Braking System

BRAKING SYSTEM
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . P– 2 DISC PAD (FRONT) REPLACEMENT

CONVENTIONAL BRAKE SYSTEM . . . . . . . . . . . P– 3 (4x4) (VEHICLES BUILT FROM 08/2002) . . . P–29
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . P– 3 CALIPER (FRONT) DISASSEMBLY/
VACUUM LINE INSPECTION . . . . . . . . . . . . . . P– 3 ASSEMBLY (VEHICLES BUILT
BRAKE PEDAL INSPECTION . . . . . . . . . . . . . . P– 3 UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . . P–29
BRAKE PEDAL REMOVAL/INSTALLATION . . P– 4 CALIPER (FRONT) DISASSEMBLY/
BRAKE SWITCH INSPECTION . . . . . . . . . . . . . P– 5 ASSEMBLY (4x4) (VEHICLES BUILT
MASTER CYLINDER REMOVAL/ FROM 08/2002) . . . . . . . . . . . . . . . . . . . . . . . . . P–30
INSTALLATION (VEHICLES BUILT REAR BRAKE (DRUM) INSPECTION . . . . . . . P–31
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . . P– 5 REAR BRAKE (DRUM) REMOVAL/
MASTER CYLINDER REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . P–31
INSTALLATION (VEHICLES BUILT BRAKE DRUM INSPECTION . . . . . . . . . . . . . . . P–32
FROM 08/2002) . . . . . . . . . . . . . . . . . . . . . . . . . P– 8 WHEEL CYLINDER DISASSEMBLY/
FLUID LEVEL SENSOR INSPECTION . . . . . . P–10 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–32
MASTER CYLINDER DISASSEMBLY/ PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . . . P–32
ASSEMBLY (VEHICLES BUILT PARKING BRAKE (STICK TYPE)
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . . P–11 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . P–32
MASTER CYLINDER DISASSEMBLY/ PARKING BRAKE (STICK TYPE)
ASSEMBLY (VEHICLES BUILT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . P–32
FROM 08/2002) . . . . . . . . . . . . . . . . . . . . . . . . . P–13 PARKING BRAKE LEVER (STICK TYPE)
POWER BRAKE UNIT INSPECTION REMOVAL/INSTALLATION . . . . . . . . . . . . . . . P–33
(VEHICLES BUILT UP TO 07/2002) . . . . . . . . P–14 PARKING BRAKE CABLE (STICK TYPE)
POWER BRAKE UNIT INSPECTION REMOVAL/INSTALLATION . . . . . . . . . . . . . . . P–34
(VEHICLES BUILT FROM 08/2002) . . . . . . . . P–15 ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . . . P–35
POWER BRAKE UNIT REMOVAL/ ABS LOCATION INDEX . . . . . . . . . . . . . . . . . . . P–35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . P–16 ABS HU/CM SYSTEM INSPECTION . . . . . . . . P–36
VACUUM SWITCH INSPECTION (DIESEL) . . P–16 ABS HU/CM REMOVAL/INSTALLATION . . . . . P–38
VACUUM SWITCH ABS HU/CM INSPECTION . . . . . . . . . . . . . . . . . P–39
REMOVAL/INSTALLATION (DIESEL) . . . . . . P–17 FRONT ABS WHEEL–SPEED SENSOR
VACUUM PUMP INSPECTION (DIESEL) . . . . P–17 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . P–42
VACUUM PUMP REMOVAL/INSTALLATION FRONT ABS WHEEL–SPEED SENSOR
(DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–17 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . P–43
LOAD SENSING PROPORTIONING REAR ABS WHEEL–SPEED SENSOR
VALVE INSPECTION (VEHICLES REMOVAL/INSTALLATION . . . . . . . . . . . . . . . P–45
BUILT UP TO 07/2002) . . . . . . . . . . . . . . . . . . . P–18 REAR ABS WHEEL–SPEED SENSOR
LOAD SENSING PROPORTIONING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . P–46
VALVE INSPECTION (VEHICLES G SENSOR REMOVAL/INSTALLATION . . . . . P–47
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . . . . P–19 G SENSOR INSPECTION . . . . . . . . . . . . . . . . . P–47
LOAD SENSING PROPORTIONING ON–BOARD DIAGNOSTIC (ANTILOCK BRAKE
VALVE ADJUSTMENT SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–48
(VEHICLES BUILT UP TO 07/2002) . . . . . . . . P–20 ABS SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . P–48
LOAD SENSING PROPORTIONING ABS ON–BOARD DIAGNOSTIC . . . . . . . . . . . . P–49
VALVE ADJUSTMENT DTC TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–51
(VEHICLES BUILT FROM 08/2002) . . . . . . . . P–21 DTC PID/DATA MONITOR TABLE . . . . . . . . . . P–53
LOAD SENSING PROPORTIONING ACTIVE COMMAND MODES TABLE . . . . . . . . P–55
VALVE REMOVAL/INSTALLATION DTC B1318 (63) . . . . . . . . . . . . . . . . . . . . . . . . . . P–56
(VEHICLES BUILT UP TO 07/2002) . . . . . . . . P–22 DTC B1342 (61) . . . . . . . . . . . . . . . . . . . . . . . . . . P–57
LOAD SENSING PROPORTIONING DTC C1095 (54), C1096 (53) . . . . . . . . . . . . . . . P–58
VALVE REMOVAL/INSTALLATION DTC C1140 (30) . . . . . . . . . . . . . . . . . . . . . . . . . . P–59
(VEHICLES BUILT FROM 08/2002) . . . . . . . . P–23 DTC C1145 (11), C1155 (12), C1165 (13),
FRONT BRAKE (DISC) INSPECTION . . . . . . . P–24 C1175 (14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–60
FRONT BRAKE (DISC) REMOVAL/ DTC 1148 (41), C1158 (42), C1168 (43),
INSTALLATION (VEHICLES BUILT C1178 (44), C1233 (46), C1234 (45)
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . . P–25 C1235 (47), C1236 (48) . . . . . . . . . . . . . . . . . . P–62
DISC PAD (FRONT) REPLACEMENT DTC 1186 (51), C1266 (52) . . . . . . . . . . . . . . . . P–65
(VEHICLES BUILT UP TO 07/2002) . . . . . . . . P–26 DTC C1194 (24), C1198 (25), C1202 (26)
FRONT BRAKE (DISC) REMOVAL/ C1206 (27), C1210 (22), C1214 (23) . . . . . . . P–67
INSTALLATION (4x4) (VEHICLES DTC C1414 (64) . . . . . . . . . . . . . . . . . . . . . . . . . . P–67
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . . . . P–27 DTC C1510 (32), C1511 (33), C1512 (34),
C1513 (35) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–68
P–1
DTC C1949 (03), C1950 (04) . . . . . . . . . . . . . . . P–69 NO.3 THERE IS A MALFUNCTION IN
TROUBLESHOOTING (ANTILOCK BRAKE SYSTEM EVEN THOUGH ABS WARNING
SYSTEM) (2003 MY ONWARDS) . . . . . . . . . . . . P–71 LIGHT INDICATES THAT THE SYSTEM
ABS SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . P–71 IS NORMAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–78
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–72
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–72
SYMPTOM TROUBLESHOOTING . . . . . . . . . . P–73
NO.1 ABS WARNING LIGHT DOES NOT
ILLUMINATE WITH IGNITION SWITCH
(ENGINE SWITCH) ON . . . . . . . . . . . . . . . . . . . P–73
NO.2 ABS WARNING LIGHT STAYS ON FOR
MORE THAN 4 SECONDS WITH IGNITION
SWITCH (ENGINE SWITCH) ON . . . . . . . . . . P–74
GENERAL PROCEDURES Brake pipe flare nut tightening

D Tighten the brake pipe flare nut by using the SST
Wheel and tires removal/installation (49 0259 770B). Be sure to modify the brake pipe
D The removal and installation procedures for the flare nut tightening torque to allow for use of a
wheels and tires are not mentioned in this section. torque wrench-SST combination. (Refer to section
When a wheel is removed, retighten the wheel nuts GI, FUNDAMENTAL PROCEDURES, TORQUE
to the specified torque. (See TD Wheels and Tires. FORMULAS.)
Brake lines disconnection/connection Connectors disconnection

D Disconnect the negative battery cable before
Caution performing any work that requires handling of
D Brake fluid will damage painted surfaces. If connectors. Reconnect the negative battery cable
brake fluid get on a painted surface, wipe it only after the work is completed.
off immediately.
ABS components operation Note
D If any brake line has been disconnected anytime D Make sure that there are no DTCs in the ABS
during the procedure, add brake fluid, bleed the memory after working on ABS components. If there
brakes, and inspect leakage after the procedure are any DTCs in the memory, clear them.
has been completed.
Fluid specification
SAE J1703 or FMVSS116 DOT–3 or DOT–4
P–2
CONVENTIONAL BRAKE SYSTEM
CONVENTIONAL BRAKE SYSTEM VACUUM LINE INSPECTION

1. Remove the clamps and the vacuum hose.
AIR BLEEDING 2. Apply both suction and pressure to the engine-side
hose (Gasoline) or vacuum pump side of the hose
Note (Diesel), and verify that air blows only toward that
D The reservoir should be kept 3/4 full during side. If air flows in both directions or not at all,
bleeding. replace the vacuum hose.
D The brakes should be bled whenever a brake
line is disconnected. If a hydraulic line is
disconnected at the master cylinder, start at the
slave cylinder farthest from the brake master
cylinder, and move to the next farthest slave
cylinder until all four cylinders have been bled. CHECK VALVE
If the disconnection point is anywhere except
the master cylinder, start at the point closest to
the disconnection, and move to the next
closest slave cylinder until all four cylinders ENG
have been bled.
1. Remove the bleeder cap and attach a vinyl tube to BRAKE PEDAL INSPECTION
the bleeder screw. Brake Pedal Height Inspection
2. Place the other end of the vinyl tube in a clear D Verify that the distance from the center of the
fluid-filled container. upper surface of the pedal pad to the floor panel is
3. One person should depress the brake pedal a few as specified.
times, and then hold it in the depressed position.
4. A second person should loosen the bleeder screw, Pedal height
drain out the fluid and retighten the screw using the L.H.D.: 214—219 mm {8.43—8.81 in}
SST. R.H.D.:219—224 mm {8.63—8.81 in}
Tightening torque
Front:
9—14 N·m {92—142 kgf·cm, 80—123 in·lbf}
Rear: PEDAL HEIGHT
5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf}
49 0259 770B
5. Repeat steps 3 and 4 until no air bubbles are seen.

6. After air bleeding, inspect the following:
(1) brake operation
(2) fluid leakage
(3) fluid level
P–3
Brake Pedal Height Adjustment

1. Disconnect the brake switch connector.
2. Loosen locknut B and turn switch A until it does not D
contact the pedal.
3. Loosen locknut D and turn rod C to adjust the height.
4. Tighten the bolt with locknut B so that clearance
between the bolt for brake light switch A and pedal
C
stopper is within the specification.
Specification
0.1—1.0 mm {0.004—0.039 in}
Tightening torque
14—17 N·m {140—180 kgf·cm, 122—156 in·lbf} 5. After adjustment, inspect the pedal height and the
brake light operation.
5. Connect the brake switch connector.
6. After adjustment, inspect the pedal play and the Pedal-to-floor Clearance Inspection
brake light operation. 1. Start the engine and verify that the distance from
the floor panel to the pedal pad center is as
specified when the pedal is depressed with a force
D of 589 N {60 kgf, 132 lbf}.
A
Clearance
105 mm {4.2 in} min.
C B
Brake Pedal Play Inspection

1. Depress the pedal a few times to eliminate the
vacuum in the system.
2. Remove the snap pin, verify that the holes in the
fork and in the pedal are aligned, and reinstall the PEDAL-TO-FLOOR
pin. CLEARANCE
3. Gently depress the pedal by hand until resistance 2. If the distance is less than specified, inspect the
is felt (approx. 20N {2 kgf, 4.4 lbf}) and inspect following:
the free play. (1) Air in brake system
(2) Malfunction of the automatic adjuster
Pedal play (3) Excessive shoe clearance
3—8 mm {0.12—0.31 in}
BRAKE PEDAL REMOVAL/INSTALLATION
R.H.D.
The brake pedal is mounted on the bracket
integrated with the clutch pedal and accelerator
pedal. Refer to section F1—F4, INTAKE AIR
SYSTEM, ACCELERATOR PEDAL
REMOVAL/INSTALLATION for the brake pedal
removal/installation.
L.H.D.
The brake pedal is mounted on the bracket
integrated with the clutch Pedal. Refer to section
H, CLUTCH PEDAL REMOVAL/INSTALLATION for
the brake pedal removal/installation.
Brake Pedal Play Adjustment
1. Remove the snap pin and clevis pin.
2. Loosen locknut D and turn rod C to align the holes
in the fork and in the pedal.
3. Install the clevis pin and the snap pin.
4. Tighten locknut D.
Tightening torque
24—34 N·m {2.4—3.5 kgf·m, 18—25 ft·lbf}
P–4
BRAKE SWITCH INSPECTION R.H.D.

1. Disconnect the brake switch connector.
2. Inspect for continuity between the terminals of the
brake switch connector using the circuit tester.
: Continuity
Terminal
Condition SST
A B
R
When the brake pedal is
depressed.
When the brake pedal is
not depressed.
SST *
12.9—21.5
A {130—220, 113—190} 9.81—15.6
{100—160, 87—138}
B
* 49 0259 770B
N·m {kgf·cm, in·lbf}
1 Brake fluid level sensor connector

3. If not as specified, replace the brake switch. 2 Brake pipe
3 Bracket (R.H.D.)
MASTER CYLINDER REMOVAL/INSTALLATION 4 Master cylinder
(VEHICLES BUILT UP TO 07/2002) + Installation Note
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal. 5 O-ring
L.H.D.
Master Cylinder Installation Note
1. Loosen the adjusting nut of the SST.
2. Place the SST on the power brake unit and tighten
the nut and washer.
Tightening torque
SST 9.81—15.6 N·m
{100—160 kgf·cm, 87—138 in·lbf}
R 3. Apply 66.7 kPa {500 mmHg, 19.7 inHg} vacuum to
the power brake unit using a vacuum pump.
9.81—15.6
{100—160, 87—138}
SST *
12.9—21.5
{130—220, 113—190}
* 49 0259 770B N·m {kgf·cm, in·lbf} 49 B043 001
P–5
4. Turn the adjusting nut of the SST counterclockwise Clearance at B

until the gauge rod just contacts the push rod end 1. Measure and record the height D1 of the gauge
of the power brake unit. Push lightly on the end of rod.
the gauge rod to be sure it is seated. Verify that
there is no gap between the adjusting nut and SST
body.
5. Remove the SST from the power brake unit.
(D1)
TOUCHING
49 B043 001
49 B043 001
2. Turn the adjusting nut until the SST body sets

TOUCHING
ADJUSTING NUT closely on the master cylinder. Turn only enough
for the body to touch.
3. Measure and record height D2 of the gauge rod.
6. Remove the SST from the power brake unit without ADJUSTING NUT
disturbing the adjusting nut. Set the SST onto the
master cylinder as shown in the figure. (D2)
7. Push lightly on the end of the SST gauge rod to be
sure that it is contacting the bottom of the master
cylinder piston, but do not push so hard that the
piston moves. Note any clearance between the
SST body and the adjusting nut: clearance B, or
between the body and the master cylinder:
clearance C. Adjust the push rod as necessary as CLEARANCE (B)
outlined in “Adjustment” below. 49 B043 001
Adjustment
4. Subtract D1 from D2. Using the SST, turn the nut
Measurement Push rod to shorten the power brake unit push rod an
Clearance at B Too long amount equal to the difference.
Clearance at C Too short
49 B043 004
No clearance at B or C Okay
CLEARANCE (C)
49 B043 001
49 E043 003A
CLEARANCE (B)
P–6
Clearance at C
1. Push lightly on the end of the SST gauge rod, and
measure the clearance between the adjusting nut
and the SST body.
CLEARANCE (C)
49 B043 001
2. Using the SSTs, turn the nut to lengthen the power

brake unit push rod an amount equal to the
clearance measured at B.
49 B043 004
49 E043 003A
P–7
MASTER CYLINDER REMOVAL/INSTALLATION

(VEHICLES BUILT FROM 08/2002)

2. Install in the reverse order of removal.
1 Brake fluid level sensor connector 3 Bracket

2 Brake pipe 4 Master cylinder
(See Master Cylinder Installation Note)
Master Cylinder Installation Note

1. Turn the nut of the SST clockwise to fully retract
the SST gauge rod. Attach the SST to the power
brake unit.
Tightening torque
9.9—15 N·m {1.0—1.6 kgf·m, 7.3—11 ft·lbf}
2. Apply vacuum of 66.7 kPa {500 mmHg, 19.7

inHg} using a vacuum pump.
Caution
D When pushing the SST gauge rod into the
master cylinder piston, only use enough
pressure to push the rod to the bottom of
the piston. If too much pressure is applied,
a false reading will occur.
3. Turn the adjusting nut of the SST counterclockwise

until the gauge rod just contacts the push rod end
of the power brake unit. Push lightly on the end of
the gauge rod to be sure it is seated. Verify that
there is no gap between the adjusting nut and SST
body.
4. Remove the SST from the power brake unit without
disturbing the adjusting nut. Set the SST onto the
master cylinder as shown in the figure.
P–8
5. Push lightly on the end of the SST gauge rod to be

sure it has contacted the bottom of the master
cylinder piston, but do not push so hard that the
piston moves. Take note of any clearance between
the SST body and the adjusting nut (clearance B)
or between the body and the master cylinder
(clearance C).
Measurement Push rod

Clearance at (B) Too short
Clearance at (C)
Too long
No clearance at (B) or (C)
Adjusting the push rod clearance at C or no
clearance at B or C
Note
D The threads of the push rod are specially
designed so that the bolt becomes harder to
turn past a certain point. This is to prevent the
bolt from coming loose. Turn the bolt only
within this range when adjusting.
1. Measure and record height D1 of the gauge rod.

2. Turn the adjusting nut until the SST body sets
squarely on the master cylinder. (Turn only enough
for the body to touch.)
Adjusting the push rod clearance at B
Note 3. Measure and record height D2 of the gauge rod.

D The threads of the push rod are specially
designed so that the bolt becomes harder to
turn past a certain point. This is to prevent the
bolt from coming loose. Turn the bolt only
within this range when adjusting.
1. Push lightly on the end of the SST gauge rod, and

measure the clearance between the adjusting nut
and the SST body.
2. Using the SST, turn the nut to lengthen the power

booster push rod an amount equal to the sum
subtracting 0.1—0.4 mm {0.004—0.016 in} from
the clearance measured at B.
P–9
4. Subtract D1 from D2 and add 0.1—0.4 mm

{0.004—0.016 in}. Using the SST, turn the nut to
shorten the power booster push rod an amount
equal to the sum.
FLUID LEVEL SENSOR INSPECTION

1. Disconnect the sensor connector.
2. Connect an ohmmeter to the connector.
3. Starting with the fluid level above MIN, verify that
there is no continuity.
4. Remove the brake fluid and verify that there is
continuity when the level is below MIN.
: Continuity
Terminal
Fluid level
A B
Below MIN.
Above MIN.
5. If not as specified, replace the sensor.
P–10
MASTER CYLINDER DISASSEMBLY/ASSEMBLY (VEHICLES BUILT UP TO 07/2002)
Caution
D If the master cylinder body is damaged, replace the unit as a component. When securing the master
cylinder in a vise, tighten only the flange of the master cylinder.
1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.
À R
1.0—1.5
{10—15, 8.7—13}
R
2.0—2.4 {20—25, 18—21}
N·m {kgf·cm , in·lbf}
1 Cap set 10 Cup

2 Screw 11 Primary piston stopper
3 Reservoir 12 Primary piston
4 Joint bushing 13 Stop screw
5 Fluid level sensor + Assembly Note
6 Snap ring 14 O-ring
7 Spacer 15 Secondary piston
8 Piston guide 16 Master cylinder body
9 O-ring
P–11
Stop Screw and O-ring Assembly Note

1. Install a new O-ring onto the stop screw.
2. Push the primary piston component in full.
3. Install and tighten the stop screw.
Tightening torque
2.0—2.4 N·m {20—25 kgf·cm, 18—21 in·lbf}
P–12
MASTER CYLINDER DISASSEMBLY/ASSEMBLY

1. After removing the brake fluid, disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
1 Cap set 11 Cup

2 Pin 12 Primary piston stopper
3 Reservoir 13 Primary piston
4 Joint bushing 14 Stop screw (without ABS)
5 Brake fluid level sensor (See Stop Screw (without ABS) Assembly Note)
6 Seal and plate assembly 15 Stop pin (with ABS)
(See Stop Pin (with ABS) Assembly Note)
7 Snap ring
16 Gasket
8 Spacer
17 Secondary piston
9 Piston guide
18 Master cylinder body
10 O–ring
Stop Screw (without ABS) Assembly Note

1. Push the primary piston component in fully.
2. Install and tighten a new gasket and the stop
screw.
3. Push and release the piston to verify that it is held
by the stop screw.
P–13
Stop Pin (with ABS) Assembly Note 49 U043 004

49 U043 005
1. Install the secondary piston component with the
piston hole facing the stop pin.
2. Install and tighten a new gasket and the stop pin.
3. Push and release the piston to verify that it is held A PEDAL DE-
by the stop pin. A PRESSION
FORCE
GAUGE
VACUUM GAUGE
49 U043 006
2. After bleeding the air from the SST, conduct the

test as described in the following steps.
a) Inspection for vacuum loss

Unloaded condition
1. Start the engine.
2. Stop the engine when the vacuum gauge reading
POWER BRAKE UNIT INSPECTION reaches 66.7 kPa {500 mmHg, 19.7 inHg}.
(VEHICLES BUILT UP TO 07/2002) 3. Observe the vacuum gauge for 15 seconds. If the
Power Brake Unit Function Inspection gauge shows 63.3—66.7 kPa {475—500 mmHg,
(Simple method) 18.7—19.7 inHg}, the unit is operating.
Loaded condition
Note
D Replace power brake unit component as
2. Depress the brake pedal with a force of 196 N {20
necessary.
kgf, 44 lbf}.
Step 1 3. With the brake pedal depressed, stop the engine
when the vacuum gauge reading reaches 66.7 kPa
1. With the engine stopped, depress the pedal a few
times. {500 mmHg, 19.7 inHg}.
4. Observe the vacuum gauge for 15 seconds. If the
2. With the pedal depressed, start the engine.
3. If the pedal moves down slightly, immediately after gauge shows 63.3—66.7 kPa {475—500 mmHg,
the engine starts, the unit is operating. 18.7—19.7 inHg}, the unit is operating.
Step 2 b) Inspection for hydraulic pressure

1. When the engine is stopped (vacuum 0 kPa {0
2. Stop the engine after it has run for 1 or 2 minutes. mmHg, 0 inHg}) and the fluid pressure is within
3. Depress the pedal with the usual force. the specification, the unit is operating.
4. If the first pedal stroke is long and becomes shorter Pedal force Fluid pressure
with subsequent strokes, the unit is operating. 196 N
790 kPa {8 kgf/cm2, 114 psi} min
{20 kgf, 44 lbf}
Note
D If a problem is found, inspect for damage on 2. Start the engine. Depress the brake pedal when
the check valve or vacuum hose, and examine the vacuum reaches 66.7 kPa {500 mmHg, 19.7
the installation. Repair as necessary, and inHg}. If the fluid pressure is within the
inspect it again. specification, the unit is operating.
Pedal force Fluid pressure
Step 3
1. Start the engine. 196 N 8,240 kPa
2. Depress the pedal with the usual force. {20 kgf, 44 lbf} {84 kgf/cm2, 1,200 psi} min
3. Stop the engine with the pedal held depressed.
4. Hold the pedal down for about 30 seconds.
5. If the pedal height does not change, the unit is
operating.
(Inspection using the testers)

1. Connect the SSTs, vacuum gauge, and pedal
depression force gauge as shown in the figure.
Note
D Use commercially available gauges and pedal
depression force gauge.
D Bleed the air from the SST at gauge A.
P–14
POWER BRAKE UNIT INSPECTION

Power Brake Unit Function Inspection (Inspection
using gauges)
1. Connect the SST gauges, a vacuum gauge, and a
pedal depression gauge as shown in the figure.
Bleed the air from the SST gauges before
performing the following tests.
Checking for vacuum loss (unloaded condition)

2. Stop the engine when the vacuum gauge indicates
66.7 kPa {500 mmHg, 19.7 inHg).
3. Observe the vacuum gauge for 15 seconds.
D If the gauge indicates 63.4—66.6 kPa
475—500 mmHg, 18.8—19.6 inHg, the unit is
operating.
Checking for vacuum loss (loaded condition)

2. Depress the brake pedal with a force of 196 N {20
kgf, 44 lbf}.
3. With the brake pedal held depressed, stop the
engine when the vacuum gauge indicates 66.7 kPa
{500 mmHg, 19.7 inHg).
4. Observe the vacuum gauge for 15 seconds.
D If the gauge indicates 63.4—66.6 kPa
475—500 mmHg, 18.8—19.6 inHg, the unit is
operating.
Checking for hydraulic pressure

1. If the engine is stopped (vacuum 0 kPa {0 mmHg,
0 inHg}) and the fluid pressure is within the
specification, the unit is operating.
196 N
790 kPa {8 kgf/cm2, 114 psi}
{20 kgf, 44 lbf}
2. Start the engine. Depress the brake pedal when

the vacuum reaches 66.7 kPa {500 mmHg, 19.7
inHg}.
D If the fluid pressure is within specification, the
unit is operating.
196 N
8,040 kPa {82 kgf/cm2, 1,166 psi}
{20 kgf, 44 lbf}
P–15
POWER BRAKE UNIT REMOVAL/INSTALLATION VACUUM SWITCH INSPECTION (DIESEL)

1. Remove the master cylinder. (Refer to 1. Remove the vacuum hose from the power brake unit.
CONVENTIONAL BRAKE SYSTEM, MASTER 2. Set the vacuum pump hose (commercially
CYLINDER REMOVAL/INSTALLATION.) available on the market) onto the power brake unit
2. Remove in the order indicated in the table. as shown.
L.H.D.
19—25 3. Turn the engine switch on.

{1.9—2.6, 14—18} 4. Release the parking brake.
5. Apply vacuum to the power brake unit using the
vacuum pump (commercially available on the
market) and verify the operating condition of the
24—34 brake light warning light.
{2.4—3.5, 18—25}
Brake warning
Vacuum kPa {mmHg, inHg}
light
Below 10.7"1.3 {80"10, 3.2"0.4} ON
Above 10.7"1.3 {80"10, 3.2"0.4} OFF
N·m {kgf·m, ft·lbf}
6. The vacuum switch is functioning normally if it
R.H.D.
corresponds to the above specifications. Replace
the vacuum switch as necessary.
19—25
{1.9—2.6, 14—18}
24—34
{2.4—3.5, 18—25}
1 Vacuum switch connector (Diesel)

2 Vacuum hose
3 Snap pin
4 Clevis pin
5 Nut
6 Power brake unit
7 Gasket
8 Fork
9 Nut
P–16
VACUUM SWITCH REMOVAL/INSTALLATION VACUUM PUMP INSPECTION (DIESEL)

(DIESEL) 1. Warm up the engine.
1. Remove in the order indicated in the table. 2. Disconnect the vacuum hose from the vacuum
2. Install in the reverse order of removal. pump and connect a vacuum gauge as shown in
the figure, then inspect the vacuum.
L.H.D.
Vacuum specification (In 20 seconds)
Engine speed 1,500 rpm
73.3 kPa {550 mmHg, 21.7 inHg}
Maximum vacuum
Engine speed 3,000 rpm
93.3 kPa {700 mmHg, 27.6 inHg}
20—24
{2.0—2.5, 15—18} N·m {kgf·m, ft·lbf}
R.H.D.
3. If the pressure is less than the specification,

inspect for the following.
20—24 (1) Malfunction of the vacuum pump
{2.0—2.5, 15—18} N·m {kgf·m, ft·lbf} (2) Shortage of the lubrication oil pressure
1 Vacuum switch connector VACUUM PUMP REMOVAL/INSTALLATION

2 Vacuum switch (DIESEL)
+ Installation Note 1. Remove in the order indicated in the table.
Vacuum Switch Installation Note
1. Remove the old sealant.
Caution
D Do not apply sealant to the tip of the
vacuum switch as a malfunction may occur.
2. Apply sealant to the area shown before installation
of the vacuum switch onto the power brake unit,
and then tighten it to the specified torque.
Tightening torque
20—24 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}
R
DO NOT APPLY
SEALANT ON
THIS AREA 19—25 {1.9—2.6, 14—18}
1 Vacuum hose
2 Bolt
3 Vacuum pump
4 O-ring
P–17
LOAD SENSING PROPORTIONING VALVE

INSPECTION (VEHICLES BUILT UP TO 07/2002)
1. Place the vehicle on level ground.
2. Inspect the tire inflations and set them to the
recommended pressure as necessary.
3. Prepare the vehicle with a person in the driver’s
seat; include the standard vehicle tools, the spare
wheel and tire, and a full tank of fuel.
4. Connect pressure gauges (commercially available)
to the front and rear calipers.
Note
D When applying the specified pressure, the brake
pedal must not be “double pumped” or released.
D Approximately two seconds after setting the front
wheel cylinder fluid pressure, read the rear pres-
sure.
5. Bleed the air from the brake system.

6. Slowly depress the brake pedal until the front
pressure gauge indicates the specified pressure
shown in the table, then note the reading on the
rear pressure gauge.
kPa {kgf/cm2, psi}
Front pressure Rear pressure
4,900 {50, 711} 2,550 {26, 370}
9,810 {100, 1,422} 3,530 {36, 512}
LOADED
A PERSON IN
DRIVER’S SEAT
REAR PRESSURE
4,900 {50, 711} 9,810 {100, 1,422}
FRONT PRESSURE
kPa {kgf/cm2, psi}
7. If not as specified, replace and adjust the LSPV.
P–18
LOAD SENSING PROPORTIONING VALVE (LSPV) 5. Inspect the fluid pressure of rear wheel cylinder
INSPECTION (VEHICLES BUILT FROM 08/2002) while the fluid pressure of front wheel cylinder is
1. Place the vehicle on level ground. 4,900 kPa {50 kgf/cm2, 711 psi} and 9,800 kPa
2. Check the tire inflations and set them to the {100 kgf/cm2, 1,422 psi}.
recommended pressure if necessary. D If not as specified, adjust the LSPV.
D If not as specified, replace or adjust.
3. Check the vehicle with a person in the drivers seat;
include the standard vehicle tools, the spare wheel
and tire, and a full tank of fuel.
4. Install the SST to the front wheel cylinder and rear
wheel cylinder, then bleed the air in the brake line
and load sensing proportioning valve (LSPV) using
a air bleed valve A.
Specification
kPa {kgf/cm2, psi}
Front wheel cylinder
Type Rear wheel cylinder
fluid pressure
4,900 {50, 711} 2,250—2,850 {22.95—29.06, 327—413}
Without ABS
9,800 {100, 1,422} 3,130—3,930 {31.92—40.07, 454—569}
4x2
4,900 {50, 711} 2,910—3,710 {29.68—37.83, 423—538}
With ABS
9,800 {100, 1,422} 4,970—6,170 {50.68—62.91, 721—894}
4,900 {50, 711} 2,250—2,850 {22.95—29.06, 327—413}
Without ABS
9,800 {100, 1,422} 3,130—3,930 {31.92—40.07, 454—569}
4x4
4,900 {50, 711} 2,650—3,450 {27.03—35.18, 385—500}
With ABS
9,800 {100, 1,422} 4,700—5,900 {47.93—60.16, 682—855}
P–19

ADJUSTMENT (VEHICLES BUILT UP TO 07/2002)
1. Place the unloaded vehicle on level ground.
Unloaded condition: Fuel tank is full. Engine
coolant and engine oil are at
specified levels. Spare tire,
jack, and tools are in
designated position.
Note
D A change of 5 mm {0.197 in} dimension L
results in a change of 853 kPa {8.7 kgf/cm2,
124 psi} for 4 2 and 1020 kPa {10.4 kgf/cm2,
148 psi} for 4 4.
2. Adjust main spring dimension L between the LSPV

and the adjustment link by loosening and
repositioning the LSPV.
(1) Decrease dimension L if the fluid pressure is
low.
(2) Increase dimension L if the fluid pressure is
high.
Reference value
Dimension L
4 2: 147.5—154.5 mm {5.808—6.082 in}
4 4: 175.5—182.5 mm {6.910—7.185 in}
MAIN SPRING
ADJUSTMENT LINK
AXLE CASING
BOLT
3. After adjustment, recheck the fluid pressure. If not

as specified, replace the LSPV as a component.
P–20
LOAD SENSING PROPORTIONING VALVE (LSPV) kPa {kgf/cm2, psi}

ADJUSTMENT (VEHICLES BUILT FROM 08/2002)
Type Change
1. Place the unloaded vehicle on level ground. without ABS 850 {8.67, 123}
Unloaded: Fuel tank is full. Engine coolant and tire, 4x2
with ABS 1,020 {10.40, 148}
jack and tools are in designated position.
without ABS 1,060 {10.81, 154}
Note 4x4
with ABS 1,080 {11.01, 157}
D A change of 5mm {0.197 in} in dimension L
results in a change of the following. 2. Adjust main spring dimension L between the LSPV
and the adjustment link loosening and
repositioning the LSPV.
D Decrease dimension L if the fluid pressure is low.

D Increase dimension L if the fluid pressure is high.
Specification
Dimension L
mm {in}
Type Dimension L
without ABS 147.5—154.5
4x2
with ABS {5.81—6.08}
without ABS 175.5—182.5
4x4
with ABS {6.91—7.18
3. Tighten the nut.
Specification
18.6—25.4 N·m {1.89—2.60 kgf·m, 13.7—18.8
ft·lbf}
4. After adjustment, recheck the fluid pressure.
D If not as specified, replace the LSPV as a
component
P–21

REMOVAL/INSTALLATION (VEHICLES BUILT UP
TO 07/2002)
Caution
D Do not disassemble the LSPV.
D Do not move the nut A.

3. After installation, adjust the main spring dimension.
(Refer to CONVENTIONAL BRAKE SYSTEM,
ADJUSTMENT.)
12.8—21.5 N·m
{130—220 kgf·cm, 113—190 in·lbf}
SST * SST * 12.8—21.5 N·m
{130—220 kgf·cm,
113—190 in·lbf}
A
19—25 {1.9—2.6, 14—18}
19—25
{1.9—2.6, 14—18}
* 49 0259 770B
1 Brake pipe
2 Nut
3 Bolt
4 Load sensing proportioning valve
P–22
LOAD SENSING PROPORTIONING VALVE (LSPV) D Do not move nut A.

REMOVAL/INSTALLATION (VEHICLES BUILT FROM
08/2002) 1. Remove in the order indicated in the table.
Caution 3. After installation, adjust the main spring dimension.
D Do not disassemble the LSPV. (See LOAD SENSING PROPORTIONING VALVE
(LSPV) ADJUSTMENT.)
1 Brake pipe 3 Bolt

(See Brake Pipe Installation Note) 4 Load sensing proportioning valve (LSPV)
2 Nut
Brake Pipe Installation Note

1. Install the brake pipe to the load sensing
proportioning valve (LSPV) and align yellow
painting on the brake pipe and LSPV.
P–23
FRONT BRAKE (DISC) INSPECTION

Disc Pad Thickness Inspection
1. Jack up the front of the vehicle and support it on safe-
ty stands.
2. Remove the wheel and tires.
3. Look through the caliper inspection hole and
inspect the remaining thickness of the pads.
Thickness
2.0 mm {0.08 in} min.
4. Replace the pads as a set (right and left wheels) if

either is at or less than the minimum thickness. Disc Plate Runout Inspection (Vehicles built up to
07/2002)
1. Verify that there is no wheel bearing looseness.
2. Measure the runout at the outer edge of the
contact surface of the disc pad.
Runout
0.05 mm {0.002 in} max.
3. If the runout is not within the specification, repair or

replace the disc plate.
Disc Plate Thickness Inspection

1. Measure the thickness of the disc plate.
Caution
D When it is necessary to machine the disc
plate, if the disc plate is removed from the
vehicle then machined, excessive runout
may result. Machine the disc plate with it
installed on the vehicle.
(Vehicles built up to 07/2002) Disc Plate Runout Inspection (Vehicles built from
08/2002)
Standard 1. Tighten the disc plate to the wheel hub using two
24 mm {0.94 in} wheel nuts. When measuring runout, measure at
Minimum the outer edge of the disc plate surface.
22 mm {0.87 in}
Minimum thickness after machining by using a Runout limit
brake lathe on-vehicle 0.05 mm {0.002 in} max.
22.8 mm {0.90 in}
(Vehicles built from 08/2002)
Standard thickness:
28.0 mm {1.10 in)
Minimum thickness:
26.0 mm {1.02 in)
Minimum thickness after machining by using a
brake lathe on-vehicle
26.8 mm {1.06 in}
2. If the thickness is not within the specification,

replace the disc plate.
P–24
FRONT BRAKE (DISC) REMOVAL/INSTALLATION

(VEHICLES BUILT UP TO 07/2002)
3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.
22—29
{2.2—3.0, 16—29}
R
29—34
{2.9—3.5, 21—25}
R
108—127
{10.4—14.0, 80—94}
SST
1 Brake hose 6 Disc pad

2 Bolt + Installation Note
3 Guide pin 7 Plate
4 Dust boot 8 Guide plate
5 Caliper 9 Mounting support
P–25
Disc Pad Installation Note

1. Push the piston fully inward using the SST.
2. Install the disc pad.
49 0221 600C
DISC PAD (FRONT) REPLACEMENT (VEHICLES

BUILT UP TO 07/2002)
29—34
{2.9—3.5, 21—25}
SST
1 Bolt
2 Caliper
3 Disc pad
+ CONVENTIONAL BRAKE SYSTEM, FRONT
BRAKE (DISC) REMOVAL/INSTALLATION,
4 Plate
5 Guide plate
P–26
FRONT BRAKE (DISC) REMOVAL/INSTALLATION (4X4)

Caution
D Performing the following procedures without first removing the ABS wheel–speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel–speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.

3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.
1 Flexible hose 7 Inner shim (cover shim)

2 Guide pin (See Outer Shim, Inner shim Installation Note)
3 Caliper 8 Inner shim (rubber coated shim)
(See Outer Shim, Inner shim Installation Note)
4 Disc pad
(See Disc Pad Installation Note) 9 Guide plate
(See Guide Plate Removal Note)
5 Outer shim (cover shim)
(See Outer Shim, Inner shim Installation Note) 10 Mounting support
6 Outer shim (rubber coated shim) 11 Disc plate

(See Outer Shim, Inner shim Installation Note) (See Disc Plate Removal Note)
(See Disc Plate Installation Note)
P–27
Guide Plate Removal Note

1. Pull up and at a slant on the supporting part of the
guide plate in the direction indicated by the arrow
(1) and (2) as shown in the figure, to remove the
guide plate from the mounting support.
Caution
D If the guide plate is removed by pulling in
the direction indicated by the arrow as
shown in the figure, the stopper may be
deformed and not able to be reused. Do not
remove in this manner
3. Assemble the cover–shim to the grease–applied
rubber coated shim.
Caution
D Be careful not to get any grease on the pad
lining surface.

1. Push the piston fully inward using the SST.
2. Install the disc pad.
Disc Plate Removal Note

1. Mark the wheel hub bolt and disc plate before
removal for reference during installation.
Disc Plate Installation Note

1. Remove any rust or grime on the contact face of
the disc plate and wheel hub.
2. Install the disc plate and align the marks made
before removal.
Outer Shim, Inner shim Installation Note

1. Assemble the rubber coated shim to the back plate
of the disc pad.
2. Apply brake grease to the rubber coated shim as
shown in the figure.
P–28
DISC PAD (FRONT) REPLACEMENT (4X4) CALIPER (FRONT) DISASSEMBLY/ASSEMBLY

(VEHICLES BUILT FROM 08/2002) (VEHICLES BUILT UP TO 07/2002)
1. Remove in the order indicated in the table. 1. Disassemble in the order indicated in the table.
2. Install in the reverse order of removal. 2. Assemble in the reverse order of disassembly.
*
SST
9—14
{92—143, 80–123}
SST
*49 0259 770B N·m {kgf·cm, in·lbf}
1 Bolt 1 Piston
+ Disassembly Note
2 Caliper
2 Dust seal
3 Guide pin
3 Piston seal
4 Disc pad + Disassembly Note
(See Disc Pad Installation Note)
4 Bleeder cap, screw
5 Outer shim (cover shim)
(See Outer Shim, Inner shim Installation Note) 5 Caliper body
6 Outer shim (rubber coated shim)
Piston Disassembly Note
(See Outer Shim, Inner shim Installation Note
7 Inner shim (cover shim) Caution
(See Outer Shim, Inner shim Installation Note) D Blow the compressed air slowly to prevent
8 Inner shim (rubber coated shim) the piston from suddenly popping out.
(See Outer shim, Inner shim Installation Note)
9 Guide plate D Place a piece of wood in the caliper, then blow
(See Guide Plate Removal Note) compressed air through the hole to force the piston
out of the caliper.
WOOD
P–29
Piston Seal Disassembly Note 1 Dust seal

D Remove the piston seal from the brake caliper
2 Piston
using the SST.
(See Piston Disassembly Note)
3 Piston seal
(See Piston Seal Disassembly Note)
4 Bleeder cap
5 Bleeder screw
6 Caliper
Piston Disassembly Note
Caution
D Blow the compressed air slowly to prevent
the piston from suddenly popping out.
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY
(4X4) (VEHICLES BUILT FROM 08/2002) 1. Place the SST in the caliper, the blow compressed
air through the hole to force the piston out of the
1. Disassemble in the order indicated in the table. caliper.
2. Assemble in the reverse order of removal.
Piston Seal Disassembly Note

1. Remove the piston seal from the brake caliper
using the SST.
P–30
REAR BRAKE (DRUM) INSPECTION

Brake Lining Thickness Inspection
1. Remove the brake drum.
2. Inspect the remaining thickness of the lining.
Thickness
1.0 mm {0.04 in} min.
3. Replace both left and right brake shoes if either is

at or less than the minimum thickness.
REAR BRAKE (DRUM) REMOVAL/INSTALLATION

3. After installation.
(1) Depress the brake pedal a few times, then verify that the brakes do not drag.
(2) Inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK
TYPE) INSPECTION, Parking Brake Lever Stroke Inspection.)
9.8—12.7
{100—130, 87—112}
* SST
12.8—21.5
{130—220, 113—190} APPLY TO SHADED EREA
*49 0259 770B N·m {kgf·cm, in·lbf}
1 Brake drum 8 Adjust strut

2 Hold spring, washer 9 Brake shoe
3 Hold pin 10 Parking brake cable
4 Lower return spring 11 Operating lever
5 Upper return spring 12 Brake pipe
6 Pawl lever spring 13 Wheel cylinder
7 Pawl lever 14 Gasket
P–31
BRAKE DRUM INSPECTION PARKING BRAKE SYSTEM

1. Measure the inner diameter of the drum.
PARKING BRAKE (STICK TYPE) INSPECTION
Maximum diameter Parking Brake Lever Stroke Inspection
4 2: 271.5 mm {10.68 in} 1. Pull the parking brake lever a few times.
4 4: 296.5 mm {11.67 in} 2. Verify that the stroke is within the specification
when the parking brake lever is pulled with a force
of 98 N {10 kgf, 22 ibf}.
2. Apply chalk to the inside of the brake drum.
3. Inspect for scratches and uneven or abnormal Stroke
wear inside the drum as shown in the figure. 1—7 notches
3. If not as specified, adjust the parking brake lever

stroke.
PARKING BRAKE (STICK TYPE) ADJUSTMENT

Parking Brake Lever Stroke Adjustment
1. Before adjustment, depress the brake pedal
several times while the vehicle is moving in
reverse.
2. Loosen the locknut A and turn the adjustment nut
B so that the stroke is within the above range.
3. After adjustment, tighten the locknut A.
4. Repair or replace the drum as necessary. Repair if
the problem is minor. Tightening torque
5. When repairing or replacing the drum, check the 6.9—9.8 N·m {70—100 kgf·cm, 43—86 in·lbf}
contact with the shoes.
6. Wipe the chalk off after inspection.
WHEEL CYLINDER DISASSEMBLY/ASSEMBLY B

1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly. A
R
SST *
4. After adjustment, inspect the following points.
5.9—8.8 (1) Turn the ignition (engine) switch on, pull the
{ 60—90 , 53—78 } parking brake lever one notch, and verify that
the brake warning light illuminates.
R (2) Verify that the rear brakes do not drag when
the wheels are turned by hand.
* 49 0259 770B N·m { kgf·cm , in·lbf }
1 Dust boot
2 Piston
3 Piston cap
4 Spring
5 Bleeder cap, screw
6 Cylinder body
P–32
PARKING BRAKE SYSTEM
PARKING BRAKE LEVER (STICK TYPE) REMOVAL/INSTALLATION

3. After installation, inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING
BRAKE (STICK TYPE) INSPECTION.)
12.8—18.6 {130—190, 113—164}
6.9—9.8
{70—100, 43—86}
N·m {kgf·cm, in·lbf}
1 Clip 9 Pin and clip

2 Joint pin 10 Spring
3 Cable connector 11 Rachet pawl
4 Parking brake switch 12 Stopper
5 Clip 13 Fork joint
6 Pin 14 Spring
7 Clip and joint pin 15 Guide
8 Lever 16 Rod
P–33
PARKING BRAKE SYSTEM
PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION

1. Remove the under guard. (Refer to section F1–F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
4. After installation, inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING
BRAKE (STICK TYPE) INSPECTION.)
4x2
16—22 {1.6—2.3, 12—16}
16—22
{1.6—2.3,
12—16}
6.9—9.8 N·m
{70—100 kgf·cm,
43—86 in·lbf}
4x4
16—22
{1.6—2.3, 12—16}
16—22 6.9—9.8 N·m

16—22 {1.6—2.3, 12—16} {70—100 kgf·cm,
{1.6—2.3, 12—16} 43—86 in·lbf}
16—22
{1.6—2.3,
12—16} 16—22
{1.6—2.3, 12—16} N·m {kgf·m, ft·lbf}
1 Nut 7 Grommet
2 Bolt 8 Bolt
3 Spring 9 Spring (4 4)
4 Front brake cable 10 Clip
5 Bolt (4 4) 11 Rear cable (left)
6 Bracket (4 4) 12 Rear cable (right)
P–34
ANTILOCK BRAKE SYSTEM

ABS LOCATION INDEX
ABS HU/CM ABS wheel speed sensor (rear)

(See ABS HU/CM SYSTEM INSPECTION) (See REAR ABS WHEEL–SPEED SENSOR
1 (See ABS HU/CM REMOVAL/ 3 REMOVAL/INSTALLATION)
INSTALLATION) (See REAR ABS WHEEL–SPEED SENSOR
(See ABS HU/CM INSPECTION) INSPECTION)
ABS wheel speed (front) G sensor (4x4)
(See FRONT ABS WHEEL–SPEED SENSOR 4 (See G SENSOR REMOVAL/INSTALLATION)
2 REMOVAL/INSTALLATION) (See G SENSOR INSPECTION)
(See FRONT ABS WHEEL–SPEED SENSOR
INSPECTION)
P–35
ABS HU/CM SYSTEM INSPECTION
System Inspection
Preparation
1. Verify that the battery is fully charged. With the ignition switch (engine switch) on, verify that the ABS warning
lights goes out after 3 seconds.
2. If the lights stays on after 3 seconds elapse, the ABS HU/CM detects a failure. Follow the troubleshooting
procedures.
3. Turn the ignition switch (engine switch) off.
4. Jack up the vehicle on level ground and support it evenly on safety stands. Shift the transmission to N position.
5. Release the parking brake.
6. Rotate the wheels by hand, and inspect for brake–drag.
Using the SST (WDS or equivalent)

1. Perform the “Preparation.” (See Preparation.)
2. Connect the SST (WDS or equivalent) to the data
link connector (DLC).
3. Set up an active command mode inspection
according to the combination of commands below.
(See ABS ON–BOARD DIAGNOSTIC.)
COMMAND NAME
COMMAND
OPERATION PMP RF RF TYPE
MOTOR OUTLET INLET
Pressure
OFF OFF ON
retention
Manual
Pressure
ON ON OFF
reduction
The chart above shows an example of a right wheel inspection.
Note
D When working with two people, one should depress the brake pedal, the other should attempt to rotate the
wheel being inspected.
4. Send the command while depressing on the brake pedal and attempting to rotate the wheel being inspected.
5. When pressure is being maintained, and a click sound indicating the solenoid is operating is heard from the
ABS HU/CM, confirm that the wheel does not rotate. When pressure is being reduced, and the click sound
indicating the solenoid is operating is heard from the ABS HU/CM, confirm that the wheel rotates, even though
the brake pedal is being depressed.
Note
D To protect the ABS HU/CM, the solenoid valve used for simulations and the ABS motor stay on for 10
seconds each time they are switched on.
D Performing the inspections above determines the following.
— The ABS HU/CM brake lines are normal.
— The ABS HU/CM hydraulic system is not significantly abnormal.
— The ABS HU/CM wiring is normal.
D However, the following items cannot be checked.
— ABS HU/CM input system harness and parts.
— Extremely small leaks in the ABS HU/CM internal hydraulic system.
— Unusual intermittent occurrences in the above items.
P–36
Without using the SST (WDS or equivalent) 6. Turn the ignition switch (engine switch) off and
1. Perform the “Preparation” (See Preparation.) remove the jumper wire.
Caution
D Connecting to the wrong data link
connector (DLC) terminal may cause a
malfunction. Carefully connect only to the
specified terminal only.
2. Use a jumper wire to short terminal TBS of the

DLC to body ground.
3. Depress the brake pedal, and have an assistant
verify that the right front wheel does not turn.
4. With the brake pedal still depressed, turn the
ignition switch on and verify that the brake is
released momentarily (approx. 0.5 seconds) and
that the wheel turns when pressure–reduction
operates.
5. Inspect the operation of the remaining wheels in

order: right front, left front, rear.
D Replace the ABS HU/CM if wheels do not
rotate.
D Inspect brake piping to ABS HU/CM if
operation of the remaining wheel order is not
within specified.
Note
D If Steps 4 and 5 show correct operation, the
following systems are okay:
— Brake piping to ABS HU/CM.
— Braking system, including ABS HU/CM.
— Electrical system in ABS HU/CM (solenoid,
ABS motor, etc.)
D The following are not inspected with above
steps:
— Input system and harness of ABS HU/CM.
— Intermittent failure.
— Fluid leakage from brake including the ABS
HU/CM and master cylinder.
P–37
ABS HU/CM REMOVAL/INSTALLATION
Caution
D Do not drop the ABS HU/CM, Replace it if it is subjected to an impact.

Connector 6 Stud
1 (See Connector Removal Note) 7 Bushing
(See Connector Installation Note)
8 Joint bolt
Brake pipe(See Brake Pipe Removal Note)(See
2 9 Gasket
Brake Pipe Installation Note)
ABS HU/CM component Joint
3 10
(See ABS HU/CM Removal/Installation Note (See Joint Installation Note)
4 Nut 11 Gasket
5 Bracket 12 ABS HU/CM
P–38
Connector Removal Note

1. Pull the lock lever to disconnect the connector.
Connector Installation Note

1. Verify that the connection part and waterproof
Brake Pipe Removal Note packing are free of foreign material, then connect
1. Mark the brake pipe connecting positions before the connector.
removal for reference during installation. 2. Verify that the lock lever is completely pushed in.
ABS HU/CM Removal/Installation Note ABS HU/CM INSPECTION

1. When removing/installing the ABS HU/CM from/to 1. Disconnect the negative battery cable.
the vehicle, attach a strip of protective tape on the 2. Connect the SST between the ABS HU/CM and
ABS HU/CM connector to prevent brake fluid from harness connector with the ignition (engine switch)
entering. off.
3. Attach the tester leads to the SST and inspect
Joint Installation Note voltage referring to the table below.
1. Install the Joint with the ABS HU/CM as shown in
the figure.
Brake Pipe Installation Note

1. When install the brake pipe, align the marks made
before removal with the ABS HU/CM DSC HU as
shown in the figure.
P–39
Terminal Voltage Table (Reference)

(Engine is idling, and connector is connected unless otherwise indicated)
Terminal Signal Connected to Test condition Voltage (V) Action

Vehicle is stopped. 0 (AC)
A RR wheel– D Inspect using the wave profile.
RR wheel–speed
B speed sensor (See Inspection Using An Oscillo-
scope (Reference))
C LR wheel– D Inspect using the wave profile.
LR wheel–speed
F speed sensor (See Inspection Using An Oscillo-
scope (Reference))
D Inspect using the wave profile. D Inspect related harness.
C LR wheel–
LR wheel–speed (See Inspection Using An Oscillo- D Inspect ABS wheel–speed
F speed sensor
scope (Reference)) sensor.
G RF wheel– D Inspect using the wave profile.
RF wheel–speed
D speed sensor (See Inspection Using An Oscillo-
scope (Reference))
I LR wheel– D Inspect using the wave profile.
LR wheel–speed
E speed sensor (See Inspection Using An Oscillo-
scope (Reference))
Vehicle is stopped
or driving with
2.4–2.6
constant speed.
D Inspect related harness.
H*1 G sensor input G sensor Vehicle driving with
2.5–1.0 D Inspect G sensor.
acceleration.
Vehicle driving with
2.5–4.0
deceleration.
J*1 G sensor ground G sensor – 0 D Inspect related harness.
K – – – – –
L – – – – –
M – – – – –
O – – – – –
P – – – – –
Q – – – – –
R – – – – –
S – – – – –
On–board KLN terminal of No need to
T – –
diagnostic DLC check
No need to
U*2 – DLC – –
check
On–board TBS terminal of
V – 10–14 D Inspect related harness.
diagnostic DLC
Ignition switch
Z Power supply – B+ D Inspect related harness.
(engine switch)
P–40
Terminal Signal Connected to Test condition Voltage (V) Action

Power supply
AA Battery – B+ D Inspect related harness.
(Solenoid valve)
Power supply
AB Battery – B+
(ABS motor) D Inspect related harness.
AC Ground Ground – 0
AD Ground Ground – 0 D Inspect related harness.
*1: 4x4 only.

*2: Use this terminal at factory only, not used for inspection and repair at field.
Inspection Using An Oscilloscope (Reference)

Wheel speed
D ABS HU/CM terminal:
RF: G (+)–D (–)
RR: A (+)–B (–)
LF: I (+)–E (–)
LR: C (+)–F (–)
D Oscilloscope setting: 1 VDIV (Y), 2 msDIV (X), AC
range.
D Vehicle condition: Driving 30 kmh {18.6 mph}
Note
D As vehicle speed increases, period of wave
shortens.
D There is a malfunction is in the sensor rotor,
the wave profile warps.
P–41
FRONT ABS WHEEL–SPEED SENSOR REMOVAL/INSTALLATION

4x2
1 Connector 3 Front ABS wheel–speed sensor

2 Bolt
P–42
4x4
1 Connector 3 Front ABS wheel–speed sensor

2 Bolt
FRONT ABS WHEEL–SPEED SENSOR Resistance Inspection

INSPECTION 1. Disconnect the ABS wheel–speed sensor
connector.
Visual Inspection 2. Inspect the resistance at the ABS wheel–speed
1. Remove the wheel and tire, and inspect the sensor sensor.
for looseness and damage. Replace the sensor if D If not as specified, replace the ABS
necessary. wheel–speed sensor.
Clearance Inspection Resistance

1. Inspect the clearance between the wheel–speed 1.2–1.6 kilohm
sensor and the sensor rotor.
Voltage Inspection
Clearance 1. Jack up the vehicle on level ground and support it
0.3–1.1 mm {0.012–0.043 in} evenly on safety stands.
2. Disconnect the ABS wheel–speed sensor
connector.
3. Inspect each sensor by rotating each wheel one
revolution per second.
D If not as specified, replace the ABS
wheel–speed sensor.
Voltage
0.15–1.2 V (AC)
P–43
Voltage Pattern Inspection

1. Jack up the vehicle on level ground and support it
evenly on safety stands.
connector.
3. Using an oscilloscope, inspect voltage pattern for
distortion and noise by rotating each wheel.
D If there is distortion or noise, inspect the ABS
sensor rotor.
P–44
REAR ABS WHEEL–SPEED SENSOR REMOVAL/INSTALLATION

1 Connector 3 Rear ABS wheel–speed sensor

2 Bolt
P–45
REAR ABS WHEEL–SPEED SENSOR INSPECTION
Visual Inspection
1. Inspect the sensor for looseness and damage.
Replace the sensor if necessary.
Clearance Inspection
1. Remove the ABS wheel–speed sensor.
2. Measure the length A and B shown in the figure
using vernier calipers.
3. Subtract B from A then verify the clearance
between the wheel–speed sensor and the sensor
rotor.
Clearance
0.3–1.1mm {0.012–0.043 in}
Resistance Inspection
connector.
2. Inspect the resistance at the ABS wheel–speed
sensor.
wheels–peed sensor..
Resistance
1.2–1.6 kilohm
Voltage Inspection
1. On level ground, jack up the vehicle and support it
connector.
3. Inspect each sensor by rotating each wheel one
revolution per second.
wheel–speed sensor.
Voltage
0.15–1.2 V (AC)
Voltage Pattern Inspection

1. Jack up the vehicle on level ground and support it
connector.
3. Using an oscilloscope, inspect voltage pattern for
distortion and noise by rotating each wheel.
D If there is distortion or noise, inspect the ABS
sensor rotor.
P–46
G SENSOR REMOVAL/INSTALLATION (2) Facing up (inclined 90° from horizontal)
Caution Voltage
D Do not drop the G sensor, Replace it if it is 1.3–1.7 V
subjected to an impact.
1. Slide the RH front seat fully backward.

(3) Facing down (declined 90° from horizontal)
Voltage
3.3–3.7 V
1 Connector
2 G sensor and bracket
3 G sensor
G SENSOR INSPECTION
1. Connect the connector.

2. Turn ignition switch (engine switch) on, and verify
the voltage between terminals A and B under the
following conditions.
D If not within the specification, replace the G
sensor.
(1) Horizontal
Voltage
2.4–2.6 V
P–47
ON–BOARD DIAGNOSTIC (ANTILOCK BRAKE SYSTEM)

ABS SYSTEM DIAGRAM
1 Ignition switch (engine switch) 10 ABS wheel–speed sensor

2 Instrument cluster 11 ABS HU/CM
3 ABS warning light 12 4x4 only
4 ABS motor relay (FET) 13 G sensor
5 Valve relay (FET) 14 DLC
6 Solenoid valve 15 KLN
7 ABS motor 16 TBS
8 Brake switch 17 GND
9 Battery
P–48
ABS ON–BOARD DIAGNOSTIC (3) After the ABS warning light illuminates for 3
seconds, the ABS warning light indicates
On–Board Diagnostic (OBD) Test Description DTCs.
D The OBD test inspects the integrity and function of (4) After completion of repairs, clear DTCs.
the ABS and outputs the results when requested
by the specific tests.
D On–board diagnostic test also:
— Provides a quick inspection of the ABS.
— Is usually performed at the start of each diag-
nostic procedure.
— Provides verification after repairs to ensure
that no other faults occurred during service.
D The OBD test is divided into 3 tests:
— Read/clear diagnostic results, PID monitor and
record and active command modes.
Read/clear diagnostic results

D This function allows you to read or clear DTCs in Clearing DTCs Procedures
the ABS HU/CM memory. Using SST (WDS or equivalent)
(1) After repairs have been made, perform the
PID/data monitor and record DTCs reading procedure.
D This function allows you to access certain data (2) Erase DTCs by SST (WDS or equivalent).
values, input signals, calculated values, and (3) Ensure that the customers concern has been
system status information. resolved.
Active command modes Without using SST (WDS or equivalent)

D This function allows you to control devices through
the SST (WDS or equivalent). Caution
D Connecting to the wrong DLC terminal may
DTCs Retrieving Procedure cause a malfunction. Carefully connect
Using SST (WDS or equivalent) only to the specified terminal.
(1) Connect SST (WDS or equivalent) to the
vehicle data link connector (DLC) located in the (1) Connect the TBS terminal at the DLC to body
left side of the engine compartment. ground using a jumper wire.
(2) Retrieve DTC by SST (WDS or equivalent). (2) Turn the ignition key (engine key) to ON
(engine OFF).
(3) Output all stored DTCs.
(4) After verifying that the first code is repeated,
depress the brake pedal 10 times or more at
intervals of less than 1 second.
(5) Turn the ignition key (engine key) to OFF and
disconnect the jumper wire.
Without using SST (WDS or equivalent)

(1) Connect the TBS terminal at DLC to body
ground using a jumper wire.
(2) Turn the ignition key (engine key) to ON
(engine OFF).
Note
D DTCs cannot be cleared if the following occur:
— If intervals of depressing the brake pedal
exceed 1 second.
— The brake switch has failed.
P–49
PID/Data Monitor and Record Procedure

vehicle DLC located in the left side of the
engine compartment.
(2) Access and monitor PIDs by SST (WDS or
equivalent).
Active Command Modes Procedure
Note
D When driving, the ABS motor and each valve
forcibly turn ABS_POWER on, and then each
command on. ABS_POWER regulates the
power supply for the ABS motor and 6 valves.

vehicle DLC located in the left side of the
engine compartment.
(2) Turn the ignition key (engine key) to ON
(Engine OFF) or start engine.
(3) Activate active command modes using SST
(WDS or equivalent).
P–50
DTC Table
DTC
SST Diagnostic
(WDS ABS ABS warning light flashing pattern system Action
or warning component
equiv- light
alent)
B1318 63 ABS HU/CM (See DTC B1318 (63))
power supply
B1342 61 ABS HU/CM (See DTC B1342 (61))
C1095 54 Motor relay, (See DTC C1095 (54),

pump motor C1096 (53))
C1096 53 Motor relay, (See DTC C1095 (54),

pump motor C1096 (53))
C1140 30 ABS HU/CM (See DTC C1140 (30))

(pump)
C1145 11 Right front ABS (See DTC C1145 (11),

wheel–speed C1155 (12), C1165 (13),
sensor C1175 (14))
C1148 41 Right front ABS (See DTC C1148 (41),
wheel speed– C1158 (42), C1168 (43),
sensor/sensor C1178 (44), C1233
rotor (46), C1234 (45),
C1235 (47), C1236
(48))
C1155 12 Left front ABS (See DTC C1145 (11),
wheel–speed C1155 (12), C1165 (13),
sensor C1175 (14))
C1158 42 Left front ABS (See DTC C1148 (41),
wheel–speed C1158 (42), C1168 (43),
rotor (46), C1234 (45),
C1235 (47), C1236
(48))
C1165 13 Right rear ABS (See DTC C1145 (11),
wheel–speed C1155 (12), C1165 (13),
sensor C1175 (14))
C1168 43 Right rear ABS (See DTC C1148 (41),
wheel speed– C1158 (42), C1168 (43),
rotor (46), C1234 (45),
C1235 (57), C1236
(48))
C1175 14 Left rear ABS (See DTC C1145 (11),
wheel–speed C1155 (12), C1165 (13),
sensor C1175 (14))
C1178 44 Left rear ABS (See DTC C1148 (41),
wheel–speed C1158 (42), C1168 (43),
rotor (46), C1234 (45),
C1235 (47), C1236
(48))
P–51
DTC
SST Diagnostic
equiv- light
alent)
C1186 51 Valve relay (See DTC C1186 (51),
C1266 (52))
C1194 24 Left front outlet (See DTC C1194 (24),

solenoid valve C1198 (25), C1202
(26), C1206 (27),
C1210 (22), C1214
(23))
C1198 25 Left front inlet (See DTC C1194 (24),
(28), C1206 (27),
C1210 (22), C1214
(23))
C1202 26 R outlet solenoid (See DTC C1194 (24),
valve C1198 (25), C1202
(26), C1206 (27),
C1210 (22), C1214
(23))
C1206 27 R inlet solenoid (See DTC C1194 (24),
valve C1198 (25), C1202
(25), C1206 (27),
C1210 (22), C1214
(23))
C1210 22 Right front outlet (See DTC C1194 (24),
(26), C1206 (27),
C1210 (22), C1214
(23))
C1214 23 Right front inlet (See DTC C1194 (24),
(26), C1206 (27),
C1210 (22), C1214
(23))
C1233 46 Left front wheel– (See DTC C1148 (41),
speed sensor/ C1158 (42), C1168 (43),
sensor rotor C1178 (44), C1233
(46), C1234 (45),
C1235 (47), c1236 (48))
C1234 45 Right front (See DTC C1148 (41),
wheel–speed C1158 (42), C1168 (43),
rotor (46), C1234 (45),
C1235 (47), C1236
(48))
C1235 47 Right rear (See DTC C1148 (41),
wheel–speed C1158 (42), C1168 (43),
rotor (46), C1234 (45),
C1235 (47), C1236
(48))
P–52
DTC
SST Diagnostic
equiv- light
alent)
C1236 48 Left rear wheel– (See DTC C1148 (41),
speed sensor/ C1158 (42), C1168 (43),
sensor rotor C1178 (44), C1233
(46), C1234 (45),
C1235 (47), C1236
(48))
C1266 52 Valve relay (See DTC C1186 (51),
C1266 (52))
C1414 64 ABS HU/CM (See DTC C1414 (64))

mismatched
installation
C1510 32 Right front sole- (See DTC C1510 (32),

noid valve, motor C1511 (33), C1512
or wheel–speed (34), C1513 (35))
sensor/sensor
rotor
C1511 33 Left front sole- (See DTC C1510 (32),
noid valve, motor C1511 (33), C1512
or wheel–speed (34), C1513 (35))
sensor/sensor
rotor
C1512 34 R solenoid (See DTC C1510 (32),
valve, motor or C1511 (33), C1512
right rear wheel– (34), C1513 (35))
speed sensor/
sensor rotor
C1513 35 R solenoid (See DTC C1510 (32),
valve, motor or C1511 (33), C1512
left rear wheel– (34), C1513 (35))
speed sensor/
sensor rotor
C1949* 03* G sensor (See DTC C1949 (03),
C1950 (04))
C1950* 04* G sensor (See DTC C1949 (03),

C1950 (04))
*: 4x4 only
PID/DATA Monitor Table

PID Name ABS HU/CM
Unit/Condition Condition/Specification Action
(Definition) terminal
D ABS warning light is Inspect ABS warning
ABS_LAMP
illuminated: ON. light.
(ABS warning lamp
ON/OFF D ABS warning light is not W
driver output state)
illuminated: OFF.
Inspect power supply
ABS_VOLT (System D Ignition key at ON: B+
V circuit. (See ABS HU/CM
battery voltage value) D Idle: Approx. 13–16 V Z
INSPECTION)
P–53
PID Name ABS HU/CM

D During ABS control: ON/ Internal fault of ABS HU/
OFF (solenoid valve is CM. Replace ABS
ABSLF_I
activated/deactivated.) HU/CM. (See ABS HU/
(LF ABS inlet valve –
ON/OFF D Not ABS control: OFF CM REMOVAL/
output state)
(solenoid valve is INSTALLATION
deactivated.)
ABSLF_O (LF ABS
outlet valve output ON/OFF –
D Not ABS control: OFF CM REMOVAL/
state)
deactivated.)
D Motor relay is activated: Inspect ABS HU/CM.
ABSPMPRLY
ON. (See ABS HU/CM
(ABS pump motor ON/OFF –
D Motor relay is deactivated: INSPECTION
relay output state)
OFF.
ABSR_I
(R ABS inlet valve ON/OFF –
output state)
deactivated.)
ABSR_O
(R ABS outlet valve ON/OFF –
output state)
deactivated.)
ABSR_I
(RF ABS inlet valve ON/OFF –
output state)
deactivated.)
ABSRF_O
(RF ABS inlet valve ON/OFF –
output state)
deactivated.)
D Valve relay is activated: Inspect ABS HU/CM.
ABSVLVRLY
ON. (See ABS HU/CM
(ABS valve relay ON/OFF –
D Valve relay is deactivated: INSPECTION
output state)
OFF
D Vehicle is stopped or Inspect G sensor. (See G
driving at a constant SENSOR INSPECTION)
speed: 0 G.
D Vehicle is driving at a
ACCLMTR*
(Accelerometer) ACCELERATION acceleration: Changes H, J
between 0 – –1.28 G.
D Vehicle is driving at a
deceleration: Changes
between 0 – 1.27 G.
D Brake pedal is depressed: Inspect brake switch.
BOO_ABS ON.
ON/OFF Y
(Brake pedal switch D Brake pedal is released:
OFF.
P–54
PID Name ABS HU/CM

Perform inspection using
CCNTABS
D DTC is detected: 1–255. appropriate DTC.
(Number of continuous – –
D DTC is not detected: 0. (See ABS ON–BOARD
trouble code set)
DIAGNOSTIC)
D Vehicle is stopped: 0 KPH Inspect wheel–speed
LF_WSPD
{0 MPH}. sensor/sensor rotor.
(LF wheel–speed KPH or MPH E, I
D Vehicle is driving:
sensor input)
Indicates vehicle speed.
LR_WSPD
(LR wheel–speed KPH or MPH C, F
sensor input)
D Pump motor is activated: Inspect ABS HU/CM.
PMPSTAT ON. (See ABS HU/CM
ON/OFF –
(ABS motor status) D Pump motor is INSPECTION)
deactivated: OFF
RF_WSPD
(RF wheel–speed KPH or MPH D, G
sensor input)
RR_WSPD
(RR wheel–speed KPH or MPH A, B
sensor input)
*: 4x4 only
Active Command Modes Table
SST (WDS or equivalent) display Operation/unit

Output part (SST (WDS or Note
Menu Command name equivalent display))
ABS_POWER Valve relay ON/OFF
LF_INLET LF inlet solenoid valve ON/OFF
LF_OUTLET LF outlet solenoid valve ON/OFF
PMP_MOTOR ABS motor ON/OFF Ignition key (engine
ABS OUTPUT
key) at ON (Engine
CONTROL REAR_INLET R inlet solenoid valve ON/OFF OFF)
REAR_OUTLET R outlet solenoid valve ON/OFF
RF_INLET RF inlet solenoid valve ON/OFF
RF_OUTLET RF outlet solenoid valve ON/OFF
P–55
DTC B1318 (63)
Caution
D When attaching the tester lead to the ABS HU/CM or the ABS HU/CM harness connector, the SST
(49 G066 001) must be used. (See ABS HU/CM INSPECTION.)
DTC B1318 (63) ABS HU/CM power supply

DETECTION
D Voltage at Z terminal of ABS HU/CM drops below 10 V when driving vehicle.
CONDITION
D Low power supply
POSSIBLE
D Battery and/or generator malfunction
CAUSE
D Poor ground or open circuit of ground
Diagnostic procedure
STEP INSPECTION ACTION

1 INSPECT ABS HU/CM POWER SUPPLY Yes Go to next step.
CIRCUIT FOR OPEN CIRCUIT
D Turn ignition key (engine key) to OFF.
D Disconnect ABS HU/CM connector.
D Connect SST (adapter harness) to ABS HU/
CM connector (harness side) with ABS HU/CM
disconnected. No Go to Step 3.
D Start engine.
D Measure voltage between terminal Z of SST
(harness side) and ground.
D Is voltage above 10 V?
2 INSPECT ABS HU/CM GROUND CIRCUIT FOR Yes Go to Step 5.
POOR GROUND AND OPEN CIRCUIT No If there is no continuity:
D Turn ignition key (engine key) to OFF. D Repair or replace harness for open between
D Measure resistance between terminal AA of ABS HU/CM and ground, then go to Step 5.
SST and ground. D Repair or replace harness for poor ground then
D Is resistance within 0–1 ohm? go to Step 5.
3 INSPECT BATTERY POWER Yes Go to next step.
D Inspect battery.
D Is it okay? No Replace battery, then go to Step 5.
4 INSPECT GENERATOR Yes Go to next step.

D Inspect generator.
D Is it okay? No Repair or replace generator, then go to Step 5.
P–56

5 VERIFY TROUBLESHOOTING COMPLETED Yes Replace ABS HU/CM, then go to next step.
D Make sure to connect all disconnected
connectors.
D Clear DTC from memory. No Go to next step.
(See Clearing DTCs Procedures)
D Is same DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to applicable DTC inspection.
D Is there any other DTC present? No Troubleshooting completed.
DTC B1342 (61)

DTC B1342 (61) ABS HU/CM
DETECTION
D The on–board diagnostic program detects computer malfunction.
CONDITION
POSSIBLE
D Malfunction of ABS HU/CM (CM part)
CAUSE

1 VERIFY CURRENT STATUS OF MALFUNCTION Yes Replace ABS HU/CM, then go to next step.
D Clear DTC memory.
D Start engine and drive vehicle at 10 km/h No Go to next step.
{6.2 mph} or above.
DTC C1095 (54), C1096 (53)
Caution
DTC B1095 (54), C1096 (53) Motor relay, ABS motor

D C1095 (54): ABS motor is stuck OFF when vehicle is started or during ABS operation, ABS motor ON is
DETECTION commanded.
CONDITION D C1096 (53): ABS motor is stuck ON when vehicle is started or during ABS operation, ABS motor OFF is
commanded.
D Open circuit, or short power or short to ground of motor relay and/or ABS motor in ABS HU/CM
POSSIBLE D Stuck motor relay and/or ABS motor
CAUSE D Open circuit of ABS motor power supply
D Open circuit of ABS motor ground
P–57

1 VERIFY OTHER DTC HAS RECORDED Yes Go to applicable DTC inspection.
D If any of DTC C1186 (51) and/or C1266 (52)
also stored? No Go to next step.
2 INSPECT ABS FUSE CONDITION Yes Go to next step.

D Is ABS fuse (60 A) okay? No Replace fuse, then go to Step 5.
3 INSPECT MOTOR RELAY POWER SUPPLY Yes Go to next step.
CIRCUIT FOR OPEN
CM connector (harness side) with ABS HU/CM No Repair or replace harness for open circuit between
disconnected. battery positive terminal and ABS HU/CM terminal
D Turn ignition key (engine key) to ON (engine AB, then go to Step 5.
OFF).
D Measure voltage between ABS HU/CM
terminal AB (harness side) and ground.
D Is voltage B+?
P–58

4 INSPECT ABS HU/CM GROUND CIRCUIT FOR Yes Go to next step.
OPEN CIRCUIT
D Turn ignition key (engine key) to OFF. No Repair or replace harness for open circuit between
D Inspect continuity between ABS HU/CM ABS HU/CM terminal AD and ground, then go to
terminal AD of SST and ground. next step.
D Is there continuity?
D Make sure to connect all disconnected
connectors.
D Clear DTC from memory.
D Start engine and drive vehicle at 10 km/h No Go to next step.
{6.2 mph} or above.
D Gradually slow down and stop vehicle.
DTC C1140 (30)

DTC C1140 (30) ABS HU/CM (pump)
DETECTION
D Left and right front wheels, or left and/or right rear wheel(s) lock is detected during ABS operation.
CONDITION
POSSIBLE
D Stuck ABS pump in ABS HU/CM
CAUSE

1 INSPECT ABS HU/CM OPERATION Yes Go to next step.
D Perform ABS HU/CM system inspection.
(See System Inspection) No Replace ABS HU/CM, then go to Step 4.
D Is it okay?
2 INSPECT CONVENTIONAL BRAKE Yes Inspect conventional brake line, then go to Step 4.
OPERATION
D Inspect brake fluid level.
D Start engine.
D Perform a road test to verify conventional No Go to next step.
vehicle braking performance.
D Is there a concern.
3 INSPECT REAR BRAKE DRAGGING Yes Repair parking brake system, then go to next step.
D Jack up vehicle and support it with safety
stand.
D Release parking brake. No Go to next step.
D Turn rear wheel by hand and inspect for rear
brake–drag.
D Is rear brake dragging?
D Clear DTC from memory.
D Start engine and drive vehicle at 10 km/h
{6.2 mph} or above at least 1 min. No Go to next step.
D Gradually slow down and stop vehicle.
P–59
DTC C1145 (11), C1155 (12), C1165 (13), C1175 (14)
Caution
DTC C1145 (11) RF ABS wheel–speed sensor

DTC C1155 (12) LF ABS wheel–speed sensor
DTC C1165 (13) RR ABS wheel–speed sensor
DTC C1175 (14) LR ABS wheel–speed sensor
DETECTION
D When open or short circuit is detected.
CONDITION
POSSIBLE D Open circuit or short to power circuit of ABS wheel–speed sensor(s) circuit
CAUSE D ABS wheel–speed sensor(s) malfunction
P–60

1 INSPECT ABS WHEEL–SPEED SENSOR Yes Go to next step.
disconnected.
D Measure resistance between suspected No Go to Step 3.
sensor terminals of SST.
— RF ABS wheel–speed sensor: G–D
— LF ABS wheel–speed sensor: I–E
— RR ABS wheel–speed sensor: A–B
— LR ABS wheel–speed sensor: C–F
D Is resistance within 1.3–1.7 kilohm?
2 INSPECT ABS WHEEL–SPEED SENSOR Yes Repair or replace harness for short to power circuit
CIRCUIT FOR SHORT TO POWER between ABS HU/CM and ABS wheel–speed
D Turn ignition key (engine key) to ON (engine sensor(s), then go to Step 5.
OFF).
D Inspect voltage between suspected sensor
terminal(s) of SST (adapter harness) and
ground(s).
— RF ABS wheel–speed sensor: G, D No Go to Step 5.
— LF ABS wheel–speed sensor: I, E
— RR ABS wheel–speed sensor: A, B
— LR ABS wheel–speed sensor: C, F
D Is voltage B+?
D Disconnect suspected sensor connector(s)
and inspect resistance between sensor No Replace ABS wheel–speed sensor, then go to Step
terminals (part side). 5.
D Is resistance within 1.3–1.7 kilohm?
4 INSPECT ABS HU/CM TO ABS Yes Repair or replace poor connections of ABS HU/CM
WHEEL–SPEED SENSOR CIRCUIT FOR connector and/or ABS wheel–speed sensor
OPEN CIRCUIT connector(s), then go to next step.
D Inspect continuity between suspected sensor
terminal(s) of SST and ABS wheel–speed
sensor connector. (vehicle harness side)
— RF ABS wheel–speed sensor (+): G–A
— RF ABS wheel–speed sensor (–): D–B No Repair or replace harness for open circuits
— LF ABS wheel–speed sensor (+): I–A
between ABS HU/CM and ABS wheel–speed
— LF ABS wheel–speed sensor (–): E–B
— RR ABS wheel–speed sensor (+): A–A sensor(s), then go to next step.
— RR ABS wheel–speed sensor (–): B–B
— LR ABS wheel–speed sensor (+): C–A
— LR ABS wheel–speed sensor (–): F–B
D Make sure to reconnect all disconnected
connectors.
D Clear DTC from memory No Go to next step.
P–61
DTC C1148 (41), C1158 (42), C1168 (43), C1178 (44), C1233 (46), C1234 (45), C1235 (47), C1236 (48)
Caution
DTC C1148 (41), C1234 (45) RF ABS wheel–speed sensor/sensor rotor

DTC C1158 (42), C1233 (46) LF ABS wheel–speed sensor/sensor rotor
DTC C1168 (43), C1235 (47) RR ABS wheel–speed sensor/sensor rotor
DTC C1178 (44), C1236 (48) LR ABS wheel–speed sensor/sensor rotor
D C1148 (41), C1158 (42), C1168 (43), C1178 (44): ABS wheel–speed signal is out of specification when
DETECTION just after vehicle has started to move.
CONDITION D C1234 (45), C1233 (46), C1235 (47), C1236 (48): ABS wheel–speed signal malfunction (distortion/
sudden change) is detected during driving.
D Short to ground circuit of ABS wheel–speed sensor(s) circuit
POSSIBLE D ABS wheel–speed sensor(s) malfunction
CAUSE D Damaged ABS sensor rotor(s)
D Incorrect clearance between ABS sensor and sensor rotor
P–62

1 VERIFY CURRENT INPUT SIGNAL STATUS OF Yes Go to Step 5.
CONCERN IS INTERMITTENT OR CONSTANT
D Connect SST (WDS or equivalent) to DLC.
D Start engine and drive vehicle.
D Access LF_WSPD, LR_WSPD, RF_WSPD No Go to next step.
and RR_WSPD PID using SST (WDS or
equivalent)
D Are PIDs display vehicle speed and 4 PIDs
equal?
CIRCUIT FOR SHORT TO GROUND
disconnected.
D Inspect continuity between suspected sensor
No Go to Step 4.
terminal(s) of SST (adapter harness) and
ground(s).
— RF ABS wheel–speed sensor: G
— LF ABS wheel–speed sensor: I
— RR ABS wheel–speed sensor: A
— LR ABS wheel–speed sensor: C
3 INSPECT ABS WHEEL–SPEED SENSOR FOR Yes Replace ABS wheel–speed sensor(s), then go to
SHORT TO GROUND Step 8.
D With ignition key (engine key) at OFF,
disconnected suspected sensor connector(s), No Repair or replace harness (short to ground)
inspect continuity between suspected sensor between ABS HU/CM and ABS wheel–speed
terminal(s) A (part side) and ground(s). sensor connector(s), then go to Step 8.
4 INSPECT SENSOR ROTOR CLEARANCE Yes Go to Step 8.
stands.
D Remove suspected wheel(s). No Replace ABS wheel–speed sensor(s), then go to
D Inspect clearance between sensor and rotor. Step 8.
D Is clearance within 0.3–1.1 mm {0.012–
0.043 in}?
5 INSPECT ABS WHEEL–SPEED SENSOR Yes Go to Step 8.
OUTPUT PULSE
D Start engine and drive vehicle.
D Inspect output voltage pattern using an
oscilloscope.
No Go to next step.
P–63

6 INSPECT SENSOR ROTOR FOR DAMAGE Yes Go to next step.
stands.
D Remove suspected wheel(s).
D Visually inspect sensor rotor for missing, No Replace rotor, then go to Step 8.
deformed and obstructed teeth.
Number of teeth: 44
D Is sensor rotor okay?
7 INSPECT SENSOR ROTOR CLEARANCE Yes Go to next step.
D Inspect clearance between sensor and rotor.
D Is clearance within 0.3–1.1 mm {0.012– No Replace ABS wheel–speed sensor(s), then go to
0.043 in}? next step.
connectors.
D Clear DTC from memory
D Start engine and drive vehicle at 10 kmh No Go to next step.
{6.2 mph} or above.
D Gradually slow down vehicle and stop.
P–64
DTC C1186 (51), C1266 (52)
Caution
DTC C1186 (51), C1266 (52) Valve relay

D C1186 (51): Valve relay in ABS HU/CM is stuck OFF when ignition switch (engine switch) is turned ON,
DETECTION valve relay ON is commanded.
CONDITION D C1266 (52): Valve relay in ABS HU/CM is stuck ON when ignition switch (engine switch) is turned ON,
valve relay OFF is commanded.
D Open circuit, short to power or short to ground circuit of valve relay in ABS HU/CM
POSSIBLE
D Stuck ON or OFF of valve relay in ABS HU/CM
CAUSE
D Open circuit of valve relay power supply circuit
P–65

1 INSPECT ABS FUSE CONDITION Yes Go to next step.
D Is ABS fuse (60 A ) okay? No Replace fuse, then go to Step 3.
2 INSPECT FAIL–SAFE RELAY POWER SUPPLY Yes Go to next step.
CM connector (harness side) with ABS HU/CM No Repair or replace harness for open circuit between
disconnected. battery positive terminal and ABS HU/CM terminal
D Turn ignition key (engine key) to ON (engine AC, then go to next step.
OFF).
D Measure voltage between terminal AC of
SST (adapter harness) and ground.
D Is voltage B+?
connectors.
D Clear DTC from memory No Go to next step.
P–66
DTC C1194 (24), C1198 (25), C1202 (26), C1206 (27), C1210 (22), C1214 (23)
DTC C1202 (26) R outlet solenoid valve
DTC C1206 (27) R inlet solenoid valve
DTC C1210 (22) RF outlet solenoid valve
DTC C1214 (23) RF inlet solenoid valve
DTC C1194 (24) LF outlet solenoid valve
DTC C1198 (25) LF inlet solenoid valve
DETECTION D Solenoid monitor signal is not output in response to solenoid ON command.
CONDITION D Solenoid monitor signal is output in response to solenoid OFF command.
POSSIBLE D Open circuit, short to power or short to ground of solenoid valve circuit in ABS HU/CM
CAUSE D Stuck solenoid valve in ABS HU/CM
Diagnostic Procedure

1 VERIFY CURRENT STATUS OF MALFUNCTION Yes Replace ABS HU/CM, then go to next step.
D Start engine and drive vehicle at 10 kmh
DTC C1414 (64)

DTC C1414 (64) ABS HU/CM unit mismatched installation
DETECTION
D When G sensor signal input for more than 400 ms to 4x2 vehicle–type ABS HU/CM.
CONDITION
POSSIBLE D Mismatched installation of ABS HU/CM
CAUSE — 4x2 vehicle type ABS HU/CM is mismatched installed on 4x4 vehicle.
P–67

1 INSPECT ABS HU/CM FOR MISMATCHED Yes Go to next step.
INSTALLATION
D Verify ABS HU/CM part number. No Replace with correct ABS HU/CM part number,
D Has a ABS HU/CM with the correct part then go to next step.
number been installed?
2 VERIFY CURRENT STATUS OF MALFUNCTION Yes Replace ABS HU/CM
(See Clearing DTCs Procedures) No Go to next step.
DTC C1510 (32), C1511 (33), C1512 (34), C1513 (35)

RF solenoid valve, ABS motor or RF ABS wheel–speed sensor/
DTC C1510 (32)
sensor rotor
LF solenoid valve, ABS motor or LF ABS wheel–speed sensor/
DTC C1511 (33)
sensor rotor
R solenoid valve, ABS motor or RR ABS wheel–speed sensor/
DTC C1512 (34)
sensor rotor
R solenoid valve, ABS motor or LR ABS wheel–speed sensor/
DTC C1513 (35)
sensor rotor
DETECTION
D Wheel lock is detected during ABS operation (pressure reduction inoperative).
CONDITION
D Low electrical power supply
D Malfunction of solenoid valve in ABS HU/CM
POSSIBLE D Malfunction of ABS wheel–speed sensor
CAUSE D Damaged ABS sensor rotor
D Stuck ABS motor in ABS HU/CM
D Malfunction of hydraulic unit of ABS HU/CM

1 VERIFY OTHER DTC HAS RECORDED Yes Go to DTC B1318 (63) inspection.
D Is DTC B1318 (63) also stored? No Go to next step.
D Is any of DTC C1202 (26), C1206 (27),
C1214 (22), C1210 (23), C1198 (24) and/or No Go to next step.
C1194 (25) also stored?
D Is any of DTC C1145 (11), C1148 (41),
C1155 (12) C1158 (42), C1165 (13),
C1168 (43), C1175 (14), C1178 (44), No Go to next step.
C1233 (46), C1234 (45), C1235 (47) and/or
C1236 (48) also stored?
D Is any of DTC C1095 (54) and/or C1096 (53)
also stored? No Go to next step.
5 INSPECT ABS HU/CM OPERATION Yes Go to next step.

D Perform ABS HU/CM system inspection.
(See System Inspection) No Replace ABS HU/CM, then go to next step.
D Is it okay?
P–68

6 VERIFY CURRENT STATUS OF MALFUNCTION Yes Replace ABS HU/CM.
D Start engine and drive vehicle at 10 kmh
DTC C1949 (03), C1950 (04)

DTC C1949 (03), C1950 (04) G sensor
D C1949 (03):
— Monitor voltage of G sensor is detected at 4.5 V or more, or 0.5 V or less.
— Monitor voltage difference of 0.4 V or more within1 cycle is detected 8 times in 1second.
DETECTION D C1950 (04):
CONDITION — G sensor 0–point correction value is default or more
— Output voltage value from G sensor remains absolutely unchanged
— Difference between estimated G force calculated from steering sensor and value output from G sensor
exceeds specification
D Malfunction of fuse (ENGINE 15 A)
D Open circuit in harness between G sensor terminal C and ignition switch (engine switch)
POSSIBLE D Open, short to power, or short to ground circuit in harness between ABS HU/CM terminal H and G
CAUSE sensor terminal B
D Open circuit in harness between ABS HU/CM terminal J and G sensor terminal A
D Malfunction of G sensor
P–69

1 INSPECT ENGINE FUSE CONDITION Yes Go to next step.
D Is ENGINE fuse (15 A) okay? No Replace fuse, then go to Step 8.
2 INSPECT G SENSOR POWER SUPPLY Yes Go to next step.
D Turn ignition switch (engine switch) to ON
(engine OFF). No Repair or replace harness for open circuit between
D Measure voltage between G sensor terminal G sensor terminal C and ignition switch, then go to
C (harness side) and ground. Step 8.
D Is voltage B+?
3 INSPECT G SENSOR GROUND CIRCUIT FOR Yes Go to next step.
OPEN CIRCUIT
D Turn ignition switch (engine switch) to OFF.
D Disconnect ABS HU/CM and G sensor
connectors. No Repair or replace harness for open circuit between
D Inspect continuity between ABS HU/CM ABS HU/CM terminal J and G sensor terminal A,
terminal J (harness side) and G sensor then go to Step 8.
terminal A (harness side).
4 INSPECT G SENSOR SIGNAL CIRCUIT FOR Yes Go to next step.
OPEN CIRCUIT
D Inspect continuity between ABS HU/CM No Repair or replace harness for open circuit between
terminal H (harness side) and G sensor ABS HU/CM terminal H and G sensor terminal B,
terminal B (harness side). then go to Step 8.
5 INSPECT G SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace harness for short to power
SHORT TO POWER between ABS HU/CM terminal H and G sensor
D Turn ignition switch (engine switch) to ON terminal B, then go to Step 8.
(engine OFF).
D Measure voltage between ABS HU/CM
terminal H (harness side) and ground. No Go to next step.
D Is voltage B+?
6 INSPECT G SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace harness for short to ground circuit
SHORT TO GROUND between ABS HU/CM terminal H and G sensor
D Turn ignition switch (engine switch) to OFF. terminal B, then go to Step 8.
D Inspect continuity between ABS HU/CM
terminal H (harness side) and ground. No Go to next step.
7 INSPECT G SENSOR Yes Go to next step.
D Inspect G sensor.
(See G SENSOR INSPECTION) No Replace G sensor, then go to next step.
(See Clearing DTCs Procedures) No Go to next step.
P–70
TROUBLESHOOTING (ANTILOCK BRAKE SYSTEM)
ABS SYSTEM DIAGRAM
1 Ignition switch (engine switch) 10 ABS wheel–speed sensor

2 Instrument cluster 11 ABS HU/CM
3 ABS warning light 12 4x4 only
4 ABS motor relay (FET) 13 G sensor
5 Valve relay (FET) 14 DLC
6 Solenoid valve 15 KLN
7 ABS motor 16 TBS
8 Brake switch 17 GND
9 Battery
P–71
FOREWORD
(1) Before performing the steps in Symptom Troubleshooting, perform the On–board Diagnostic Inspection. To
check the DTC, follow the DTC Inspection steps.
PRECAUTION
When inspecting or servicing the ABS, note the following points:

(1) The ABS warning light illuminates even when the system is normal.
ABS control when
Cases Remedy warning light
illuminates
Under the following conditions: After turning ignition switch (engine If ABS is operating,
When the rear wheels are jacked up, stuck, or placed switch) off, vehicle is driven at speed stop control after
on a chassis roller, and only the rear wheels” ABS greater than 10 kmh {6.2 mph} and operation. If ABS is not
wheel speed sensors are spun for more than normal operation is confirmed. operating, stop control
20 seconds immediately.
Parking brake is not fully released while driving.
Brake drag.
Sudden acceleration/deceleration.
Left/right or front/rear tires are different. (Size, radius,
tire pressure, or wear is other than that listed on tire
label.)
Battery voltage at ABS HU/CM ignition terminal Z drops Battery voltage rises above Operate control.
below about 9 to10 V. (*) about 10 V.
* : If battery voltage drops below about 9 to 10 V while vehicle speed is greater than 6 kmh {3.7 mph}, ABS
HU/CM records DTC B1318 (DTC 63).
(2) Precautions during servicing of ABS

The ABS is composed of electrical and mechanical parts. It is necessary to categorize malfunctions as
being either electrical or hydraulic when performing troubleshooting.
D Malfunction in electrical system
— The ABS control module (ABS HU/CM) has an on–board diagnostic function. With this function, the ABS
warning light will turn on when there is a problem in the electrical system. Also, past and present
malfunctions are recorded in the ABS HU/CM. This function can find malfunctions that do not occur during
periodic inspections. Turn the ignition switch (engine switch) to ON position, shorting the TBS terminal of
the data link connector and the body ground, or connecting the SST (WDS or equivalent) to the DLC, and
approximately 5 seconds later the stored malfunctions will be displayed in the order of occurrence. To
find out the causes of ABS malfunctions, use these on–board diagnostic results.
— If a malfunction occurred in the past but is now normal, the cause is likely a temporary poor connection of
the harness. The ABS HU/CM usually operates normally. Be careful when searching for the cause of
malfunction.
— After repair, it is necessary to erase the DTC from the ABS HU/CM memory. Also, if the ABS related parts
have been replaced, verify that the no DTC has been displayed after repairs.
— After repairing the ABS wheel–speed sensor or ABS sensor rotor, or after replacing the ABS HU/CM (ABS
motor or ABS motor relay or solenoid valve), the ABS warning light may not go off even when the ignition
switch (engine switch) is turned to ON position. IN this case, drive the vehicle at a speed of more than 10
kmh {6.2 mph}, make sure the ABS warning light goes off, and then erase the DTC.
— When repairing, if the ABS related connectors are disconnected and the ignition switch (engine switch) is
turned to ON position, the ABS HU/CM will mistakenly detect a fault and record it as a malfunction.
— To protect the ABS HU/CM, make sure the ignition is off before connecting or disconnecting the ABS HU/
CM connector.
D Malfunctions in hydraulic system
— Symptoms in a hydraulic system malfunction are similar to those in a conventional brake malfunction.
However, it is necessary to determine if the malfunction is in an ABS component or the conventional brake
system.
— The ABS hydraulic unit contains delicate mechanical parts. If foreign materials get into the component, the
ABS may fail to operate. Also, it will likely become extremely difficult to find the location of the malfunction
in the event that the brakes operate but the ABS does not. Make sure foreign materials do not get inside
when servicing the ABS (e.g. brake fluid replacement, pipe removal).
P–72
SYMPTOM TROUBLESHOOTING
Verify the symptom, and perform troubleshooting according to the appropriate number.
No. Symptom
1 ABS warning light does not illuminate with ignition switch (engine switch) on.
2 ABS warning light stays on for more than 4 seconds with ignition switch (engine switch) on.
3 There is a malfunction in the system even though ABS warning light indicates that the system is normal.
Quick Diagnostic Chart
NO.1 ABS WARNING LIGHT DOES NOT ILLUMINATE WITH IGNITION SWITCH (ENGINE SWITCH) ON
D When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
performing the inspection to discover whether poor contact points are the cause of any intermittent
malfunctions. If there is a problem, check to make sure connectors, terminals, and wiring harness are
connected correctly and undamaged.
1 Air bag system warning light does not illuminate when ignition switch is turned to ON position.
[TROUBLESHOOTING HINTS]
D ABS warning light circuit open or shorted to ground

1 CHECK TO SEE WHETHER MALFUNCTION IS Yes Go to step 4.
IN COMMON POWER SUPPLY FOR ABS
WARNING LIGHT OR OTHER WARNING
LIGHTS
Does either of the following warning lights
illuminate when ignition switch (engine switch) is No Go to next step.
turned to ON position?
D Air bag system warning light
D Generator warning light
2 INSPECT INSTRUMENT CLUSTER POWER Yes Go to next step.
SUPPLY FUSE No Check for a short to ground on blown fuse circuit.
Is instrument cluster ignition power supply fuse Repair or replace if necessary. Install appropriate
okay? amperage fuse.
P–73

*3 INSPECT WIRING HARNESS BETWEEN Yes Inspect warning light circuits in instrument cluster
INSTRUMENT CLUSTER POWER SUPPLY (open circuit in instrument cluster).
AND INSTRUMENT CLUSTER FOR
CONTINUITY
Turn ignition switch (engine switch) to ON
position. No Repair wiring harness between fuse block and
Measure voltage at instrument cluster connector instrument cluster (Terminal 1J).
terminal 1J.
Is voltage approximately 12 V?
4 CHECK FOR OPEN CIRCUIT IN ABS HU/CM Yes Go to next step.
Does ABS warning light illuminate when the
ignition switch (engine switch) is at ON position No Go to step 6.
and the ABS HU/CM is disconnected?
5 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Temporary poor connection at ABS HU/CM
DO NOT REOCCUR AFTER ABS HU/CM IS connector Terminal W.
CONNECTED Inspect ABS HU/CM connector and Terminal W.
Reconnect ABS HU/CM.
Does ABS warning light illuminate when the No
ignition switch (engine switch) is at ON position?
6 INSPECT ABS WARNING LIGHT BULB Yes Go to next step.
Remove instrument cluster.
Inspect ABS warning light bulb. No Replace ABS warning light bulb.
Is it okay?
*7 CHECK TO SEE WHETHER MALFUNCTION Yes Replace instrument cluster (open circuit in
(LACK OF CONTINUITY) IS IN WIRING instrument cluster).
HARNESS (BETWEEN INSTRUMENT
CLUSTER AND ABS HU/CM) OR INSTRUMENT
CLUSTER
Caution
D Attach a wire to the tester lead to avoid No Repair wiring harness between instrument cluster
damaging the ABS HU/CM terminal. and ABS HU/CM (Terminal W).
Disconnect ABS HU/CM connector and

instrument cluster connectors. Is there continuity
between instrument cluster connector terminal 2B
and ABS HU/CM connector terminal W?
NO.2 ABS WARNING LIGHT STAYS ON FOR MORE THAN 4 SECONDS WITH IGNITION SWITCH (ENGINE
SWITCH) ON
Using SST (WDS or equivalent)

2 ABS warning stays on for more than 4 seconds with ignition switch (engine switch) on.
D ABS HU/CM detects ABS system malfunction
D ABS HU/CM detects low voltage in power supply (ABS HU/CM ignition terminal Z voltage is below about 9 to 10 V)
D ABS HU/CM does not operate
D ABS warning light circuit open or shorted to high voltage (approximately 12 V)

1 INSPECT ABS HU/CM IGNITION POWER Yes Go to next step.
Is ABS HU/CM power supply fuse okay? Repair or replace if necessary.
Install appropriate amperage fuse.
P–74

2 INSPECT WIRING HARNESS BETWEEN ABS Yes If a communication error message is displayed
HU/CM AND DLC (DATA LINK CONNECTOR) even after inspecting according to procedures
FOR CONTINUITY OR SHORTS displayed on the SST (WDS or equivalent), go to
Perform DTC inspection. Step 6.
Is error message displayed regarding
communication between ABS HU/CM and SST No Go to next step.
(WDS or equivalent)?
3 CHECK FOR DTCS IN ABS HU/CM Yes Perform inspection using appropriate DTC.
Have DTCs been recorded in memory? No Go to next step.
4 INSPECT PID/DATA IN ABS HU/CM Yes Go to next step.
Inspect the following items using SST (WDS or
equivalent).
D ABS_LAMP (ABS warning light)
D ABS_VOLT (power supply voltage) No ABS system is normal.
Is ABS_LAMP ON after more than 4 seconds
with ignition switch (engine switch) to ON position.
5 INSPECT ABS HU/CM IGNITION POWER Yes Go to Step 16.
SUPPLY SYSTEM (TERMINAL Z)
Check the voltage for PID/DATA monitor
ABS_VOLT item. No Go to next step.
Specification: above 10 V
Is voltage within specification?
6 INSPECT BATTERY Yes If a communication error message is displayed on
Is battery voltage normal? SST (WDS or equivalent) in Step 2 inspection, go
to next step.
If a communication error message is not displayed
on SST (WDS or equivalent) in Step 2 inspection,
go to Step 9.
No Perform inspection of battery and charging system.
7 VERIFY THAT ABS HU/CM IS CONNECTED Yes Go to Step 9.
Is ABS HU/CM securely connected? No Connect ABS HU/CM connector securely, then go
to next step.
8 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Temporary poor connection in ABS HU/CM
DO NOT REOCCUR AFTER ABS HU/CM IS connector.
CONNECTED Inspect connector and terminal.
Does ABS warning light go out after more than 4
seconds with ignition switch (engine switch) at No Go to next step.
ON position?
*9 VERIFY THAT ABS HU/CM CONNECTOR Yes Connect ABS HU/CM connector terminals Z and
TERMINALS Z AND AC ARE CONNECTED AC securely, then go to next step.
Does malfunction symptom reoccur when ABS
HU/CM connector terminals Z and AC are shaken
while the ignition switch (engine switch) is at ON No Go to Step 11.
position?
10 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Temporary poor connection at terminal.
DO NOT REOCCUR AFTER ABS HU/CM Inspect ABS HU/CM connector and terminal.
CONNECTOR TERMINALS Z AND AC ARE
CONNECTED
Does ABS warning light go out after more than 4 No Go to next step.
seconds with ignition switch (engine switch) at
ON position?
P–75

*11 INSPECT WIRING HARNESS BETWEEN FUSE Yes Go to next step.
BLOCK AND ABS HU/CM (TERMINAL Z) FOR
CONTINUITY
Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal. No Repair wiring harness between fuse block and ABS
HU/CM (Terminal Z).
Turn ignition switch (engine switch) to LOCK
position.
Disconnect ABS HU/CM connector.
Is voltage approximately 12 V at ABS HU/CM
terminal Z?
*12 INSPECT WIRING HARNESS BETWEEN ABS Yes If a communication error message is displayed on
HU/CM (TERMINAL AC) AND GROUND FOR SST (WDS or equivalent) in Step 2 inspection, go
CONTINUITY to next step.
If a communication error message is not displayed
Caution on SST (WDS or equivalent) in Step 2 inspection,
D Attach a wire to the tester lead to avoid recheck malfunction symptoms.
damaging the ABS HU/CM terminal.
No Repair wiring harness between ABS HU/CM
Is there continuity between ABS HU/CM (terminal AC) and ground.
connector terminal AC and ground?
*13 INSPECT WIRING HARNESS BETWEEN ABS Yes Go to next step.
HU/CM AND DLC (DATA LINK CONNECTOR)
FOR CONTINUITY
Caution
D Attach a wire to the tester lead to avoid No Repair wiring harness between ABS HU/CM
damaging the ABS HU/CM terminal. (Terminal T) and data link connector (DLC).
Is there continuity between ABS HU/CM

connector terminal T and data link connector
(DLC)?
*14 INSPECT WIRING HARNESS BETWEEN ABS Yes Repair wiring harness between ABS HU/CM
HU/CM AND DLC (DATA LINK CONNECTOR) (Terminal T) and data link connector (DLC).
FOR SHORT TO B+
Caution
No Go to next step.
Turn ignition switch (engine switch) to ON
position.
connector terminal T?
*15 INSPECT WIRING HARNESS BETWEEN ABS Yes Repair wiring harness between ABS HU/CM
HU/CM AND DLC (DATA LINK CONNECTOR) (Terminal T) and data link connector (DLC).
FOR SHORT TO GROUND
Caution
No Replace ABS HU/CM (communication circuit or
ABS HU/CM power supply circuit malfunction in
ABS HU/CM).
connector terminal T and ground?
16 VERIFY THAT ABS HU/CM CONNECTOR Yes Connect ABS HU/CM connector terminal W
TERMINAL W IS CONNECTED securely, then go to next step.
Does malfunction symptom happen again when
ABS HU/CM connector terminal W is shaken
while the ignition switch (engine switch) is ON No Go to Step 18.
position?
P–76

17 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Temporary poor connection at terminal.
DO NOT REOCCUR AFTER ABS HU/CM Inspect ABS HU/CM connector and terminal.
CONNECTOR TERMINAL W IS CONNECTED
seconds with ignition switch (engine switch) to No Go to next step.
ON position?
*18 CHECK TO SEE WHETHER MALFUNCTION IS Yes Go to next step.
IN INSTRUMENT CLUSTER (SHORT TO
GROUND) OR ELSEWHERE
Disconnect all instrument cluster connectors. No Replace instrument cluster (short to ground circuit
Is there continuity between instrument cluster in instrument cluster).
connector terminal 2B and ground?
*19 INSPECT WIRING HARNESS BETWEEN Yes Repair wiring harness between ABS HU/CM
INSTRUMENT CLUSTER AND ABS HU/CM (Terminal W) and instrument cluster.
FOR SHORT TO GROUND
Disconnect ABS HU/CM No Replace ABS HU/CM (short to ground or B+ circuit
Is there continuity between instrument cluster in ABS HU/CM).
Without using SST (WDS or equivalent)

2 ABS warning stays on for more than 4 seconds with ignition switch (engine switch) on.
D ABS HU/CM detects ABS system malfunction
D ABS HU/CM detects low voltage in power supply (ABS HU/CM ignition terminal Z voltage is below 10 V)
D ABS HU/CM does not operate
D ABS warning light circuit open or shorted to high voltage (approximately 12 V)

1 INSPECT ABS HU/CM IGNITION POWER Yes Go to next step.
Is ABS HU/CM power supply fuse okay? Repair or replace if necessary.
Install appropriate amperage fuse.
3 INSPECT BATTERY Yes Go to next step.
Is battery voltage normal?
No Perform inspection of battery and charging system.
4 VERIFY THAT ABS HU/CM IS CONNECTED Yes Go to Step 6.
Is ABS HU/CM securely connected? No Connect ABS HU/CM connector securely, then go
to next step.
5 VERIFY THAT MALFUNCTION SYMPTOMS Yes Temporary poor connection in ABS HU/CM
DO NOT REOCCUR AFTER ABS HU/CM IS connector.
CONNECTED Inspect connector and terminal.
ON position?
*6 VERIFY THAT ABS HU/CM CONNECTOR Yes Connect ABS HU/CM connector terminals W. AC
TERMINALS W, AC AND Z ARE CONNECTED and Z securely, then go to next step.
Does malfunction symptom happen again when
ABS HU/CM connector terminals W, AC and Z
are shaken while the ignition switch (engine No Go to Step 8.
switch) is at ON position?
P–77

7 VERIFY THAT MALFUNCTION SYMPTOM Yes Temporary poor connection at terminal.
OCCURS AFTER ABS HU/CM CONNECTOR Inspect ABS HU/CM connector and terminal.
TERMINALS W, AC AND Z ARE CONNECTED
ON position?
*8 INSPECT WIRING HARNESS BETWEEN FUSE Yes Go to next step.
BLOCK AND ABS HU/CM (TERMINAL Z) FOR
CONTINUITY
Caution
damaging the ABS HU/CM terminal. No Repair wiring harness between fuse block and ABS
HU/CM (Terminal Z).
Turn ignition switch (engine switch) to LOCK
position.
Disconnect ABS HU/CM connector.
terminal Z?
*9 INSPECT WIRING HARNESS BETWEEN ABS Yes Go to next step.
HU/CM (TERMINAL AC) AND GROUND FOR
CONTINUITY
Caution
D Attach a wire to the tester lead to avoid No Repair wiring harness between ABS HU/CM
damaging the ABS HU/CM terminal. (terminal AC) and ground.

connector terminal AC and ground?
*10 CHECK TO SEE WHETHER MALFUNCTION Yes Go to next step.
(SHORT TO GROUND) IS IN ABS HU/CM AND
WIRING HARNESS (BETWEEN INSTRUMENT
CLUSTER AND ABS HU/CM) OR INSTRUMENT
CLUSTER
Turn ignition switch (engine switch) to LOCK No Replace instrument cluster (short to ground circuit
position. in instrument cluster).
Disconnect instrument cluster connector.
Connect ABS HU/CM connector.
Is there continuity between instrument cluster
*11 INSPECT WIRING HARNESS BETWEEN Yes Repair wiring harness between ABS HU/CM
ABS HU/CM AND INSTRUMENT CLUSTER (Terminal W) and instrument cluster.
FOR SHORT TO GROUND
Disconnect ABS HU/CM connector. No Replace ABS HU/CM (short to ground or B+ circuit
Is there continuity between instrument cluster in ABS HU/CM).
NO.3 THERE IS A MALFUNCTION IN SYSTEM EVEN THOUGH ABS WARNING LIGHT INDICATES THAT
THE SYSTEM IS NORMAL
3 There is a malfunction in the system even though ABS warning light indicates that the system is normal.
There is a mechanical malfunction in system.

P–78
2 INSPECT ABS HYDRAULIC UNIT Yes Inspect conventional brake system.

Perform “ABS hydraulic unit system inspection”. No If wheels do not rotate:
Is system okay? Replace ABS HU/CM
If wheels rotate but order in which wheels rotate
is incorrect:
Inspect brake pipe passage to ABS HU/CM.
P–79

Braking System

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Braking System

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BRAKING SYSTEM

GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . P– 2 DISC PAD (FRONT) REPLACEMENT

GENERAL PROCEDURES Brake pipe flare nut tightening

Brake lines disconnection/connection Connectors disconnection

CONVENTIONAL BRAKE SYSTEM VACUUM LINE INSPECTION

5. Repeat steps 3 and 4 until no air bubbles are seen.

Brake Pedal Height Adjustment

Brake Pedal Play Inspection

BRAKE SWITCH INSPECTION R.H.D.

1 Brake fluid level sensor connector

4. Turn the adjusting nut of the SST counterclockwise Clearance at B

2. Turn the adjusting nut until the SST body sets

2. Using the SSTs, turn the nut to lengthen the power

MASTER CYLINDER REMOVAL/INSTALLATION

1. Remove in the order indicated in the table.

1 Brake fluid level sensor connector 3 Bracket

Master Cylinder Installation Note

2. Apply vacuum of 66.7 kPa {500 mmHg, 19.7

3. Turn the adjusting nut of the SST counterclockwise

5. Push lightly on the end of the SST gauge rod to be

Measurement Push rod

1. Measure and record height D1 of the gauge rod.

Adjusting the push rod clearance at B

Note 3. Measure and record height D2 of the gauge rod.

1. Push lightly on the end of the SST gauge rod, and

2. Using the SST, turn the nut to lengthen the power

4. Subtract D1 from D2 and add 0.1—0.4 mm

FLUID LEVEL SENSOR INSPECTION

5. If not as specified, replace the sensor.

MASTER CYLINDER DISASSEMBLY/ASSEMBLY (VEHICLES BUILT UP TO 07/2002)

1. Disassemble in the order indicated in the table.

2.0—2.4 {20—25, 18—21}

N·m {kgf·cm , in·lbf}

1 Cap set 10 Cup

7 Spacer 15 Secondary piston

8 Piston guide 16 Master cylinder body

Stop Screw and O-ring Assembly Note

MASTER CYLINDER DISASSEMBLY/ASSEMBLY

1 Cap set 11 Cup

Stop Screw (without ABS) Assembly Note

Stop Pin (with ABS) Assembly Note 49 U043 004

2. After bleeding the air from the SST, conduct the

a) Inspection for vacuum loss

Step 2 b) Inspection for hydraulic pressure

(Inspection using the testers)

POWER BRAKE UNIT INSPECTION

Checking for vacuum loss (unloaded condition)

Checking for vacuum loss (loaded condition)

Checking for hydraulic pressure

2. Start the engine. Depress the brake pedal when

POWER BRAKE UNIT REMOVAL/INSTALLATION VACUUM SWITCH INSPECTION (DIESEL)

19—25 3. Turn the engine switch on.

N·m {kgf·m, ft·lbf}

1 Vacuum switch connector (Diesel)

VACUUM SWITCH REMOVAL/INSTALLATION VACUUM PUMP INSPECTION (DIESEL)

3. If the pressure is less than the specification,

1 Vacuum switch connector VACUUM PUMP REMOVAL/INSTALLATION

N·m {kgf·m, ft·lbf}