brake appleaton and laasa | (hump suspension, squeak: tees) | 785 operation (Long baking |For oad eutacos such enow-covred snd gravel oad, he Baking ‘sane. ‘Stange for voices wth ABS can sommes be ngerhan that fr ‘thr waios. Ascrdingy, seco th customer to rive sall on | Such oad by ower te veil spood Pedal etback We normal oration iagosis detection coaliona can vary depending onthe dagresis code, When shocking to voube Sylar ‘stor he agnosis cde hasbeen erase, ensure tha Ihe Yogurement atin “Cornet tm.ABS (ANTLLOCK BRAKE SYSTEM) R27 ABS CHECK SHEET esas ABS Check Sheet Inspectors a Ta ae 7 ue 77 | Otani & Seer ones! 7 7 Peper tOmeesathen [C Gomune __ meem (eee ees Pee [Glaiont cece Cone Se eee, [a ronamson A ooo Diagnostic | tettime 7. Noemal Cacia: 0 Mattunctinn Ande (Cada. » se eae eeBR 38 HESCAN CHECK coon 2 “Turn ho gniton “OFF” Connect the H-Szan or M-Scan Proto the data ine ‘onact lasted underneath low ras pad pane. Turn he igniton “ON Use ne H- scan to checker agnosie cades _xtorcomplaion he repro craction ofthe prob lem tum ha gation sth; then erage tho trod ‘ate codea sng fe ar ey on the Seen Disconnect he HSean BRAKE SYSTEM oe CPPErre \Ghelelehal holy r INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES Inspect according othe nspestion chart hat is appropri Die on Sean Deserpton cot [Toe high Baty woiape (over 16¥) ‘eri02 Too ow bary vatage alow BV) ‘e1200 [FL wheel sonsor:opon or short o ground ‘er201 lenge / Performance: excor or epee jurb ener er20e No sia: airgap oror ‘or208 [FR whoo! sensor : open or short fo ground ~ ‘or208 [Range Peromance : exter orapsea ure evar ‘or208 Ne sigal: gap oor er206 FL whee sensor : open or short ground or207 ange / Peformance : ect or epsed jaro rer or208 No signal: aiegap eror ‘orz08| TAR esl sensor: open or short io groune a cr210 ~ Range /Porormance : exer oF spaed imp enor crit "No slgpal : l-gap error - Sensor signal tl ‘G-soeorrangalperormance* open or shor fo ground 821 Mode select switch wvDiaWD) creo Hardware (reading vale fares) can ae eay Gnlaig fee fale) ~ case lotic! (Pump Mots)BR -40 BRAKE SYSTEM5 BRR ny Bc cn eeecceeectceen a bbb oidBR 42 BRAKE SYSTEM INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES cscs FE nn Cran, crs, Ci, C0 T yonanu case ‘espe aes ep or neo rand est | “Ihe HECU determines tat an open or short ert has ooered in more than o ‘wed speed a Te Neasue heHECU comacors NG, [Checkin otowna comes Na, Eso Eno, Foe, ror. Fan, E2a, ee Disconnect connor and measur rm ne haeas side, 7 ‘Resistance vale beta NG, [Gres tenarnss we botoon 5, 1920, 2028 ‘Ghock eyreions ofvoube Pm] each whoo pect sosor and OK’ abd sS0%00 ECU! and rapa i neoseary Weel speed seneorhepection 1, Ne ack otoing comes atinepasion > [Raps re 1 woe, weve, For Foe ea as fee Jo [resraympins orveube—] [Whee bang pasionABS (ANTLLOCK BRAKE SYSTEM) R43 [BTC Ne, Cr20r, ciaos, Ciao crai0 Probable cause amg or wong exoter) _ | peed sensor opus an abnormal signal ~ morper nial whoo! apoed sensor (other han an open shore 1 Matteton of wea poed sensor 1 Matneton of rt | ‘+ Maiiurtion of whee! bearing * Matton of wing harness o connector 1 Matseion of HECU ct wel pend sensor]. NS. toler p> Pepa & Insc wheel speed sensor [NS [inspect whet spaed sensor 19 F=acs ino hel wpm Or Upurvonogewapecion_|->L Enos tres, Fer Foe eae, cas] —>LEepc th whol Pe Fa Chas comecor Na + Na Ehosnroa For, Foe, [nf inpeatotornspesion| [ofeach tor Emen x ox i £ re ([Geeckommsions avoabe Checkampiams clvoibe_ }° +] Creacie ames wie between ne och wheel soos sone ans ECU and repay necessaryBras [Dre Na. cta0e, 1206, cr208, cratt | (Lege ai oa 7 whee! 5 oF eupus pe signal Probable BRAKE SYSTEM |» Makan of wheel apacd sensor * Improper istalaton of whoo! spend sone Metuntone tor (ctor * Mstuneton of wing Rare 6 connacter Melton ot HECU Tepes whelapeadsereor 1 NG, feet o> repr Trapea a gap bebvoen whos! Sbood snsor ae ono who ‘Asap 0.209 mm F ‘Ghack he folowing comector £25, E4t, £08, FO? FOS, EMO ‘Relace he ECU Na Hs nepsieABS (ANTLLOCK BRAKE SYSTEM) BR as (DTC No. CHO, C1702 Vetage ot of ange T (ow ana ver vag). Probate cause of th= HECU power supply ops lower an or than he spaced van. he votage rls Yo the spaced alu, code lan longer cv ‘i, cauTION Ioatery voltage rops or rises during inspection, this code wil be output as wel If the voltage re- {urns othe standard value, the code sno longer output. Batre carying out the flowing inspec tion check th Battery ove andrei ifnecessary ~ Mettunction of wieng hamess or connector reton of HECU ne, 15, Tessie te HECU comeciar | ~—>{ Chock he se ni Pusa box [> Repair © Disconnecthe connector and pe ‘passe rem ne haress ste] [Check symptoms of vouia >| Chacha areas wre betas Str he engin, Votagebe- P ach whoo! seed sorsor and tween Body ground 5K es Ok System atone ECU 03 oN opoeesey | Ghockche batery Na, Choc sploms of eae epics tha REGUBRAKE SYSTEM BR 46 ‘OTE No. C160 ECU Hardware (EEPROM an ECU faire) “The HECU alvaye montore he solenoid vake dive cea I tornios at ter ean open or shotereut nthe flora col orn a harness even # no cunt fous in the solenoid or trough te HECU DTG Na G2I12 Vaio way (heudngtas ture) Probable cause 7 Maturation of wig hamess * Matureten of hyeraue unt * atuneton of HECU Probable cause ‘Wine the ignon swith is turned ON, fe HECU evaches ho ae relay of and en dug taal chock. In that way, te RECU, amps the sgl sent to the vane relay wih veltage in the vale powar mantorbe. That how fo check ho vee ‘ots eporating normaly, The HECU aways cnckaT eurort | fowsin th vehe power montor ine. Ketrminas tha re |v open cut when no curren ows no ure ws he ~ Maluneien a wg harness 6 connector 1 Matuneton f HECU ‘ave ower monior ine, th dagnoss code oul eStase (10a) mapecton JS e[ Replace the tana ne eT i apasn ESOABS (ANTLLOCK BRAKE SYSTEM) 47 TG Ne. C2402 Vat aay . (Motor rey. mot Print one When th rar power tne normal bu no snl snp + Makinaton of HEOU tothe mao montane, his sbooril, ¢Matuncton owing heres connector Ay cawmion Because powering of the motor withthe HiSean ‘or Scan pro wil alscharge the batter, the e ‘gine should be run fra whit ater testing i comm piotea HiScan scwator test ves The harass ana oper? Ist sound ofthe operating ae Ietorresrs? “ ye eres Scenes crac pect eee ae ot reBR 43 BRAKE SYSTEM [ro no, Crara Caesar sa! ne (Oni awwo) - - eeseeie coos [This exe cit tte lowna ime” ———SCS*~dSC ‘clon Ge re op tom Goa betwen 3 an 30% 1 Manson wring hmess or cemneor Aneto on ics rm ese tn. 2 Maeno eC Ng, 1g, Caenaornepacion ‘>| Checks olowng connector J“ Repate 50, E05, Me? Tisssure RECO eanodor NG, [Check he tatowingconnscor S ae Fes aot Ga eu San a eae toweg comer TNS agay qe ‘Gheck owe srrptons yr ‘Repace he ECUABS (ANTI OCK BRAKE SYSTEM ABS WARNING LAMP INSPECTION 49 suse Whan tw gion kay is ted "ON", te ABS warning lamp sores on fr approxima 2 seconds and tan 99 Check that he ABS warning lamp tuminetee as fo. oi INSPECTION CHART FOR TROUBLE SYMPTOMS Sos route sypts and check asa thea ten procedure cart Towle symoions| iapecion poeaire Na ‘Conmuncaton wit H-Ssan | Comiricaon wit sims rol publ 3 I nt peels Communication wh ABS nye ot ete 2 Ton heen ky tued “ON engine opp), te ABS > waring lap des ot tur, ‘Ate he engine san. the mp ane Rania - a Faulty ABS operation ‘Uses ang power on Bh ee j [jaicen tng poner | ABS operates vce normal bang coon 5 ABS operates boos vetlesope under rermaltraang consans | {he whee rom locking and isnot an abnormal. iBR. BRAKE SYSTEM INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS esc INSPECTION PROCEDURE 1 | Earrmaneaton win Hc Sean ie rot posse | (Commaricaton wh as systems ht posto) eee “The 950m probaly a delect he power spy sytem 7 Mafincion of comecor (eluing grou) Sorte dagress Ine { Matuncon ot wemg hatrase INSPECTION PROCEDURE 2 ‘oneraricaton wih HiSean isnt posse — | {Communaten wth ABS onl i nat posse) Probes | Wines communeaton with He Sean snot posstin the cause 7 Bion fase ' prcably an open veut ine HEU power veut or an 1 Matuncten of wring harness connector ‘open ere nthe dlagretseubut iat 1 Matuneon of HECU Tease aagnase crneosr Corinansecentie (NO [otnacmetetonigcemeae 18S y Repair =e a eo i Seas owen | 4 fesestgacos ee [neers ES aia F OK yen etage [Giaccone ofoete +(e eae ae SOnermetbo comet a |, oGaninaybemeen ogy [> Pepa a = eagache owing cormsctor [uo repairABS (ANTLLOCK BRAKE SYSTEM) BRS INSPECTION PROCEDURE 3 ‘Wem th ipnion fay trnad “ON (eng stopped), [ABS warring lamp doos ot iuminate ‘Wine curt flows trough the HECU, the ABS relay ums tem | Blown uso ‘anise heinal chock The ABS warang lenp wil urinate. | + Bunt ou ABS warning amp bulb than the ABS relay OF even theo fea presum wih he | + Mafancion of wring namoss or connect ‘Shout betwgen the ABS waring mp and the HECU, Probable case ‘Teco, he lamp does no iui, th cause may ‘be en opan crcut in help power eupoly rut, a own bu oan open eet in ath theorcute Betwoon tho ABS ‘nating lamp ei the HEGU and in he cicul baba the [3S warning lamp and te ABS rly [a1 use (10) nepecon Pe SS NG, [hacker ABS 18, Role he ABS wang ano ao Ssinglanp tu bu ou [>] ba Ire at be pn Jo Boerthe A varang arp ox min en trina 46, ‘roundee? heck the corneas YS» Repatr Ok: lumintes| hoot ic [Gheckheharnacs boon [ABS relay) ana eonnect MOS Repar. trecorsary Replace recombination materR52 BRAKE SYSTEM INSPECTION PROCEDURE 4 von aie the orgie i sarod, to ABS warring lamp remains lumina Tho caus & probably a dhreaaut i he ABS ware lamp iluminaton eeu Probable cause ~ Mafuncion of combination mater + Matuneon of HECU ¢Matuncton owing hares ‘This trouble symptom Is limited to cases where com Imunlction with the H-Sean is possible (HECU power ‘Supply fs normal) ana the diagnosis code ls norma Disconnect somectorENOG and uinteigntion | yes Eo 2 Does the ABS warning lamp remain illuminated? place the nom ‘> Daconnee HEGU comecer ESS re © lntion swash “ON place fe 7E00 ABS Waring lamp swich ff? 2 owe No — ‘Ghack the harnsses btwoen tha comnation mer ndiba HEC Fepair nocessay.ABS (ANTLLOCK BRAKE SYSTEM) R53 INSPECTION PROCEDURE 5 Brae operation abnormal Probable cause This varies deponcng on ering * improper Wstalaton of wheat + Malutcion of wheal speed | ctmaitone na readeutace condtons, |” speed sensor ‘eneor fe preblem dgrosis dieu + Inarot sensor harness + Matron of tr Howevor # a norma! dagnass contact + Matuncten of wheal bsanng ‘ode ie epaye cary out he + Fovoign material adhering fo + Maonton of Myra unt folowing inspector, whoo! speed sensor ¢ Maltuncton ot HECU Iepact weaned e071 pape ee NG. NG Inspect wheel sped cubut OK [Greek efowna connections [NG E26, 1, F06, 07. MFO, EMos_|-—™ Repair Checrrect ie comocrana [> Real rmeabse atthe hamess de |. Restance value baton termine 1-2, 56, 19-20 and 2225 ok" 11000 50% (ite senator namess na on eto shou be raved around while these inspection are aid ut tet trite ennoctons} OK Na place the HECUBR54 BLEEDING OF BRAKE SYSTEM) csc Ths ecoaue sod be lowe 0 ese sabe boedg ofa ana ing of th ABS uni, rake In raster ener uth brace ae 1. Remove the resaroecap andi th bake rsenie ‘tbe i, caution I ther is any brake fold on any painted surtace, ‘wash off immediatly Gaore 2. Comect a clear paste tube tothe whee! eyinder Sead plug ar rgert bo ahr endothe no hat lod oar plate od, ‘8, Conect he HiScan (Pr) othe Data Link Connector Tecate underneath he dash pare! BRAKE SYSTEM Solel ana eprate acorn to the instructions en the iSean Pro crear Ay eavmew Youmustoty the masinum operating tine ofthe ‘285 motor th Hse ro fo prevent he ‘motor pump tom borin. 1), Select tyundal vile dlagnoss. 2). Solo vice name 3). Selct An-Lock Brake syst. 4) Select a eosing mode. 5) Press £5 operate meso punp and solenoid(ANTI-LOCK BRAKE SYSTEM) 6) Wal 60 soe. blore operating he ar bscing. (nat yeu may aamage the mater). 5. Pano the brake pal several mes, an then loosen bubbles, Thon een te Booder sre 5. Ropoa! stop Suni here ae no mere bubbles Inthe ‘utter esch who 7. Tighon the bloeor seen ‘Blood srw ighioning rave 731m (7080 kgem, 568 bt) BRSBR 56 ANTI-LOCK BRAKING SYSTEM CONTROL MODULE COMPONENTS cca — ost natallation Operation air Cleaner inaaion| Bake Fad Supping Brake Lin Bobag 6 Hyeaule Unit Chek Removal steps 2 ako tbe comecton Sida unt 4 Ryde unt racket 5. Damper sow REMOVAL «sow 1. Tum te nin ton ot andromove th a Sanat 2, llth» HECU double lock connector wad BRAKE SYSTEM & caurion The hydraulic unit is heavy, and so care hou taken when removing ‘The hydra unit i not tbe disassembled: Ina nuts and bolts should absolutely not Be loosens ‘he hyeraulle unt must not be cropped or cothonse subjected fo impact shocks.ABS (ANTLLOCK BRAKE SYSTEM) BRST 4. The hydraulic unit must not be tumed upside do ora ons sce HYDRAULIC MODULE INSPECTION as A cauion Turn the ignition switch of before connecting or adsconneeting the HeScan. 1. dao the vile up sod support the vehicle with ai ache wih specie jack-up ports oF rplace ‘ho wheols whieh are chesked co he roles ot braking Tce ost. ) caurion ‘The role of the braking force tester and the ire shut be dry during testing, 2 When testing te front rakes, apply the park- Ing brake, and when tstng the rear brakes, ‘top the front wheel By choking tem. 2 Release th parking bake and oot e orap toe (crag tru) on each ross wee ‘nen using ne rain oe ot, ako a reading ot te rake aay toe 3. Tum the ignon key “OFF” and gt the HiScan 35 4. Ator checking tht he shit eer oes {orlser len neta stat the engine. Grote 1h ho ABS has boon ire by he fase incon tab Sean actuator testing cannot ue. 5. Uso he HiScan to frce-dvehe aust,BRB BRAKE SYSTEM ANTI-LOCK BRAKING SYSTEM RELAY ABS RELAY INSPECTION ess CONNECTOR CONFIGURATION sco Temvel] + [a] als Psion 2. Chock or continuity betwoon he trials Bate vokape ve upping ots Batory vetape supped oteABS (ANTLLOCK BRAKE SYSTEM) 3. Insrtapobe of est amp harness sie connector termina Not and ground the oer probe (OK Test lap ON 4 Insert a probe ost lamp to harness se connor ‘Gein NO' and ground the ane robe. 5. Aopy ne batary vag othe terminal No [REMEDY FOR A FLAT BATTERY DISCHARGE ‘nen booster cabies are used to start he engine when tho bata s completly dacharged and thon the ve ts nmedatly dren witout wathg rhe ater recharge tte some exe he engine may isi, and ‘eg might nt be posse “This happens because ABS corsumes great amount ‘ot eurent er ts sa-check uncon; te remedy i To ‘hor allow etry 1 ecnarge suey oro remove ‘ho foil nk br ABS cut, hus sabi the an std baka system, ‘The ABS warning amp wlluniate when the fui (te ABS) eared ‘Morbo bateryhassutcionty charged, tahoe lnk (or ABS) anesthe eng hencheck aba ure tho ABS warning lamp sro lumina,BR 60 BRAKE SYSTEM ANTI-LOCK BRAKING SYSTEM WHEEL SPEED SENSOR COMPONENTS esas [FRONT]ABS (ANI REMOVAL, FRONT WHEEL SPEED SENSOR 1 Remove th Hon whee! speed sensor mounting bo 2. Remove to Fort wheel speed sontor ater scan recng the woo epood sngor connecter. REAR WHEEL SPEED SENSOR Famovs ho rear wheel speed sensor ater asconnacting tno whee! speed sonsr comet. INSPECTION WHEEL SPEED SENSOR OUTPUT VOLTAGE check 1. Litup he vehi ne lease he parking brake, 2, Disconnact he HECU harness connetor and mas Sure tam ho armas sido connector G cauTion ‘Be cure toremove the connector double lock nd Insert he probe int the hamess de. Inserting Inte the termina sige wl result in @ 3. Rotate the whee! to be mossures at approximately "12-1 roto po sac an check he ouput vl 8 Using aero str oan octloseope, Whoa tot | FONT | Rear ian | Rea pred | Fonten) eor ran Teeminal |_t 18 2 Ce Supt vonage ‘hon measug wih an oscilsscope WHEEL SPEED SENSOR INSPECTION 1. Chock hater any mettle frcign maori! has diorad fo fe pars shown inte usaton a he Speed sansa tp. anit orn IBR 62 ‘The seatan shown i the lusratin ean bacome Imagnotied because ofthe magnet bu it the {Speed senor win the result hat foreign meta material easy chores to 2 Measure the resistance botwon the speed sensor I the ioral resistance of tho speed sonsor i not wth he sani vate, Replace wih new speed Oj ‘Sian vale i= |3 sce pe spec sensor cane breakage, camage tr daconnecton replace wat a now ene probom ‘eure nore non enecing for eablo damage, remove the able ‘np pat rom he body an thon ban andl ho ano roar he clamp io chook whether ona tampo. ‘ary eseonnecton ees ‘Gheck ne connector canmecton and the terminal in 9 al conmacions from the spec senso. and thon measze the resitance betweon trmasis() {and @) and the booy of tre speed senso. BRAKE SYSTEM “Brander vale: 100K or mere ‘ooTHED ROTOR (Check whether rear eth ee broken oF detormed, an, 50 rplace the wrABS (ANTLLOCK BRAKE SYSTEM) BR s3 G-SENSOR COMPONENTS: excas 1.708 2. Gesensr and bracket nove | Beste to instal he G-sensor ‘wth the arrow mato be acing voLTase INSPECTION taco 1 nat he probe of veer fo he back! he nar rest sdeo Gsensor connector 2 and 2 “Turn ho jnion ate to ON and cack he out otage of sensor Torwara rection ‘caution tages Bi) wt ae eee Peesnminn: 3a 98 arma? ‘orsubjectitte shocks. ourpur cuaRacrenisrc ‘Secura the senso 90 thal ho arom mark of he Sensor mousing srs aac sgt don, sn than check a ouput votag betwen ena and IO Sandia valve > BV ‘Standard wae 35 4. ne case nat ne otage is outside te standard ‘aus, and ere no tory in power upp and ground wes, pace ine G-sensr,