BRAKE CONTROL SYSTEM

F BRAKES

SECTION

BRAKE CONTROL SYSTEM

BRC

CONTENTS
PRECAUTIONS ..................................................... ..... 2 Precautions for Supplemental Restraint System (SRS) AIR BAG and SEAT BELT PRE-TENSIONER ............................................................. ..... 2 Brake System Precautions .................................. ..... 2 PREPARATION ...................................................... ..... 3 Commercial Service Tools ................................... ..... 3 ANTI-LOCK BRAKE SYSTEM (ABS) ................... ..... 4 System Description ............................................. ..... 4 ABS FUNCTION .............................................. ..... 4 System Component ............................................. ..... 4 ABS Hydraulic Circuit .......................................... ..... 5 TROUBLE DIAGNOSIS ......................................... ..... 6 How to Proceed with Diagnosis .......................... ..... 6 BASIC CONCEPT ............................................ ..... 6 DIAGNOSIS FLOW .......................................... ..... 7 ASKING COMPLAINTS ................................... ..... 8 EXAMPLE OF DIAGNOSIS SHEET ................ ..... 8 Location of System Components ........................ ..... 9 Circuit Diagram ................................................... ... 10 Wiring Diagram ABS .................................. ....11 Control Module Input/Output Signal Standard (Standard with CONSULT-II) ....................................... ... 14 Self-Diagnosis ..................................................... ... 14 FUNCTION ....................................................... ... 14 SELF-DIAGNOSIS PROCEDURE ................... ... 14 HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) ............................... ... 15 HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) .............. ... 16 MALFUNCTION CODE/SYMPTOM CHART ... ... 16 CONSULT-II Function .......................................... ... 17 CONSULT-II FUNCTION APPLICATION TABLE ... 17 SELF-DIAGNOSIS ........................................... ... 17 DATA MONITOR. ............................................. ... 20 ACTIVE TEST .................................................. ... 21 Basic Inspection .................................................. ... 22 BASIC INSPECTION 1 BRAKE FLUID LEVEL AND LEAK INSPECTION ................................. ... 22 BASIC INSPECTION 2 INSPECTION FOR LOOSE POWER SUPPLY TERMINAL ............ ... 22 BASIC INSPECTION 3 ABS WARNING LAMP INSPECTION ................................................... ... 22 Wheel Sensor System ......................................... ... 23 INSPECTION PROCEDURE ........................... ... 23 Control Unit Power Supply System ..................... ... 24 INSPECTION PROCEDURE ........................... ... 24 ABS Function Is Activated Frequently ................. ... 24 Unexpected Pedal Reaction ................................ ... 25 Longer Stopping Distance ................................... ... 25 ABS Does Not Work ............................................ ... 25 Pedal Vibration and Noise ................................... ... 26 WHEEL SENSORS ................................................ ... 27 Removal and Installation ..................................... ... 27 SENSOR ROTOR .................................................. ... 28 Removal and Installation ..................................... ... 28 REMOVAL ........................................................ ... 28 INSTALLATION ................................................ ... 28 ABS ACTUATOR AND CONTROL UNIT .............. ... 29 Removal and Installation ..................................... ... 29 REMOVAL ........................................................ ... 29 INSTALLATION ................................................ ... 29

BRC

BRC-1

PRECAUTIONS PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) AIR BAG and SEAT BELT PRE-TENSIONER

EFS0044A

The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE-TENSIONER, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: G To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. G Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. G Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.

Brake System Precautions

G G G

EFS001KI

Recommend fluid is brake DOT 3. Never reuse drained brake fluid. Be careful not to splash brake fluid on painted areas such as the body. If brake fluid is splashed, wipe it off and flush the area with water immediately. Never use mineral oils such as gasoline or kerosene to clean. They will ruin the rubber parts and cause improper operation. Using a flare nut torque wrench, securely tighten the brake tube flare nuts. Brake system is an important safety part. If a brake fluid leak is detected, always disassemble the suspect parts. If any nonstandard condition is detected, replace part with a new one. Before working, turn ignition switch OFF and disconnect connectors for the ABS actuator and control module or the battery cables. When installing brake piping, be sure to check torque.
SBR686C

BRC-2

PREPARATION PREPARATION Commercial Service Tools

Tool name Description
PFP:00002

A
EFS001KJ

1. Flare nut crowfoot 2. Torque wrench a: 10 mm (0.39 in)

S-NT360

Removing and installing brake piping

BRC

BRC-3

ANTI-LOCK BRAKE SYSTEM (ABS) ANTI-LOCK BRAKE SYSTEM (ABS) System Description
ABS FUNCTION
G

PFP:47660
EFS001O8

During ABS operation, brake pedal lightly vibrates and its mechanical noise may be heard. This is a normal condition. When starting engine, or just after starting vehicle, brake pedal may vibrate. Also motor operating noise may be heard from engine compartment. This is a normal status of operation check. When vehicle drives on rough, gravel, or snowy (fresh deep snow) road, the following conditions occur. Stopping distance may be longer than that of vehicles without ABS.
EFS001O9

System Component

SFIA0461E

BRC-4

ANTI-LOCK BRAKE SYSTEM (ABS) ABS Hydraulic Circuit

EFS001OA

BRC

SBR984D

1. 4. 7.

Inlet solenoid valve Pump Out let valve

2. 5. 8.

Outlet solenoid valve Motor Bypass check valve

3. 6. 9.

Reservoir Inlet valve Damper

BRC-5

TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS How to Proceed with Diagnosis

BASIC CONCEPT
G

PFP:00004
EFS001LC

The most important point in performing diagnosis is to thoroughly understand the vehicle systems (both control and mechanical). It is also important to clarify the customer complaints before inspection. First of all, reproduce the symptom, and understand it fully. Ask the customer about his/her complaints carefully. In some cases, it will be necessary to check symptoms by driving the vehicle with the customer. CAUTION: Customers are not professionals. It is dangerous to assume maybe the customer means that... or maybe the customer mentioned this symptom.
SEF234G

It is essential to check symptoms right from the beginning in order to repair an error completely. For an intermittent error, it is important to reproduce the symptom based on an interview with the customer and past examples. Do not perform an inspection on an ad hoc basis. Most intermittent errors are caused by poor contacts. In this case, it will be effective to shake the suspected harness or connector by hand. When repairs are performed without any symptom diagnosis, no one can judge if the error has actually been corrected. After the diagnosis, make sure to carry out erase memory. Refer to BRC-17, "Operation Procedure" . SEF233G For an intermittent malfunction, move the harness or harness connector by hand to check for a poor contact or false open circuit. Always read the section titled General Information to confirm the general precautions. Refer to GI-3, "General Precautions" .

BRC-6

TROUBLE DIAGNOSIS
DIAGNOSIS FLOW
A

BRC

SFIA0293E

BRC-7

TROUBLE DIAGNOSIS
ASKING COMPLAINTS
G

Complaints of a malfunction vary depending on each person. It is important to clarify customer complaints. Ask the customer what symptoms are present and under what conditions. Use the information to reproduce the symptom while driving. It is also important to use the diagnosis sheet so as not to miss any information.

SBR339B

EXAMPLE OF DIAGNOSIS SHEET

SFIA0029E

BRC-8

TROUBLE DIAGNOSIS Location of System Components

EFS001LD

BRC

J
SFIA0454E

BRC-9

TROUBLE DIAGNOSIS Circuit Diagram

EFS001LE

TFWH0001E

BRC-10

TROUBLE DIAGNOSIS Wiring Diagram ABS

EFS001LF

BRC

TFWH0002E

BRC-11

TROUBLE DIAGNOSIS

TFWH0003E

BRC-12

TROUBLE DIAGNOSIS
A

BRC

TFWH0004E

BRC-13

TROUBLE DIAGNOSIS Control Module Input/Output Signal Standard (Standard with CONSULT-II)
EFS001LG

CAUTION: Displayed item is data calculated by control unit. Therefore, it may indicate a normal value even if output circuit (harness) is open or shorted.
Data monitor. Monitor item Condition WHEEL SENSOR (km/h) WARNING LAMP (ON-OFF) While driving (Note 1) Reference value in normal operation Almost same as the speedometer indication (within 10) When warning lamp is ON (Note 2): ON When warning lamp is OFF (Note 2): OFF Brake pedal is depressed: ON Brake pedal is not depressed: OFF When motor and motor relay are active. (Active test with CONSULTII): ON When motor and motor relay are not activated: OFF When actuator relay is activated: ON When actuator relay is not activated (in fail-safe mode): OFF When actuator (Solenoid valve) is activated (Active test with CONSULT-II): ON Actuator (Solenoid) is not activated (Vehicle stopped): OFF Approximately 10 - 16V ABS activated: ON ABS not activated: OFF Control unit power supply route External signal route Items to be checked when an error exists. Wheel sensor system

ABS warning lamp ON

ABS warning lamp path

Stop lamp switch (ON-OFF)

Brake pedal status

Stop lamp switch and route

ABS MOTOR RELAY (ON-OFF)

Motor relay and motor operation

ABS motor and motor relay route

ABS ACTUATOR RELAY (ON-OFF)

Actuator relay activated

ABS actuator relay and route

IN ABS solenoid (ON-OFF) ABS OUTLET SOLENOID [ON - OFF] Power supply voltage (V) ABS operation signal (ON-OFF)

Solenoid valve operation

ABS solenoid path

Solenoid valve operation Power supply voltage to C/U (When key SW is ON) ABS operation

Note 1: Confirm tire pressure is normal. Note 2: ON/OFF timing of ABS warning lamp ON: For approximately 1 second after ignition switch is turned ON, or when malfunction is detected. OFF: Approximately 1 second after ignition switch is turned ON (When system is in normal operation.)

Self-Diagnosis
FUNCTION
G

EFS001OB

When a problem occurs in the ABS, the ABS warning lamp on the instrument panel comes on. To start the self-diagnostic results mode, ground the self-diagnostic (check) terminal located on Data link connector. The location of the malfunction is indicated by the ABS warning lamp flashing. Drive vehicle over 30 km/h (19 MPH) for at least one minute. Turn ignition switch OFF.

SELF-DIAGNOSIS PROCEDURE
1. 2.

BRC-14

TROUBLE DIAGNOSIS
3. 4. Ground terminal 9 of Data link connector with a suitableharness. Turn ignition switch ON while grounding terminal 9. Do not depress brake pedal. Do not start engine.
A

C
SFIA0491E

5. 6.

7. 8.

After 3.0 seconds, the ABS warning lamp starts flashing to indicate the malfunction code No. (See NOTE.) Verify the location of the malfunction with the malfunction codechart. Refer toBRC-16 . Then make the necessary repairs following the diagnostic procedures. After the malfunctions are repaired, erase the malfunction codes stored in the control unit. Refer to BRC-16 Rerun the self-diagnostic results mode to verify that the malfunction codes have been erased.
SBR588E

BRC

9.

Disconnect the check terminal from the ground. The self-diagnostic results mode is now complete. 10. Check ABS warning lamp for deactivation after driving vehicle over 30 km/h (19 MPH) for at least one minute. 11. After making certain that ABS warning lamp does not come on, test the ABS SELF-DIAGNOSIS in a safe area to verify that it functions properly. NOTE: The indication terminates after five minutes. However, when the ignition switch is turned from OFF to ON, the indication starts flashing again.

SFIA0491E

HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)

1. 2. 3. Determine the code No. By counting the number of times the ABS warning lamp flashes on and off. When several malfunctions occur at one time, up to three code numbers can be stored; the latest malfunction will be indicated first. The indication begins with the start code 12. After that a maxi-mum of three code numbers appear in the order of the latest one first. The indication then returns to the start code 12 to repeat (the indication will stay on for five minutes at the most). The malfunction code chart is given on the BR-61 page.
L

4.

SBR457D

BRC-15

TROUBLE DIAGNOSIS
HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)
1. 2. Disconnect the check terminal from ground (ABS warning lamp ill stay lit). Within 12.5 seconds, ground the check terminal 3 times. Each terminal ground must last more than 1 second. The ABS warning lamp goes out after the erase operation has been completed. Perform self-diagnosis again. Refer to BRC-14 . Only the start code should appear, no malfunction codes.

3.

ABR256

MALFUNCTION CODE/SYMPTOM CHART

Code No. (No.of LED flashes) 12 21 22 25 26 31 32 35 36 41 42 45 46 51 52 55 56 57 61 63 71 ABS warning lamp stays on when ignition switch is turned on ABS warning lamp stays on, during selfdiagnosis. ABS warning lamp does not come on when ignition switch is turned on. ABS warning lamp does not come on during self-diagnosis. Pedal vibration and noise Long stopping distance Unexpected pedal action Malfunctioning part Self-diagnosis not could any malfunction Front right sensor (open-circuit) Front right sensor (short-circuit) Front left sensor (open-circuit) Front left sensor (short-circuit) Rear right sensor (open-circuit) Rear right sensor (short-circuit) Rear left sensor (open-circuit) Rear left sensor (short-circuit) Actuator front right outlet solenoid valve Actuator front right inlet solenoid valve Actuator front left outlet solenoid valve Actuator front left inlet solenoid valve Actuator rear right outlet solenoid valve Actuator rear right inlet solenoid valve Actuator rear left outlet solenoid valve Actuator rear left inlet solenoid valve Power supply (low voltage) Actuator motor or motor relay Solenoid valve relay Control unit Control unit power supply circuit Warning lamp bulb circuit Control unit or control unit connector Solenoid valve relay stuck Control unit Fuse, warning lamp bulb or warning lamp circuit Control unit Control unit Reference page BRC-23 BRC-23 BRC-23 BRC-23 BRC-23 BRC-23 BRC-23 BRC-23 BRC-11 BRC-11 BRC-11 BRC-11 BRC-11 BRC-11 BRC-11 BRC-11 BRC-24 BRC-11 BRC-11 BRC-24

BRC-26 BRC-25 BRC-25

BRC-16

TROUBLE DIAGNOSIS
Code No. (No.of LED flashes) ABS dose not work ABS works frequently Malfunctioning part Reference page BRC-25 BRC-24
EFS001LH

CONSULT-II Function
CONSULT-II FUNCTION APPLICATION TABLE
Item FR RH SENSOR FR LH SENSOR RR RH SENSOR RR LH SENSOR Wheel sensor Stop lamp switch FR RH IN ABS SOL FR RH OUT ABS SOL FR LH IN ABS SOL FR LH OUT ABS SOL Rear IN ABS solenoid Rear OUT ABS solenoid ABS ACTUATOR RELAY ABS MOTOR RELAY ABS warning lamp Battery voltage C/U : Applicable : Not applicable Self-diagnosis Data monitor. Active test

BRC

SELF-DIAGNOSIS Operation Procedure

1. 2. Before performing basic inspections, obtain information about customer concerns. Refer to BRC-22, "Basic Inspection" . After turning the ignition switch OFF, connect CONSULT-II to the data link connector on the vehicle.

PBIB0209E

BRC-17

TROUBLE DIAGNOSIS

PBIB0210E

Start the engine and drive at approximately 30 km/h for approximately 1 minute. After stopping the vehicle, with the engine still idling, touch START, ABS and SELF-DIAG RESULTS on the CONSULT-II screen in this order. CAUTION: Just after starting engine, or turning ignition switch ON, ABS may not be displayed on system selection screen even if START is touched. In this case, start self-diagnosis again from step 2. 5. The self-diagnosis result is displayed. (If necessary, touch PRINT to print the self-diagnosis result.) G When No self-diagnosis malfunction indicated is displayed, check ABS warning lamp. Refer to BRC22, "BASIC INSPECTION 3 ABS WARNING LAMP INSPECTION" . 6. Go to appropriate Inspection chart according to Indication item list and repair or replace as necessary. 7. Start the engine and drive at approximately 30 km/h for approximately 1 minute. CAUTION: G Check again to make sure that there is no malfunction in other parts. G If wheel sensor [SHORT] is detected, the ABS warning lamp does not turn off until the vehicle is driven at approximately 30km/h for approximately 1 minute, even in normal conditions. 8. Turn ignition switch OFF to prepare for erasing the memory. 9. Start the engine, and touch START, ABS, SELF-DIAG RESULTS and ERASE MEMORY on the CONSULT-II screen in this order to erase the memory. CAUTION: If memory cannot be erased, go to 6. 10. Drive vehicle at approximately 30 km/h for approximately 1 minute, and confirm that ABS warning lamp is OFF.

3. 4.

BRC-18

TROUBLE DIAGNOSIS
Items to Be Displayed
Possible location Front RH wheel sensor [OPEN] Front LH wheel sensor [OPEN] RR RH SENSOR [OPEN] Malfunction detecting condition Circuit of front RH wheel sensor is open, or unusually high input voltage is caused by a short to power supply in signal lines. Circuit of front LH wheel sensor is open, or unusually high input voltage is caused by a short to power supply in signal lines. Circuit of rear RH wheel sensor is open, or unusually high input voltage is caused by a short to power supply in signal lines. Circuit of rear LH wheel sensor is open, or unexpectedly high input voltage is caused by a short to power supply on signal lines. At front RH wheel sensor: signal line is shorted to power supply or to ground. As a result, input voltage is excessively high/low, or input signal is implausible. At front LH wheel sensor: signal line is shorted to power supply or to ground. As a result, input voltage is excessively high/low, or input signal is implausible. At rear RH wheel sensor: signal line is shorted to power supply or to ground. As a result, input voltage is excessively high/low, or input signal is implausible. At rear LH wheel sensor: signal line is shorted to power supply or to ground. As a result, input voltage is excessively high/low, or input signal is implausible. Wheel speed error or sensor noise caused by improper tire size or wheel sensor rotor tooth damage. At front RH ABS inlet solenoid valve: circuit is open, or control line is shorted to ground or to power supply. As a result, output voltage is excessively higher/lower than control value. At front LH ABS inlet solenoid: circuit is open, or control line is shorted to ground or to power supply. As a result, output voltage is excessively higher/lower than control value. At rear IN ABS inlet solenoid: circuit is open, or control line shorted to ground or power supply. As a result, output voltage is excessively higher/lower than control value. At front RH ABS outlet solenoid: circuit is open, or control line is shorted to ground or to power supply. As a result, output voltage is excessively higher/lower than control value. At front LH ABS outlet solenoid: circuit is open, or control line is shorted to ground or to power supply. As a result, output voltage is excessively higher/lower than control value. At rear ABS outlet solenoid: circuit is shorted, or control line shorted to ground or power supply. As a result, output voltage is excessively higher/lower than control value.
G

Check route

RR LH SENSOR [OPEN] Front RH wheel sensor [SHORT] Note 1, Note 2 Front LH wheel sensor [SHORT] Note 1, Note 2 Rear RH wheel sensor [SHORT] Note 1, Note 2 Rear LH wheel sensor [SHORT] Note 1, Note 2 Wheel sensor [INPUT ERROR] FR RH IN ABS SOL [OPEN] [SHORT] FR LH IN ABS SOL [OPEN] [SHORT] Rear IN ABS solenoid [OPEN] [SHORT] FR RH OUT ABS SOL [OPEN] [SHORT] FR LH OUT ABS SOL [OPEN] [SHORT] Rear OUT ABS solenoid [OPEN] [SHORT] ABS MOTOR RELAY [MALFUNCTIONING]

D
Wheel sensor route

BRC

ABS solenoid valve and actuator relay route

At ABS motor relay: circuit is open or shorted, or motor relay is stuck ON. Motor circuit is open or shorted to power supply or ground.

ABS motor and motor relay route ABS solenoid valve and actuator relay route ABS control unit power supply and ground route ABS control unit, ABS control unit power supply, and ground circuit

ABS ACTUATOR RELAY [ERROR] BATTERY VOLT [NON-STANDARD VOLTAGE] C/U

ABS actuator relay turned ON while it is controlled OFF. ABS actuator relay turned OFF while it is controlled ON. Relay control line is open, or shorted to ground. Battery voltage is incorrect (either more than approximately 16V or less than approximately 10V). Processing function of ABS control module is malfunctioning.

Note 1: When vehicle is stuck on a slippery road and its wheels spin for approximately 10 - 80 seconds (period depends on vehicle speed), ABS warning lamp may illuminate. However, this is not a malfunction.

BRC-19

TROUBLE DIAGNOSIS
Note 2: After short circuit in sensor is repaired, ABS warning lamp will illuminate after ignition switch is turned ON. According to self-diagnosis operation procedure, drive vehicle at approximately 30 km/h. Then confirm that ABS warning lamp goes out in approximately 1 minute. CAUTION: If ABS is not displayed on system selection screen, check ABS actuator, control unit and diagnostic connector route, and confirm program card number on CONSULT-II.

DATA MONITOR.
G

For details of the data monitor function, refer to the CONSULT-II Owner's Manual. Turn ignition switch to OFF. Connect the CONSULT-II connector to the data link connector on the vehicle. Turn ignition switch to ON. Touch Start on the display. Touch ABS on the display. CAUTION: Just after starting engine, or turning ignition switch ON, ABS may not be displayed on system selection screen even if START is touched. In this case, start self-diagnosis again from step 2. Touch DATA MONITOR. Return to monitor item selection screen, and touch any of Control Unit INPUT ITEM, MAIN ITEM or ITEM MENU SELECTION. Refer to the following Data monitor item chart. Touch MONITOR START. Screen of data monitor is displayed.

Operation Procedure
1. 2. 3. 4. 5.

6. 7.

8. 9.

Items to Be Displayed
Monitor item selection Item (Unit) WHEEL SENSOR F/L (km/h) WHEEL SENSOR F/R (km/h) WHEEL SENSOR R/L (km/h) WHEEL SENSOR R/R (km/h) WARNING LAMP (ON/OFF) Major item Item menu select Remarks Displays wheel speed calculated by front LH wheel sensor signal. Displays wheel speed calculated by front RH wheel sensor signal. Displays wheel speed calculated by rear LH wheel sensor signal. Displays wheel speed calculated by rear RH wheel sensor signal. Displays ABS warning lamp control condition in control unit. Displays operating condition (ON/ OFF) of stop lamp switch (ON/ OFF). Displays condition (ON/OFF) of ABS motor relay. Displays condition (ON/OFF) of ABS actuator relay. Displays ABS operation condition (ON/OFF). Displays operating condition (ON/ OFF) of front LH ABS outlet solenoid. Displays operating condition (ON/ OFF) of front LH ABS inlet solenoid. Displays operating condition (ON/ OFF) of front RH ABS outlet solenoid.

Stop lamp switch (ON/OFF)

ABS motor relay (ON/OFF) ABS ACTUATOR RELAY (ON-OFF) ABS operation signal (ON/OFF)

ABS outlet S/V-FL (ON/OFF)

ABS inlet S/V-FL (ON/OFF)

ABS outlet S/V-FR (ON/OFF)

BRC-20

TROUBLE DIAGNOSIS
Monitor item selection Item (Unit) Major item Item menu select Remarks Displays operating condition (ON/ OFF) of front RH ABS inlet solenoid. Displays operating condition of rear outlet ABS solenoid (ON/OFF) Displays operating condition of rear inlet ABS solenoid (ON/OFF) Displays voltage supplied to ABS control unit. Displays values measured by voltage probe.

ABS inlet S/V-FR (ON/OFF)

ABS outlet S/V-R (ON-OFF) ABS inlet S/V-R (ON-OFF) Power supply voltage (V) Voltage (V) : Applicable : Not applicable

ACTIVE TEST Operation Procedure

CAUTION: G Do not perform the active test while driving. G Make sure to completely bleed air from the brake system. G The active test cannot be performed with the ABS warning lamp on. 1. Connect CONSULT-II connector to diagnosis connector, then start engine. 2. Touch Start on the display. 3. Touch ABS. 4. Touch ACTIVE TEST. 5. The test item selection screen is displayed. 6. Touch test item.

BRC

L
PBR385C

7. 8.

Touch START with MAIN SIGNALS line inverted. The active test screen is displayed.

Items to Be Displayed
ABS solenoid valve Touch UP, KEEP and DOWN to check that the ABS solenoid valves (inlet/outlet) operate in accordance with the following chart.
Operation ABS inlet S/V ABS outlet S/V Up OFF OFF Keep ON OFF Down ON ON*

*: ON for 1 to 2 seconds after the touch, and then OFF

SFIA0395E

BRC-21

TROUBLE DIAGNOSIS
NOTE: G If active test is performed with brake pedal depressed, pedal stroke may be changed. This is a normal condition. G TEST STOP is displayed 10 seconds after starting the operation. G After TEST STOP is displayed, to perform the test again, repeat step 6 of the operation procedure.

SFIA0396E

ABS motor Touch ON and OFF on the screen to check that the ABS motor relay operates as shown in the following chart.
Operation ABS actuator ABS motor ON ON ON OFF ON OFF

NOTE: G If active test is performed with brake pedal depressed, pedal stroke may be changed. This is a normal condition. G TEST STOP is displayed 10 seconds after starting the operation.

SFIA0397E

Basic Inspection
BASIC INSPECTION 1 BRAKE FLUID LEVEL AND LEAK INSPECTION
1. 2.

EFS001LI

Check the fluid level in the brake reservoir tank. If the fluid level is low, refill the brake fluid. Check area around the brake piping and ABS actuator for leaks. If a leak or oozing is detected, check as follows: G If the connections at the ABS actuator are loose, tighten the piping to the specified torque. Then check again for leaks, and make sure that there is no fluid leak. G If flare nuts at the connections and the threads of the ABS actuator are damaged, replace damaged parts. Then check again for leaks, and make sure there is no fluid leak. G If a leak or oozing is detected on parts other than the ABS actuator connections, wipe the applicable part with a clean cloth. Then check again for leaks, and if there is still a leak or oozing, replace the damaged part. G If a leak or oozing is detected on the ABS actuator body, wipe the applicable part with a clean cloth. Then check again for leaks, and if there is still a leak or oozing, replace the ABS actuator and control module. CAUTION: ABS actuator body cannot be disassembled. Do not attempt to disassemble it.

BASIC INSPECTION 2 INSPECTION FOR LOOSE POWER SUPPLY TERMINAL

Check battery for looseness on the battery positive/negative terminals and ground connection.

BASIC INSPECTION 3 ABS WARNING LAMP INSPECTION

1. 2. 3. 4. Make sure ABS warning lamp turns on when ignition switch is turned ON. If it does not turn on, check ABS warning lamp path. Make sure that the ABS warning lamp turns off after approximately a 1 second delay when the ignition switch is turned ON. If it does not turn off, perform the self-diagnosis. Make sure ABS warning lamp remains off after the vehicle has been driven at approximately 30 km/h for approximately 1 minute. If it turns on, perform self-diagnosis. After completing self-diagnosis, always erase the diagnostic memory. Refer toBRC-16, "HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)" or BRC-17, "Operation Procedure" .

BRC-22

TROUBLE DIAGNOSIS Wheel Sensor System

INSPECTION PROCEDURE
Malfunctioning wheel sensor can be identified by self-diagnosis result using CONSULT-II.
EFS001LJ

1. INSPECTION START
Wheel sensor inspection >> GO TO 2.

E
SFIA0487E

2. CONNECTOR INSPECTION
1. Disconnect connector between control unit and malfunctioning wheel sensor. Check terminal for deformation, and check connector for improper connection. Then connect connector. 2. Perform self-diagnosis. Does ABS warning lamp illuminate? YES >> GO TO 3. NO >> Inspection End

BRC

3. WHEEL SENSOR CIRCUIT INSPECTION

1. 2. Disconnect ABS actuator and electric unit harness connector M134. Check resistance between terminals. (Check resistance when turning steering wheel to right and left, or moving sensor harness in wheel housing.) Front RH Front LH Rear RH Rear LH Resistance OK or NG OK >> GO TO 5. NG >> GO TO 4. : Terminal 4 (B) - 5 (W) : Terminal 6 (G) - 7 (R) : Terminal 1 (LG) - 2 (PU) : Terminal 8 (L) - 9 (P) Front Rear :1.44 - 1.76 k :1.44 - 1.76 k

L
SFIA0488E

BRC-23

TROUBLE DIAGNOSIS

4. WHEEL SENSOR INSPECTION

Check internal resistance of wheel sensor. Resistance Front Rear :1.44 - 1.76 k :1.44 - 1.76 k

OK or NG OK >> Repair harness and connector between control unit and wheel sensor. NG >> Replace wheel sensor.

SFIA0186E

5. TIRE INSPECTION
Check air pressure, wear, and size. Are air pressure, wear, and size within standard? YES >> GO TO 6. NO >> Adjust air pressure, or replace tire.

6. SENSOR ROTOR INSPECTION

Check sensor rotor tooth for damage. OK or NG OK >> Check control unit pin terminals for damage. Also check that connector is properly connected. If necessary, connect connector again, and recheck it. NG >> Replace sensor rotor.

Control Unit Power Supply System

INSPECTION PROCEDURE
Disconnect ABS actuator and control unit connector. Check continuity and voltage between vehicle-side connector terminals and body ground.
Terminal No. (Wire color) 15 (GY), 17 (BR), 18 (Y) 16 (B) Signal name Power supply Ground Measurement condition Ignition switch ON Ignition switch OFF Measurement Battery voltage Continuity should exist.

EFS001LK

SFIA0187E

ABS Function Is Activated Frequently

EFS001LL

1. INSPECTION START
Check brake force distribution. OK or NG OK >> GO TO 2. NG >> Check brake system

2. WHEEL SENSOR INSPECTION

1. Check wheel sensor connector terminals for deformation, and check connector for improper connection. 2. Check wheel sensor. Refer to BRC-23, "Wheel Sensor System" . Is wheel sensor functioning properly? YES >> GO TO 3. NO >> Repair the sensor.

BRC-24

TROUBLE DIAGNOSIS

3. FRONT AND REAR AXLE INSPECTION

Check front and rear axle for excessive looseness. OK or NG OK >> GO TO 3.Warning Lamp Indicator Inspection in BRC-25, "Unexpected Pedal Reaction" . NG >> Repair the axle.

Unexpected Pedal Reaction

EFS001LM

1. BRAKE PEDAL STROKE INSPECTION

Check brake pedal stroke. Is brake pedal stroke excessive? YES >> G Bleed air from the brake piping. G Check brake system. NO >> GO TO 2.

2. CONNECTOR INSPECTION AND PERFORMANCE CHECK

Disconnect ABS actuator and control unit connector to deactivate ABS. In this condition, check if braking force is normal. After inspection, connect connector. OK or NG OK >> GO TO 3. NG >> Check brake system.

BRC

3. WARNING LAMP INDICATOR INSPECTION

During driving, check that warning lamp does not illuminate. OK or NG OK >> GO TO 4. NG >> Perform self-diagnosis. Refer to BRC-14, "SELF-DIAGNOSIS PROCEDURE" or BRC-17, "Operation Procedure" .

4. WHEEL SENSOR INSPECTION

K

1. Check wheel sensor connector terminals for deformation, and check connector for improper connection. 2. Check wheel sensor. Refer to BRC-23, "Wheel Sensor System" . Is wheel sensor functioning properly? YES >> Check control unit connector terminal for deformation, and check connector for improper connection. Then connect connector, and check again. NO >> Repair the sensor.

Longer Stopping Distance

EFS001LN

CAUTION: On slippery road, vehicles with ABS may require longer braking distance than vehicles without ABS.

1. CONNECTOR AND PERFORMANCE INSPECTION

Disconnect ABS actuator and control unit connector to deactivate ABS. In this condition, check stopping distance. After inspection, connect connector. OK or NG OK >> G Bleed air from the brake piping. G Check brake system. NG >> GO TO 3.Warning Lamp Indicator Inspection in BRC-25, "Unexpected Pedal Reaction" .

ABS Does Not Work

CAUTION: When vehicle speed is 10 km/h or lower, ABS does not operate.

EFS001LO

BRC-25

TROUBLE DIAGNOSIS

1. WARNING LAMP INDICATOR INSPECTION

Confirm ABS warning lamp operation. Does ABS warning lamp operate? YES >> Perform self-diagnosis. Refer to BRC-14, "SELF-DIAGNOSIS PROCEDURE" or BRC-17, "Operation Procedure" . NO >> GO TO 3.Warning Lamp Indicator Inspection in BRC-25, "Unexpected Pedal Reaction" .

Pedal Vibration and Noise

EFS001LP

CAUTION: Under the following conditions, when brake pedal is lightly depressed (just placing a foot on it), ABS is activated and vibration is felt. However, this is normal. G When shifting gears or operating clutch G When driving on slippery road G During cornering at high speed G When passing over bumps or grooves (50 mm (1.97 in) or more) G When pulling away just after starting engine (at approximately 10 km/h (6 MPH) or higher)

1. INSPECTION START
Pedal vibration and noise inspection >> GO TO 2.

2. SYMPTOM INSPECTION
Apply parking brake, and start engine. Does symptom occur when engine started? YES >> Perform self-diagnosis. Refer to BRC-14, "SELF-DIAGNOSIS PROCEDURE" or BRC-17, "Operation Procedure" . NO >> GO TO 3.

3. SYMPTOM INSPECTION
Operate electrical equipment (head lamp or equivalents), and confirm symptoms. When electrical equipment (head lamp or equivalents) switch is operated, do symptoms occur? YES >> GO TO 4. NO >> GO TO 3.Warning Lamp Indicator Inspection in BRC-25, "Unexpected Pedal Reaction" .

4. WHEEL SENSOR INSPECTION

Inspect shield wire of wheel sensor harness for proper grounding. For location of shield ground, refer to BRC11, "Wiring Diagram ABS " . OK or NG OK >> Check control unit connector terminal for deformation, and check connector for improper connection. Then connect connector, and check again. NG >> Repair the sensor.

BRC-26

WHEEL SENSORS WHEEL SENSORS Removal and Installation

PFP:47910

A
EFS001LQ

BRC

I
SFIA0149E

CAUTION: G Ensure that sensor edges and rotor teeth are not damaged. When removing front or rear wheel hub, first remove wheel sensor. This is to prevent sensor wire damages and resultant sensor malfunctions. G To remove sensor, pull it off straightly. Do not turn sensor or pull on sensor harness. G Before installation, check following: foreign objects such as metal fragments on sensor pickup, deposits on inner wall of sensor installation hole, foreign objects caught between rotor mounting face. If any unusual condition is found, thoroughly clean contaminated faces. After installing sensor, tighten retaining nuts and bolts to specified torque.

BRC-27

SENSOR ROTOR SENSOR ROTOR Removal and Installation

REMOVAL Front
G

PFP:47970
EFS001L9

Remove sensor rotor from front hub. Refer to FAX-6, "DISASSEMBLY" . Remove wheel hub and sensor rotor. Refer to RAX-12, "DISASSEMBLY" .

Rear
G

INSTALLATION Front
G

Install sensor rotor to front hub. Refer to FAX-6, "ASSEMBLY" . Install sensor rotor to wheel hub. Then install wheel hub to vehicle. Refer to RAX-14, "ASSEMBLY" .

Rear
G

BRC-28

ABS ACTUATOR AND CONTROL UNIT ABS ACTUATOR AND CONTROL UNIT Removal and Installation
PFP:47660

A
EFS001LA

BRC

I
SFIA0145E

REMOVAL
Be careful of the following. CAUTION: G Before servicing, disconnect battery cables. G When removing brake tubes, always use flare nut wrench. Do not damage flare nuts and brake tubes. To install, make sure to use flare nut torque wrench to tighten flare nuts to specified torque.

INSTALLATION
Be careful of the following. G Tighten mounting nuts and bolts to the specified torque. G After installation, bleed brake piping. Refer to BR-9, "Bleeding Brake System" .

BRC-29

ABS ACTUATOR AND CONTROL UNIT

BRC-30