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Mitel 8662 IP Phone User Manual

1. PISTON BOOT PISTON REMOVAL Protect caliper body with cloth Blow compressed air through brake hose to remove piston boot and piston Caution Blow compressed air gently PISTON SEAL REMOVAL 1 Remove piston seal with finger tip Caution Do not use a flat tipped screwdriver or other tool to prevent damage to inner cylinder 2 Clean piston surface inner cylinder with trichloroethylene alcohol or specified brake fluid Specified brake fluid DOT3 or DOTA REASSEMBLY SERVICE POINT LOCK PIN GUIDE PIN INSTALLATION Install the guide pin and lock pin as illustrated that each head mark of the guide pin and the lock pin matches the indication mark G or L located on the caliper body INSPECTION 35100630081 e Check cylinder for wear damage or rust e Check piston surface for wear damage or rust e Check caliper body or sleeve for wear e Check pad for damage or adhesion of grease check backing metal for damage 35A 24 BASIC BRAKE SYSTEM Rear Drum Brake REAR DRUM BRAKE 35100750145 REMOVAL AND INSTALLATION Pre removal Operation Post installation Operation e Loosening the Parking Brake Cable Adjusting Nut e Brake Line Bleeding Refer to P 35A 10 e Brake Fluid Draining e Parking Brake Lever Stroke Adjustment Refer to GROUP 36 On vehicle Service 1410069 00005623 1420013 1450079 1450078 Specified grease Brake grease SAE J310 NLGI No 1 Remov
2. 2 Pad assembly 3 Pad liner 4 Outer shim A14S0191 4 n order to measure the brake drag force after pad installation measure the rotary sliding resistance of the hub with the pads removed Refer to P 35A 19 5 Install the pads and the caliper assembly and then check the brake drag force Refer to P 35A 19 35A 12 BASIC BRAKE SYSTEM On vehicle Service DISC BRAKE ROTOR CHECK 35100290012 Caution When servicing disc brakes it is necessary to exercise caution to keep the disc brakes within the allowable service values in order to maintain normal brake operation Before re finishing or re processing the brake disc surface the following conditions should be checked Inspection items Remarks Scratches rust saturated lining materials e If the vehicle is not driven for a certain period the sections of and wear the discs that are not in contact with lining will become rusty causing noise and shuddering If grooves resulting from excessive disc wear and scratches are not removed prior to installing a new pad assembly there will momentarily be inappropriate contact between the disc and the lining pad Run out or drift Excessive run out or drift of the discs will increase the pedal depression resistance due to piston knock back Change in thickness parallelism If the thickness of the disc changes this will cause pedal pulsation shuddering and surging Inset or warping flatness Overheating an
3. 26 reete 10 PROPORTIONING VALVE 28 GENERAL INFORMATION The brake system offers high dependability and durability along with improved braking performance and brake sensitivity Items BASIC BRAKE SYSTEM General Information 35A 3 35100010182 Specifications Master cylinder Type Tandem type with level sensor 1 0 mm 23 8 Brake booster Type Vacuum type single Effective dia of power cylinder mm 230 Boosting ratio 6 0 Proportioning valve Type Dual type Decompression ratio 0 25 Front brakes Type Floating caliper 1 piston ventilated disc Disc effective dia x thickness mm 256 x 24 Wheel cylinder mm 60 3 Pad thickness mm 10 0 Clearance adjustment Automatic Rear disc brakes Type Floating caliper 1 piston solid disc Disc effective dia x thickness mm 262 x 24 Wheel cylinder mm 34 9 Pad thickness mm 10 0 Clearance adjustment Automatic Rear drum brakes Type Leading trailing Drum I D mm 203 Wheel cylinder mm 20 6 Lining thickness mm 44 Clearance adjustment Automatic Brake fluid DOTS3 or DOT4 General Information 35A 4 BASIC BRAKE SYSTEM Service Specifications CONSTRUCTION DIAGRAM Brake booster Master cylinder p s Rear brake Proportion
4. Long braking distance vehicles with ABS can sometimes be longer than thatfor other vehicles Accordingly advise the 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 trouble symptom again DIAGNOSIS FUNCTION 35201120221 DIAGNOSIS CODES CHECK Read a diagnosis code by the MUT II or ABS warning lamp Refer to GROUP 00 Howto Use Troubleshooting Inspection Service Points ERASING DIAGNOSIS CODES With the MUT II Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points ABS lt 2WD gt Troubleshooting 35B 7 With the ABS Warning Lamp 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 Stop the engine Turn on the stop lamp switch Depress the brake 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 lamp switch on and off a total of 10 times NOTE If the ABS ECU function has been stopped because of fail safe operation it will not be possible to erase the diagnosis codes AON ON Ignition switch OFF ON Stop lam
5. 1 Before removing the brake disc chalk both sides of the wheel stud on the side at which run out is greatest 214L0087 2 Remove the brake disc and then place a dial gauge as shown in the illustration then move the hub in the axial direction and measure the play Limit 0 05 mm If the play is equivalent to or exceeds the limit disassemble the hub knuckle and check each part 3 If the play does not exceed the limit specification install the brake disc at a position 180 away from the chalk mark and then check the run out of the brake disc once again 2 Ifthe run out cannot be corrected by changing the phase of the brake disc replace the disc or turn rotor with on the car type brake lathe MAD DL 8700PF or equivalent 14C0009 35A 14 BASIC BRAKE SYSTEM On vehicle Service BRAKE LINING THICKNESS CHECK 35100300166 1 Remove the brake drum 2 Measure the wear of the brake lining at the place worn the most Standard value 4 4 mm Limit 1 0 mm Replace the shoe and lining assembly if brake lining thickness is less than the limit or if it is not worn evenly For information concerning the procedures for installation of the shoe and lining assembly refer to P 35A 24 Caution 1 Whenever the shoe and lining assembly is replaced replace both R H and L H assemblies as a set to prevent car from pulling to one side when braking 2 If there is a significant difference in the thickness of the sho
6. 18 BASIC BRAKE SYSTEM Master Cylinder and Brake Booster MASTER CYLINDER DISASSEMBLY AND REASSEMBLY ij i 1410113 00006084 Disassembly steps Reservoir cap assembly Reservoir cap Diaphragm Brake fluid level indicator assembly Float Spring pin 35100420145 gs en B s 1410112 Master cylinder kit 12 11 1420006 Brake fluid DOT3 or DOTA Reservoir tank Reservoir seal Piston retainer 10 Primary piston assembly 11 Secondary piston assembly 12 Master cylinder body ON BASIC BRAKE SYSTEM Disc Brake 35A 19 DISC BRAKE 35100800017 REMOVAL AND INSTALLATION Pre removal Operation Post installation Operation Brake Fluid Draining e Brake Fluid Supplying e Brake Line Bleeding Refer to P 35A 10 Front E ps e AS 4 90 110 Nm 9 7 A 19 14 0211 lt gt 29 Nm Pda 2 55 14P0052 00006080 Removal steps 1 Brake hose connection 3 Disc brake assembly 2 Gasket 4 Brake disc INSTALLATION SERVICE POIINT MB990998 D P A DISC BRAKE ASSEMBLY INSTALLATION lt 1 In order to measure the brake drag torque after installtion measure the rotary sliding resistance of the hub by the following procedure with the pads removed lt Front gt T n 1 Remove the drive shaft Tant
7. 5 surface and the ABS toothed rotor mm Wheel speed sensor insulation resistance kO 100 or more L U B R l CA N TS 35200040054 Items Specified lubricant Brake fluid DOT3 or DOT4 SPECIAL TOOLS 35200060210 Number Name Use MB991502 MUT II sub For checking of ABS Diagnosis code display assembly when using the MUT II MB991529 Diagnosis code For checking of ABS Diagnosis code display check harness when using the ABS warning lamp B991529 35B 6 ABS lt 2WD gt Troubleshooting TROUBLESHOOTING 35201110129 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 Explanation of phenomenon System check sound When starting the engine a thudding sound can sometimes be heard coming from inside the engine compartment but this is because the system operation check is being performed and is not an abnormality ABS operation sound 1 Sound of the motor inside the ABS hydraulic unit operation whine 2 Sound is the generated along with vibration of the brake pedal scraping 3 When ABS operates sound is generated from the vehicle chassis due to repeated brake application and release Thump suspension squeak tyres ABS operation For road surfaces such as snow covered roads and gravel roads the braking distance for
8. A 04 I Wheel speed sensor check Refer to P 35B 29 e Disconnect the connector and measure at the harness side OK NG connector Qeon between 20 and 19 2 and 1 22 and 23 6 and Replace Check the following connectors I L H drive vehicles A 09 C 115 C 75 A 39 C 74 E 14 E 13 E 11 C 123 E 12 Wheel speed sensor output voltage check Refer to P 35B 19 R H drive vehicles OK NG A 09 A 41 A 39 C 115 C 75 E 14 E 13 E 11 C 121 E 12 NG OK Wheel speed sensor Replace Y check Refer to Check the trouble symp P 35B 29 tom OK NG Y NG Y ABS rotor check Refer Replace Check the harness wire and repair if necessary to P 35B 29 e Between each wheel speed sensor and ABS ECU OK Y Wheel bearing check Re fer to GROUP 26 and GROUP 27 On vehicle Service Y Check the following connector A 04 OK Y Check the trouble symp Repair tom NG Y Replace the hydraulic unit 35B 10 ABS 2WD Troubleshooting Code No 15 Wheel speed sensor abnormal output signal Probable cause This code is output when there is an abnormality in the output signal from any one of the four wheel speed sensors while driving except for an open circuit or short circuit The four vehicle tires are of different sizes Improper installation of wheel speed sensor Malfunction of wheel speed sensor Malfunction of wiring harness or connector Malfunction of A
9. On vehicle Service Flared brake line nuts d 14X0343 14X0214 14X0146 00004486 Removal steps gt 1 Brake pipe 2 Proportioning valve INSTALLATION SERVICE POINT A lt BRAKE PIPE CONNECTION Connect the pipes to the hydraulic unit as shown in the illustration 1 Proportioning valve Rear brake L H 2 Proportioning valve Rear brake R H 3 Proportioning valve Hydraulic unit 1410340 4 Proportioning valve Hydraulic unit 35B 26 ABS lt 2WD gt Hydraulic Unit HYDRAULIC UNIT 35200860261 REMOVAL AND INSTALLATION Pre removal Operation Post installation Operation Brake Fluid Draining e Brake Fluid Supplying e Brake Line Bleeding Refer to GROUP 35A On vehicle Service e Brake Pedal Adjustment Refer to GROUP 35A On vehicle Service L H drive vehicles R H drive vehicles 2 45Nm 14X0343 1410121 1410068 00006096 Removal steps 1 Harness connector 2 Brake pipe connection B 3 Hydraulic unit and ABS ECU 4 Hydraulic unit bracket assembly ees p d A1410117 1410042 ABS lt 2WD gt Hydraulic Unit 35B 27 REMOVAL SERVICE POINT A HARNESS CONNECTOR REMOVAL Raise the locking lever as shown in the illustration and then disconnect the harness connector B HYDRAULIC UNIT ASSEMBLY REMOVAL Caution 1 2 3 4 The hydraulic unit assembly is heavy and so care should be taken when
10. assembly and auto adjuster assembly contact surfaces Shoe and lever assembly and auto adjuster assembly contact surfaces SEALA NTS 35100050153 Items Specified sealant Remarks Thread part fitting 3M ATD Part No 8661 or equivalent Semi drying sealant Vacuum switch SPECIAL TOOLS 35100060071 Number Name Use MB990964 Brake tool set e Pushing in of the disc brake piston MB990520 e Installation of drum brake wheel cylinder MB990619 piston cup MB990998 Front hub remover Provisional holding of the wheel bearing and installer B990998 35A 6 Pedal up BASIC BRAKE SYSTEM On vehicle Service ON VEHICLE SERVICE 35100090186 BRAKE PEDAL CHECK AND ADJUSTMENT BRAKE PEDAL HEIGHT 1 Turn up the carpet etc under the brake pedal 2 Measure the brake pedal height as illustrated If the brake pedal height is not within the standard value follow the procedure below Standard value 162 8 165 8 mm switch B14W0001 0 5 1 0mm 14 0002 1 2 3 Disconnect the stop lamp switch connector Adjust the brake pedal height by turning the operating rod with pliers with the operating rod lock nut loosened until the correct brake pedal height is obtained Secure by tightening the lock nut of the operating rod Push the stop lamp switch in the direction of the pedal stroke until it stops The switch will slide if it is pushed firmly Lift up the pedal unt
11. e Between diagnosis connector and earth Replace the MUT II ABS lt 2WD gt Troubleshooting Inspection Procedure 2 Communication between MUT II and the ABS ECU is not possible 35B 13 Probable cause The cause may be an open circuit in the ABS ECU power supply circuit or an open circuit in the diagnosis output circuit e Blown fuse e Malfunction of wiring harness or connector e Malfunction of hydraulic unit Measure at the diagnosis connector C 20 and the ABS ECU con nector A 04 e Disconnect the connector and measure at the harness side connector Continuity between the following terminals ABS ECU side Diagnosis connector side 14 1 7 7 OK Continuity OK Measure at the ABS ECU connector A 04 e Disconnect the connector and measure at the harness side connector Ignition switch ON Voltage between 4 and body earth OK Battery voltage OK Measure at the ABS ECU connector A 04 e Disconnect the connector and measure at the harness side connector Continuity between 8 and body earth between 11 and body earth and between 24 and body earth OK Continuity NG m Check the following connectors PETROL POWERED VEHICLES C 51 C 49 C 83 C 66 C 20 DIESEL POWERED VEHICLES C 51 C 56 C 83 C 66 C 20 OK NG Check the trouble symp Repair tom NG Check the harness wire and repair if
12. rear brakes stop the front wheels by chocking them 2 Release the parking brake and feel the drag force drag torque on each road wheel When using the braking force tester take a reading of the brake drag force 3 Turn the ignition key to the OFF position and set the MUT II 4 After checking that the shift lever M T or the selector lever A T is in neutral start the engine 5 Use the MUT II to force drive the actuator NOTE 1 During the actuator test the ABS warning lamp will illuminate and the anti skid control will be cancelled 2 When the ABS has been interrupted by the fail safe function the MUT II actuator testing cannot be used 6 Turn the wheel by hand and check the change in braking force when the brake pedal is depressed When using the braking force tester depress the brake pedal until the braking force is at the following values and check that the braking force decreases when the actuator is force driven Front wheel 785 981N Rear wheel 588 784 N The result should be as shown in the following diagram Depressed EE Pedal operation MUT II actuator test Released Item No 01 02 03 04 start Increase in pressure Solenoid valve 2 seconds position Steady pressure TRE 1 seconds Reduction in pressure when not working Lock Checking the brake force Drag force when the pedal is free 3 seconds 14X0168 7 If the result of inspection is abnormal correct according to
13. the Diagnosis Table Refer to P 35B 23 8 After inspection disconnect the MUT II immediately after turning the ignition switch to OFF ABS 2WD On vehicle Service Diagnosis Table Operation Judgement Normal Judgement Abnormal Probable cause 35B 23 Remedy 1 Depress brake pedal to lock wheel Using the MUT II select the wheel to be checked and force the actuator to operate Turn the selected wheel manually to check the change of brake force Brake force released for 3 seconds after locking Wheel does not lock when brake pedal is de pressed Clogged brake line other than hydraulic unit Check and clean brake line Clogged hydrau lic circuit in hydraulic unit Replace hydrau lic unit assembly Brake force is not released Incorrect hydrau lic unit brake tube connection Connect correct ly Hydraulic unit Replace hydrau solenoid valve not functioning correctly lic unit assembly REMEDY FOR A FLAT BATTERY When booster cables are used to start the engine when the battery is completely flat and then the vehicle is immediately driven without waiting for the battery to recharge itself to some extent the engine may misfire and driving might not be possible This happens because ABS consumes a great amount of current for its self check function the remedy is to either allow the battery to recharge sufficiently or to remove the
14. 35A 1 SERVICE BRAKES CONTENTS 35109000159 BASIC BRAKE SYSTEM 35A ANTI SKID BRAKING SYSTEM ABS lt 2WD gt 35B ANTI SKID BRAKING SYSTEM ABS lt 4WD gt 35C NOTE THE GROUPS MARKED BY ARE NOT IN THIS MANUAL 35A 2 BASIC BRAKE SYSTEM CONTENTS 35109000302 GENERAL INFORMATION 3 Disc Brake Pad Check and Replacement 10 VICE SPECIFICATIONS 4 Disc Brake Rotor Check 12 SERVICE Sr OW CANONS Seda Brake Lining Thickness Check 14 LUBRICANTS 225 22 Ras 5 Brake Drum Inside Diameter Check 14 Brake Lining and Brake Drum Connection SEALANTS i 99 b Xa eee aes ERA 5 Ch6Ckx i uem Ote es 14 SPECIAL TOOLS 5 BRAKE PEDAL 15 ON VEHICLE SERVICE 6 MASTER CYLINDER AND BRAKE Brake Pedal Check and Adjustment NOE 6 BOOSTER m BOR BON BOB BON BOB EON BOB HO BON BOR BON BOR HON x 16 Stop Lamp Switch Check 7 Master Cylinder 18 Brake Booster Operating Test 7 DISC BRAKE 19 Check Valve Operation 8 Proportioning Valve Function Test 9 REAR DRUM BRAKE 24 Brake Fluid Level Sensor Check 9 Wheel Cylinder
15. BS rotor Malfunction of wheel bearing Malfunction of hydraulic unit NO Are the sizes of all four tires identical Equip the vehicle with tires of identical sizes YES Y Check the trouble symptom NG NG Wheel speed sensor installation check I gt Repair OK Y NG Wheel speed sensor output voltage check Refer to P 35B 19 Wheel speed sensor check Refer to P 35B 29 JoK OK Ne Check the following connector A 04 Replace OK NG Y Y ABS rotor check Refer to P 35B 29 iret the trouble symp Repair OK jna om 8 Replace Replace the hydraulic unit Wheel bearing check Refer to GROUP 26 and GROUP 27 On vehicle Service NG Y Check the harness wire and repair if necessary e Between each wheel speed sensor ABS ECU Code No 16 ABS ECU power supply system abnormal Probable cause voltage drop or rise This code is output if the ABS ECU power supply voltage drops below or rises above e Malfunction of battery the rated values e Malfunction of wiring harness or connector Furthermore if the voltage returns to normal this code is no longer output e Malfunction of hydraulic unit Caution If battery voltage drops or rises during inspection this code will be output as well If the voltage returns to standard value this code is no longer out
16. M DR Refer to GROUP 35A 5 Brake Lining Thickness Check DISCE TOT m Refer to GROUP 35A TES 6 Brake Drum Inside Diameter Check nw c ATE Refer to GROUP 35A MICE 19 Brake Lining and Brake Drum Connection Refer to GROUP 35A GROUP 35A Wheel Speed Sensor Output Voltage GEG RT 19 35 ABS Warning Lamp Relay Continuity pus xU Re Xon doe ees 21 GROUP 35A Hydraulic Unit Check 22 Remedy for a Flat Battery 23 m GROUP 35A GROUP 35A CONTINUED ON NEXT PAGE GROUP 35A 35B 2 BRAKE PEDAL Refer to GROUP 35A Wheel Oylinder Refer to GROUP 35A MASTER CYLINDER AND BRAKE PROPORTIONING VALVE 25 BOOSTER gt oil EAD DLE 24 Master Cylinder 24 HYDRAULIC 26 DISC BRAKE Refer to GROUP 35A WHEEL SPEED SENSOR 28 REAR DRUM BRAKE ABS 2WD General Information 35B 3 GENERAL INFORMATION The ABS consists of components such as the wheel speed sensors stop lamp switch hydraulic unit assembly ABS control unit ABS ECU and the ABS warning lamp If a problem occurs in the system the malfunctioning components can be Items 35200010222 identified and the trouble symptoms will be memorized by the diagnosis function In addition reading of diagnosis codes and service data and actuator testing are possible by using the MUT II Spec
17. SS SIDE CONNECTOR TERMINALS 1 Turn the ignition switch off and disconnect the ABS ECU connectors before checking resistance and continuity 2 Check them between the terminals indicated in the table below 3 The terminal layouts are shown in the illustrations below Ts RLZTETSTAT3IZTI m Censinio 25 24 5123122 121120 18 L8 177 os 1410064 Terminal No Signal Normal condition 1 2 Wheel speed sensor front left 1 0 1 5 kQ 5 6 Wheel speed sensor rear left 1 0 1 5 kQ 19 20 Wheel speed sensor front right 1 0 1 5 kQ ABS lt 2WD gt Troubleshooting On vehicle Service 35B 19 Terminal No Signal Normal condition 23 22 Wheel speed sensor rear right 1 0 1 5 kQ 8 Body earth Solenoid valve earth Continuity 24 Body earth Motor earth ON VEHICLE SERVICE 35200160224 WHEEL SPEED SENSOR OUTPUT VOLTAGE CHECK 1 Lift up the vehicle and release the parking brake 2 Disconnect the ABS ECU connector and then use the special tool inspection harness for connector pin contact pressure to measure the output voltage at the 1410064 harness side connector 3 Rotate the wheel to be measured at approximately 1 2 1 rotation per second and check the output voltage using a circuit tester or an oscilloscope ABS ECU connector harness side Wheel Front left Rear left speed sensor Terminal No Output voltage When measur
18. al steps 1 Brake drum 11 Shoe and lever assembly 2 Lever return spring A B 4 12 Retainer 3 Shoe to lever spring 13 Wave washer 4 Adjuster lever 14 Parking lever 5 Auto adjuster assembly 15 Shoe and lining assembly 6 Retainer spring 16 Shoe hold down pin 7 Shoe hold down cup 17 Brake pipe connection 8 Shoe hold down spring 18 Snap ring 9 Shoe to shoe spring 19 Rear hub assembly 0 Shoe and lining assembly 20 Backing plate BASIC BRAKE SYSTEM Rear Drum Brake 35A 25 REMOVAL SERVICE POINT Pimonshoeese ply RETAINER REMOVAL Use a flat tipped screwdriver or the like to open up the retainer joint and remove retainer Retainer 1410257 INSTALLATION SERVICE POINTS Et p A WAVE WASHER INSTALLATION Wass EI ee Install the washer in the direction shown in the illustration Parking lever 14 0255 B lt RETAINER INSTALLATION Use pliers or the like to install the retainer or the pin positively Pin of shoe assembly Retainer 14 0256 35A 26 BASIC BRAKE SYSTEM Rear Drum Brake WHEEL CYLINDER 35100930082 REMOVAL AND INSTALLATION Pre removal Operation Post installation Operation Brake Fluid draining e Brake Fluid Supplying e Brake Line Bleeding Refer to P 35A 10 A14X0123 Removal steps 1 Brake drum 5 Brake pipe connection 2 Shoe to lever spring 6 Wheel cylinder 3 Shoe to shoe spring 7 Bleeder screw 4 Auto adjuster assemb
19. and dragging in the parking brake Adjust and replace defective parts as required 4 Return the carpet etc STOP LAMP SWITCH CHECK 35100890120 Connect a circuit tester to the stop lamp switch and check whether or not there is continuity when the plunger of the stop lamp switch is pushed in and when it is released The stop lamp switch is in good condition if there is no continuity when the plunger is pushed in to a depth of within 4 mm from the outer case edge surface and if there is continuity when it is released BRAKE BOOSTER OPERATING TEST 35100100117 For simple checking of the brake booster operation carry out 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 gradually becomes higher when depressed succeeding times the booster is operating properly if the pedal height remains unchanged the booster is defective 35A 8 BASIC BRAKE SYSTEM On vehicle Service When ndinie 18 Wh ire dihecis 2 With the engine stopped step on the brake pedal several stopped started times Then step on the brake pedal and start the engine If the pedal moves downward slightly the booster is in good condition If there is no change the booster is defective SY SLY 3 With the engine running step on the brake pedal and A Q then stop the engine Hold the pedal depressed for 30 seconds If the pedal height does not change the booster is in good co
20. and then bend and pull the cable near the clamp to check whether or not temporary disconnection occurs 35B 30 ABS 2WD Wheel Speed Sensor SENSOR INSULATION INSPECTION Remove all connections from the speed sensor and then measure the resistance between terminals 1 and 2 and the body of the speed sensor Standard value 100 or more 2 If the speed sensor insulation resistance is outside the standard value range replace with a new speed sensor ABS TOOTHED ROTOR Check whether ABS rotor teeth are broken or deformed and if so replace the ABS rotor
21. arness short circuit Malfunction of hydraulic unit NOTE This trouble symptom is limited to cases where communication with the MUT II is possible ABS ECU power supply is normal and the diagnosis code is a normal diagnosis code YES Does the ABS warning lamp stay illuminated when the connector Replace the combination meter C 50 is disconnected and the ignition switch is turned to ON NO E NG ABS warning lamp relay check Refer to P 35B 21 gt Replace the ABS warning lamp relay OK NG Disconnect the ABS warning lamp relay connector A 05X and ABS Check the following connectors A 05X A 04 ECU connector A 04 and measure at the harness side connector OK NG of ABS warning lamp relay Y e Ignition switch ON Check the trouble symp Repair e Voltage between 2 and body earth tom P OK Battery voltage NG I Y Check the harness wire and repair if necessary Replace the hydraulic unit e Between ABS warning lamp and ABS warning lamp relay e Between ABS warning lamp relay and ABS ECU 35B 16 ABS lt 2WD gt Troubleshooting Inspection Procedure 5 Faulty ABS operation 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 Improper installation of wheel speed sensor Mal
22. aster cylinder 1 Fill the reserve tank with brake fluid 2 Keep the brake pedal depressed 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 BRAKE PIPE LINE BLEEDING Bleed the air in the sequence shown in the figure DISC BRAKE PAD CHECK AND REPLACEMENT 35100230014 NOTE The left side outer brake pad has a wear indicator The wear indicator contacts the brake disc when the brake pad thickness becomes 2 mm and emit a squealing sound to warn the driver BASIC BRAKE SYSTEM On vehicle Service 35A 11 1 Check brake pad thickness through caliper body check port Standard value 10 mm Limit 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 thickness A1480088 of the pads on the left and right sides check the sliding condition of the piston and guide pin 2 Remove the guide pin Lift caliper assembly and retain with wires Caution Do not wipe off the special grease that is on the guide pin or allow it to contaminate the guide pin A14L0289 3 Remove the following parts from caliper support 1 Pad and wear indicator assembly lt L H gt and pad assembly lt R H gt
23. at the ABS ECU connector A 04 Repair e Disconnect the connector and measure at the harness side Y connector Stop lamp switch check Refer to GROUP 35A Brake Pedal e Stop lamp switch ON e Voltage between 18 and body earth OK Ne OK Battery voltage Replace Ne Check the following Check the following Check the following connectors connector A 04 connectors C 12 lt R H drive vehicles C 142 C 134 C 02 C 65 C 75 A 04 OK 04 2 65 Ne Ne Check the trouble symp Repair Repair tom Repair 4 Check the trouble NG tom Check the trouble symp Y tom Check the harness wire and repair if necessary Na e Between fusible link 1 ABS ECU Replace the hydraulic unit Check the harness wire and repair if necessary e Between stop lamp switch and ABS ECU ABS WARNING LAMP INSPECTION 35201200123 amp 35 B Check that the ABS warning lamp illuminates as follows 1 When the ignition key is turned to ON the ABS warning lamp illuminates for approximately 3 seconds and then switches off 2 When the ignition key is turned to START the ABS warning lamp remains illuminated 3 When the ignition key is turned from START back to ON the ABS warning lamp illuminates for approximately 3 seconds and then switches off ABS warning lamp NOTE Approx 3s Approx 3s The ABS warning lamp may remain on until the vehicle reaches a spee
24. ccurred while driving under such conditions as these During ABS operation the brake pedal may vibrate or may not be able to be depressed Such phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is not an abnormality INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 Communication between the MUT II and the whole system Probable cause is not possible The cause may be a malfunction of the power supply circuit or the earth circuit of e Malfunction of diagnosis connector the diagnosis connector e Malfunction of wiring harness or connector NG Measure at the diagnosis connector C 20 I Check the following connectors e Voltage between 16 and body earth L H drive vehicles OK Battery voltage C 20 C 66 C 63 C 132 C 141 OK R H drive vehicles C 20 C 66 C 62 C 14 OK Ne Y Check the trouble symp Repair tom NG Check the harness wire and repair if necessary e Between power supply and diagnosis connector Y NG Measure at the diagnosis connector C 20 I Check the following connector C 20 e Continuity between 4 and body earth and between 5 and body OK NG earth Y OK Continuity Check the trouble symp Repair OK tom T NG Check the trouble symptom Y NG Check the harness wire and repair if necessary Y
25. connector C 50 Check whether the ABS warning lamp bulb is burnt out e Disconnect the connector and measure at the combination OK NG meter side connector e Ignition switch ON Replace the ABS warning e ABS warning lamp condition when terminal 2 LHD or terminal lamp bulb 7 lt RHD gt is earthed OK Illuminates NG I Check the following Repair connectors ABS warning lamp relay check Refer to P 35B 21 D 01 D 03 C 135 C 131 OK NG Replace the ABS warning Check the trouble symp lamp relay tom NG Y Replace the combination meter NG Disconnect the ABS warning lamp relay connector A 05X and ABS Check the following connector A 05X ECU connector A 04 and measure at the harness side connector OK NG of ABS warning lamp relay Y e Ignition switch ON Check the trouble symp Repair e Voltage between 5 and body earth tom OK Battery voltage IN G I Replace the hydraulic unit Check the harness wire and repair if necessary e Between ABS warning lamp and ABS warning lamp relay e Between ABS warning lamp relay and earth ABS lt 2WD gt Troubleshooting 35B 15 Inspection Procedure 4 Even after the engine is started the ABS warning lamp Probable cause remains illuminated The cause is probably a short circuit in the ABS warning lamp illumination circuit Malfunction of combination meter Malfunction of ABS warning lamp relay Malfunction of wiring h
26. d improper handling while servicing will cause inset or warping THICKNESS CHECK 35100240017 1 Using a micrometer measure disc thickness at eight positions approximately 45 apart and 10 mm in from the outer edge of the disc Brake disc thickness Standard value 24 0 mm Front 10 0 mm Rear Limit 22 4 mm Front 8 4 mm Rear Thickness variation at least 8 positions The difference between any thickness measurements 142611 should not be more than 0 015 mm 2 If the disc is beyond the limits for thickness remove it and install a new one If thickness variation exceeds the specification replace the brake disc or turn rotor with on the car type brake lathe MAD DL 8700PF or equivalent BASIC BRAKE SYSTEM On vehicle Service 35A 13 RUN OUT CHECK 35100250010 1 Remove the caliper support then raise the caliper assembly 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 outer circumference of the brake disc and measure the run out of the disc Limit 0 06 mm or less lt Front gt 0 08 mm or less Rear NOTE Tighten the nuts in order to secure the disc to the hub RUN OUT CORRECTION 35100180081 1 Ifthe run out of the brake disc is equivalent to or exceeds the limit specification change the phase of the disc and hub and then measure the run out again
27. d of several km h This is limited to cases ABS c pex Aperi where diagnosis code Nos 21 24 and 55 have been lamps eats 4 recorded because of a previous problem occurring In START this case the ABS ECU keeps the warning lamp Ignition o m c illuminated until the problem corresponding to that switch diagnosis code can be detected 097 14 0054 4 f the illumination is other than the above check the 00006094 diagnosis codes 35B 12 ABS lt 2WD gt Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOMS 35201140289 Get an understanding of the trouble symptoms and check according to the inspection procedure chart Trouble symptoms Inspection procedure No Reference page Communication between the MUT II and the whole system is not possible 1 35B 12 Communication between the MUT II and the ABS ECU is not possible 35B 13 When the ignition key is turned to ON engine stopped the ABS warning lamp does not illuminate 35B 14 Even after the engine is started the ABS warning lamp remains illuminated 35B 15 Faulty ABS operation Caution 35B 16 1 If steering movements are made when driving at high speed or when driving on road surfaces with low frictional resistance or when passing over bumps the ABS may operate even though sudden braking is not being applied Because of this when getting information from the customer check if the problem o
28. e Line Bleeding Refer to P 35A 10 e Brake Pedal Adjustment Refer to P 35A 6 goes 2 14 Nm 1410107 00006083 L H drive vehicles 4G6 6 1 gt lt L H drive vehicles 4D6 gt R H drive vehicles 4G6 6A1 K 7 15Nm 6 1410105 1410104 1410073 lt R H drive vehicles 4D6 gt 14W565 14Z0003 Sealant 3M ATD Part No 8661 or equivalent 1410106 BASIC BRAKE SYSTEM Master Cylinder and Brake Booster 35A 17 Removal steps 1 Brake pipe connection 7 Fitting 2 Brake fluid level sensor connector 8 Snap pin 3 Master cylinder assembly 9 Pin assembly p B Push rod protruding length check and 10 Clevis adjustment 11 Vacuum switch connector lt 4D6 gt 4 Vacuum hose lt 4D6 gt 12 Vacuum switch lt 4D6 gt 5 Vacuum pipe lt 4D6 gt 13 Brake booster gt 6 Vacuum hose 14 Sealer with built in check valve INSTALLATION SERVICE POINTS VACUUM HOSE CONNECTION Insert securely and completely until the vacuum hose at the engine side contacts the edge of the hexagonal part of the fitting and then secure by using the hose clip p B PUSH ROD PROTRUDING LENGTH CHECK AND ADJUSTMENT 1 Measure dimension A Standard value 9 65 9 90 mm Block gauge 1410088 2 If the protruding length is not within the standard value range adjust by changing the push rod length by turning the end of the push rod 14Z0005 35A
29. e and lining assemblies on the left and right sides check the sliding condition of the piston BRAKE DRUM INSIDE DIAMETER CHECK 35100320148 1 Remove the brake drum 2 Measure the inside diameter of the brake drum at two or more locations Standard value 203 mm Limit 205 mm 3 Replace brake drums shoe and lining assembly when 14X0366 wear exceeds the limit value or is badly imbalanced BRAKE LINING AND BRAKE DRUM CONNECTION CHECK 35100310169 1 Remove the brake drum 2 Remove the shoe and lining assembly Refer to P 35A 24 3 Chalk inner surface of brake drum and rub with shoe and lining assembly 4 Replace shoe and lining assembly or brake drums if there are any irregular contact area 14U0077 NOTE Clean off chalk after check BASIC BRAKE SYSTEM Brake Pedal 35A 15 BRAKE PEDAL 35100340243 REMOVAL AND INSTALLATION Post installation Operation Brake Pedal Adjustment Refer to P 35A 6 14M0064 7 1410110 00006081 Removal steps 1 Stop lamp switch connector 7 Brake pedal pad 2 Stop lamp switch 8 Brake pedal return spring 3 Snap pin 9 Bushing 4 Pin assembly 10 Pipe 5 Brake pedal shaft bolt 11 Pedal support member 6 Brake pedal 35A 16 BASIC BRAKE SYSTEM Master Cylinder and Brake Booster MASTER CYLINDER AND BRAKE BOOSTER 35100370242 REMOVAL AND INSTALLATION Pre removal Operation Post installation Operation Brake Fluid Draining e Brake Fluid Supplying e Brak
30. en trie nut with Refer to GROUP 26 Front Axle F1iXoo43 35A 20 BASIC BRAKE SYSTEM Disc Brake 14A0014 10 2 Attach the special tool to the front hub assembly as shown in the illustration and tighten it to the specified torque Tightening torque 196 255 Nm 8 Use a spring balance to measure the rotary sliding resistance of the hub in the forward direction Rear Use a spring balance to measure the rotary sliding resistance of the hub in the forward direction After installing the caliper support to the knuckle install the pad clips and the pads to the caliper support Caution Do not let any oil grease or other contamination get onto the friction surfaces of the pads and brake discs Clean piston and insert into cylinder with special tool Be careful that the piston boot does not become caught when lowering the caliper assembly and tighten the guide pin to the specified torque Tightening torque 74 Nm Start the engine and then depress the brake pedal 2 3 times Stop engine Turn brake disc forward 10 times Use a spring balance to measure the rotation sliding resistance of the hub in the forward direction Calculate the drag force of the disc brake difference between of values measured in item 8 and item 1 Standard value 69 N or less If the drag force of the disc brake exceeds the standard value disassemble piston and clean piston Check for corros
31. entric or with large runout Replace hub excessively this is no problem if the minimum amplitude is 100 mV or more Noisy or disturbed waveform Open circuit in sensor Replace sensor Open circuit in harness Correct harness Incorrectly mounted wheel speed sensor Mount correctly Rotor with missing or damaged teeth Replace rotor Caution Because the wheel speed sensor cables move together with the front and rear suspension they vibrate greatly when driving over poor road surfaces As a result the sensor harnesses should also be shaken when monitoring of output waveforms of the wheel speed sensors in order to simulate conditions such as driving over poor road surfaces ABS lt 2WD gt On vehicle Service 35B 21 ABS WARNING LAMP RELAY CONTINUITY CHECK 35200930023 Battery voltage Terminal No 2 Power is not sup plied Power is supplied 00006092 35B 22 ABS lt 2WD gt On vehicle Service HYDRAULIC UNIT CHECK 35200170227 Caution Turn the ignition switch off before connecting or disconnecting the MUT II 1 Jack up the vehicle and support the vehicle with rigid racks placed at the specified jack up points or place the wheels which are checked on the rollers of the braking force tester Caution 1 The roller of the braking force tester and the tyre should be dry during testing 2 When testing the front brakes apply the parking brake and when testing the
32. function of wiring harness or connector Malfunction of wheel speed sensor Malfunction of ABS rotor Foreign material adhering to wheel speed sensor Malfunction of wheel bearing Malfunction of hydraulic unit out the following inspection NG Wheel speed sensor installation check m gt Repair OK OK Wheel speed sensor output voltage check Refer to P 35B 19 Hydraulic unit check Refer to P 35B 22 NG Y NG Wheel speed sensor check Refer to P 35B 29 __ Replace the wheel speed sensor OK Y NG ABS rotor check Refer to P 35B 29 I gt Repair OK NG Wheel bearing check Refer to GROUP 26 and GROUP 27 Repair On vehicle Service OK Check the following connectors Repair L H drive vehicles A 09 C 115 C 75 A 39 C 74 E 14 E 13 E 11 C 123 E 12 lt R H drive vehicles A 09 A 41 A 39 C 115 C 75 E 14 E 13 E 11 C 121 E 12 OK Y Check the trouble symptom NG Y NG Measure at the ABS ECU connector A 04 I Repair e Disconnect the connector and measure at the harness side connector e Resistances between 20 and 19 2 and 1 22 and 23 6 and 5 OK 1 0 1 5 kQ The sensor harness and connector should be moved while these inspections are carried out OK Y Check the following connector A 04 OK Y Check the trouble sympto
33. fusible link for ABS circuit thus disabling the anti skid brake system The ABS warning lamp will illuminate when the fusible link for ABS is removed After the battery has sufficiently recharged install the fusible link for ABS and restart the engine then check to be sure the ABS warning lamp is not illuminated 35200350188 Fusible link e Ore BOX l A1610115 35B 24 ABS lt 2WD gt Master Cylinder and Brake Booster MASTER CYLINDER AND BRAKE BOOSTER 35200400142 REMOVAL AND INSTALLATION Refer to GROUP 35A MASTER CYLINDER 35200450147 DISASSEMBLY AND REASSEMBLY 12 1410120 1420006 1410119 00006095 Brake fluid DOT3 or DOTA Disassembly steps 1 Reservoir cap assembly 8 Reservoir tank 2 Reservoir cap 9 Reservoir seal 3 Diaphragm 10 Pin 4 Filter 11 Piston retainer 5 Brake fluid level indicator assembly 12 Primary piston assembly 6 Float 13 Secondary piston assembly 7 Spring pin 14 Master cylinder body INSPECTION 35200460027 e Check the inner surface of master cylinder body for rust or pitting e Check the primary and secondary pistons for rust scoring wear damage or wear e Check the diaphragm for cracks and wear ABS lt 2WD gt Proportioning Valve 35B 25 PROPORTIONING VALVE 35200570126 REMOVAL AND INSTALLATION Pre removal Operation Post installation Operation Brake Fluid Draining e Brake Fluid Supplying e Brake Line Bleeding Refer to GROUP 35A
34. ge of the rotor so as not to damage them by striking against other parts 1410085 ABS 2WD Wheel Speed Sensor 35B 29 rotor s toothed surface 1 00000081 14N0103 INSTALLATION SERVICE POINT A lt FRONT SPEED SENSOR REAR SPEED SENSOR INSTALLATION The clearance between the wheel speed sensor and the ABS rotor s toothed surface is not adjustable but measure the distance between the sensor installation surface and the ABS rotor s toothed surface Standard value 28 2 28 5 mm INSPECTION 35200840227 SPEED SENSOR 1 Check whether any metallic foreign material has adhered to the pole piece at the speed sensor tip and if so remove it Also check whether the pole piece is damaged and if so replace it with a new one NOTE The pole piece can become magnetized because of the magnet but into the speed sensor with the result that metallic foreign material easily adheres to it Moreover the pole piece may not be able to function to correctly sense the wheel rotation speed if it is damaged 2 Measure the resistance between the speed sensor terminals Standard value 1 0 1 5 ko If the internal resistance of the speed sensor is not within the standard value replace with a new speed sensor 3 Check the speed sensor cable for breakage damage or disconnection replace with a new one if a problem is found NOTE When checking for cable damage remove the cable clamp part from the body
35. ifications Master cylinder Type Tandem type with level sensor 1 0 mm 25 4 Brake booster Type Vacuum type tandem Effective dia of power cylinder mm 180 205 Boosting ratio 6 5 Proportioning valve Type Dual type Decompression ratio 0 25 Front brakes Type Floating caliper 1 piston ventilated disc Disc effective dia x thickness mm 256 x 24 Wheel cylinder mm 60 3 Pad thickness mm 10 0 Clearance adjustment Automatic Rear drum brakes Type Leading trailing Drum I D mm 203 Wheel cylinder mm 20 6 Lining thickness mm 44 Clearance adjustment Automatic Brake fluid DOTS3 or DOT4 ABS type 4 sensor 3 channel method Speed sensor Magnet coil type on 4 wheels Front ABS rotor teeth 43 Rear ABS rotor teeth 43 35B 4 ABS 2WD General Information CONSTRUCTION DIAGRAM lt L H drive vehicles gt 1410115 lt R H drive vehicles gt 1410118 00006093 1 ABS relay 5 Wheel speed sensor 2 ABS warning lamp 6 ABS ECU 3 Stop lamp switch 7 Diagnosis connector 4 ABS rotor 8 Hydraulic unit ABS 2WD Service Specifications Lubricants Special Tools 35B 5 SERVICE SPECIFICATIONS 35200030242 Items Standard value Wheel speed sensor internal resistance 1 0 1 5 Clearance between the wheel speed sensor mounting 28 2 28
36. il the operating rod is fully extended and then slide the stop lamp switch back to the required position Adjust the position of the switch by turning it until the distance shown in the illustration is correct Connect the connector of the stop lamp switch Check that the stop lamp is not illuminated with the brake pedal unpressed 3 Return the carpet etc BRAKE PEDAL FREE PLAY With the engine stopped depress the brake pedal two or three times After eliminating the vacuum in the power brake booster press the pedal down by hand and confirm that the amount of movement before resistance is met the free play is within the standard value range BASIC BRAKE SYSTEM On vehicle Service 35A 7 14W0003 No continuity Continuity E Hm zs 4 mm 14W0007 14X0354 14X0357 00000182 Standard value 3 8 mm If the free play exceeds the standard value it is probably due to excessive play between the retaining ring bolt and brake pedal arm Check for excessive clearance and replace faulty parts as required CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR BOARD 1 Turn back the carpet etc under the brake pedal 2 Start the engine depress the brake pedal with approximately 490 N of force and measure the clearance between the brake pedal and the floorboard Standard value 90 mm or more 3 If the clearance is outside the standard value check for air trapped in the brake line clearance between the lining and the drum
37. ing valve Brake pedal A1410098 Front brake SERVICE SPECIFICATIONS 35100030201 Items Standard value Brake pedal height mm 162 8 165 8 Brake pedal free play mm 3 8 Brake pedal to floor board clearance mm 90 or more Proportioning valve Split point MPa Sedan 2 94 0 25 Wagon 3 43 0 25 Output fluid pressure Sedan 4 66 0 39 9 81 Input fluid pressure MPa Wagon 5 80 0 39 9 81 Output fluid pressure difference between left and right MPa Brake booster push rod protruding length mm 9 65 9 90 Front disc brake Pad thickness mm 10 0 Disc thickness mm 24 0 Disc runout mm Drag force tangential force of wheel mounting 69 or less bolts N Service Specifications Lubricants BASIC BRAKE SYSTEM Sealants Special Tools 35A 5 Items Standard value Rear disc brake Pad thickness mm 10 0 Disc thickness mm 10 0 Disc runout mm Drag force tangential force of wheel mounting 69 or less bolts N Rear drum brake Lining thickness mm 4 4 Drum inside diameter mm 203 LU BRICANTS 35100040082 Items Specified Lubricant Brake fluid DOTS3 or DOT4 Brake piston seal Repair kit grease orange Slide pin boot and slide pin bush inner surfaces Brake piston boot inner surfaces Piston boot mounting grooves Rear brake shoe and backing plate contact surfaces Brake grease SAE J310 NLGI No 1 Shoe
38. ing with a circuit tester 42 mV or more When measuring with an oscilloscope 120 mV p p or more 4 If the output voltage is lower than the above values the reason could be as follow e Faulty wheel speed sensor So replace the wheel speed sensor 35B 20 ABS lt 2WD gt On vehicle Service Inspecting Waveforms With An Oscilloscope Use the following method to observe the output voltage When turning by hand waveform from each wheel sensor with an oscilloscope Ld e Start the engine and rotate the front wheels by engaging 1st gear vehicles with manual transmission or D range 0 41 7 r 1 dasni me vehicles with automatic transmission Turn the rear Pu wheels manually so that they rotate at a constant speed E NOTE M 1 Check the connection of the sensor harness When idling 5 6 km h connector before using the oscilloscope z tst gi TEA ps 2 The waveform measurements can also be taken while mission or D range auto Ae transition the vehicle is actually moving SH e deed 3 The output voltage will be small when the wheel speed P a is low and similarly it will be large when the wheel speed is high Ma _ 10 0 ms DI 1 t R L 2i H 1 l Li Points In Waveform Measurement Symptom Probable causes Remedy Too small or zero waveform Faulty wheel speed sensor Replace sensor amplitude Waveform amplitude fluctuates Axle hub ecc
39. ion or worn piston seal and check the sliding condition of the lock pin and guide pin BASIC BRAKE SYSTEM Disc Brake 35A 21 DISASSEMBLY AND REASSEMBLY 35100820013 14P0031 00005620 1440538 14P0032 D Po 14A0540 Brake caliper kit Pad repair kit Seal and boots repair kit Caliper assembly disassembly steps Guide pin Lock pin Bushing gt Boo Boot ring Piston boot Piston Piston seal Caliper body 4 B Caliper support pad clip shim t Pad assembly disassembly steps A 1 A 2 3 4 11 12 13 14 Guide pin Lock pin Bushing Caliper support pad clip shim Pad and wear indicator assembly Pad assembly Outer shim coated with rubber Clip 35A 22 BASIC BRAKE SYSTEM Disc Brake LUBRICATION POINTS Piston seal i 14A0541 Grease Repair kit grease 14X0302 14X0301 Caution The piston seal inside the seal and boot kit is coated with special grease so do not wipe this grease off Brake fluid DOT3 or DOT4 1440538 00005622 1410128 14A0541 Grease Repair kit grease Grease Repair kit grease DISASSEMBLY SERVICE POINTS When disassembling the disc brakes disassemble both sides left and right as a set BASIC BRAKE SYSTEM Disc Brake 35A 23 14NO139 A14LO294
40. lit point Standard value a MPa NU d Sedan Wagon uel Z 2 94 0 25 3 43 0 25 Input pressure 1400055 2 Check to be sure that the output fluid pressure is at the standard value when the pedal depression force is increased so that the input fluid pressure is at the values shown in the table below Standard value MPa Wagon Output fluid pressure 4 66 0 39 5 80 0 39 Input fluid pressure 9 81 8 Output pressure difference between left and right brake lines Limit 0 39 MPa 4 lf the measured pressures are not within the permissible ranges replace the proportioning valve BRAKE FLUID LEVEL SENSOR CHECK 35100910123 The brake fluid level sensor is in good condition if there is no continuity when the float surface is above MIN and if there is continuity when the float surface is below MIN 1410086 35A 10 BASIC BRAKE SYSTEM On vehicle Service 1420009 drive vehicles When new Wear indicator 14A0454 When worn Brake disc P 14 0017 BLEEDING 35100140089 Caution Use the specified brake fluid Avoid using a mixture of the specified brake fluid and other fluid Specified brake fluid DOT3 or DOTA MASTER CYLINDER BLEEDING The master cylinder used has no check valve so if bleeding is carried out by the following procedure bleeding of air from the brake pipeline will become easier When brake fluid is not contained in the m
41. ly BASIC BRAKE SYSTEM Rear Drum Brake 35A 27 DISASSEMBLY AND REASSEMBLY 35100770097 3 1420012 14Y554 Grease Repair kit grease Brake fluid DOT3 or DOTA 2 M1 Te E 6 2 S dee P _ 00005625 1 4 2 d Grease Wheel cylinder repair kit Disassembly steps 1 Boots 4 Piston cups 2 Piston assembly 5 Spring 3 Pistons 6 Wheel cylinder body REASSEMBLY SERVICE POINT PISTON CUP PISTON REASSEMBLY 1 Use alcohol or specified brake fluid to clean the wheel cylinder and the piston 2 Apply the specified brake fluid to the piston cups and the special tool Specified brake fluid DOT3 or DOTA 3 Set the piston cup on the special tool with the lip of the cup facing up fit the cup onto the special tool and then slide it down the outside of the tool into the piston groove Caution In order to keep the piston cup from becoming twisted or slanted slide the piston cup down the tool slowly and carefully without stopping MB990619 Have the lip facing upwards B14U0093 35A 28 BASIC BRAKE SYSTEM Rear Drum Brake Proportioning Valve INSPECTION 35100780038 Check the piston and wheel cylinder walls for rust or damage andifthere is any abnormality replace the entire wheel cylinder assembly PROPORTIONING VALVE 35100570154 REMOVAL AND INSTALLATION Pre removal Operation Post installation Operation Brake Fluid Draining e Brake Fluid Su
42. m NG Y Replace the hydraulic unit ABS lt 2WD gt Troubleshooting 35B 17 DATA LIST REFERENCE TABLE 35201150206 The following items can be read by the MUT II from the ABS ECU input data 1 When the system is normal Item No Check item Checking requirements Normal value 11 Front right wheel speed sensor Perform a test run Vehicle speeds displayed on the 12 Front left wheel speed sensor speedometer and MUT II are 13 Rear right wheel speed sensor identical 14 Rear left wheel speed sensor 16 ABS ECU power supply Ignition switch power supply voltage and valve 92 17 5 V voltage monitor voltage 33 Stop lamp switch Depress the brake pedal ON Release the brake pedal 2 When the ABS ECU shut off ABS operation When the diagnosis system stops the ABS ECU the MUT II display data will be unreliable ACTUATOR TEST REFERENCE TABLE 35201160025 The MUT II activates the following actuators for testing NOTE 1 If the ABS 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 canceled 3 During the actuator test the ABS warning lamp will illuminate and the anti skid control will be cancelled ACTUATOR TEST SPECIFICATIONS Activation pattern Item Solenoid valve for front left Solenoid valves and pump wheel mot
43. ndition if the pedal rises the booster is defective If the above three tests are okay the booster performance can be determined as good If one of the above three tests is not okay at last the check valve vacuum hose or booster will be defective 14X0353 14X0352 00000183 CHECK VALVE OPERATION CHECK 35100900151 1 Remove the vacuum hose Refer to P 35A 16 Caution The check valve should not be removed from the vacuum hose 2 Checkthe operation of the check valve by using a vacuum ump GE Anis Vacuum pump connection Accept reject criteria Booster aie Connection at the brake A negative pressure vacu booster side A um is created and held Connection at the intake A negative pressure vacu manifold side B um is not created Caution If the check valve is defective replace it as an assembly unit together with the vacuum hose BASIC BRAKE SYSTEM On vehicle Service 35A 9 Pressure gauge PROPORTIONING VALVE FUNCTION TEST 35100110172 1 Connect two pressure gauges one each to the input side and output side of the proportioning valve as shown 2 Bleed the air in the brake line and the pressure gauge 3 While gradually depressing the brake pedal make the following measurements and check to be sure that the measured values are within the allowable range Proportioning valve A14L0181 1 Output pressure begins to drop relative to input pressure split point Sp
44. necessary e Between ABS ECU and diagnosis connector NG Check the following connectors A 04 C 75 C 66 L H drive vehicles C 134 C 131 OK Y Check the trouble symp Repair tom NG Check the harness wire and repair if necessary e Between ignition switch and ABS ECU NG Check the following connector A 04 OK N js Check the trouble symp Repair tom NG Check the following connector A 04 OK pne Y Check the trouble symp Repair tom NG Y Replace the hydraulic unit Check the harness wire and repair if necessary e Between ABS ECU and earth 35B 14 Inspection Procedure 3 When the ignition key is turned to ON engine stopped the ABS warning lamp does not illuminate ABS lt 2WD gt Troubleshooting Probable cause The cause may be an open circuit in the lamp power supply circuit a blown lamp a malfunction of the ABS warning lamp relay or an open circuit between the ABS warning lamp and the earth Blown fuse Burn out ABS warning lamp bulb Malfunction of ABS warning lamp relay Malfunction of wiring harness or connector Malfunction of hydraulic unit NG Fuse check I Refer to GROUP 00 Inspection Service Points for Blown Fuse Multi purpose fuse No 13 I NG Measure at the
45. oblem stays off 54 Motor relay problem stays on 55 Motor system seized pump motor 63 ABS ECU ABS lt 2WD gt Troubleshooting 35B 9 INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code Nos 11 12 13 and 14 Wheel speed sensor Probable cause open circuit or short circuit Code Nos 21 22 23 and 24 Wheel speed sensor Code Nos 11 12 13 and 14 are output if the ABS ECU detects an open circuit or Malfunction of wheel speed sensor short circuit in the wire or wire in any one of the four wheel speed sensors Malfunction of wiring harness or connector Malfunction of hydraulic unit Code Nos 21 22 23 and 24 are output in the following cases Malfunction of wheel speed sensor e Whenthere is no input from any one ofthe four wheel speed sensors whentravelling Malfunction of wiring harness or connector at several km h or more even though open circuit can not be verified Malfunction of ABS rotor e When a chipped or blocked up ABS rotor is detected and if the anti lock system Too much gap between the sensor and the rotor operates continuously because a malfunctioning sensor or a warped ABS rotor Malfunction of hydraulic unit is causing sensor output to drop Malfunction of wheel bearing NG Wheel speed sensor installation check m gt Repair I NG Measure at the ABS ECU connector
46. ors in the hydraulic unit A Solenoid valve 5 Solenoid valve for front right Simple Inspection mode wheel Solenoid valve for rear left wheel Solenoid valve for rear right wheel NOTE A Hydraulic pressure increase B Hydraulic pressure holds C Hydraulic pressure decrease 35B 18 ABS lt 2WD gt Troubleshooting CHECK AT ABS ECU 35201180229 TERMINAL VOLTAGE CHECK CHART 1 Measure the voltage between each terminal and earth 2 The terminal layout is shown in the illustration below Kio ir i2 323 ae 15 16 18 19 20 21 2 2 1410029 Terminal No Check item Checking requirements Normal condition 4 ABS ECU power sup Ignition switch ON Battery voltage ply Ignition switch START OV MUT II When the MUT II is connected Serial communication with MUT II When the MUT II is not connected 1Vorless Solenoid valve power Always Battery voltage supply Diagnosis changeover When the MUT II is connected OV input When the MUT II is not connected Approx 12 V ABS valve transistor Ignition switch ON When the lamp is 2Vorless output switched off When the lamp is Battery voltage illuminated Stop lamp switch input Ignition switch ON Stop lamp switch ON Battery voltage Stop lamp switch OFF 1 V or less Motor power supply Always Battery voltage RESISTANCE AND CONTINUITY BETWEEN HARNE
47. p switch OFF ON ABS warning lamp OFF ABS ECU memory 1 i i 1 1 1 Within 3 Within Within Within Within iy Within within within Within Within Within seconds second second secondisecond second second Second Isecondisecond second i i re B1 Ret T era hr hk t t e t t er i 4st 2nd 3rd 4th 5th 6th 7th 8th 9th 4oth Erasing op ABS ECU diagnosis codes complete 35B 8 ABS lt 2WD gt Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES 35201130323 Inspect according to the inspection chart that is appropriate for the malfunction code Diagnosis Inspection item Diagnosis content Reference page code No 11 Front right wheel speed sensor Open circuit 35B 9 12 Front left wheel speed sensor 13 Rear right wheel speed sensor 14 Rear left wheel speed sensor 15 Wheel speed sensor Abnormal output signal 16 Power supply system 21 Front right wheel speed sensor Short circuit 22 Front left wheel speed sensor 23 Rear right wheel speed sensor 24 Rear left wheel speed sensor 33 Stop lamp switch system 35B 11 41 Front right solenoid valve 35B 26 Replace the hydraulic unit 42 Front left solenoid valve 43 Rear right solenoid valve 44 Rear left solenoid valve 51 Valve relay problem stays on 52 Valve relay problem stays off 53 Motor relay pr
48. pplying e Brake Line Bleeding Refer to P 35A 10 Flared brake line nuts Pag 15 Nm 1 14X0343 1 14X0214 14X0146 00004624 Removal steps gt 1 Brake pipe 2 Proportioning valve INSTALLATION SERVICE POINT BRAKE PIPE CONNECTION Connect the pipes to the hydraulic unit as shown in the illustration 1 Proportioning valve Rear brake L H 2 Proportioning valve Rear brake R H 3 Proportioning valve Front brake R H 4 Proportioning valve Front brake L H 5 6 A14L 0339 Proportioning valve Master cylinder secondary Proportioning valve Master cylinder primary 35B 1 ANTI SKID BRAKING SYSTEM ABS lt 2WD gt GENERAL INFORMATION SERVICE SPECIFICATIONS LUBRICANTS SPECIAL TOOLS TROUBLESHOOTING ON VEHICLE SERVICE Brake Pedal Check and Adjustment iod PUT Map ANA E Refer to Q Refer to Brake Booster Operating Test THREE Refer to Check Valve Operation Check Hn Refer to Proportioning Valve Function Test nici os e pes ffs Refer to Brake Fluid Level Sensor Check ioa Les saad teehee s o Eris Refer to CONTENTS 35209000206 3 Bleeding Refer to GROUP 35A Disc Brake Pad Check and Replacement TEE 5 eese Refer to GROUP 35A 5 Disc Brake Rotor Check LUNES PUN e
49. put Before carrying out the following inspection check the battery level and refill it if necessary NG Measure at the ABS ECU connector A 04 gt Check the following connectors e Disconnect the connector and measure at the harness side A 04 C 75 C 66 L H drive vehicles C 134 C 131 connector OK NG e Start the engine Voltage between 4 and body earth OK Battery voltage Repair Y ak Check the following connector A 04 bae tie Trouble sympe Check Ine battery or NG NG dian the trouble symp Repair Check the harness wire and repair if necessary om e Between ignition switch and ABS ECU e Replace the hydraulic unit ABS lt 2WD gt Troubleshooting 35B 11 Code No 33 Stop lamp switch system open circuit or stop Probable cause lamp stays ON This code is output in the following cases e Malfunction of stop lamp switch e lf the stop lamp switch is continuously on for 15 minutes or more even though Malfunction of wiring harness or connector the ABS system is not operating e Malfunction of hydraulic unit e f there is an open circuit in the stop lamp switch input circuit harness NO Does the stop lamp turn on and off normally I Stop lamp switch installation check 5 OK Ne Measure
50. removing it The hydraulic unit assembly is not to be disassem bled its nuts and bolts should absolutely not be loos ened The hydraulic unit assembly must not be dropped or otherwise subjected to impact shocks The hydraulic unit assembly must not be turned upside down or laid on its side INSTALLATION SERVICE POINT BRAKE PIPE CONNECTION Connect the pipes to the hydraulic unit assembly as shown in the illustration OEE ues To the proportioning valve RH To the proportioning valve LH From the master cylinder Primary From the master cylinder Secondary To the front brake RH To the front brake LH 35B 28 ABS 2WD Wheel Speed Sensor WHEEL SPEED SENSOR 35200830279 REMOVAL AND INSTALLATION Post installation Operation Wheel Speed Sensor Output Voltage Check Refer to P 35B 19 Front Rear 1410010 1410008 00005608 Front speed sensor removal steps e Splash Shield Removal Refer to NOTE GROUP 42 Fender The front rotor is integrated with the drive shaft and is not A 1 Front speed sensor disassembled 2 Front ABS rotor Refer to GROUP 26 Drive Shaft Rear speed sensor removal steps A 3 Rear speed sensor 4 Rear ABS rotor Refer to GROUP 27 Rear Axle Hub REMOVAL SERVICE POINT Ap FRONT SPEED SENSOR REAR SPEED SENSOR REMOVAL Caution Be careful when handling the pole piece at the tip of the speed sensor and the toothed ed

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