Brake System - BR1 BRAKE SYSTEM BR2 BRAKE SYSTEM GENERAL...

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Unformatted text preview: BR1 BRAKE SYSTEM BR2 BRAKE SYSTEM GENERAL DESCRIPTION, PREPARATION BR03E09 GENERAL DESCRIPTION 1. Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts of the same part number or equivalent. It is very important to keep parts and the area clean when repairing the brake system. If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. BR03J0D 2. 3. PREPARATION SST (SPECIAL SERVICE TOOLS) LUBRICANT Vernier calipers Dial indicator Micrometer Torque wrench EQUIPMENT RECOMMENDED TOOLS Brake fluid Item Capacity BRAKE SYSTEM PREPARATION SAE J1703 or FMVSS No. 116 DOT3 Classification Brake disc Brake disc Brake disc BR3 BR0EB06 BR03K08 BR03L05 BR4 BRAKE SYSTEM TROUBLESHOOTING BR03M0A TROUBLESHOOTING Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. BR17, 22 BR17, 22 BR17, 22 BR17, 22 BR17, 22 BR17, 22 BR17, 22 BR17, 22 BR17, 22 BR17, 22 BR17, 22 BR17, 22 BR17, 22 BR15 BR27 BR5 BR9 BR31 BR8 BR6 BR27 BR5 BRAKE SYSTEM CHECK AND ADJUSTMENT BR0X101 CHECK AND ADJUSTMENT BRAKE PEDAL CHECK AND ADJUSTMENT 1. CHECK PEDAL HEIGHT Pedal height from asphalt sheet: 136.0146.0 mm (5.355.75 in.) If the pedal height is incorrect, adjust it. 2. IF NECESSARY, ADJUST PEDAL HEIGHT (a) Disconnect the connector from the stop light switch. (b) Loosen the stop light switch lock nut and remove the stop light switch. (c) Loosen the push rod lock nut. (d) Adjust the pedal height by turning the pedal push rod. (e) Tighten the push rod lock nut. Torque: 25 Nm (260 kgfcm, 19 ftlbf) (f) Install the stop light switch and turn it until it lightly contacts the pedal stopper. (g) Turn the stop light switch back one turn. (h) Check the clearance (A) between the stop light switch and pedal. Clearance: 0.52.4 mm (0.020.09 in.) (i) (j) (k) (l) Tighten the stop light switch lock nut. Connect the connector to the stop light switch. Check that the stop lights come on when the brake pedal is depressed, and go off when the brake pedal is released. After adjusting the pedal height, check the pedal freeplay. HINT: If clearance (A) between the stop light switch and the brake pedal stopper has been adjusted correctly, the pedal freeplay will meet the specifications. 3. CHECK PEDAL FREEPLAY (a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster. (b) Push in the pedal by hand until the beginning of the second point of resistance is felt, then measure the distance, as shown. Pedal freeplay: 16 mm (0.040.24 in.) If incorrect, check the stop light switch clearance. And if the clearance is OK, then troubleshoot the brake system. HINT: The freeplay to the 1st point of resistance is due to the play between the clevis and pin. It is 13 mm (0.040.12 in.) on the pedal. BR6 BRAKE SYSTEM CHECK AND ADJUSTMENT 4. CHECK PEDAL RESERVE DISTANCE Release the parking brake. With the engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance at 490 N (50 kgf, 110.2 lbf): More than 75 mm (2.95 in.) If the reserve distance is incorrect, troubleshoot the brake system. BR03P0F BRAKE BOOSTER OPERATIONAL TEST 1. OPERATING CHECK (a) Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. (b) Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. 2. AIR TIGHTNESS CHECK (a) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. If the pedal goes down farthest the 1st time, but gradually rises after the 2nd or 3rd time, the booster is air tight. (b) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is air tight. BR0X201 HINT: If any work is done on the brake system or if air in the brake lines is suspected, bleed the system of air. BRAKE SYSTEM BLEEDING NOTICE: Do not let brake fluid remain on painted surfaces. Wash it off immediately. 1. REMOVE RESERVOIR CAP Turn the reservoir cap to the "open" side and remove it. FILL RESERVOIR WITH BRAKE FLUID Fluid: SAE J1703 or FMVSS NO.116 DOT3 2. 3. BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Disconnect the brake lines from the master cylinder. (b) Slowly depress the brake pedal and hold it. BR7 BRAKE SYSTEM CHECK AND ADJUSTMENT (c) Block off the outer holes with your fingers, and release the brake pedal. (d) Repeat (b) and (c) 3 or 4 times. 4. BLEED BRAKE LINE (a) Connect the vinyl tube to the brake caliper. (b) Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down. (c) At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal. (d) Repeat (b) and (c) until all the air in the fluid has been bled out. (e) Repeat the above procedure to bleed the air out of the brake line for each wheel. Torque: 11 Nm (110 kgfcm, 8 ftlbf) 5. CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS NO.116 DOT3 6. INSTALL RESERVOIR CAP (a) Align the matchmark on the reservoir cap with the matchmark on the "open" side of the reservoir. (b) Push down on the reservoir cap and turn it clockwise until it locks. (c) Check that the matchmark on the reservoir cap is now aligned with the matchmark on the "close" side of the reservoir. BR0EE05 TRAC CONTROL SYSTEM BLEEDING 1. BLEED TRACTION CONTROL SYSTEM CAUTION: The fluid is under high pressure, and could spray out with great force, so exercise caution. When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC system. BR8 BRAKE SYSTEM CHECK AND ADJUSTMENT (a) Connect a vinyl tube to the bleeder plug of accumulator, then loosen the bleeder plug. (b) Start the engine to allow the TRAC pump motor to operate until all the air has been bled out of the fluid. (c) Tighten the bleeder plug and stop the engine. Torque: 8.3 Nm (85 kgfcm, 74 in.lbf) (d) Connect a vinyl tube to the bleeder plug of the TRAC actuator, then loosen the bleeder plug. (e) Start the engine to allow the TRAC pump motor to operate until all the air has been bled out of the fluid. (f) Tighten the bleeder plug and stop the engine. Torque: 8.3 Nm (85 kgfcm, 74 in.lbf) (g) Check if any diagnostic trouble code is output which indicates trouble. If there is, clear the diagnostic trouble code. 2. CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS NO.116 DOT3 HINT: Add fluid with the engine idling. BR0CJ06 PARKING BRAKE CHECK AND ADJUSTMENT 1. CHECK PARKING BRAKE PEDAL TRAVEL Depress the parking brake pedal all the way and count the number of clicks. Parking brake pedal travel at 294 N (30 kgf, 66.1 lbf): 5 7 clicks 2. IF NECESSARY, ADJUST PARKING BRAKE (a) Adjust the parking brake shoe clearance. (b) Loosen the adjuster lock nut and adjust until the parking brake pedal travel is correct. HINT: If the adjustment can not be made within the range of travel of the adjuster, remove the propeller shaft and make the adjustment at the pull rod. BR9 BRAKE SYSTEM MASTER CYLINDER BR0EF06 MASTER CYLINDER MASTER CYLINDER REMOVAL BR10 BRAKE SYSTEM MASTER CYLINDER DRAIN OUT HIGH PRESSURE FLUID 1. w/ TRAC: (a) Connect a vinyl tube to the bleeder plug of the TRAC actuator, then loosen the bleeder plug with the ignition switch in the OFF position. CAUTION: The fluid is under high pressure, and could spray out with great force, so exercise caution. (b) Tighten the plug when fluid stops flowing out. Torque: 8.3 Nm (85 kgfcm, 74 in.lbf) 2. 3. DISCONNECT LEVEL WARNING SWITCH CONNECTOR DRAW OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 4. DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the master cylinder. SST 0902300100 5. REMOVE MASTER CYLINDER (a) Remove the nuts and clamp. (b) Remove the master cylinder and gasket from the brake booster. BR11 BRAKE SYSTEM MASTER CYLINDER BR03T0D COMPONENTS BR0X301 MASTER CYLINDER DISASSEMBLY Assembly is in the reverse order of disassembly. ASSEMBLY NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows (See COMPONENTS). 1. REMOVE MASTER CYLINDER BOOT Using a screwdriver, remove the master cylinder boot. ASSEMBLY NOTICE: Facing the UP mark on the master cylinder boot upwards, install the cylinder boot to the master cylinder. 2. 3. REMOVE RESERVOIR CAP AND STRAINER REMOVE RESERVOIR Remove the set screw and pull out the reservoir. Torque: 1.7 Nm (17.5 kgfcm, 15.2 in.lbf) 4. 5. REMOVE 2 GROMMETS PLACE CYLINDER IN VISE BR12 BRAKE SYSTEM MASTER CYLINDER 6. w/ TRAC: REMOVE NO.1 PISTON STOPPER BOLT Using a screwdriver, push the pistons in all the way and remove the No.1 piston stopper bolt and gasket. HINT: Tape the screwdriver tip before use. Torque: 10 Nm (100 kgfcm, 7 ftlbf) 7. REMOVE NO.2 PISTON STOPPER BOLT Using a screwdriver, push the pistons in all the way and remove the No.2 piston stopper bolt and gasket. Torque: 10 Nm (100 kgfcm, 7 ftlbf) 8. REMOVE 2 PISTONS (a) Push in the piston with a screwdriver and remove the snap ring with snap ring pliers. HINT: Tape the screwdriver tip before use. (b) Remove the No.1 piston and spring by hand, pulling straight out, not at an angle. NOTICE: If pulled out and installed at an angle, there is a possibility that the cylinder bore could be damaged. ASSEMBLY NOTICE: Be careful not to damage the rubber lips on the pistons. (c) Place a rag and 2 wooden blocks on the work table and lightly tap the cylinder flange against the block edges until the piston drops out of the cylinder. DISASSEMBLY HINT: Make sure the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 in.). BR03V0A MASTER CYLINDER COMPONENTS INSPECTION 1. 2. HINT: Clean the disassembled parts with compressed air. INSPECT CYLINDER BORE FOR RUST OR SCORING INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. BR03V0A MASTER CYLINDER INSTALLATION 1. ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD BEFORE INSTALLING MASTER CYLINDER (See page BR15) INSTALL MASTER CYLINDER Install the master cylinder and a new gasket on the brake booster with the 3 nuts. Torque: 13 Nm (130 kgfcm, 9 ftlbf) 2. BR13 BRAKE SYSTEM MASTER CYLINDER 3. CONNECT 2 BRAKE LINES Using SST, connect the brake lines to the master cylinder. Torque the union nuts. SST 0975136011 Torque: 15 Nm (155 kgfcm, 11 ftlbf) 4. 5. 6. 7. 8. CONNECT LEVEL WARNING SWITCH CONNECTOR FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR6) w/ TRAC: BLEED TRAC SYSTEM (See page BR7) CHECK FOR FLUID LEAKAGE CHECK AND ADJUST BRAKE PEDAL (See page BR5) BR14 BRAKE SYSTEM BRAKE BOOSTER BR0X501 BRAKE BOOSTER BRAKE BOOSTER REMOVAL BR15 BRAKE SYSTEM BRAKE BOOSTER 1. 2. w/ TRAC: DRAIN OUT HIGH PRESSURE FLUID (See step 1. on page BR10) REMOVE THESE PARTS: Master cylinder (See page BR9) w/ TRAC: TRAC pump assembly (See page BR107) Vacuum hose Theft deterrent horn Tilt and telescopic ECU Clip, clevis pin and return spring 3. (a) (b) (c) REMOVE BRAKE BOOSTER Remove the booster installation nuts. Remove the clevis. Remove the booster and gasket. BR03Z0D BRAKE BOOSTER INSTALLATION 1. (a) (b) (c) INSTALL BRAKE BOOSTER Install the booster and a new gasket. Install the clevis. Install and torque the booster installation nuts. Torque: 13 Nm (130 kgfcm, 9 ftlbf) (d) Insert the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin. (e) Install the pedal return spring. 2. ADJUST LENGTH OF BOOSTER PUSH ROD (a) Install a new gasket on the master cylinder. (b) Set the SST on the gasket, and lower the pin until its tip slightly touches the piston. SST 0973700010 BR16 BRAKE SYSTEM BRAKE BOOSTER (c) Turn the SST upside down, and set it on the booster. SST 0973700010 (d) Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 in.) (e) Adjust the booster push rod length until the push rod lightly touches the pin head. HINT: When adjusting the push rod, depress the brake pedal enough so that the push rod sticks out. 3. INSTALL THESE PARTS: Tilt and telescopic ECU Theft deterrent horn Vacuum hose Master cylinder (See page BR9) w/ TRAC: TRAC pump assembly (See page BR107) 4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR6) 5. w/ TRAC: BLEED TRAC SYSTEM (See page BR7) 6. 7. 8. CHECK FOR FLUID LEAKAGE CHECK AND ADJUST BRAKE PEDAL (See page BR5) DO OPERATIONAL CHECK (See page BR6) BR17 BRAKE SYSTEM FRONT BRAKE BR0400E FRONT BRAKE COMPONENTS BRAKE PADS REPLACEMENT BR0X602 1. 2. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace the pads if they are not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFT UP CALIPER (a) Hold the sliding pin on the bottom and loosen the installation bolt. (b) Remove the installation bolt. (c) Lift up the caliper and suspend it securely. HINT: Do not disconnect the flexible hose from the caliper. BR18 BRAKE SYSTEM FRONT BRAKE REMOVE THESE PARTS: 2 antisqueal springs 2 brake pads 4 antisqueal shims 4 pad support plates CHECK DISC THICKNESS AND RUNOUT (See page BR20) 6. INSTALL UNDER SIDE PAD SUPPORT PLATES 7. INSTALL UPPER SIDE PAD SUPPORT PLATES (a) Using a cleaner, wipe off dust, water, oil, etc. from the pad support plate contact area of the torque plate. (b) Remove the pad support cover sheet from new pad support plates. (c) Install the pad support plates. 8. INSTALL NEW PADS NOTICE: When replacing worn pads, the antisqueal shims and support plate must be replaced together with the pad. 4. (a) (b) (c) (d) 5. (a) Install the 2 antisqueal shims to each pad. HINT: Apply disc brake grease to both sides of the inner anti squeal shim. (b) Install the 2 pads with the pad wear indicator plates facing downward. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. (c) Install the 2 antisqueal springs. 9. INSTALL CALIPER (a) Draw out a small amount of brake fluid from the reservoir. (b) Press in the pistons with a hammer handle or similar implement. HINT: If the pistons are difficult to push in, loosen the bleeder plug and push in the pistons while letting some brake fluid escape. (c) Install the caliper. (d) Hold the sliding pin and torque the installation bolt. Torque: 34 Nm (350 kgfcm, 25 ftlbf) 10. INSTALL FRONT WHEEL 11. CHECK THAT FLUID LEVEL IS AT MAX LINE BR0X701 CALIPER REMOVAL Installation is in the reverse order of removal. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM (See page BR6) AND CHECK FOR LEAKS BR19 BRAKE SYSTEM FRONT BRAKE 1. DISCONNECT BRAKE HOSE (a) Remove the union bolt and 2 gaskets from the caliper, then disconnect the brake hose from the caliper. Torque: 30 Nm (310 kgfcm, 22 ftlbf) INSTALLATION HINT: Install the flexible hose lock securely in the lock hole in the caliper. (b) Use a container to catch the brake fluid as it drains out. 2. REMOVE CALIPER (a) Hold the sliding pin and loosen the 2 installation bolts. Torque: 34 Nm (350 kgfcm, 25 ftlbf) (b) (c) 3. (a) (b) Remove the 2 installation bolts. Remove the caliper from the torque plate. REMOVE THESE PARTS: 2 antisqueal springs 2 brake pads with antisqueal shims BR0430H CALIPER DISASSEMBLY Assembly is in the reverse order of disassembly. ASSEMBLY NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR 17). REMOVE CYLINDER BOOT SET RINGS AND BOOTS Using a screwdriver, remove the cylinder boot set rings and cylinder boots from the cylinder. 1. 2. REMOVE PISTONS (a) Place a piece of cloth or similar article between the piston and the caliper. (b) Use compressed air to remove the pistons from the cylinder. DISASSEMBLY CAUTION: Do not place your fingers in front of the piston when using compressed air. 3. REMOVE PISTON SEALS Using a screwdriver, remove the piston seals from the cylinder. BR20 BRAKE SYSTEM FRONT BRAKE 4. REMOVE SLIDING PINS AND DUST BOOTS (a) Remove the 2 sliding pins from the torque plate. ASSEMBLY NOTICE: Insert the sliding pin with sliding bushing A into the upper part, and insert the sliding pin with sliding bushing B into the lower part. (b) Using a screwdriver and hammer, tap out the 2 dust boots. ASSEMBLY HINT: Use a 21 mm socket and tap in 2 new dust boots into the torque plate. ASSEMBLY NOTICE: Confirm that the metal plate portion of the dust boot fits snugly in the torque plate. BR0440C FRONT BRAKE COMPONENTS INSPECTION AND REPAIR 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 11.0 mm (0.433 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad's thickness is at the minimum thickness or less, or if the pad has severe, uneven wear. 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 32 mm (1.260 in.) Minimum thickness: 30 mm (1.181 in.) Replace the disc if the thickness of the disc is at the minimum thickness or less. Replace the disc or grind it on a lathe if it is scored or is worn unevenly. BR21 BRAKE SYSTEM FRONT BRAKE 3. MEASURE DISC RUNOUT Using a dial indicator, measure the disc runout at a position 10 mm (0.39 in.) from the outside edge. Maximum disc runout: 0.05 mm (0.0020 in.) If the disc's runout is at the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout (See page SA14). If the bearing play and axle hub runout are not abnormal, adjust the disc runout. 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the 2 bolts and torque plate. (b) Remove the hub nuts and the disc. Reinstall the disc 1/5 of a turn round from its original position on the hub. Install and torque the hub nuts. Torque: 103 Nm (1,050 kgfcm, 76 ftlbf) Remeasure the disc runout. Make a note of the runout and disc's position on the hub. (c) Repeat (b) until the disc has been installed on the 3 remaining hub positions. (d) If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020 in.), install the disc in that position. (e) If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3. (f) Install the torque plate and torque the 2 bolts. Torque: 118 Nm (1,200 kgfcm, 87 ftlbf) BR22 BRAKE SYSTEM REAR BRAKE (Disc Brake) BR0470E REAR BRAKE (Disc Brake) COMPONENTS BR0X801 BRAKE PADS REPLACEMENT 1. REMOVE REAR WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace pads if the thickness is not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 2. BR23 BRAKE SYSTEM REAR BRAKE (Disc Brake) 3. LIFT UP CALIPER (a) Hold the sliding pin on the bottom and loosen the installation bolt. (b) Remove the installation bolt. (c) Lift up the caliper and suspend it securely. HINT: Do not disconnect the flexible hose from the caliper. 4. REMOVE THESE PARTS: (a) 2 antisqueal springs (b) 2 brake pads (c) 4 antisqueal shims (d) 4 pad support plates 5. CHECK DISC THICKNESS AND RUNOUT (See page BR25) 6. INSTALL 4 PAD SUPPORT PLATES 7. INSTALL NEW PADS NOTICE: When replacing worn pads, the antisqueal shims and support plate must be replaced together with the pad. (a) Apply disc brake grease to both sides of the inner antisqueal shims. (b) Install the 2 antisqueal shims on each pad. (c) Install 2 pads with the pad wear indicator plates facing downward. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. (d) Install the 2 antisqueal springs. 8. INSTALL CALIPER (a) Draw out a small amount of brake fluid from the reservoir. (b) Press in the piston with a hammer handle or similar implement. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. (c) Install the caliper. (d) Hold the sliding pin and torque the installation bolt. Torque: 34 Nm (350 kgfcm, 25 ftlbf) 9. INSTALL REAR WHEEL 10. CHECK THAT FLUID LEVEL IS AT MAX LINE BR24 BRAKE SYSTEM REAR BRAKE (Disc Brake) BR0X901 CALIPER REMOVAL Installation is in the reverse order of removal. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM (See page BR6) 1. DISCONNECT BRAKE HOSE (a) Remove the union bolt and 2 gaskets from the caliper, then disconnect the brake hose from the caliper. Torque: 30 Nm (310 kgfcm, 22 ftlbf) INSTALLATION HINT: Install the flexible hose lock securely in the lock hole in the caliper. (b) Use a container to catch the brake fluid as it drains out. 2. REMOVE CALIPER (a) Hold the sliding pin and loosen the 2 installation bolts. Torque: 34 Nm (350 kgfcm, 25 ftlbf) (b) (c) 3. (a) (b) Remove the 2 installation bolts. Remove the caliper from the torque plate. REMOVE THESE PARTS: 2 antisqueal springs 2 brake pads with antisqueal shims BR0XA01 CALIPER DISASSEMBLY Assembly is in the reverse order of disassembly. ASSEMBLY NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR 22). REMOVE CYLINDER BOOT SET RING AND BOOT Using a screwdriver, remove the cylinder boot set ring and cylinder boot from the cylinder. 1. 2. REMOVE PISTON (a) Place a piece of cloth or similar article between the piston and the caliper. (b) Use compressed air to remove the piston from the cylinder. DISASSEMBLY CAUTION: Do not place your fingers in front of the piston when using compressed air. BR25 BRAKE SYSTEM REAR BRAKE (Disc Brake) 3. REMOVE PISTON SEAL Using a screwdriver, remove the piston seal from the cylinder. 4. REMOVE SLIDING PINS AND DUST BOOTS (a) Remove the 2 sliding pins from the torque plate. ASSEMBLY NOTICE: Insert the sliding pin with the sliding bushing into the bottom side. (b) Using a screwdriver and hammer, tap out the 2 dust boots. ASSEMBLY HINT: Use a 19 mm socket and tap in 2 new dust boots into the torque plate. ASSEMBLY NOTICE: Confirm that the metal plate portion of the dust boot fits snugly in the torque plate. BR0XB01 REAR BRAKE COMPONENTS INSPECTION AND REPAIR 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad's thickness is at the minimum thickness or less, or if the pad has severe, uneven wear. 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 16.0 mm (0.630 in.) Minimum thickness: 15.0 mm (0.591 in.) Replace the disc if the thickness of the disc is at the minimum thickness or less. Replace the disc or grind it on a lathe if it is badly scored or worn unevenly. BR26 BRAKE SYSTEM REAR BRAKE (Disc Brake) 3. MEASURE DISC RUNOUT Using a dial indicator, measure disc runout 10 mm (0.39 in.) from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in.) If the disc's runout is at the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout (See page SA37). If the bearing play and axle hub runout are not abnormal, adjust the disc runout. 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the 2 bolt and torque plate. (b) Remove the hub nuts and the disc. Reinstall the disc 1/5 of a turn round from its original position on the hub. Install and torque the hub nuts. Torque: 103 Nm (1,050 kgfcm, 76 ftlbf) (c) Remeasure the disc runout. Make a note of the runout and the disc's position on the hub. Repeat (b) until the disc has been installed on the 3 remaining hub positions. (d) If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020 in.), install the disc in that position. (e) If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3. (f) Install the torque plate and tighten the 2 bolts. Torque: 104 Nm (1,065 kgfcm, 77 ftlbf) BR27 BRAKE SYSTEM REAR BRAKE (Parking Brake) BR04E0D REAR BRAKE (Parking Brake) COMPONENTS BR0XC01 PARKING BRAKE DISASSEMBLY 1. REMOVE REAR WHEEL 2. REMOVE REAR DISC BRAKE ASSEMBLY (a) Remove the 2 mounting bolts and remove the disc brake assembly. (b) Suspend the disc brake securely and so the hose is not stretched. 3. REMOVE DISC (a) Place matchmarks on the disc and rear axle hub. (b) Remove the disc. HINT: If the disc can not be removed easily, turn the shoe adjuster until the wheel turns freely. BR28 BRAKE SYSTEM REAR BRAKE (Parking Brake) 4. 5. REMOVE SHOE RETURN SPRINGS Using needlenose pliers, remove the 2 shoe return springs. REMOVE SHOE STRUT WITH SPRING 6. (a) (b) 7. (a) (b) REMOVE FRONT SHOE AND ADJUSTER Slide out the front shoe and remove the shoe adjuster. Disconnect the tension spring and remove the front shoe. REMOVE REAR SHOE AND TENSION SPRING Slide out the rear shoe. Remove the tension spring from the rear shoe. (c) Disconnect the parking brake cable from the parking brake shoe lever. (d) Remove the shoe holddown spring cups, springs and pins. BR04G0G PARKING BRAKE COMPONENTS INSPECTION AND REPAIR 1. 2. INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage. MEASURE BRAKE SHOE LINING THICKNESS Using a ruler, measure the thickness of the shoe lining. Standard thickness: 2.5 mm (0.098 in.) Minimum thickness: 1.0 mm (0.039 in.) If the lining thickness is at the minimum thickness or less or if there is severe, uneven wear, replace the brake shoe. BR29 BRAKE SYSTEM REAR BRAKE (Parking Brake) 3. MEASURE BRAKE DISC INSIDE DIAMETER Using a vernier caliper, measure the inside diameter of the disc. Standard inside diameter: 190 mm (7.48 in.) Maximum inside diameter: 191 mm (7.52 in.) Replace the disc if the inside diameter is at the maximum value or more. Replace the disc or grind it with a lathe if the disc is scored or is worn unevenly. 4. INSPECT PARKING BRAKE LINING AND DISC FOR PROPER CONTACT Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit. If the contact between the disc and the brake shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly. 5. MEASURE CLEARANCE BETWEEN PARKING BRAKE SHOE AND LEVER Using a feeler gauge, measure the clearance. Standard clearance: Less than 0.35 mm (0.0138 in.) If the clearance is not within the specification, replace the shim with one of the correct size. Thickness mm (in.) Thickness mm (in.) 0.3 (0.012) 0.6 (0.024) 0.9 (0.035) 6. IF NECESSARY, REPLACE SHIM (a) Remove the parking brake shoe lever, and install the correct size shim. (b) Install the parking brake shoe lever with a new Cwasher. (c) Remeasure the clearance. BR30 BRAKE SYSTEM REAR BRAKE (Parking Brake) BR0XD01 PARKING BRAKE ASSEMBLY 1. APPLY HIGH TEMPERATURE GREASE ON THESE PARTS: (a) Rubbing surface of the backing plate and shoe (b) Adjuster 3. CONNECT PARKING BRAKE CABLE TO PARKING BRAKE LEVER (a) Install the shoe holddown springs, cups and pins. (b) Connect the parking brake cable to the parking brake shoe lever of the rear shoe. 4. INSTALL REAR SHOE Slide in the rear shoe between the shoe holddown spring cup and the backing plate. NOTICE: Do not allow oil or grease to get on the rubbing face. 5. INSTALL TENSION SPRING, FRONT SHOE AND ADJUSTER (a) Install the tension spring on the rear shoe. (b) Install the front shoe on the tension spring. (c) Install the adjuster between the front and rear shoes. (d) Slide in the front shoe between the shoe holddown spring cup and the backing plate. 6. INSTALL STRUT WITH SPRING Install the strut with the spring forward. 7. INSTALL SHOE RETURN SPRINGS Using needlenose pliers, install the front shoe return spring and then install the rear shoe return spring. 8. INSTALL DISC (a) Before installing, polish the disc and shoe surfaces with sandpaper. (b) Align the matchmarks and install the disc. HINT: If there are no matchmarks, temporarily install the disc, then measure the disc runout and install the disc in position. (See page BR26) BR31 BRAKE SYSTEM REAR BRAKE (Parking Brake) 9. (a) (b) (c) (d) (e) 10. ADJUST PARKING BRAKE SHOE CLEARANCE Temporarily install the hub nuts. Remove the hole plug. Turn the adjuster and expand the shoes until the disc locks. Return the adjuster 8 notches. Install the hole plug. INSTALL REAR DISC BRAKE ASSEMBLY Install the disc brake assembly and torque the 2 mounting bolts. Torque: 104 Nm (1,065 kgfcm, 77 ftlbf) 11. INSTALL REAR WHEEL 12. SETTLING PARKING BRAKE SHOES AND DISC (a) Depress the parking brake pedal with a force of 147 N (15 kgf, 33 lbf). (b) Drive the vehicle at about 50 km/h (31 mph) on a safe, level and dry road. (c) Drive the vehicle for about 400 meters (0.25 mile) in this condition. (d) Repeat this procedure 2 or 3 times. 13. CHECK AND ADJUST PARKING BRAKE PEDAL TRAVEL (See page BR8) BR32 BRAKE SYSTEM PARKING BRAKE PEDAL BR0K403 PARKING BRAKE PEDAL COMPONENT BR33 BRAKE SYSTEM PARKING BRAKE PEDAL BR0D207 PARKING BRAKE PEDAL DISASSEMBLY 1. (a) (b) (c) (d) (e) (f) 2. (a) (b) REMOVE THESE PARTS: (See page BO78) Scuff plate No.1 under cover Finish plate End pad Outside rear view mirror switch Lower pad REMOVE PARKING BRAKE PEDAL ASSEMBLY Disconnect the parking brake switch connector. Remove the 2 bolts and parking brake release lever. Torque: 5.4 Nm (55 kgfcm, 48 in.lbf) (c) Remove the pin clip and pull out the pin. (d) Remove the clip and disconnect the parking brake wire. BR34 BRAKE SYSTEM PARKING BRAKE PEDAL (e) Remove the bolt, 3 nuts and parking brake pedal assembly. Torque: 13 Nm (130 kgfcm, 9 ftlbf) 3. 4. 5. REMOVE PARKING BRAKE SWITCH FROM PARKING BRAKE PEDAL BRACKET REMOVE PARKING BRAKE RELEASE LEVER REMOVE PARKING BRAKE PEDAL Remove the bolt, nut, 2 bushings, collar and pedal. 6. IF NECESSARY, REPLACE SHOCK ABSORBER (a) Loosen the union lock nut. (b) Install the shock absorber to the pin on the pedal bracket side, then extend the piston rod fully. (c) Return the pedal until it hits the cushion. (d) Make adjustments so that the shock absorber's union and the pin on the pedal side are aligned, then turn the union 1 turn counterclockwise. (e) Install the shock absorber to the pedal and tighten the lock nut. Torque: 13 Nm (130 kgfcm, 9 ftlbf) BR35 BRAKE SYSTEM PROPORTIONING AND BYPASS VALVE (P & B VALVE) BR0ET05 PROPORTIONING AND BYPASS VALVE (P & B VALVE) FLUID PRESSURE INSPECTION 1. INSTALL LSPV GAUGE (SST) AND BLEED AIR SST 0970929017 2. 3. BLEED AIR FROM FLUID PRESSURE GAUGE RAISE MASTER CYLINDER PRESSURE AND CHECK REAR WHEEL CYLINDER PRESSURE Master cylinder pressure 1,961 kPa 7,845 kPa (20 kgf/cm2, 284 psi) Rear wheel cylinder pressure 1,961 kPa 5,099 kPa (20 kgf/cm2, 284 psi) (52 kgf/cm2, 740 psi) (80 kgf/cm2, 1,138 psi) 4. 5. If the rear wheel cylinder pressure is incorrect, replace the master cylinder. BLEED BRAKE SYSTEM (See page BR6) CHECK FOR FLUID LEAKAGE BR36 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) ANTILOCK BRAKE SYSTEM (ABS) ABS ACTUATOR COMPONENTS BR0XE01 BR37 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR38 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR0XF01 ABS ACTUATOR REMOVAL Installation is in the reverse order of removal. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM (See page BR6) AND CHECK FOR LEAKS 1. w/TRAC: DRAIN OUT HIGH PRESSURE FLUID (See step 1. on page BR10) 2. REMOVE AIR CLEANER DUCT AND AIR CLEANER ASSEMBLY (a) Remove the nut and air cleaner duct. (b) Disconnect the VAF meter connector. (c) Remove the 2 bolts and loosen the hose clamp. (d) Remove the air cleaner assembly. 3. DISCONNECT BRAKE LINES w/ TRAC: Using SST, disconnect the 7 brake lines from the ABS actuator. SST 0975136011 Torque: 10 mm nut: 15 Nm (155 kgfcm, 11 ftlbf) 12 mm nut: 20 Nm (200 kgfcm, 14 ftlbf) w/o TRAC: Using SST, disconnect the 5 brake lines from the ABS actuator. SST 0975136011 Torque: 15 Nm (155 kgfcm, 11 ftlbf) 4. REMOVE ABS ACTUATOR ASSEMBLY (a) Disconnect the 2 connectors. (b) Remove the 4 bolts and ABS actuator assembly. Torque: 19 Nm (195 kgfcm, 14 ftlbf) 5. REMOVE 2WAY (a) Using SST, disconnect the 2 (w/o TRAC) or 3 (w/ TRAC) brake lines from the 2way and actuator. SST 0975136011 Torque: 15 Nm (155 kgfcm, 11 ftlbf) (b) Remove the 2 bolts and 2way from the actuator. Torque: 8.8 Nm (90 kgfcm, 78 in.lbf) 6. REMOVE ABS ACTUATOR Remove the 3 (w/o TRAC) or 4 (w/ TRAC) nuts and actuator from the bracket. Torque: 5.4 Nm (55 kgfcm, 48 in.lbf) 7. REMOVE 3 (w/o TRAC) OR 4 (w/ TRAC) HOLDERS AND CUSHIONS BR39 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) ABS ACTUATOR INSPECTION BR0XG01 HINT: Using the ABS actuator checker (SST), check the operation of the actuator. If the actuator does not operate, check the operation of subwire harness G according to instructions on pages BR63 and BR66. If the solenoid and/ or pump motor relay are abnormal, replace the relay and inspect the actuator operation again. w/o TRAC: 1. INSPECT BATTERY POSITIVE VOLTAGE Battery positive voltage: 1014 V 2. DISCONNECT CONNECTORS FROM ACTUATOR Disconnect the 2 connectors from the actuator. 3. CONNECT ACTUATOR CHECKER (SST) TO ACTUATOR (a) Connect the actuator checker (SST) to the actuator side wire harnesses via the subwire harnesses (SST) as shown. SST 0999000150, 0999000210, 0999000250, 0999000280 (b) Connect the red cable of the checker to the battery positive (+) terminal and the black cable to the negative () terminal. Connect the black cable of the subwire harnesses to the battery negative () terminal or body ground. BR40 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 4. INSPECT BRAKE ACTUATOR OPERATION (a) Start the engine, and run it at idle speed. (b) Turn the MAIN selector switch of the actuator checker to the "FRONT RH" position. (c) Push and hold in the SUB MOTOR switch for a few seconds. (d) Depress the brake pedal and hold it until step (g) is completed. (e) Push the MAIN push switch and check that the brake pedal cannot be depressed. NOTICE: Do not keep the MAIN push switch pushed in for more than 10 seconds. (f) Release the switch, and check that the pedal can be depressed. (g) Push and hold in the SUB MOTOR switch for a few seconds, and check that the pedal returns. (h) Release the brake pedal. (i) (j) Push and hold in the SUB MOTOR switch for a few seconds. Depress the brake pedal and hold it for about 15 seconds. As you hold the pedal down, push the SUB MOTOR switch for a few seconds. Check that the brake pedal does not pulsate. 5. INSPECT FOR OTHER WHEELS (a) Turn the MAIN selector switch to the "FRONT LH" position. (b) Repeat (c) to (j) of step 4, checking the actuator operation in the same way. (c) Also, inspect the "REAR" position following the same procedure. 6. PUSH SUB MOTOR SWITCH Push and hold in the SUB MOTOR switch for a few seconds. BR41 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 7. DISCONNECT ACTUATOR CHECKER (SST) FROM ACTUATOR (a) Disconnect the actuator checker (SST) and subwire harnesses (SST) from the actuator. SST 0999000150, 0999000210, 0999000250, 0999000280 (b) Connect the actuator connectors. (c) Clear the diagnostic trouble codes. (See page BR51) w/ TRAC: 1. INSPECT BATTERY POSITIVE VOLTAGE Battery positive voltage: 1014 V 2. DISCONNECT CONNECTORS FROM ACTUATOR Disconnect the 2 connectors from the actuator. 3. CONNECT ACTUATOR CHECKER (SST) TO ACTUATOR (a) Connect the actuator checker (SST) to the actuator side wire harnesses via the subwire harnesses (SST) as shown. SST 0999000150, 0999000210, 0999000250, 0999000280 (b) Connect the red cable of the checker to the battery positive (+) terminal and the black cable to the negative () terminal. Connect the black cable of the subwire harnesses to the battery negative () terminal or body ground. (c) Place "SHEET A" (SST) on the actuator checker. SST 0999000163 BR42 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 4. INSPECT BRAKE ACTUATOR OPERATION (a) Start the engine, and run it at idle speed. (b) Turn the selector switch of the actuator checker to the "FRONT RH" position. (c) Push and hold in the MOTOR switch for a few seconds. (d) Depress the brake pedal and hold it until step (g) is completed. (e) Push the POWER SWITCH, and check that the brake pedal cannot be depressed. NOTICE: Do not keep the POWER SWITCH pushed in for more than 10 seconds. (f) Release the switch, and check that the pedal can be depressed. (g) Push and hold in the MOTOR switch for a few seconds, and check that the pedal returns. (h) Release the brake pedal. (i) (j) Push and hold in the MOTOR switch for a few seconds. Depress the brake pedal and hold it for about 15 seconds. As you hold the pedal down, push the MOTOR switch for a few seconds. Check that the brake pedal does not pulsate. BR43 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 5. INSPECT FOR OTHER WHEELS (a) Turn the MAIN selector switch to the "FRONT LH" position. (b) Repeat (c) to (j) of step 4, checking the actuator operation in the same way. (c) Also, inspect the "REAR RH" and "REAR LH" positions following the same procedure. HINT: When inspecting the "REAR LH" position, push the REAR LH switch instead of the POWER SWITCH. This makes it possible to inspect wherever the selector switch position indicates. 6. PUSH MOTOR SWITCH Push and hold in the MOTOR switch for a few seconds. 7. DISCONNECT ACTUATOR CHECKER (SST) FROM ACTUATOR (a) Disconnect the actuator checker (SST) and subwire harnesses (SST) from the actuator. SST 0999000150, 0999000163, 0999000210, 0999000250, 0999000280 (b) Connect the actuator connectors. (c) Clear the diagnostic trouble codes. (See page BR51) BR44 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR02Z0K FRONT SPEED SENSOR COMPONENTS BR02Z0K FRONT SPEED SENSOR REMOVAL Installation is in the reverse order of removal. AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page BR58) 1. DISCONNECT CONNECTOR (a) Remove the opening moulding. (b) Remove the fender liner. (c) Disconnect the speed sensor connector. 2. REMOVE SPEED SENSOR (a) Remove the 3 clamp bolts holding the sensor harness to the body, upper arm and steering knuckle. Torque: 5.4 Nm (55 kgfcm, 48 in.lbf) (b) Remove the speed sensor from the steering knuckle. Torque: 7.8 Nm (80 kgfcm, 69 in.lbf) BR45 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR0340K REAR SPEED SENSOR COMPONENTS BR0XJ01 REAR SPEED SENSOR REMOVAL Installation is in the reverse order of removal. AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page BR58) 1. DISCONNECT SPEED SENSOR CONNECTOR (a) Remove the front trim of the luggage compartment. (b) Disconnect the speed sensor connector, and pull out the sensor wire harness with the grommet. 2. REMOVE SPEED SENSOR (a) Remove the 2 clamp bolts and nuts holding the sensor wire harness to the body and upper arm. Torque: 5.4 Nm (55 kgfcm, 48 in.lbf) (b) Remove the speed sensor from the axle carrier. Torque: 7.8 Nm (80 kgfcm, 69 in.lbf) BR46 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) MEMO BR47 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING BR48 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshooting in accordance with the procedure on the following pages. P. BR49 P. BR50 BR53 P. IN23 P. BR50 P. BR52 P. BR60 P. BR61 BR105 P. BR106 BR49 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) CUSTOMER PROBLEM ANALYSIS CHECK SHEET ABS Check Sheet Inspectors Name : BR50 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DIAGNOSIS SYSTEM INDICATOR CHECK When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. HINT: If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit (See page BR100). DIAGNOSTIC TROUBLE CODE CHECK 1. 2. Turn the ignition switch ON. Disconnect the Short Pin from DLC1. 3. 4. Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 0984318020 Read the diagnostic trouble code from the ABS warning light on the combination meter. HINT: If no code appears, inspect the diagnostic circuit or ABS warning light circuit (See page BR103 or BR100). 5. 6. As an example, the blinking patterns for normal code and codes 11 and 21 are shown on the left. Codes are explained in the code table on page BR52. After completing the check, disconnect terminals Tc and E1, and turn off the display. If 2 or more malfunctions are indicated at the same time, the lowest numbered diagnostic trouble code will be displayed first. BR51 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) ECU DATA MONITOR USING LEXUS HANDHELD TESTER 1. 2. Hook up the LEXUS handheld tester to the DLC2. Monitor the ECU data by following the prompts on the tester screen. HINT: LEXUS handheld tester has a "Snapshot" function which records the monitored data. Please refer to the LEXUS handheld tester operator's manual for further datails. DIAGNOSTIC TROUBLE CODE CLEARANCE 1. 2. 3. Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 0984318020 IG switch ON. Clear the diagnostic trouble codes stored in ECU by depressing the brake pedal 8 or more times within 3 seconds. HINT: DTC No.53 is cleared by removing the ECUB fuse during the IG switch OFF. Check that the warning light shows the normal code. Remove the SST from the terminals of DLC2 or DLC1. Connect the Short Pin to DLC1. HINT: Cancellation can also be done by removing the ECUB fuse, but in this case, other memory systems will also be cancelled out. 4. 5. 6. ECU TERMINAL VALUES MEASUREMENT USING LEXUS BREAKOUTBOX AND LEXUS HANDHELD TESTER 1. 2. Hook up the LEXUS handheld tester and LEXUS breakoutbox to the vehicle. Read the ECU input/output values by following the prompts on the tester screen. HINT: LEXUS handheld tester has a "Snapshot" function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the LEXUS handheld tester/LEXUS breakoutbox operators manual for further details. BR52 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that code in the table below and proceed to the relevant page. HINT: Using SST 0984318020, connect the terminals Tc and E1, and remove the Short Pin. BR61 BR61 BR64 BR64 BR67 BR67 BR70 BR70 BR73 BR73 BR73 BR73 BR76 BR76 BR76 BR78 BR78 BR78 BR78 BR53 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) BR78 BR78 BR82 BR85 BR86 BR89 BR91 BR93 BR93 BR95 BR78 *1: : Only vehicles with TRAC Even if the malfunction's indication code is detected, the ABS warning light does not light up. *2: When a malfunction causing code No. 17, 18, 53, 54, 55, 56, 57, 61 or 62 is detected, the ABS warning light does not light up, but the TRAC indicator light does. However, when checking the DTC, check the blinking pattern of the ABS warning light. BR54 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) PARTS LOCATION SRR (A19 12) (A1912) D/G (A2021) (A20 21) BAT (A20 22) (A2022) RL+ (A2014) (A20 14) RR+ (A2019) (A20 19) Tc (A2017) (A20 17) PKB (A2016) WA (A2010) MR (A1911) (A19 11) IG (A2011) (A20 11) SFR (A20 1) (A201) FL+ (A193) FR+ (A191) (A19 1) Ts (A206) (A20 6) STP (A207) AST (A198) (A19 8) SFL (A19 6) (A196) SR (A195) (A19 5) Symbols (Terminals No.) -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- GND (A2013) (A20 13) GND (A20 13) (A2013) GND (A20 13) (A2013) RR (A20 20) (A2020) GND (A20 13) (A2013) GND (A20 13) (A2013) GND (A20 13) (A2013) FL FL (A1910) GND (A2013) GND (A2013) FR (A19 7) (A197) GND (A20 2) (A202) GND (A20 2) (A202) R (A19 4) (A194) R (A19 4) (A194) GND (A20 2) (A202) GND (A202) RL (A20 3) (A203) STD Voltage (V) AC generation ti AC generation ti AC generation AC generation ti Below 1.5 Below 1.5 Below 2.0 Below 1.0 B l 10 8.314 8 3 14 1014 10 14 1014 10 14 1014 10 14 1014 1014 1014 10 14 1014 10 14 1014 10 14 1014 10 14 1014 10 14 1014 10 14 814 IG switch ON Slowly turn left rear wheel IG switch ON it h IG switch ON it h Stop light switch ON Stop light switch OFF IG switch ON it h IG switch O it h On Always Al w/o TRAC: ECU TERMINALS STANDARD VALUE BRAKE SYSTEM IG switch ON Slowly turn right rear wheel IG switch ON Slowly turn right front wheel IG switch ON Slowly turn right front wheel IG switch ON, ABS warning light OFF it h ON i li ht IG switch ON, PKB switch OFF IG switch ON, PKB switch ON IG switch ON, ABS warning light ON ANTILOCK BRAKE SYSTEM (ABS) IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF it h ON i li ht IG switch ON, ABS warning light OFF it h ON i li ht IG switch ON, ABS warning light OFF it h ON i li ht IG switch ON, ABS warning light OFF it h ON i li ht IG switch ON, ABS warning light OFF it h ON i li ht Condition BR5385 BR55 SRR (A16 26) (A1626) PKB (A1812) ALT (A1619) PR (A1622) (A16 22) AST (A1621) (A16 21) SFL (A1613) (A16 13) TMR (A1614) (A16 14) SR (A1615) (A16 15) IG (A1624) (A16 24) SRC (A188) (A18 8) SFR (A18 1) (A181) BAT (A167) (A16 7) WA (A185) VC (A163) (A16 3) SMC (A182) (A18 2) SAC (A183) (A18 3) SRL (A187) (A18 7) TSR (A161) (A16 1) MR (A162) (A16 2) Symbols (Terminals No.) -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- E2 (A1616) (A16 16) R (A1612) (A16 12) E2 (A1616) (A16 16) GND (A1625) (A16 25) GND (A16 25) (A1625) GND (A1625) (A16 25) R (A1612) (A16 12) R (A16 12) (A1612) R (A16 12) (A1612) GND (A16 25) (A1625) GND (A1625) (A16 25) GND (A1625) GND (A189) (A18 9) GND (A189) (A18 9) GND (A184) (A18 4) GND (A189) (A18 9) GND (A18 9) (A189) GND (A184) GND (A184) STD Voltage (V) Below 1.5 Below 2.0 1014 Below 1.0 1014 Below 1.0 Below 1.0 8.3 14 8.314 8.314 10 14 1014 10 14 1014 10 14 1014 10 14 1014 10 14 1014 10 14 1014 10 14 1014 10 14 1014 1014 10 14 1014 10 14 4 6 46 5 7 57 1014 IG switch ON, PKB switch ON, Fluid in M/C reservoir above MIN level IG switch ON, PKB switch OFF, Fluid in M/C reservoir above MIN level IG switch ON, ABS warning light ON IG switch ON, ABS warning light OFF IG switch ON Idling IG switch ON IG switch ON IG switch ON IG switch ON IG switch ON it h Always Al IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch On, ABS warning light OFF ANTILOCK BRAKE SYSTEM (ABS) w/ TRAC: BR56 BRAKE SYSTEM IG switch ON, TRAC indicator light OFF IG switch ON, TRAC indicator light OFF IG switch ON, TRAC indicator light OFF IG switch ON, TRAC indicator light OFF Condition BR5385 FRO (A17 13) (A1713) D/G (A18 10) (A1810) LBL (A16 10) (A1610) FLO (A17 15) (A1715) FR+ (A1617) (A16 17) Tc (A1623) (A16 23) Ts (A16 11) (A1611) RLO (A17 4) (A174) RRO (A176) (A17 6) RL+ (A179) (A17 9) RR+ (A172) (A17 2) FL+ (A165) (A16 5) STP (A186) Symbols (Terminals No.) -- -- -- -- -- -- -- -- -- -- -- -- -- GND (A16 25) (A1625) RR (A17 10) (A1710) FL (A16 18) (A1618) GND (A16 25) (A1625) GND (A16 25) (A1625) GND (A18 4) (A184) GND (A18 4) (A184) RL (A17 1) (A171) GND (A184) GND (A18 4) (A184) GND (A18 4) (A184) FR (A16 4) (A164) GND (A18 9) (A189) Pulse P l generation ti Pulse P l generation ti Pulse P l generation ti Pulse P l generation ti AC generation ti AC generation ti AC generation ti AC generation ti Below 1.5 1014 10 14 1014 10 14 1014 10 14 1014 10 14 814 STD Voltage (V) BRAKE SYSTEM IG switch ON Slowly turn left rear wheel wheel. IG switch ON Slowly turn left rear wheel wheel. IG switch ON it h IG switch ON it h Stop light switch ON IG switch ON Slowly turn right rear wheel wheel. IG switch ON Slowly turn left front wheel wheel. IG switch ON Slowly turn left front wheel wheel. IG switch ON Slowly turn right rear wheel wheel. IG switch ON Slowly turn right front wheel wheel. IG switch ON Slowly turn right front wheel wheel. IG switch ON Fluid in M/C reservoir above MIN level level. Stop light switch OFF IG switch ON, ABS warning light OFF it h ON i li ht ANTILOCK BRAKE SYSTEM (ABS) Condition BR57 BR58 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) SPEED SENSOR SIGNAL CHECK 1. 2. 3. Turn the ignition switch OFF. Using SST, connect terminals Ts and E1 of DLC1. SST 0984318020 Start the engine. 4. 5. 6. 7. 8. Check that the ABS warning light blinks. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit (See page BR100). Drive the vehicle faster than 45 km/h (28 mph) for several seconds. Stop the vehicle. Using SST, connect terminals Tc and E1 of DLC1. SST 0984318020 Read the number of blinks of the ABS warning light. HINT: See the list of diagnostic trouble codes shown on the next page. If every sensor is normal, a normal code is output (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated). If 2 or more malfunctions are indicated at the same time, the lowest numbered code will be displayed 1st. 9. After doing the check, disconnect terminals Ts and E1, Tc and E1 of DLC1, and turn ignition switch OFF. BR59 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) ECU DATA MONITOR USING LEXUS HANDHELD TESTER 1. 2. Hook up the LEXUS handheld tester to the DLC2. Monitor the ECU data by following the prompts on the tester screen. HINT: LEXUS handheld tester has a "Snapshot" function which records the monitored data. Please refer to the LEXUS handheld tester operator's manual for further details. Diagnostic Trouble Code of Speed Sensor Check Function Code No. Diagnosis Trouble Area 71 72 73 74 75 76 77 78 Low output voltage of right front speed sensor Low output voltage of left front speed sensor Low output voltage of right rear speed sensor Low output voltage of left rear speed sensor Abnormal change in output voltage of right front speed sensor Abnormal change in output voltage of left front speed sensor Abnormal change in output voltage of left rear speed sensor Abnormal change in output voltage of right rear speed sensor S S S S S S S S S S S S Right front speed sensor Sensor installation Left front speed sensor Sensor installation Right rear speed sensor Sensor installation Left rear speed sensor Sensor installation Right rear speed sensor rotor Left front speed sensor rotor Right rear speed sensor rotor Left rear speed sensor rotor If a normal code is displayed during the diagnostic trouble code check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. PROBLEM SYMPTOMS CHART BR60 Speed sensor signal g check cannot be performed ABS warning light is g g abnormal ABS does not operate. Symptoms Diagnostic trouble code check cannot be performed Only when 1. ~ 4. are all normal and the problem is still occuring, roblem replace the ABS ( TRAC) ECU S (& C) ECU. CU 1. 1 Check the diagnostic trouble code, reconfirming that the normal code code i out ut. d is output. t t ABS does not operate 2. 2 Speed sensor circuit efficiently 3. Stop light switch circuit Sto 4. 4 Check the ABS actuator with a checker checker. If they are abnormal, check the hydraulic circuit for leakage (See page BR 106) BR106). 1. Ts terminal circuit 2. ABS ( TRAC) ECU (& ) Only when 1. and 2. are all normal and the problem is still occuring. roblem replace the ABS ( TRAC) ECU. (& ) 1. ABS warning light circuit g g 2. Tc terminal circuit 1. ABS warning light circuit g g 2. ABS (& TRAC) ECU BRAKE SYSTEM Only when 1. ~ 4. are all normal and the problem is still occuring. replace the ABS (& TRAC) ECU. 1. Check the diagnostic trouble code, reconfirming that the normal code is output. 2. IG power source circuit 3. Speed sensor circuit 4. Check the ABS actuator with a checker. If they are abnormal, check the hydraulic circuit for leakage (See page BR106). Inspection Circuit ANTILOCK BRAKE SYSTEM (ABS) BR82 BR98 BR39 BR 39 or 41 BR82 BR98 BR39 or 41 See page BR105 BR100 BR103 BR100 BR50 BR50 BR61 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) CIRCUIT INSPECTION DTC 11, 12 ABS Solenoid Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. DTC No. DTC Detection Condition Conditions (1) and (2) continue for 0.2 sec. or more: (1) ABS solenoid relay terminal (SR) 11 voltage: Battery positive voltage (2) Solenoid relay monitor terminal (AST) voltage: 0 V Conditions (1) and (2) continue for 0.2 sec. or more: (1) ABS solenoid relay terminal (SR) 12 voltage: 0 V (2) Solenoid relay monitor terminal (AST) voltage: Battery positive voltage S ABS solenoid relay S B+ short in ABS solenoid relay circuit S ECU Trouble Area S ABS solenoid relay S Open or short in ABS solenoid relay circuit S ECU Fail safe function: If trouble occurs in the solenoid relay circuit, the ECU cuts off current to the solenoid relay and prohibits ABS control. WIRING DIAGRAM BR62 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 Check voltage between terminals 1 and 2 of R/B No. 2 (for ABS solenoid relay). P C Remove ABS solenoid relay from R/B No.2 . Measure voltage between terminals 1 and 2 of R/B No. 2 (for ABS solenoid relay). 10 14 V OK Voltage: OK NG Check and repair harness and connector. 2 Check continuity between terminal 3 of R/B No. 2 (for ABS solenoid relay) and terminal AST of ABS (&TRAC) ECU. Check continuity between terminal 3 of R/B No.2 (for C ABS solenoid relay) and terminal AST of ABS (& TRAC) ECU. OK Continuity HINT: There is a resistance of 4 6 W between terminals 4 and 2 of ABS actuator. OK NG Repair or replace harness or ABS actuator. BR63 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 3 Check ABS solenoid relay. P C OK Remove solenoid relay from R/B No.2. Check continuity between each terminal of ABS solenoid relay shown below. C 3. 4. Apply battery voltage between terminals 4 and 6. Check continuity between each terminal of ABS solenoid relay shown below. OK OK NG Replace ABS solenoid relay. 4 OK Check for open and short in harness and connector between ABS solenoid relay and ABS (& TRAC) ECU (See page IN29). NG Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR64 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC 13, 14 ABS Motor Relay Circuit CIRCUIT DESCRIPTION The ABS motor relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the motor relay ON and operates the ABS pump motor. DTC No. DTC Detection Condition Conditions (1) and (2) continue for 0.2 sec. or more: (1) ABS motor relay terminal (MR) 13 voltage: Battery positive voltage (2) Motor relay monitor terminal (MT) voltage: 0 V Conditions (1) and (2) continue for 4 sec. or More: (1) ABS motor relay terminal (MR) 14 Voltage: 0 V (2) Motor relay monitor terminal (MT) voltage: Battery positive voltage S ABS motor relay S B+ short in ABS motor relay circuit S ECU S ABS motor relay S Open or short in ABS motor relay circuit S ECU Trouble Area Fail safe function: If trouble occurs in the motor relay circuit, the ECU cuts off the current to the solenoid relay and prohibits ABS control. WIRING DIAGRAM BR65 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 Check voltage between terminal 1 of ABS motor relay and body ground. P C OK Remove ABS motor relay from R/B No.2 . Measure voltage between terminal 1 of ABS motor relay and body ground. Voltage: 10 14 V OK NG Check and repair harness and connector. 2 Check continuity between terminal 2 of R/B No. 2 (for ABS motor relay) and terminal MT of ABS (&TRAC) ECU. Check continuity between terminal 2 of R/B No.2 (for C ABS motor relay) and terminal MT of ABS (& TRAC) ECU. OK Continuity HINT: There is a resistance of 4 6 W between terminals A4 3 and A4 5 of ABS actuator. OK NG Repair or replace harness or ABS actuator. BR66 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 3 Check ABS motor relay. P C OK Remove motor relay from R/B No.2. Check continuity between each terminal of motor relay shown below. C OK 1. 2. Apply battery voltage between terminals 3 and 4. Check continuity between terminals shown below. OK NG Replace ABS motor relay. 4 OK Check for open and short in harness and connector between ABS motor relay and ABS (& TRAC) ECU (See page IN29). NG Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR67 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC 15, 16 TRAC Solenoid Relay Circuit CIRCUIT DESCRIPTION This relay circuit supplies power to each traction actuator solenoid. When the ignition switch is turned ON, the relay goes on. DTC No. DTC Detection Condition Conditions (1) through (3) continue for 0.2 sec. or more: (1) TRAC solenoid relay terminal (TSR) 15 voltage: Battery positive voltage (2) All TRAC actuator solenoids: OFF (3) All TRAC actuator solenoid monitor voltages (in ECU): 0 V Conditions (1) through (3) continue for 0.2 sec. or more: (1) TRAC solenoid relay terminal (TSR) 16 voltage: 0 V (2) All TRAC actuator solenoids: OFF (3) TRAC actuator solenoid monitor voltage (in ECU): Battery positive voltage S TRAC solenoid relay S B+ short in TRAC solenoid relay circuit S ECU S TRAC solenoid relay S Open or short in TRAC solenoid relay circuit S ECU Trouble Area Fail safe function: If trouble occurs in this relay circuit, the ECU cuts off current to the ABS and TRAC solenoid relays and prohibits ABS and TRAC control. WIRING DIAGRAM BR68 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 Check voltage between terminals 1 of TRAC solenoid relay and body ground. P C OK Remove TRAC solenoid relay. Measure voltage between terminal 1 of TRAC solenoid relay and body ground. Voltage: 10 14 V OK NG Repair or replace harness and connector. 2 Check continuity between terminal 2 of TRAC solenoid relay and terminals SAC, SMC, SRC of ABS & TRAC ECU. C Check continuity between terminal 2 of TRAC solenoid relay and terminals SAC, SMC, and SRC of ABS & TRAC ECU. OK Continuity HINT: Resistance of the TRAC actuator solenoid is 2 W. OK NG Repair or replace harness or TRAC actuator. BR69 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 3 Check TRAC solenoid relay. P C Remove solenoid relay. Check continuity between each terminal of TRAC solenoid relay shown below. OK C 1. 2. Apply battery voltage between terminals 3 and 4. Check continuity between terminals shown below. OK OK NG Replace TRAC solenoid relay. 4 OK Check for open and short in harness and connector between TRAC solenoid relay and ABS & TRAC ECU (See page IN29). NG Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR70 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC 17, 18 TRAC Motor Relay Circuit CIRCUIT DESCRIPTION This relay circuit supplies power to the TRAC pump motor. While the TRAC is activated, the ECU switches the motor relay ON and operates the TRAC pump motor. DTC No. DTC Detection Condition Conditions (1) and (2) continue for 0.2 sec. or more: (1) TRAC motor relay terminal (TMR) 17 voltage: Battery positive voltage (2) Voltage of ABS & TRAC ECU terminal MTT: 0 V Conditions (1) and (2) continue for 2 sec. or More: (1) TRAC motor relay terminal (TMR) 18 voltage: 0 V (2) Voltage of ABS & TRAC ECU terminal MTT: Battery positive voltage S TRAC motor relay S B+ short in TRAC motor relay circuit S ECU S TRAC motor relay S Open or short in TRAC motor relay circuit S ECU Trouble Area Fail safe function: If trouble occurs in this relay circuit, the ECU cuts off current to the TRAC solenoid relay and prohibits TRAC control. WIRING DIAGRAM BR71 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 Check voltage between terminal 1 of R/B No.2 (for TRAC motor relay). P C Remove TRAC motor relay from R/B No.2 . Measure voltage between terminal 1 of R/B No. 2 (for TRAC motor relay). 10 14 V OK Voltage: OK NG Check and repair harness and connector. 2 Check continuity between terminal 2 of R/B No. 2 (for TRAC motor relay) and terminal MTT of ABS &TRAC ECU. Check continuity between terminal 2 of R/B No.2 (for C TRAC motor relay) and terminal MTT of ABS & TRAC ECU. OK Continuity HINT: There is a resistance of 4 6 W between terminal 3 of TRAC pump motor and terminal MTT of ABS & TRAC ECU. OK NG Repair or replace harness or TRAC pump motor. BR72 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 3 Check TRAC motor relay. P C Remove motor relay from R/B No.2.. Check continuity between each pair of terminal of motor relay shown below. OK C OK 1. 2. Apply battery voltage between terminals 3 and 4. Check continuity between terminals shown below. OK NG Replace TRAC motor relay. 4 OK Check for open and short in harness and connector between TRAC motor relay and ABS & TRAC ECU (See page IN29). NG Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR73 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC 21, 22, ABS Actuator Solenoid Circuit 23, 24 CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the fluid pressure acting on the brake cylinders, thus controlling the braking force. DTC No. DTC Detection Condition Conditions (1) through (3) continue for 0.05 sec. or more: (1) ABS solenoid relay terminal (SR) voltage: Battery positive voltage (2) Voltage of ABS (& TRAC) ECU terminal AST: Battery positive voltage (3) When power transistor of ECU is ON, voltage of terminal SFR is 0 V or battery positive voltage. Conditions (1) through (3) continue for 0.05 sec. or more: (1) ABS solenoid relay terminal (SR) voltage: Battery positive voltage (2) Voltage of ABS (& TRAC) ECU terminal AST: Battery positive voltage (3) When power transistor of ECU is ON, voltage of terminal SFL is 0 V or battery positive voltage. Conditions (1) through (3) continue for 0.05 sec. or more: (1) ABS solenoid relay terminal (SR) voltage: Battery positive voltage (2) Voltage of ABS (& TRAC) ECU terminal AST: Battery positive voltage (3) When power transistor of ECU is ON, voltage of terminal SRR is 0 V or battery positive voltage. Conditions (1) through (3) continue for 0.05 sec. or more: (1) ABS solenoid relay terminal (SR) voltage: Battery positive voltage (2) Voltage of ABS & TRAC ECU terminal AST: Battery positive voltage (3) When power transistor of ECU is ON, voltage of terminal SRL is 0 V or battery positive voltage. Trouble Area S ABS actuator S Open or short in SFR circuit S ECU 21 S ABS actuator S Open or short in SFL circuit S ECU 22 23 ABS actuator Open or short in SRR circuit ECU 24 (Only vehicles with TRAC) ABS actuator Open or short in SRL circuit ECU Fail safe function: If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the solenoid relay and prohibits ABS control. BR74 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM BR75 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 Check ABS actuator solenoid. w/o TRAC C OK Check continuity between terminals 3, 4 of the ABS actuator connector. Continuity HINT: Resistance of each solenoid coil is 1.1 W. 4 and 1, w/ TRAC C OK Check continuity between terminals 4 and 1, 3, 4, 6 of the ABS actuator connector. Continuity HINT: Resistance of each solenoid coil is 1.1 W. OK NG Replace ABS actuator. 2 OK Check for open and short in harness and connector between ABS (& TRAC) ECU and actuator (See page IN29). NG Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR76 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC 25, 26, 27 TRAC Actuator Solenoid Circuit CIRCUIT DESCRIPTION The TRAC actuator solenoid operates in accordance with signals from the ECU, changing TRAC to the normal, pressure increase, pressure reduction or holding mode. DTC No. DTC Detection Condition Conditions (1) and (2) continue for 0.05 sec. or more: (1) TRAC solenoid relay terminal (TSR) voltage: Battery positive voltage (2) Voltage of ABS & TRAC ECU terminal SMC: 0 V Conditions (1) and (2) continue for 0.05 sec. or more: (1) TRAC solenoid relay terminal (TSR) voltage: Battery positive voltage (2) Voltage of ABS & TRAC ECU terminal SAC: 0 V Conditions (1) and (2) continue for 0.05 sec. or more: (1) TRAC solenoid relay terminal (TSR) voltage: Battery positive voltage (2) Voltage of ABS & TRAC ECU terminal SRC: 0 V Trouble Area S TRAC actuator S Open or short in SMC circuit S ECU 25 S TRAC actuator S Open or short in SAC circuit S ECU 26 S TRAC actuator S Open or short in SRC circuit S ECU 27 Fail safe function: If trouble occurs in this solenoid circuit, the ECU cuts off current to the ABS and TRAC solenoid relays and prohibits ABS and TRAC control. WIRING DIAGRAM BR77 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 Check TRAC actuator solenoid. P C OK Disconnect TRAC actuator connector. Check continuity between each terminal of TRAC actuator shown below. OK NG Replace TRAC actuator. 2 OK Check for open and short in harness and connector between solenoid relay and ECU (See page IN29). NG Repair or replace harness or connector. 3 OK Check for short in harness and connector between SMC and SRC, SAC and SMC, and SAC and SRC terminals with TRAC actuator and ECU connectors are disconnected. NG Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR78 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC 31, 32, 33 Speed Sensor Circuit 34, 35, 36 CIRCUIT DESCRIPTION The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used to control both the ABS and TRAC control systems. The front and rear rotors each have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotors (wheels) the frequency is used by the ECU to detect the speed of each wheel. DTC No. DTC Detection Condition Detection of any of conditions (1) through (3): (1) At vehicle speed of 10 km/h (6 mph) or more, pulses are not input for 5 sec. (2) Momentary interruption of the vehicle 31, 32 33, 34 speed sensor signal occurs at least 7 times in the time between switching the ignition switch ON and switching it OFF (3) Abnormal fluctuation of speed sensor signals with the vehicle speed 20 km/h (12 mph) or more. Speed sensor signal is not input for about 1 sec. while the left front and right rear speed 35 sensor signals are being checked with the IG switch ON. Speed sensor signal is not input for about 1 sec. while the right front and left rear speed 36 sensor signals are being checked with the IG switch ON. S Open in right front, left rear speed sensor circuit S ECU S Open in left front, right rear speed sensor circuit S ECU S Right front, left front, right rear and left rear speed sensor S Open or short in each speed sensor circuit S ECU Trouble Area HINT: DTC No. 31 is for the right front speed sensor. DTC No. 32 is for the left front speed sensor. DTC No. 33 is for the right rear speed sensor. DTC No. 34 is for the left rear speed sensor. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. BR79 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM BR80 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 1 Check speed sensor. P Front 1. Remove the front fender liner. 2. Disconnect the speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector. C OK Resistance: 0.7 1.7 kW C Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK Resistance: 1 MW or higher Rear P 1. 2. C Remove the rear seat cushion, seat back and quarter trim. Disconnect the speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector. OK Resistance: 0.7 1.7 kW C Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK Resistance: 1 MW or higher OK NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page BR58) 2 OK Check for open and short in harness and connector between each speed sensor and ECU (See page IN29). NG Repair or replace harness or connector. BR81 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 4 Check sensor rotor and sensor installation. Front P Remove the front speed sensor rotor (See page SA20) Check the sensor rotor serrations. C OK No scratches or missing teeth. C OK Check the front speed sensor installation. The installation bolt is tightened properly. Rear P C OK Remove the drive shaft (See page SA71). Check the sensor rotor serrations No scratches or missing teeth. C Check the rear speed sensor installation. OK The installation bolt is tightened properly and there is no clearance between the sensor and rear axle carrier. OK NG Replace speed sensor or rotor. NOTICE: Check the speed sensor signal last (See page BR58). Check and replace ABS (& TRAC) ECU. BR82 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the CPU and the actuators. DTC No. DTC Detection Condition Trouble Area 41 When either of the following (1) or (2) is detected: (1) Voltage at ECU terminal IG is less than 9.5 V for more than 10 sec. while vehicle speed is 3 km/h (1.9 mph) or more. (2) Voltage at ECU terminal IG is more than 17 V for more than 1.2 sec. S S S S Battery IC regulator Open or short in power source circuit ECU Fail safe function: If trouble occurs in the power source circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. WIRING DIAGRAM BR83 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 OK Check battery positive voltage. Voltage: 10 14 V OK NG Check and repair the charging system. 2 Check voltage between terminals IG and GND of ABS (& TRAC) ECU connector. P C Remove ABS (& TRAC) ECU with connectors still connected. 1. 2. Turn ignition switch ON. Measure voltage between terminals IG and GND of ABS (& TRAC) ECU connector. 10 14 V OK Voltage: NG OK Check and replace ABS (& TRAC) ECU. BR84 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 3 Check continuity between terminal GND of ABS (& TRAC) ECU connector and body ground. C Measure resistance between terminals GND of ABS (& TRAC) ECU connector and body ground. OK Resistance: 1 W or less. OK NG Check ECUIG fuse. Repair or replace harness or connector. 4 P C OK Remove ECUIG fuse from J/B No. 1. Check continuity of ECUIG fuse. Continuity OK NG Check for short in all the harness and components connected to ECUIG fuse (See attached wiring diagram). Check for open in harness and connector between ABS (& TRAC) ECU and battery (See page IN29). BR85 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC DTC No. 51 51 ABS Pump Motor Lock Trouble Area S ABS pump motor CIRCUIT DESCRIPTION DTC Detection Condition Pump motor is not operating normally during initial check. Fail safe function: If trouble occurs in the ABS pump motor, the ECU cuts off the current to the solenoid relay and prohibits ABS control. WIRING DIAGRAM BR86 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC DTC No. 53 TRAC Pump Motor Lock Trouble Area S TRAC pump motor S Harness or connector between TRAC pump & motor and body ground S TRAC actuator S ABS & TRAC ECU CIRCUIT DESCRIPTION DTC Detection Condition 53 S TRAC pump motor is locked. S Open for TRAC pump motor ground. WIRING DIAGRAM BR87 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 Check operation of TRAC pump & motor. P C Disconnect TRAC pump & motor connector. Connect positive + lead to terminal 3 of TRAC pump & motor connector and negative lead to terminal 1. Notice: OK Do not apply battery voltage for more than 3 sec. The TRAC pump motor should emit an operating sound. NG OK Go to step 3. 2 Check continuity between terminal 1 of TRAC pump & motor connector and body ground. C OK Measure resistance between terminal 1 of TRAC pump & motor connector and body ground. Resistance: 0 W (Continuity) OK Replace TRAC pump & motor. NG Repair or replace harness or connector. BR88 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 3 OK Check harness and connector between ABS & TRAC ECU and TRAC pump & motor (See page IN29). NG Repair or replace harness or connector. 4 Check voltage between terminals PR and E2 of ABS & TRAC ECU connector. P 1. 2. Remove ABS & TRAC ECU with connectors still connected. Run the engine for about 30 seconds at idle speed to raise the pressure of the TRAC actuator to a high level. Stop the engine and then turn ignition switch ON. Measure voltage between terminals PR and E2 of ABS & TRAC ECU connector. 4 8 V C 1. 2. OK C Voltage: 1. 2. Drain the fluid out of the actuator to reduce the pressure. Measure voltage between terminal PR and E2 of ABS &TRAC ECU connector. 10 14 V Add fluid to reservoir after the check. OK Voltage: Notice: NG OK Check and replace ABS & TRAC ECU. 5 OK Check harness and connector between ABS & TRAC ECU and TRAC actuator (See page IN29). NG Repair or replace harness or connector. Replace TRAC actuator. BR89 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC DTC No. 54 Excessive Operation of TRAC Pump Motor Trouble Area S TRAC actuator S Brake fluid leakage S ECU S TRAC accumulator CIRCUIT DESCRIPTION DTC Detection Condition TRAC motor relay ON is output continuously 54 10 times at intervals of less than 24 sec. when traction control is not being executed. WIRING DIAGRAM BR90 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 Check voltage between terminals PR and E2 of ABS & TRAC ECU connector. P 1. 2. Remove ABS & TRAC ECU with connectors still connected. Run the engine for about 30 seconds at idle speed to raise the pressure of the TRAC actuator to a high level. Stop the engine and then turn ignition switch ON. Measure voltage between terminals PR and E2 of ABS & TRAC ECU connector. 4 8 V for more than 24 sec. C 1. 2. OK Voltage: NG OK Check for brake fluid leakage. Check and replace ABS & TRAC ECU. 2 OK See page BR106. NG Repair brake fluid leakage and add fluid. Replace TRAC accumulator. If TRAC accumulator is replase and the problem is still occurring, replace TRAC actuator. BR91 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC 55 Brake Fluid Level Warning Switch Circuit CIRCUIT DESCRIPTION The brake fluid level warning switch sends the appropriate signal to the ECU when the brake fluid level drops. DTC No. DTC Detection Condition S Brake fluid level 55 Voltage at ECU terminal LBL is OV continuously for 10 sec. or more while brake fluid level warning switch is OK. S Brake fluid level warning switch S Short in brake fluid level warning switch circuit S ECU Trouble Area Fail safe function: If trouble occurs in this circuit, the ECU cuts off current to the TRAC solenoid relay and prohibits TRAC control. WIRING DIAGRAM BR92 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 C Check brake fluid level. Check the amount of fluid in the brake reservoir. OK NG Check and repair brake fluid leakage and add fluid. 2 Check brake fluid level warning switch. See page BE68. OK NG Repair brake fluid level warning switch. 3 OK Check for short in all the harness and components connected to brake fluid level warning light (See page IN29). NG Repair or replace harness or connector. Check and replace ABS & TRAC ECU. BR93 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC 56, 57 Pressure Sensor Circuit CIRCUIT DESCRIPTION The pressure sensor detects the TRAC accumulator hydraulic pressure and if it is low, it sends signals to the ECU to operate the pump. If the pressure is high, it sends signals to the ECU to stop the pump. DTC No. 56 DTC Detection Condition Pressure sensor terminal PR outputs below 1 V for about 1 sec. or more. TRAC control is executed continuously more than 255 times while pressure sensor ON signal is not output. Trouble Area S Open or short in pressure sensor circuit 57 S Pressure sensor Fail safe function: If trouble occurs in the pressure sensor circuit, the ECU cuts off the current to the TRAC solenoid relay and prohibits TRAC control. WIRING DIAGRAM BR94 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 Check voltage between terminals PR and E2 of ABS & TRAC ECU connector. P 1. 2. Remove ABS & TRAC ECU with connectors still connected. Run the engine for about 30 seconds at idle speed to raise the pressure of the TRAC actuator to a high level. Stop the engine and then turn ignition switch ON. Measure voltage between terminals PR and E2 of ABS & TRAC ECU connector. 4 8 V C 1. 2. OK C Voltage: 1. 2. Drain the fluid out of the actuator to reduce the pressure (See page BR41). Measure voltage between terminal PR and E2 of ABS &TRAC ECU connector. 10 14 V Add fluid to reservoir after the check. OK Voltage: Notice: NG OK Check and replace ABS & TRAC ECU. 2 OK Check harness and connector between ABS & TRAC ECU and TRAC actuator (See page IN29). Repair or replace harness or connector. NG Replace TRAC actuator. BR95 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC 61 TRAC ECU Communication Circuit Malfunction Trouble Area CIRCUIT DESCRIPTION DTC No. DTC Detection Condition Either of the following (1) or (2) continues for more than 8 sec.: (1) Vehicle speed signal of 4 wheels is less than 1 km/h (1 mph) when TRCO signal is input. (2) Voltage of ABS & TRAC ECU terminal THFA is 0 V when TRCO signal is not input. S Open or short in THFA, TRCO circuit S ABS & TRAC ECU S TRAC ECU 61 WIRING DIAGRAM BR96 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 Check voltage between terminals THFA, TRCO of ABS & TRAC ECU and body ground. P C Remove ABS & TRAC ECU with connectors still connected. Measure voltage between terminals THFA, TRCO of ABS & TRAC ECU and body ground when ignition switch is turned ON. Voltage: 10 14 V OK NG OK Check and replace ABS & TRAC ECU. 2 Check voltage between terminals THFA, TRCO of ABS & TRAC ECU and body ground with ABS & TRAC ECU connector is disconnected. P Disconnect ABS & TRAC ECU connector. C Measure voltage between terminals THFA, TRCO of ABS & TRAC ECU and body ground when ignition switch is turned ON. Voltage: 10 14 V OK NG OK Check and replace ABS & TRAC ECU. 3 OK Check for open and short in harness and connector between ABS & TRAC ECU and TRAC ECU (See page IN29). NG Repair or replace harness or connector. Check and replace TRAC ECU. BR97 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) DTC DTC No. 62 62 TRAC Vehicle Speed Malfunction Trouble Area S ECU CIRCUIT DESCRIPTION DTC Detection Condition At vehicle speed of 10 km/h (6 mph) or more pulses are not input for 5 sec. HINT: When DTC Nos.3136 are recorded in memory, DTC No.62 is not recorded. INSPECTION PROCEDURE 1 NO Are there any codes (besides DTC No. 62) being output? YES Go to relevant DTC chart. Replace ABS & TRAC ECU. BR98 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) Stop Light Switch Circuit CIRCUIT DESCRIPTION The stop light switch detects whether the brake pedal is depressed or released, and transmits a signal to the ECU. WIRING DIAGRAM BR99 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 C Check operation of stop light. Check that the stop light lights up when the brake pedal is depressed and turns off when the brake pedal is released. Repair stop light circuit. OK NG 2 Check voltage between terminal STP of ABS (& TRAC) ECU and body ground. P C Remove the ABS (& TRAC) ECU with connectors still connected. Measure voltage between terminal STP of ABS (& TRAC) ECU and body ground when brake pedal is depressed. Voltage: 8 14 V OK NG OK Proceed to next circuit inspection shown on problem symptoms chart (See page BR60). 3 OK Check for open in harness and connector between ABS (& TRAC ECU) ECU and stop light switch (See page IN29). NG Repair or replace harness or connector. Check and replace ABS (& TRAC) ECU. BR100 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a diagnostic trouble code in memory. After removing the short pin of the DLC1, connect terminals Tc and E1 of the DLC1 or DLC2 to make the ABS warning light blink and output the diagnostic trouble code. WIRING DIAGRAM BR101 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Troubleshoot in accordance with the chart below for each trouble symptom. ABS warning light does not light up ABS warning light remains on Go to step 1 Go to step 3 1 Check ABS warning light. See Combination meter troubleshooting on page BE75. OK NG Check ABS solenoid relay. Replace bulb or combination meter assembly. 2 P C OK Remove solenoid relay from R/B No.2. Check continuity between each terminal of ABS solenoid relay shown below. C 3. 4. Apply battery positive voltage between terminals 4 and 6. Check continuity between each terminal of ABS solenoid relay shown below. OK OK NG Replace ABS solenoid relay. Repair or replace and check for open in harness and connector between DLC1 and ABS solenoid relay and body ground (See page IN29). BR102 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) 3 Is diagnostic trouble code output? Do diagnostic trouble code check on page BR50. NO YES Repair circuit indicated by the code output. 4 YES Does ABS warning light go off if short pin is removed? NO Check for short in harness and connector between warning light and DLC1 and ECU (See page IN29). 5 OK Check ABS solenoid relay (See step No. 2). NG Replace ABS solenoid relay. Repair or replace and check for short in harness and connector between DLC1 and ABS solenoid relay (See page IN29). BR103 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting between terminals Tc and E1 of the DLC1 or the DLC2 causes the ECU to display the diagnostic trouble code by flashing the ABS warning light. WIRING DIAGRAM BR104 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC2 or DLC 1. P C OK Turn ignition switch ON. Measure voltage between terminals Tc and E1 of DLC2 or DLC1. Voltage: 10 14 V NG OK If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective. 2 OK Check for open and short in harness and connector between ABS (& TRAC) ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN29). NG Repair or replace harness or connector. Check and replace ABS (& TRAC) ECU. BR105 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the diagnostic trouble code check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check. WIRING DIAGRAM INSPECTION PROCEDURE 1 Check voltage between terminals Ts and E1 of DLC 1. P C OK Turn ignition switch ON. Measure voltage between terminals Tc and E1 of DLC1. Voltage: 10 14 V NG OK If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective. 2 OK Check for open and short in harness and connector between ABS (& TRAC) ECU and DLC2 or DLC1, DLC1 and body ground (See page IN29). NG Repair or replace harness or connector. Check and replace ABS (& TRAC) ECU. BR106 BRAKE SYSTEM ANTILOCK BRAKE SYSTEM (ABS) Check for Fluid Leakage BR107 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) TRACTION CONTROL SYSTEM (TRAC) TRAC PUMP AND ACCUMULATOR COMPONENTS BR0XX01 BR108 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) BR109 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) BR0XL01 TRAC PUMP AND ACCUMULATOR REMOVAL Installation is in the reverse order of removal. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM (See page BR6), BLEED TRAC SYSTEM (See page BR7) AND CHECK FOR LEAKS DRAIN OUT HIGH PRESSURE FLUID (See step 1. on page BR10) DISCONNECT BRAKE LINE Using SST, disconnect the brake line from the accumulator. SST 0975136011 Torque: 15 Nm (155 kgfcm, 11 ftlbf) 1. 2. 3. REMOVE TRAC PUMP AND ACCUMULATOR ASSEMBLY (a) Disconnect the connector and brake hose. (b) Remove 2 nuts, bolts and TRAC pump and accumulator assembly. Torque: Bolt 12 Nm (125 kgfcm, 9 ftlbf) Nut 19 Nm (195 kgfcm, 14 ftlbf) BR0XM01 TRAC PUMP AND ACCUMULATOR DISASSEMBLY Assembly is in the reverse order of disassembly. 1. REMOVE PRESSURE HOSE (a) Remove the union bolt and 2 Orings. Torque: 46 Nm (465 kgfcm, 34 ftlbf) (b) Remove the union bolt with bleeder plug, 2 Orings and pressure hose. Torque: 46 Nm (465 kgfcm, 34 ftlbf) 2. REMOVE TRAC PUMP (a) Remove the bolt and TRAC pump assembly from No.1 pump bracket. Torque: 7.8 Nm (80 kgfcm, 69 in.lbf) (b) Remove the 3 bushings, 2 wave washers and collar from the pump assembly. (c) Remove the 4 bolts and No.2 pump bracket from the pump. Torque: 7.8 Nm (80 kgfcm, 69 in.lbf) 3. REMOVE ACCUMULATOR (a) Remove the 2 bolts, 2 washers, 4 bushings, 2 spacers and accumulator assembly from No.1 pump bracket. Torque: 7.8 Nm (80 kgfcm, 69 in.lbf) BR110 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) (b) Remove the nut, 2 washers and accumulator assembly from the No.1 pump bracket. Torque: 7.8 Nm (80 kgfcm, 69 in.lbf) 4. DISPOSAL METHOD OF TRAC ACCUMULATOR (a) Loosen the gas plug about 2 turns to a position where the gas can leak out. (b) After confirming that all the gas has been drained out remove the gas plug and dispose of the accumulator. HINT: If the gas does not leak out even after the gas plug has been loosened 2 turns, repeat the operation, turning the gas plug a half turn to the left or right. BR111 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) BR0FB05 TRAC ACTUATOR COMPONENTS BR112 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) BR0XS01 TRAC ACTUATOR Installation is in the reverse order of removal. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM (See page BR6), BLEED TRAC SYSTEM (See page BR7) AND CHECK FOR LEAKS DRAIN OUT HIGH PRESSURE FLUID (See step 1. on page BR10) 1. 2. 3. REMOVE AIR CLEANER HOSE Loosen the 2 clamp bolts and remove the air cleaner hose. DISCONNECT TRAC SOLENOID RELAY 4. DISCONNECT BRAKE LINES Using a SST, disconnect the 5 brake lines from the TRAC actuator. SST 0975136011 Torque: 15 Nm (155 kgfcm, 11 ftlbf) 5. 6. (a) (b) REMOVE 3 BRAKE LINES FROM CLAMP REMOVE TRAC ACTUATOR ASSEMBLY Disconnect the 2 connectors from actuator. Remove the 2 bolts, nut and TRAC actuator assembly. Torque: Bolt 12 Nm (125 kgfcm, 9 ftlbf) Nut 19 Nm (195 kgfcm, 14 ftlbf) 7. REMOVE CONNECTOR CLAMP (a) Disconnect the 2 connectors from clamp. (b) Remove the bolt and clamp from actuator. Torque: 5.4 Nm (55 kgfcm, 48 in.lbf) 8. REMOVE TRAC ACTUATOR (a) Remove the 3 bolts from actuator. Torque: 13 Nm (130 kgfcm, 9 ftlbf) (b) Remove the No.1 TRAC bracket, 3 bushings and 3 spacers. 9. REMOVE NO.2 TRAC ACTUATOR BRACKET Remove the bolt and bracket from actuator. BR113 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) TROUBLESHOOTING BR114 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) HOW TO PROCEED WITH TROUBLESHOOTING Perfrom troubleshooting in accordance with the procedure on the following pages. P. BR115 P. BR116 BR118 P. IN23 P. BR116 P. BR118 P. BR124 P. BR125 BR158 P. BR158 BR115 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) CUSTOMER PROBLEM ANALYSIS CHECK SHEET TRAC Check Sheet Inspectors Name : BR116 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) DIAGNOSIS SYSTEM INDICATOR CHECK When the ignition switch is turned ON, check that the TRAC indicator light goes on for 3 seconds. HINT: If the indicator check result is not normal, proceed to troubleshooting for the TRAC indicator light circuit (See page BR156). DIAGNOSTIC TROUBLE CODE CHECK 1. Turn the ignition switch ON. 2. Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 0984318020 3. Read the diagnostic trouble code from the TRAC indicator light on the combination meter. HINT: If no code appears, inspect the diagnostic circuit or TRAC indicator light circuit (See page BR157 or BR156). As an example, the blinking patterns for normal code and code 32 are shown on the left. Codes are explained in the code table on page BR118. After completing the check, disconnect the terminals Tc and E1, and turn off the display. If 2 or more malfunctions are indicated at the same time, the lowest numbered diagnostic trouble code will be displayed first. 4. 5. ECU DATA MONITOR USING LEXUS HANDHELD TESTER 1. 2. Hook up the LEXUS handheld tester to the DLC2. Monitor the ECU data by following the prompts on the scan tool screen. HINT: LEXUS handheld tester has a "Snapshot" function which records the monitored data. Please refer to the LEXUS handheld tester operator's manual for further datails. BR117 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) DIAGNOSTIC TROUBLE CODE CLEARANCE 1. Using SST, connect the terminals Tc and E1 of DLC2 or DLC1. SST 0984318020 IG switch ON Clear the diagnostic trouble codes stored in ECU by depressing the brake pedal 8 or more times within 3 seconds. Check that the TRAC indicator light shows the normal code. Remove the SST from the terminals of DLC2 or DLC1. HINT: Cancellation can also be done by removing the ECUB fuse, but in this case, other memory systems will also be cancelled out. 2. 3. 4. 5. BR118 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that code in the table below and proceed to the relevant page. HINT: If the TRAC indicator light lights up and the TRAC indicator light does not blink when the DTC is checked, check the blinking pattern of the ABS warning light and troubleshoot the ABS system. BR125 BR128 BR128 BR128 BR129 BR129 BR129 BR129 BR133 BR136 BR138 BR140 BR140 BR145 BR145 BR150 BR151 BR152 *1: If a malfunction is detected in ABS, the TRAC OFF indicator light lights up instead of the TRAC indicator light. The TRAC indicator light does not light up even if an error is detected. *3: If a malfunction is detected, the TRAC OFF indicator light or TRAC indicator light lights up. *2: BR119 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) PARTS LOCATION PKB -- (A 18 12) 1812) ALT -- (A 1619) WA -- (A 185) Symbols (Terminals No.) BAT GND -- (A 167) (A 1625) IG GND -- (A 1624) (A 1625) SR R R -- (A 1615) (A 1612) MR R R -- (A 162) (A 1612) TSR R R -- (A 161) (A 1612) TMR R R -- (A 1614) (A 1612) SFR GND -- (A 181) (A 189) SFL GND -- (A 1613) (A 1625) SRR GND -- (A 1626) (A 1625) SRL GND -- (A 187) (A 189) AST GND -- (A 1621) (A 1625) SAC GND -- (A 183) (A 184) SMC GND -- (A 182) (A 189) SRC GND -- (A 188) (A 189) PR E2 -- (A 1622) (A 1616) VC E2 -- (A 163) (A 1616) GND (A 1625) GND (A 18 4) 184) GND (A 184) STD Voltage (V) Below 1 5 1.5 Below 1.0 1014 Below 2.0 1014 Below 1 0 1.0 Below 1 0 1.0 8.314 8 3 14 8.314 8 3 14 1014 10 14 1014 10 14 1014 10 14 1014 10 14 1014 10 14 1014 10 14 1014 10 14 1014 10 14 1014 10 14 1014 10 14 46 4 6 57 5 7 1014 10 14 IG switch ON Idling IG switch ON, ABS warning light ON IG switch ON, ABS warning light OFF IG switch ON, PKB switch ON, Fluid in M/C reservoir above MIN level IG switch ON, PKB switch OFF, Fluid in M/C reservoir above MIN level IG switch ON IG switch ON IG switch ON IG switch ON IG switch ON Always ABS & TRAC ECU: ECU TERMINALS STANDARD VALUE BR120 BRAKE SYSTEM IG switch ON, TRAC indicator light OFF ON IG switch ON, TRAC indicator light OFF ON IG switch ON, TRAC indicator light OFF ON IG switch ON, ABS warning light OFF ON IG switch ON, ABS warning light OFF ON IG switch ON, ABS warning light OFF ON IG switch ON, ABS warning light OFF ON IG switch ON, ABS warning light OFF ON IG switch ON, ABS warning light OFF ON Condition IG switch ON, TRAC indicator light OFF ON TRACTION CONTROL SYSTEM (TRAC) R05698 FLO -- (A1715) FRO -- (A1713) FR+ -- (A1617) Tc -- (A1623) D/G -- (A1810) LBL -- (A1610) Ts -- (A1611) RLO -- (A174) RRO -- (A176) RL+ -- (A179) RR+ -- (A172) FL+ -- (A165) STP -- (A186) Symbols (Terminals No.) RR RR (A1710) FL FL (A1618) GND (A1625) GND (A1625) GND (A1625) GND (A184) GND (A184) RL RL (A171) GND (A184) GND (A184) GND (A184) FR FR (A164) GND (A189) Pulse generation Pulse generation Pulse generation Pulse generation AC generation AC generation AC generation AC generation Below 1.5 814 1014 1014 1014 1014 STD Voltage (V) BRAKE SYSTEM IG switch ON Slowly turn left rear wheel. IG switch ON Slowly turn left rear wheel. IG switch ON IG switch ON IG switch ON Slowly turn right rear wheel. IG switch ON Slowly turn left front wheel. IG switch ON Slowly turn left front wheel. IG switch ON Slowly turn right rear wheel. IG switch ON Slowly turn right front wheel. IG switch ON Slowly turn right front wheel. IG switch ON, ABS warning light OFF ON Condition IG switch ON Fluid in M/C reservoir above MIN level. Stop light switch OFF Stop light switch ON TRACTION CONTROL SYSTEM (TRAC) BR121 CSW -- (T1413) TR2 -- (T1321) VSH -- (T1319) IDL2 -- (T1322) TR5 -- (T1316) B -- (T1325) B -- (T1324) BCM -- (T1326) A -- (T1312) ACM -- (T1313) BM -- (T1315) A -- (T1311) PKB -- (T131) ( ) NEO -- (T136) VTH -- (T138) IG -- (T132) BAT -- (T148) IDL1 -- (1310) Symbols (Terminals No.) GND ( (T1314) ) E1 (T1320) GND (T1314) E1 (T1320) E1 (T1320) E1 (T1320) E1 (T1320) E1 (T1320) E1 (T1320) GND (T1314) GND (T1314) GND (T1314) GND (T1314) GND (T1314) GND (T1314) GND (T1314) GND (T1314) GND (T1314) Pulse generation STD Voltage (V) Below 1.5 15 1014 1014 1014 1014 45 45 45 45 45 45 Below 1.5 1014 Below 1.5 3.05.5 Below 1.5 3.05.5 Below 1.0 1014 Below 1.0 1014 Below 1.0 1014 1014 IG switch ON, PKB switch ON Fluid in M/C reservoir above MIN level IG switch ON, PKB switch OFF Fluid in M/C reservoir above MIN level Idling TRAC ECU: BR122 BRAKE SYSTEM IG switch ON, TRAC cut switch pushed in IG switch ON, TRAC cut switch released IG switch ON IG switch ON Always Always IG switch ON Sub throttle valve fully open IG switch ON, Engine stopped Idling IG switch ON Sub throttle valve fully open IG switch ON Sub throttle valve fully open IG switch ON Sub throttle valve fully open IG switch ON Sub throttle valve fully open IG switch ON Sub throttle valve fully open TRACTION CONTROL SYSTEM (TRAC) IG switch ON, Subthrottle valve fully closed IG switch ON, Subthrottle valve fully open IG switch ON, Subthrottle valve fully closed IG switch ON, Subthrottle valve fully open Condition BR5386 IG switch ON, Main throttle valve fully closed IG switch ON, Main throttle valve fully open IG switch ON, Main throttle valve fully closed IG switch ON, Main throttle valve fully open RRO -- (T1412) FRO -- (T1410) WT -- (T1414) IND -- (T1411) FLO -- (T143) Tc -- (T146) P -- (T147) STP -- (T142) RLO -- (T145) Symbols (Terminals No.) GND (T1314) GND (T1314) GND (T1314) GND (T1314) GND (T1314) GND (T1314) GND (T1314) GND (T1314) GND (T1314) Pulse generation Pulse generation Pulse generation Pulse generation 1014 Below 1.5 Below 2.0 1014 Below 1.5 814 1014 1014 STD Voltage (V) BRAKE SYSTEM IG switch ON Slowly turn left rear wheel IG switch ON IG switch ON Slowly turn right rear wheel IG switch ON Slowly turn left front wheel IG switch ON Slowly turn right front wheel IG switch ON, Shift position in "P" or "N" position IG switch ON, except "P" and "N" positions IG switch ON, TRAC OFF indicator light ON IG switch ON, TRAC OFF indicator light OFF Stop light switch OFF Stop light switch ON IG switch ON, TRAC indicator light OFF ON Condition TRACTION CONTROL SYSTEM (TRAC) BR123 If a normal code is displayed during the diagnostic trouble code check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. PROBLEM SYMPTOMS CHART BR124 Diagnostic trouble code check cannot be b performed. f d TRAC does not operate. Symptoms TRAC OFF indicator light is abnormal g TRAC indicator light g is b i abnormal. l 2. Tc terminal circuit 2. TRAC ECU 1. TRAC indicator light circuit 2. TRAC cut switch circuit 1. TRAC indicator light circuit 4. Speed sensor circuit 2. IG power source circuit BRAKE SYSTEM Only when 1. and 2. are all normal and the problem is still occurring, replace the TRAC ECU. 1. TRAC OFF indicator light circuit Only when 1. and 2. are all normal and the problem is still occurring, replace the TRAC ECU. 5. Park/neutral position switch circuit 3. Check the hydraulic circuit for leakage. 1. Check the diagnostic trouble code, reconfirming that the normal code is output. Inspection Circuit TRACTION CONTROL SYSTEM (TRAC) Only when 1.5. are all normal and the problem is still occurring, replace the TRAC ECU. See page BR157 BR154 BR154 BR154 BR156 BR129 BR158 BR133 BR116 AT82 BR125 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) CIRCUIT INSPECTION DTC 24 TRAC SubThrottle Actuator Circuit CIRCUIT DESCRIPTION The subthrottle actuator operates in accordance with signals from the ECU, controlling the opening and closing of the subthrottle valve. DTC No. DTC Detection Condition S TRAC fuse S Open or short in BM circuit 24 Open or short in subthrottle actuator circuit S Subthrottle actuator S Open or short in subthrottle actuator circuit S ECU Trouble Area WIRING DIAGRAM BR126 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) INSPECTION PROCEDURE 1 Check TRAC fuse. P C OK Remove the TRAC fuse from R/B No.2. Check continuity of TRAC fuse. Continuity OK NG Check for short in all harness and components connected to TRAC fuse (See attached wiring diagram). 2 Check voltage between terminals BM and GND. P C OK Remove the TRAC ECU with connectors still connected. Measure voltage between terminals BM and GND. Voltage: 10 14 V OK NG Check and repair harness or connector. BR127 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) 3 Check subthrottle actuator. P C OK Disconnect the subthrottle actuator connector. Check continuity between each terminal of subthrottle actuator connector shown below. OK NG Replace subthrottle actuator. 4 OK Check for open and short in harness and connector between TRAC ECU and subthrottle actuator (See page IN29). NG Repair or replace harness or connector. Check and replace TRAC ECU. BR128 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) DTC DTC No. 25, 26, TRAC SubThrottle Valve 27 DTC Detection Condition Trouble Area S Subthrottle actuator S Throttle body (subthrottle valve is stuck or operation is faulty) S Subthrottle position sensor S TRAC ECU S Open or short in subthrottle position sensor circuit (See page BR145) S Subthrottle actuator Even when subthrottle valve is driven to the fully open position, input voltage at terminal S Throttle body (subthrottle valve is stuck or operation is faulty) S Subthrottle position sensor S TRAC ECU S Open or short in subthrottle position sensor circuit (See page BR145) S Subthrottle actuator (return spring is disconnected) S Subthrottle position sensor S TRAC ECU S Open or short in subthrottle position sensor circuit (See page BR145) The difference between the subthrottle 25 sensor signal voltage and the voltage required by the step count is 1 V or more. 26 VSH does not come within range of the specifications 3 4.5 V. When input voltage at ECU terminal VSH is 27 less than the specification by about 2.5 V for 0.2 sec. or more. P C OK Remove the air cleaner duct. Open and close the subthrottle valve manually and check the condition during operation. The valve should operate smoothly without catching. HINT: If subthrottle actuator, subthrottle valve and subthrottle position sensor and subthrottle position sensor circuit are free from any mechanical defect, the ECM may be defective. If ECM is free from any defect, TRAC ECU may be defective. BR129 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) DTC 31, 32 Speed Sensor Circuit 33, 34 CIRCUIT DESCRIPTION The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. THese signals are used to control both ABS and TRAC control systems. The front and rear rotors each have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotors (wheels), the frequency is used by the ECU to detect the speed of each wheel. DTC No. DTC Detection Condition Detection of any of conditions (1) through (3): (1) At vehicle speed of 10 km/h (6 mph) or more, pulses are not input for 5 sec. Trouble Area 31, 32 33, 34 (2) Momentary interruption of the speed sensor signal occurs at least 7 times in the time between switching the ignition ON and switching it OFF. (3) Abnormal fluctuation of speed sensor signals with the vehicle speed 10 km/h (12 mph) or more. S Right front, left front, right rear and left rear speed sensor S Open or short in each speed sensor circuit S ECU HINT: DTC No. 31 is for the right front speed sensor. DTC No. 32 is for the left front speed sensor. DTC No. 33 is for the right rear speed sensor. DTC No. 34 is for the left rear speed sensor. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU prohibits TRAC control. BR130 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) WIRING DIAGRAM BR131 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) INSPECTION PROCEDURE HINT: If the same code is output from the ABS warning light, troubleshoot the ABS first. 1 OK Check for open and short in harness and connector between terminals FRO, FLO, RRO, RLO of ABS & TRAC ECU and TRAC ECU (See page IN29). NG Check speed sensor. Repair or replace harness or connector. 2 P Front 1. Remove the front fender liner. 2. Disconnect the speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. Resistance: 0.7 1.7 kW Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. Resistance: 1 MW or higher Rear C OK C OK P 1. 2. Remove the rear seat cushion, seat back and quarter trim. Disconnect the speed sensor connector. C OK C OK Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. Resistance: 0.7 1.7 kW Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. Resistance: 1 MW or higher OK NG Replace speed connector. Notice: Check the speed sensor signal last (See page BR58) 3 OK Check for open and short in harness and connector between each speed sensor and ECU (See page IN29). NG Repair or replace harness or connector. BR132 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) 4 Check sensor rotor and sensor installation. P Front Remove the front speed sensor rotor. (See page SA19) Check the sensor rotor serrations. No scratches or missing teeth C OK C OK Check the front speed sensor installation. The installation bolt is tightened properly. P C OK Rear Remove the drive shaft (See page SA68). Check the sensor rotor serrations. No scratches or missing teeth C OK Check the rear speed sensor installation. The installation bolt is tightened properly and there is no clearance between the sensor and rear axle carrier. OK NG Replace speed sensor or rotor. NOTICE: Check the speed sensor signal last (See page BR58). Check and replace ABS (& TRAC) ECU. BR133 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) DTC 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the CPU and the actuators. DTC No. DTC Detection Condition When either of the following (1) or (2) is detected: (1) Voltage at ECU terminal IG is less than 9.5 41 V for more than 10 sec. while engine speed is 500 rpm or higher. (2) Voltage at ECU terminal IG is more than 17 V for more than 5 sec. S Battery S IC regulator S Open or short in power source circuit S ECU Trouble Area Fail safe function: If trouble occurs in the power source circuit, the ECU prohibits TRAC control. WIRING DIAGRAM BR134 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) INSPECTION PROCEDURE 1 OK Check battery positive voltage. Voltage: 10 14 V OK NG Check and repair the charging system. 2 Check voltage between terminals IG and GND of TRAC ECU connector. P 1. 2. C OK Remove TRAC ECU with connectors still connected. Turn ignition switch ON. Measure voltage between terminals IG and GND of TRAC ECU connector. Voltage: 10 14 V NG OK Check and replace TRAC ECU. 3 Check continuity between terminal GND of TRAC ECU connector and body ground. C OK Measure resistance between terminal GND of TRAC ECU connector and body ground. Resistance: 1 W or less OK NG Repair or replace harness or connector. BR135 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) 4 Check ECUIG fuse. P C OK Remove ECUIG fuse from J/B No.1. Check continuity of ECUIG fuse. Continuity OK NG Check for short in all the harness and components connected to ECUIG fuse (See attached wiring diagram). Check for open in harness and connector between TRAC ECU and battery (See page IN29). BR136 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) DTC DTC No. 43 43 ABS & TRAC ECU Malfunction Trouble Area CIRCUIT DESCRIPTION DTC Detection Condition ABS control system or TRAC (BRAKE) con- S ABS & TRAC ECU trol system or communication circuit is abS Open or short in BRFA circuit normal WIRING DIAGRAM BR137 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) INSPECTION PROCEDURE 1 Check voltage between terminal BRFA of TRAC ECU and body ground. P 1. 2. C OK Remove TRAC ECU with connectors still connected. Turn ignition switch ON. Measure voltage between terminal BRFA of TRAC ECU and body ground. Voltage: About 6 V (Pulse) NG OK Check and replace TRAC ECU. 2 Check voltage between terminal BRFA of TRAC ECU and body ground with TRAC ECU connector disconnected. P Disconnect TRAC ECU connector. C Measure voltage between terminal BRFA of TRAC ECU connector and body ground. HINT: Measure voltage within 8 seconds from the time TRAC ECU connector is disconnected. OK Voltage: See step 1. NG OK Check and replace TRAC ECU. 3 OK Check for open and short in harness and connector between ABS & TRAC ECU and TRAC ECU (See page IN29). NG Repair or replace harness or connector. Check and replace ABS & TRAC ECU. BR138 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) DTC 44 NE Signal Circuit CIRCUIT DESCRIPTION The TRAC ECU receives engine speed signals (NE signals) from the ECM. DTC No. 44 DTC Detection Condition Trouble Area S Open or short in NEO circuit No signal is input to terminal NEO 0.24 sec. S ECM after traction control is initiated. S TRAC ECU WIRING DIAGRAM BR139 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) INSPECTION PROCEDURE 1 OK Check for open and short in harness and connector between terminal NEO of TRAC ECU and terminal NEO of ECM (See page IN29). NG Repair or replace harness or connector. 2 Check voltage between terminal NEO of TRAC ECU and body ground. P 1. 2. C OK Remove TRAC ECU with connectors still connected. Turn ignition switch ON. Measure voltage between terminal NEO of TRAC ECU and body ground for the engine conditions below. OK NG Check and replace TRAC ECU or ECM. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. BR140 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) DTC 45, 46 Main Throttle Position Sensor Circuit CIRCUIT DESCRIPTION This circuit is not directly related to the TRAC control, but as it has an influence on TRAC control when trouble occurs in this circuit, it is used to switch off the TRAC system as a fail safe function. DTC No. DTC Detection Condition Either of the following (1) and (2) continues for 0.12 sec.: (1) IDL switch of main throttle position sensor is ON. (2) Input voltage of TRAC ECU terminal VTH: 1.45 V or more Either of the following (1) or (2) continues for 0.12 sec.: 46 (1) Input voltage of TRAC ECU terminal VTH: 4.3 V or more (2) Input voltage of TRAC ECU terminal VTH while IDL 1 switch is OFF: 0.2 V or less Trouble Area S Main throttle position sensor S Open in VTH circuit S Short in IDL 1 circuit S ECM S TRAC ECU S Main throttle position sensor S Short in VTH circuit S ECM S TRAC ECU 44 WIRING DIAGRAM BR141 BRAKE SYSTEM TRACTION CONTROL SYSTEM INSPECTION PROCEDURE HINT: The main throttle position sensor signal is transmitted to the TRAC ECU from ECM, so if an error occurs at the engine side, the TRAC ECU also detects it. If diagnostic trouble code No.41 is being output for the engine, troubleshoot the engine first. 1 Is diagnostic trouble code output for the engine? Do diagnostic trouble code check on page EG251. NO YES Repair or replace harness or connector. 2 Check voltage between terminal VTH of TRAC ECU and body ground. P 1. 2. 3. C Remove the TRAC ECU with connector still connected. Remove the intake air duct. Turn ignition switch ON. Measure voltage between terminal VTH of TRAC ECU and body ground, when the main throttle valve is turned from fully closed position to fully opened position by hand. OK In addition, as the main throttle valve is turned, the voltage should increase gradually without interruption. NG OK Go to step 7. 3 OK Check for open and short in harness and connector between terminal VTH of TRAC ECU and terminal VTO1 of ECM (See page IN29). NG Repair or replace harness or connector. BR142 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) 4 Check voltage between terminal VT01 of ECM and body ground with TRAC ECU connector disconnected. P 1. Connect the Check Harness A. (See page EG256) 2. Disconnect the TRAC ECU connector. 3. Turn ignition switch ON. C Measure voltage between terminal VT01 of ECM and body ground, when the main throttle valve is fully closed and fully opened. OK NG OK Check and replace TRAC ECU. 5 NG Check voltage of terminal VTA 1 of ECM (See page EG296). OK Check and replace ECM. BR143 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) 6 OK Check for open and short in harness and connector between terminal VTA1 of ECM and main throttle position sensor (See page IN29). NG Repair or replace harness or connector. Adjust or replace main throttle position sensor (See page EG157). 7 Check voltage between terminal IDL1 of TRAC ECU and body ground. P C Turn ignition switch ON. Measure voltage between terminal IDL1 of TRAC ECU and body ground, when the main throttle valve is fully closed and fully opened. OK NG OK Check and replace TRAC ECU. BR144 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) 8 Check voltage between terminal IDL1 of TRAC ECU connector and body ground with TRAC ECU connector disconnected. P 1. Disconnect the TRAC ECU connector. 2. Turn ignition switch ON. C Measure voltage between terminal IDL1 of TRAC ECU connector and body ground, when the main throttle valve is fully closed and fully opened. OK NG OK Check and replace TRAC ECU. 9 OK Check for open and short in harness and connector between terminal IDL1 of TRAC ECU and ECM (See page IN29). NG Repair or replace harness or connector. 10 OK Check main throttle position sensor (See page EG152). Adjust or replace main throttle position sensor (See page EG157). NG Check and replace ECM. BR145 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) DTC 47, 48 SubThrottle Position Sensor Circuit CIRCUIT DESCRIPTION This sensor detects the opening angle of the subthrottle valve and sends the appropriate signals to the ECU. If a trouble signal is input, the ECU prohibits TRAC control. DTC No. DTC Detection Condition When any of the following (1) through (3) is detected: (1) Deviation of 5 steps or more to the closed side of the idle step during subthrottle initial check. 47 (2) Voltage at terminal IDL2 switch is OFF even after subthrottle is driven to fully closed position during subthrottle initial check 4. (3) Voltage at terminal VSH is 1.45 V or more for at least 0.15 sec. while idle switch is ON. Either of the following (1) or (2) continues for at least 0.12 sec. 48 (1) Input voltage of TRAC ECU terminal VSH: 4.3 V or more. (2) Input voltage of TRAC ECU terminal VSH is 0.2 V or less while IDL2 switch is OFF. Trouble Area S Subthrottle position sensor S Open or short in IDL2 circuit S ECM S TRAC ECU S Subthrottle position sensor S Open or short in VSH circuit S ECM S TRAC ECU WIRING DIAGRAM BR146 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) INSPECTION PROCEDURE HINT: The subthrottle position sensor signal is transmitted to the TRAC ECU from ECM, so if an error occurs at the engine side, the TRAC ECU also detects it. If diagnostic trouble code No.47 is being output for the engine, troubleshoot the engine first. 1 Is diagnostic trouble code output for the engine? Do diagnostic trouble code check on page EG251. NO YES Repair circuit indicated by the code output. 2 Check voltage between terminal VSH of TRAC ECU and body ground. P 1. 2. 3. 4. C Remove the TRAC ECU with connecters still connected. Remove the intake air duct. Disconnect the step motor connector. Turn ignition switch ON. Measure voltage between terminal VSH of TRAC ECU and body ground, when the subthrottle valve is turned from fully opened position to fully closed position. OK In addition, as the subthrottle valve is turned, the voltage should increase gradually without interruption. NG OK Go to step 7. 3 OK Check for open and short in harness and connector between terminal VSH of TRAC ECU and terminal VTO2 of ECM (See page IN29). NG Repair or replace harness or connector. BR147 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) 4 Check voltage between terminal VTO2 of ECM and body ground with TRAC ECU connector disconnected. P 1. Connect the Check Harness A. (See Page EG256) 2. Disconnect the TRAC ECU connector. 3. Turn ignition switch ON. C Measure voltage between terminal VTO2 of ECM and body ground, when the subthrottle valve is fully closed and fully opened. OK NG OK Check and replace TRAC ECU. 5 NG Check voltage of terminal VTA2 of ECM (See page EG296). OK Check and replace ECM. BR148 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) 6 NO Check for open and short in harness and connector between terminal VTA2 of ECM and sub throttle position sensor (See page IN29). NG Repair or replace harness or connector. Adjust or replace subthrottle position sensor (See page EG158). 7 Check voltage between terminal VSH of TRAC ECU and body ground. P C Turn ignition switch ON. Measure voltage between terminal IDL2 of TRAC ECU connector and body ground, when the subthrottle valve is fully closed and fully opened. OK NG OK Check and replace TRAC ECU. BR149 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) 8 Check voltage between terminal IDL2 of TRAC ECU connector and body ground with TRAC ECU connector disconnected. P 1. Disconnect the TRAC ECU connector. 2. Turn ignition switch ON. C Measure voltage between terminal IDL2 of TRAC ECU connector and body ground, when the subthrottle valve is fully closed and fully opened. OK NG OK Check and replace TRAC ECU. 9 OK Check for open and short in harness and connector between terminal IDL2 of TRAC ECU and ECM (See page IN29). NG Repair or replace harness or connector. 10 OK Check subthrottle position sensor (See page EG157). Adjust or replace subthrottle position sensor (See page EG158). NG Check and replace ECM. BR150 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) DTC 49 Engine Communication Circuit CIRCUIT DESCRIPTION This circuit is used to send ignition timing retard request signals from the TRAC ECU to the ECM in order to retard the engine ignition timing. DTC No. 49 DTC Detection Condition TR2 output voltage differs from TR2 monitor voltage in TRAC ECU. Trouble Area S Open or short in TR2 circuit S ECM S TRAC ECU WIRING DIAGRAM INSPECTION PROCEDURE 1 Check voltage between terminal TR2 of TRAC ECU and body ground. P 1. 2. Disconnect TRAC ECU connector. Turn ignition switch on. C OK Measure voltage between terminal TR2 of TRAC ECU and body ground. Voltage: 8 14 V NG OK Check and replace TRAC ECU. 2 OK Check for open and short in harness and connector between TRAC ECU and ECM (See page IN29). NG Repair or replace harness or connector. Check and replace ECM. BR151 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) DTC 51 Engine Malfunction Detection Circuit CIRCUIT DESCRIPTION If trouble (trouble which causes the malfunction indicator lamp to light up) occurs in the engine control system, this circuit detects the trouble and prohibits TRAC control. DTC No. DTC Detection Condition Conditions (1) and (2) continue for more than 1 sec.: (1) Engine speed: 500 rpm or more (2) Voltage of TRAC ECU terminal TR5: 1 V or less Trouble Area S Short in TR5 circuit S ECM S TRAC ECU 51 WIRING DIAGRAM INSPECTION PROCEDURE 1 Check the diagnostic trouble code for the engine (See page EG251). Malfunction indicator lamp remains ON. Output NG Code Repair engine control system according to the code output. Check for short in all the harness and ECU connected to malfunction indicator lamp. BR152 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) DTC 61 ABS & TRAC ECU Communication Circuit Malfunction Trouble Area S Open or short in ABSO, BRC, BRP circuit S ABS & TRAC ECU S TRAC ECU CIRCUIT DESCRIPTION DTC No. 61 DTC Detection Condition Malfunction in ABS & TRAC ECU communication circuit. WIRING DIAGRAM BR153 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) INSPECTION PROCEDURE 1 Check voltage between terminals ABSO, BRC, BRP of TRAC ECU and body ground. P C Remove the TRAC ECU with connectors still connected. Measure voltage between terminals ABSO, BRC, BRP of TRAC ECU and body ground when ignition switch is turned on. Voltage: ABSO, BRC: 6 14 V BRP: About 7 V (Pulse) OK NG OK Check and replace TRAC ECU. 2 Check voltage between terminals ABSO, BRC, BRP of TRAC ECU and body ground with TRAC ECU connector is disconnected. P Disconnect the TRAC ECU connector. C Measure voltage between terminals ABSO, BRC, BRP of TRAC ECU connector and body ground when ignition switch is turned ON. TR2 of TRAC ECU and body ground. Voltage: See step 1. OK NG OK Check and replace TRAC ECU. 3 OK Check for open and short in harness and connector between ABS & TRAC ECU and TRACK ECU (See page IN29). NG Repair or replace harness or connector. Check and replace ABS & TRAC ECU. BR154 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) TRAC OFF Indicator, TRAC Cut Switch Circuit CIRCUIT DESCRIPTION This is the TRAC control main switch. When the TRAC cut switch is pushed on, TRAC control goes off and the TRAC OFF indicator lights up. This indicator is also used for warnings when the trouble occurs. WIRING DIAGRAM BR155 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) INSPECTION PROCEDURE 1 Is diagnostic trouble code output? Do diagnostic trouble code check on page BR116. NO YES Check TRAC cut switch. Repair circuit indicated by the code output. 2 P 1. 2. Remove the TRAC cut switch. Disconnect the TRAC cut switch connector. C OK Measure resistance between terminals 1 and 2 of TRAC cut switch when TRAC cut switch is on and off. OK NG Replace TRAC cut switch. 3 OK Check for open and short in harness and connector between terminal CSW of TRAC ECU and TRAC cut switch and body ground (See page IN29). NG Check TRAC OFF indicator light. Repair or replace harness or connector. 4 See combination meter troubleshooting on page BE75. OK NG Repair or replace combination meter. 5 OK Check for open and short in harness and connector between terminal WT of TRAC ECU and battery or TRAC solenoid relay (See page IN29). NG Repair or replace harness or connector. Check and replace TRAC ECU. BR156 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) TRAC Indicator Light Circuit CIRCUIT DESCRIPTION The TRAC indicator blinks during TRAC operation. This indicator is also used for warnings when the trouble occurs and for displaying diagnostic trouble codes. WIRING DIAGRAM INSPECTION PROCEDURE Troubleshoot in accordance with flow chart instructions for each trouble symptom. TRAC Indicator light does not light up Go to combination meter troubleshooting on page BE75. TRAC Indicator light remains ON 1 Check the diagnostic trouble code (See page BR116). Indicator light remains ON Output NG code Repair engine control system according to the code output. 2 OK Check for short in harness and connector between TRAC ECU and TRAC indicator light. (See page IN29). NG Repair or replace harness or connector. Check and replace TRAC ECU. BR157 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) Tc Terminal Circuit CIRCUIT DESCRIPTION By connecting between terminals Tc and E1 of DLC1 or DLC2, the ECU displays the diagnostic trouble code by blinking the TRAC indicator light. WIRING DIAGRAM INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC2 or DLC1. P C OK Turn ignition switch ON. Measure voltage between terminals Tc and E1 of DLC2 or DLC1. Voltage: 10 14 V NG OK Proceed to next circuit inspection shown on problem symptoms chart (See page BR124) 2 OK Check for open and short in harness and connector between ABS & TRAC ECU, TRAC ECU and DLC2 (or DLC1, DLC2 (or DLC1) and body ground (See page IN29). NG Repair or replace harness or connector. Check and replace TRAC ECU. BR158 BRAKE SYSTEM TRACTION CONTROL SYSTEM (TRAC) Check for Fluid Leakage ...
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This note was uploaded on 05/03/2010 for the course BUSINESS econ203 taught by Professor Shivaggo during the Spring '10 term at Columbia College.

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