Bodywork Part
Bodywork Part
E3 BRAKE CONTROL
ABS ---------------------------------------------------- E3 - 1
ABS ACTUATOR UNIT ----------------------- E3 - 1
REMOVAL AND INSTALLATION-------- E3 - 1
FRONT WHEEL SPEED SENSOR ------- E3 - 4
REMOVAL AND INSTALLATION-------- E3 - 4
REAR WHEEL SPEED SENSOR --------- E3 - 6
REMOVAL AND INSTALLATION-------- E3 - 6
CONTROL SYSTEM -------------------------- E3 - 9
ARTICLES TO BE PREPARED --------- E3 - 9
HANDLING INSTRUCTIONS OF
CONTROL SYSTEM ----------------------- E3 - 9
SYSTEM WIRING DIAGRAM ---------- E3 - 10
ARRANGEMENT OF ECU
TERMINAL----------------------------------- E3 - 11
ARRANGEMENT OF VEHICLE
HARNESS SIDE CONNECTOR
TERMINALS -------------------------------- E3 - 12
LOCATION OF COMPONENTS ------- E3 - 13
HOW TO PROCEED WITH
TROUBLE SHOOTING ------------------ E3 - 14
INQUIRY ------------------------------------- E3 - 16
CONFIRMATION, RECORD AND
ERASURE OF DIAGNOSIS CODE--- E3 - 19
SENSOR CHECK FUNCTION (TEST
MODE)---------------------------------------- E3 - 23
BASIC CHECK ----------------------------- E3 - 25
TROUBLE SHOOTING ACCORDING
TO DIAGNOSIS CODE ------------------ E3 - 26
TROUBLE SHOOTING ACCORDING
TO MALFUNCTION PHENOMENA -- E3 - 32
UNIT CHECK ------------------------------- E3 - 36
ECU INPUT/OUTPUT SIGNAL
CHECK --------------------------------------- E3 - 38
E3
E3–1
Ä ABS
1 ABS ACTUATOR UNIT
1-1 REMOVAL AND INSTALLATION
1-1-1 ARTICLES TO BE PREPARED
SST
Shape Part No. Part name
Tool
Brake pedal pusher,Long TORXO wrench T25
Instrument
Torque wrench
(2) Connect a bottle for air bleeding to the bleeder plug of the front disc brake caliper Ay RH/LH. Then,
open the bleeder plug.
(3) Fully depress the brake pedal Ay. At this point, secure
the brake pedal Ay.
TOOL: Brake pedal pusher
NOTE
• This closes the brake master cylinder S/A port, thus
preventing the brake fluid from flowing out from the
brake hydraulic circuit.
(4) Close the bleeder plug of the RH/LH front disc brake
caliper Ay. H11C5036T10
f
g
h
e
T:15.2&2.4 {155&24}
j
j
T:19.5&4.0 {199&40} B T:8.0&2.0 {82&19}
T:48.0&9.6 {489&97}
T11C5067S24
Unit:N;m{kgf;cm}
(2) Removal and installation procedures
j i 1 a Tube, front brake, No.1 i 7 g Bracket, brake actuator (Upper side)
j i 2 b Tube, front brake, No.4 i 8 h Cushion, brake actuator bracket
j i 3 c Tube, front brake, No.2 j 9 i Actuator Ay, Brake
j i 4 d Tube, front brake, No.3 i 10 j Cushion, brake actuator bracket
j i 5 e Tube, rear brake, No.2 i 11 k Bracket, brake actuator (Low side)
j i 6 f Tube, rear brake, No.4
1
3
T11C5066T10
B T:8.4&1.4 {85&14}
T:20.6&3.9 {210&39} B
T11C5034S20
Unit:N;m{kgf;cm}
(2) Removal and installation procedures
i 1 a Sensor, speed, front RH/LH
T11C5035T10
E3–5
2-1-5 OPERATION AFTER INSTALLATION
1.Connect the connector of the RH/LH front speed sensors.
2.Install the disc wheels. (Front)
Refer to Page C3-3.
Instrument
Torque wrench
6.Detach the clip at one point of the rear RH/LH quarter trim
panel Ay. Float the rear RH/LH quarter trim panel Ay.
7.Disconnect the connectors of the RH/LH speed sensor
wires.
8.Remove the drum brake.
Refer to Page E1-65.
E3–7
3-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) Components
T:80.0&16.0 {816&162}
a
~B
~B T:80.0&16.0 {816&162}
T11C5036S20
2.Slowly pull out the hub & bearing assembly from the rear suspension arm assembly. Disconnect the
connector from the speed sensor wire RH/LH.
3-1-5 POINTS OF INSTALLATION
(1) Hub & bearing Ay, rear axle
1.Connect the connectors of the RH/LH speed sensor wires to the hub & bearing Ay. Install the hub &
bearing Ay to the rear suspension arm Ay.
2.Secure the hub & bearing assembly and rear brake backing plate subassembly RH/LH, using a long
Torx wrench T55.
TOOL: Long TORX® wrench T55
E3–8
3-1-6 OPERATION AFTER INSTALLATION
1.Install the drum brake.
Refer to Page E1-65.
5.Place the carpet around the RH/LH rear seat Ay. Return the cushion to the original place.
6.Tilt the seatback of the RH/LH rear seat Ay and install the
carpet clips.
7.Install the rear door scuff plate RH/LH.
Refer to Page I2-48.
T11C5063T10
E3–9
4 CONTROL SYSTEM
4-1 ARTICLES TO BE PREPARED
SST
Shape Part No. Part name
09991-87404-000
Wire,engine control system inspection
(09991-87401-000)
Instrument
Electrical Tester
ABS2
13 +BS
M
ABS1
26 +BM
AM
20 +IG
IG SW ECU IG1
F/L
24 STP
STOP Stop lamp switch
DLC 22 SIO
Battery
Stop lamp
To meter 17 HCAN
To EFI ECU
ABS ECU
To A/T ECU 19 LCAN
(CAN communication)
+ 8 FR+
FR
- 9 FR-
+ 6 FL+
FL
- 5 FL-
Wheel speed sensor
+ 2 RR+
RR
- 3 RR-
+ 12 RL+
RL
- 11 RL-
14 GND
ABS actuator
T11C5516ES36
E3–11
4-4 ARRANGEMENT OF ECU TERMINAL
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
T11C5001S10
Terminal name
Terminal No. Terminal code Terminal name
1 ( (
2 RR' Input of the rear right wheel speed sensor (')
3 RR( Input of the rear right wheel speed sensor (()
4 ( (
5 FL( Input of the front left wheel speed sensor (()
6 FL' Input of the front left wheel speed sensor (')
7 ( (
8 FR' Input of the front right wheel speed sensor (')
9 FR( Input of the front right wheel speed sensor (()
10 ( (
11 RL( Input of the rear left wheel speed sensor (()
12 RL' Input of the rear left wheel speed sensor (')
13 'BS Solenoid valve power supply
14 GND Earth
15 ( (
16 ( (
17 HCAN CAN communication HI
18 ( (
19 LCAN CAN communication LO
20 'IG Power supply through IG SW
21 ( (
22 SIO External communication
23 ( (
24 STP Input of the stop lamp SW
25 ( (
26 'BM Motor power supply
E3–12
4-5 ARRANGEMENT OF VEHICLE HARNESS SIDE CONNECTOR TERMINALS
ABS ECU
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
T11C5002S10
As for the terminal names of computer at the ABS ECU vehicle harness side, refer to the computer connector terminal arrange-
ment diagram.
Wheel speed sensor
( ' ( '
2 1 1 2
FR RR
T11C5032S10
Stop lamp SW
( '
1 2
3 4
M21C7411S10
E3–13
4-6 LOCATION OF COMPONENTS
g e i d
f
j
k
h
a
b
T11C5517S30
2.Ensure that the LCD inside the meter indicates the diagnosis code (Including the normal codes).
SPECIFIED VALUE: Indicated
NOTE
• It is permissible that codes other than the CAN-related codes are outputted.
çGo to è6.
çGo to è8.
çGo to è9.
çIf the malfunction is reproduced and the normal code is outputted, proceed to è11.
çIf the malfunction is not reproduced and the normal code is outputted, proceed to è11.
çIf an abnormal code is outputted, proceed to è12.
çGo to è13.
çGo to è13.
4-8 INQUIRY
1.When the vehicle is encountered with a malfunction, even if an attempt is made to remove its cause, it
is impossible to find out the cause, unless the malfunction phenomenon can be actually confirmed.
Hence, the vehicle may not be remedied to the normal condition regardless of the repairing operations
if the cause is not known. The diagnosis through inquiries to the customer is to be performed in order
to collect information from the customer before confirming the malfunction phenomenon. This step will
be a very important help in reproducing the malfunction phenomenon.
2.Since the information obtained by the diagnosis through interviews is referred to during the trouble
shooting, it is imperative to make an inquiry of the customer, centering on the items related to the mal-
function, instead of simply asking general questions.
3.In addition, during the diagnosis through interviews, utmost attention must be paid to complaints of the
customer, for it may include phenomena peculiar to the ABS-equipped vehicles.
E3–17
4-8-1 DIAGNOSIS INTERVIEW SHEET FOR ABS SYSTEM
Day Month
Checked by Check date
(Day of week)
Customer information
Gender of customer
Age [Approx. ] Occupation [ ]
Name of (Male, Female)
customer Area where vehi- Urban, suburb, seashore, Parking Outdoor,
Mr./Ms. cle is mainly used mountain, others place indoor
Details of vehicle
Date when
Date when
vehicle was No, Yes (How many
Day Month malfunction Day Month Repair history
brought to times? )
took place
workshop
(Day of week) (Day of week)
Registration
Frame No. Day Month Year Vehicle model
date
5M/T;3A/T;4A/T;CVT
Engine type Transmission Driving 2WD;4WD
electronically-controlled 4A/T
Running
Equipment Tire [ ]; Wheel [Steel ; Aluminum]
distance km
Weather
Fine Cloudy Rainy Snow Other( )
Temperature(Approx. )
Frequency of malfunction
Always Under certain condition( ) Sometimes( )
Road conditions
Urban Suburb Express way Mountain road (uphill, downhill)
Snowy road Icy road Dry concrete Wet asphalt
Driving conditions
When the brake pedal is depressed lightly.
When the brake pedal is depressed at a vehicle speed of ( ) km/h during driving.
During hard braking at vehicle speed of ( ) km/h.
When the brake pedal is depressed at a vehicle speed of ( ) km/h during curve driving (right curve, left curve).
Others
State of parts
Wear of tire
Wear breakage of brake
Others
E3–18
Phenomena
Always illuminated when IG SW is turned ON.
ABS warning lamp
Does not illuminate for three seconds after IG SW is turned ON.
Always illuminated when IG SW is turned ON.
Brake warning lamp
Does not illuminate for three seconds after IG SW is turned ON.
Uneven brake application.
Lack of brake efficiency.
Brake malfunction
ABS is actuated during normal braking.
Pedal vibrates during ABS operation.
ABS warning lamp is illuminated during running.
Others
SST: 09991-87404-000
SST: 09991-87403-000
3.After setting the IG SW "ON" position, read out the flashing number of the ABS warning lamp.
(1) When the system is functioning normally, the flashing interval is 0.25 second.
(2) If there is one malfunction code, after a pause of four seconds, the same code will be outputted.
(3) If plural codes are outputted, the respective codes will be outputted at an interval of 2.5 seconds.
After all the codes have been outputted, there will be another 4 second pause before the output
of the codes starts over again.
NOTE
• When the DLC is short-circuited, the warning lamps other than that for ABS will flash. However,
this does not represent a malfunction of the system.
• When plural codes are outputted, they will appear in the order of the code number, starting from
the smaller one.
ON ON
IG SW IG SW
LOCK LOCK
Shorted Shorted
ECU-T ECU-T
Open Open
0.5sec.
0.25sec. 0.5sec.
Glowing Glowing
ABS warning lamp ABS warning lamp
Extinguished Extinguished
2.5sec. 4sec.
3sec. 0.25sec. 3sec. 4sec. 0.5sec. 1.5sec.
Code21 Code31 Repetition
0.25sec.
3When system is functioning normally5 3System is malfunctioning(Plural codes No.21 and 31)5
T11C5011ES16
E3–20
4-9-2 CANCELING METHOD OF DIAGNOSIS
NOTE
• When the section for which codes are outputted has been repaired, erase the abnormality code
memorized in the ECU by the following method given below.
• When the memory is erased, the test mode function (See the next item) will automatically start,
and the ABS warning lamp will flash. In this case, perform the test mode function and check that
each sensor has no abnormality.
• If the abnormal code can not erased, again carry out the check and repair for the abnormal code
generating point.
CAUTION
• Be sure to employ the specified SST for short-circuiting the DLC.
• If the short-circuit of the DLC is made for wrong positions, it may cause a malfunction. Be very
careful not to select wrong terminals.
SST: 09991-87404-000
SST: 09991-87403-000
code.
• If there is no malfunction, the test mode code only is
outputted.
• If the diagnosis code cannot be erased, set the IG SW
"LOCK" position. Then, perform the operation above
again.
E3–21
4.Open the ECU-T terminal and E terminal.
NOTE
• If there is no malfunction when the ECU-T terminal and the E terminal are opened, the ABS warn-
ing lamp flashes (Test mode indication). At this point, release the short-circuiting. With the IG SW
"LOCK" position again, run the vehicle to check the function of each sensor.
ON
IG SW
LOCK
Shorted
ECU-T Once Three 5times 7times
Open times
Twice 4times 6times 8times
ON
Stop lamp switch
OFF
0.12sec.
Clowing
ABS warning lamp
Extinguished
0.12sec.
3sec. 4sec. 4sec. Flashing(Test mode indication)
Test mode code
Diagnosis code output output
T11C5012ES20
E3–22
4-9-3 CONTENTS OF DIAGNOSIS
Contents of diagnosis
Warning indication
Code No. (Provided: <,Not- Code memory Contents of diagnosis
provided:=) (Provided: <,Not-
Two Four provided:=)
ABS Brake System diagnosed Diagnosis items
digit digit
11 C0278 < < < Solenoid relay Open/short
15 C1241 < =/<~1 < Power supply Voltage dropping/rise
21 C0200 < =~2 < Wheel speed sensor front right Open/short
22 C0205 < =~2 < Wheel speed sensor front left Open/short
23 C0210 < =~2 < Wheel speed sensor rear right Open/short
24 C0215 < =~2 < Wheel speed sensor rear left Open/short
25 C1235 < =~2 < Wheel speed sensor front right Abnormal intervals
26 C1236 < =~2 < Wheel speed sensor front left Abnormal intervals
27 C1238 < =~2 < Wheel speed sensor rear right Abnormal intervals
28 C1239 < =~2 < Wheel speed sensor rear left Abnormal intervals
29 C1237 < =~2 < Rotor Missing teeth
C1251 Abnormality of non-
51 < = < Motor pump
rotation
C0226 Holding or front/right pressure-
52 < < < Abnormal
reducing solenoid
C0236 Holding or front/left pressure-
54 < < < Abnormal
reducing solenoid
C0246 Holding or rear/right pressure-
56 < < < Abnormal
reducing solenoid
C0256 Holding or rear/left pressure-
58 < < < Abnormal
reducing solenoid
C1300 ECU internal abnor-
77 < < < ABS ECU
mality
~1:When the voltage rises: "<", When the voltage drops:"="
~2:When failure occurred on two or more wheels: "<"
E3–23
4-10 SENSOR CHECK FUNCTION (TEST MODE)
1.The test mode is executed, immediately after any abnormal code has been erased through the brake
pedal operation or at the time when the IG SW is turned "ON" for the first time after a new ABS actua-
tor has been installed. Then, the test mode checks the following items to detect any abnormal output
of each sensor, the rotor deformation or missing tooth, etc.
(1) Output voltage of wheel speed sensor
(2) Output interval of wheel speed sensor
During the test mode, the ABS warning lamp flashes. When the check of each sensor completes normal-
ly, the lamp is extinguished.
4-10-1 OUTPUT OF TEST MODE CODE
1.The indicating method of the test mode code output is the same as that of the diagnosis code output.
Refer to Page E3-19.
T11C5013ET10
ON ON
IG SW IG SW
LOCK LOCK
Shorted Shorted
ECU-T ECU-T
Open Open
0.12sec. 0.12sec. 3sec.
Glowing Glowing
ABS warning lamp ABS warning lamp
Extinguished Extinguished
3sec. Test mode indication
SST: 09991-87403-000
è2. Check of continuity between the ABS2 fusible link and ABS actuator
1.After setting the IG SW "LOCK" position, remove the negative (() terminal of the battery.
2.Separate the connectors of the ABS2 fusible link and ABS actuator. Check the harness.
(1) Terminal between the ABS2 fusible link connector downstream side and the ABS actuator harness
side connector 13 ('BS)
(2) Between the ABS actuator harness side connector 14 (GND) and the body earth
SPECIFIED VALUE: Continuity exists.
çIf NG, repair the harness and connectors between the ABS actuator and the ABS2 fusible link.
è3. Check continuity between the ABS2 fusible link and the ABS actuator.
1.After setting the IG SW "LOCK" position, remove the negative (() terminal of the battery.
2.Separate the connectors of the ABS2 fusible link and ABS actuator. Check the harness.
(1) Between the ABS2 fusible link connector downstream side and the body earth
SPECIFIED VALUE: No continuity exists.
è2. Continuity check between the ABS2 fuse and the ABS actuator
1.After setting the IG SW "LOCK" position, measure the resistance between the following terminals given
below.
(1) Between the ABS actuator harness side connector 13 ('BS) terminal and the ABS2 fuse down-
stream side terminal
SPECIFIED VALUE: Continuity exists.
è3. Check continuity between the ABS actuator and the earth.
1.After the IG SW has been set to "LOCK" position, disconnect the connector from the ABS actuator.
2.Measure the resistance between the following terminals.
(1) Between the ABS actuator harness side connector 14 (GND) and the body earth
SPECIFIED VALUE: No continuity exists.
è3. Check the harness between the wheel speed sensor and the ABS actuator.
1.Visually check the wheel speed sensor concerned and the harness between the wheel speed sensor
and the ABS actuator. Check to see if each harness is damaged or the connector has poor contact.
çIf it is OK, go to è4.
çIf NG, repair the harness and connectors between the wheel speed sensor and the ABS actuator.
çIf NG, repair the installing condition of the wheel speed sensor and replace the wheel speed sensor
rotor.
E3–30
4-12-4 NO.51 (MOTOR PUMP SYSTEM)
(1) Diagnostic code output conditions
1.When the motor pump is not operating
(2) Checking points
1.Is the ABS 1 fusible link normal?
2.Is the harness between the ABS 1 fusible link and ABS actuator normal?
(3) Checking method
è1. Check of ABS1fusible link
SPECIFIED VALUE: Not burnt out
è2. Continuity check between the ABS1 fusible link and the ABS actuator
1.After setting the IG SW "LOCK" position, remove the negative (() terminal of the battery.
2.Separate the connectors of the ABS1fusible link and ABS actuator. Check the harness.
(1) Between the ABS1 fusible link connector downstream side and the ABS actuator harness side con-
nector 26 ('BM) terminal.
SPECIFIED VALUE: Continuity exists.
çIf NG, repair the harness and connectors between the ABS1fusible link and the ABS actuator.
è3. Continuity check between the ABS1 fusible link and the ABS actuator
1.After setting the IG SW "LOCK" position, remove the negative (() terminal of the battery.
2.Separate the connectors of the ABS1 fusible link and ABS actuator. Check the harness.
(1) Between the ABS1 fusible link connector downstream side and the body earth
SPECIFIED VALUE: No continuity exists.
2.After turning "ON" the IG SW, check the lightening state of the ABS warning lamp.
SPECIFIED VALUE: Output the abnormal codes.
çIf OK, perform the trouble-shooting according to the diagnosis code table.
Refer to Page E3-19.
çIf OK, perform the trouble-shooting according to the diagnosis code table.
Refer to Page E3-19.
çIf NG, repair the harness between the ABS actuator and the combination meter.
E3–34
4-13-2 THE BRAKE WARNING LAMP REMAINS ILLUMINATED BY TURNING "ON" IG SW.
(1) Checking points
1.When the brake warning lamp is illuminated at the same time with the ABS warning lamp, perform the
troubleshooting for the case The ABS warning lamp is illuminated at all times with the IG SW "ON" posi-
tion.
Refer to Page E3-32.
2.If the brake warning lamp only is illuminated at all times, refer to the following.
(1) Is the parking brake SW "ON" position?
(2) Is the brake fluid level normal?
(3) Is the parking brake SW normal?
(4) Is the brake fluid level SW normal?
(5) Are the brake fluid level SW and parking brake SW system circuit normal?
(6) Is there open wire in the brake warning lamp system circuit?
(7) Is the combination meter normal?
NOTE
• Perform the check with the parking brake released.
4-13-3 THE ABS WARNING LAMP DOES NOT GO ON FOR THREE SECONDS AFTER IG SW IS SET
TO "ON" POSITION.
(1) Checking points
NOTE
• The ABS warning lamp illuminates about three seconds.
4-13-4 THE BRAKE WARNING LAMP DOES NOT GO TO ON FOR THREE SECONDS AFTER IG SW
IS SET TO "ON" POSITION.
(1) Checking points
NOTE
• The brake warning lamp illuminates about three seconds.
2.After turning "ON" the IG SW, check the lightening state of the ABS warning lamp.
SPECIFIED VALUE: The normal code is flashing.
è3. Continuity check between the terminals of each wheel speed sensor
1.Disconnect the connector of the ABS actuator. Check continuity between the terminals of each harness
side sensor.
çIf it is OK, go to è4.
çIf NG, the wire harness is faulty.
M21C7079T10
NOTE
• Air gap between wheel speed sensor and sensor rotor: 1.2&0.5 mm (Reference)
E3–37
4-14-4 REAR WHEEL SPEED SENSOR
(1) Measurement and visual Inspection
1.Measure the resistance between the connector terminals.
SPECIFIED VALUE: 1.11&0.20k+ (At time of 20°C)
2 1
M21C7304T10
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
T11C5002S10