Group 35A

35A-1
GROUP 35A
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 35A-3 HBB MOTOR RELAY CHECK . . . . . . . . . . 35A-121

BRAKE FLUID LEVEL INSPECTION AND
BASIC BRAKE SYSTEM DIAGNOSIS 35A-6 BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 35A-122
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 35A-6 BRAKE FLUID LEVEL SWITCH CHECK . . 35A-127
DIAGNOSTIC TROUBLESHOOTING DISC BRAKE PAD CHECK AND
STRATEGY. . . . . . . . . . . . . . . . . . . . . . . . . 35A-6 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 35A-127
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 35A-6 DISC BRAKE ROTOR CHECK . . . . . . . . . . 35A-129
SYMPTOM PROCEDURES . . . . . . . . . . . . 35A-7 BRAKE DISC THICKNESS CHECK . . . . . . 35A-130
BRAKE DISC RUN-OUT CHECK AND
CORRECTION . . . . . . . . . . . . . . . . . . . . . . 35A-130
HYDRAULIC BRAKE BOOSTER (HBB)
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 35A-13
BRAKE PEDAL. . . . . . . . . . . . . . . . . . 35A-132
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 35A-13
REMOVAL AND INSTALLATION . . . . . . . . 35A-132
DIAGNOSTIC TROUBLESHOOTING
STRATEGY. . . . . . . . . . . . . . . . . . . . . . . . . 35A-13
BRAKE WARNING LIGHT CHECK . . . . . . 35A-14 HYDRAULIC BRAKE BOOSTER
TROUBLE CODE DIAGNOSIS. . . . . . . . . . 35A-14
(HBB) . . . . . . . . . . . . . . . . . . . . . . . . . 35A-133
DIAGNOSTIC TROUBLE CODE CHART . . 35A-15 REMOVAL AND INSTALLATION . . . . . . . . 35A-133
HBB DIAGNOSTIC TROUBLE CODE ACCUMULATOR REPLACEMENT . . . . . . . 35A-134
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 35A-16 ACCUMULATOR DISPOSAL . . . . . . . . . . . 35A-135
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 35A-80 DISASSEMBLY AND ASSEMBLY . . . . . . . 35A-136
HBB SYMPTOM PROCEDURES . . . . . . . . 35A-81
DATA LIST REFERENCE TABLE . . . . . . . 35A-110 BUZZER . . . . . . . . . . . . . . . . . . . . . . . 35A-139
ACTUATOR TEST REFERENCE TABLE. . 35A-110 REMOVAL AND INSTALLATION . . . . . . . . 35A-139
CHECK AT M-ASTC-ECU . . . . . . . . . . . . . 35A-111 BUZZER CHECK. . . . . . . . . . . . . . . . . . . . . 35A-139
SPECIAL TOOLS. . . . . . . . . . . . . . . . 35A-114 FRONT DISC BRAKE ASSEMBLY . . 35A-140

REMOVAL AND INSTALLATION . . . . . . . . 35A-140
ON-VEHICLE SERVICE. . . . . . . . . . . 35A-115 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-141
BRAKE PEDAL CHECK AND DISASSEMBLY AND ASSEMBLY . . . . . . . 35A-142
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 35A-115 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 35A-145
STOPLIGHT SWITCH CHECK . . . . . . . . . . 35A-116
HBB OPERATING CHECK . . . . . . . . . . . . . 35A-117 Continued on next page
HBB CHECK . . . . . . . . . . . . . . . . . . . . . . . . 35A-119
35A-2
REAR DISC BRAKE ASSEMBLY . . . 35A-146 SPECIFICATIONS . . . . . . . . . . . . . . . 35A-152

REMOVAL AND INSTALLATION . . . . . . . . 35A-146 FASTENER TIGHTENING
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 35A-147 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 35A-152
DISASSEMBLY AND ASSEMBLY . . . . . . . 35A-148 GENERAL SPECIFICATIONS . . . . . . . . . . 35A-152
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 35A-151 SERVICE SPECIFICATIONS . . . . . . . . . . . 35A-153
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 35A-154
BASIC BRAKE SYSTEM
GENERAL DESCRIPTION
35A-3
.
GENERAL DESCRIPTION
M1351000100235
The brake system has been designed to give greater
reliability and durability and to provide excellent brak-
ing performance.
• Adoption of independent front and rear wheel
.
FEATURES
brake lines (H piping).
Improved Braking Performance • Ventilated discs have been adopted for front
• Adoption of a hydraulic brake booster (HBB) wheel and rear wheel in order to improve anti-
which maintains a high brake-assisting force fading performance.
even in high deceleration ranges.
• 16-inch ventilated disc brakes have been
.
adopted to provide stable braking force and Improved Serviceability

improved braking feel. • A diagnosis function has been adopted for the
HBB system in order to make inspection easier.
.
• For the front and rear disc brakes, an outer disc
Improved Stability method separated hub and rotor has been
• Adoption of an electronic brake-force distribution adopted to make removal and installation easier.
(EBD) which makes it possible to maintain the • The HBB reservoir tank cap has been colored
maximum amount of braking force even when the white to make identification easier.
vehicle's load is unevenly distributed.
CONFIGURATION DIAGRAM
HYDRAULIC BRAKE
BOOSTER (HBB)
REAR DISC BRAKE

PARKING BRAKE
FRONT DISC BRAKE ACX01742 AB
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35A-4 BASIC BRAKE SYSTEM
GENERAL DESCRIPTION

The master cylinder hydraulic pressure for the front
brakes is assisted by a brake booster which utilizes
accumulator pressure; the hydraulic pressure gener-
ated by the accumulator is introduced directly to the
rear brakes.
ACCUMULATOR
RESERVOIR (BUILT-IN BRAKE
PUMP CHECK VALVE FLUID LEVEL WARNING SWITCH)
MOTOR
PRESSURE
SWITCH
MASTER CYLINDER PISTON
RELIEF VALVE
REACTION DISC BOOSTER POWER PISTON
CHAMBER
OPERATING ROD
MASTER CYLINDER AND

REACTION SPOOL BRAKE BOOSTER
ROD VALVE REGULATOR PISTON
HYDRAULIC UNIT
SELECT SOLENOID VALVE
IN IN IN IN
CONTROL SOLENOID VALVE
OUT OUT OUT OUT
AC000675 AB
REAR-LEFT REAR-RIGHT FRONT-LEFT FRONT-RIGHT
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BASIC BRAKE SYSTEM
GENERAL DESCRIPTION
35A-5
HYDRAULIC BRAKE BOOSTER (HBB) 3. Then, when the pressure in the booster chamber
OPERATION increases, the pressure which is applied to the
rear (left side) of the reaction disc also increases,
1. When the pedal operating force is transmitted in
and the reaction disc starts to change shape. The
turn by the operating rod, the power piston and
reaction disc contacts the reaction rod, and the
the master cylinder piston, the regulator piston
reaction rod in turn contacts the spool valve, so
and the spool valve move to the left.
that the master cylinder pressure being applied
2. When the spool valve opens line A and closes line towards the left and the booster pressure being
B, the accumulator pressure is supplied to the applied to the right are brought into balance by the
rear brakes. This pressure is introduced to the reaction disc. This allows the power-assist
booster chamber and provides power assistance hydraulic pressure generated by the pedal
to move the master cylinder piston to the left. operating force to be kept at an equilibrium.
.
<When booster is not operating>

ACCUMULATOR
CHECK
PUMP VALVE RESERVOIR
MOTOR
PRESSURE
SWITCH
LINE A (CLOSED) BOOSTER CHAMBER

LINE B (OPEN)
RETURN SPRING OPERATING ROD
POWER PISTON
REACTION DISC MASTER CYLINDER PISTON

REACTION ROD SPOOL
VALVE MASTER CYLINDER RETURN SPRING
REAR FRONT MASTER CYLINDER
REGULATOR PISTON MECHANISM AC000676 AB
<When booster is operating>

ACCUMULATOR
PRESSURE ASSIST
FORCE BOOSTER
LINE B LINE A SPOOL CHAMBER
(CLOSED) (OPEN) VALVE
OPERATING ROD
REACTION
DISC
POWER PISTON
REACTION ROD
AC000677AB
REAR FRONT
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BASIC BRAKE SYSTEM DIAGNOSIS
<When a loss of accumulator pressure occurs>

If a loss of accumulator pressure occurs because of
a problem such as a pump motor problem, the power
assist force and rear brake pressure cannot increase
in response to the input from the brake pedal.
Accordingly, the front brakes can be operated
directly by depressing the brake pedal, but the rear
brakes do not operate at all.

INTRODUCTION
M1351009700223
The hydraulic brake system consists of the brake
pedal, the hydraulic brake booster (HBB), and the
disc brakes. Insufficient braking power or noise may
occur due to wear, damage or incorrect adjustment
of these parts.
DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1351009800220
Use these steps to plan your diagnostic strategy. If 2. Verify that the condition described by the
you follow them carefully, you will be sure that you customer exists.
have exhausted most of the possible ways to find a 3. Find the malfunction by following the symptom
basic brake system fault. chart.
1. Gather information from the customer. 4. Verify malfunction is eliminated.
SYMPTOM CHART
M1351009900238
SYMPTOM INSPECTION REFERENCE

PROCEDURE PAGE
Vehicle pulls to one side when brakes are applied 1 P.35A-7
Insufficient braking power 2 P.35A-8
Increased pedal stroke (Reduced pedal-to-floor board clearance) 3 P.35A-9
Brake drag 4 P.35A-9
Scraping or grinding noise when brake are applied 5 P.35A-10
Squealing, groaning or chattering noise when brake are applied 6 P.35A-11
Squealing noise when brakes are not applied 7 P.35A-11
Groaning, clicking or rattling noise when brakes are not applied 8 P.35A-12
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BASIC BRAKE SYSTEM
35A-7
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Vehicle Pulls to One Side when Brakes are Applied
DIAGNOSIS STEP 3. Check brake disc(s) for run-out.

Refer to P.35A-130.
STEP 1. Check for oil, water, etc., on the pad Q: Is run-out outside of specifications?
contact surface of all brakes. YES : Repair or replace as necessary. Then go to
Q: Is oil, water, etc., on the pad contact surface? Step 5.
YES : Replace the pads on both left and right NO : Go to Step 4.
wheels as a set and determine the source/
cause of foreign material. Then go to Step 5. STEP 4. Check brake discs for correct thickness.
NO : Go to Step 2.
Refer to P.35A-130.
Q: Is the thickness outside of specifications?
STEP 2. Check disc brake pistons for smooth YES : Repair or replace as necessary. Then go to
operation. Step 5.
(1) Depress the brake pedal repeatedly more than NO : Go to Step 5.
40 times with the ignition switch at the "LOCK"
(OFF) position to release the pressure in the HBB
power supply system. STEP 5. Retest the system.
(2) Test each disc brake assembly one at a time. Q: Is the symptom eliminated?
a. Remove the lower caliper bolt, then remove YES : The procedure is complete.
caliper from mount. NO : Start over at Step 1. If a new symptom
b. Have an assistant slowly depress the brake appears, refer to the appropriate symptom
pedal. Confirm piston(s) extend slowly and chart (P.35A-6).
smoothly with no jumpiness. Repeat for each
disc brake assembly.
Q: Do (does) the piston(s) move correctly?
YES : Go to Step 3.
NO : Disassemble and inspect brake assembly
(Front: Refer to P.35A-142/Rear: Refer to
P.35A-148). Then go to Step 5.
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INSPECTION PROCEDURE 2: Insufficient Braking Power
DIAGNOSIS STEP 3. Check the HBB function.

Refer to P.35A-117.
STEP 1. Check whether the brake fluid is low, is Q: Is the HBB malfunctioning?
the correct fluid (transmission fluid, engine oil, YES : Check the HBB (Refer to P.35A-136) and
etc.), or is contaminated (debris, sand, etc.). replace the faulty part as necessary. Then
Q: Is there fault? go to Step 6.
YES : Refill or replace with the specified brake NO : Go to Step 4.
fluid DOT 3 or DOT 4. Bleed the brakes if
necessary (Refer to P.35A-122). Then go to STEP 4. Check for pinched or restricted brake
Step 6. tube or hose.
NO : Go to Step 2.
Q: Is there a pinched or restricted brake tube or hose?
YES : Replace that complete section of brake tube
STEP 2. Check for spongy (not firm brakes). or brake hose. Then go to Step 6.
(1) Depress the brake pedal repeatedly more than NO : Go to Step 5.
40 times with the ignition switch at the "LOCK"
(OFF) position to release the pressure in the HBB
power supply system. STEP 5. Check for oil, water, etc., on the pad
(2) With the brake pedal fully released, depress the contact surfaces of all brakes.
brake pedal slowly until it stops. Q: Is oil, water, etc., on the pad contact surface?
(3) With a measuring stick (ruler, etc.) next to the YES : Replace the pads on both left and right
brake pedal, depress the pedal firmly and wheels as a set and determine the source/
measure the distance the pedal traveled. cause of foreign material. Then go to Step 6.
NO : Go to Step 6.
Q: Is the distance greater than 20 mm (0.8 inch)?
YES : Bleed the brakes to remove air in the fluid
(Refer to P.35A-122). Then go to Step 6. STEP 6. Retest the system.
NO : Go to Step 3.
Q: Is the symptom eliminated?
YES : The procedure is complete.
NO : Start over at Step 1. If a new symptom
appears, refer to the appropriate symptom
chart (P.35A-6).
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BASIC BRAKE SYSTEM
35A-9
INSPECTION PROCEDURE 3: Increased Pedal Stroke (Reduced Pedal-to-floor Board Clearance)
DIAGNOSIS STEP 3. Check for brake fluid leaks.

Q: Are there brake fluid leaks?
STEP 1. Check for spongy (not firm brakes). YES : Check the connection for looseness,
(1) Depress the brake pedal repeatedly more than corrosion, etc. Clean and repair as
40 times with the ignition switch at the "LOCK" necessary. If there is a leak in any tube or
(OFF) position to release the pressure in the HBB hose section, replace the complete tube or
power supply system. hose. Then go to Step 5.
(2) With the brake pedal fully released, depress the NO : Go to Step 4.
brake pedal slowly until it stops.
(3) With a measuring stick (ruler, etc.) next to the
brake pedal, depress the pedal firmly and STEP 4. Check the HBB's master cylinder
measure the distance the pedal traveled. pistons.
(1) Remove the HBB (Refer to P.35A-133).
Q: Is the distance greater than 20 mm (0.8 inch)? (2) Check the power piston assembly and the master
YES : Bleed the brakes to remove air in the fluid cylinder piston assembly (Refer to P.35A-136).
(Refer to P.35A-122). Then go to Step 5.
NO : Go to Step 2. Q: Are the HBB master cylinder pistons
malfunctioning?
YES : Replace the faulty part. Then go to Step 5.
STEP 2. Check the pad for wear. NO : Go to Step 5.
Refer to P.35A-127.
Q: Is the pad thickness outside of specifications? STEP 5. Retest the system.
YES : Replace the pads on both left and right
wheels as a set. Then go to Step 5. Q: Is the symptom eliminated?
NO : Go to Step 3. YES : The procedure is complete.
chart (P.35A-6).
INSPECTION PROCEDURE 4: Brake Drag
DIAGNOSIS STEP 3. Inspect the brake pedal return spring for

deterioration.
STEP 1. Check the parking brake lever return. Q: Is there deterioration?
Q: Does the lever return abnormally? YES : Replace the spring. Then go to Step 8.
YES : When a foreign matter is caught in the NO : Go to Step 4.
parking brake lever assembly, remove it.
When the foreign matter is not found, STEP 4. Inspect the brake shoe springs for
replace the lever assembly (Refer to breakage.
GROUP 36, Parking Brake Lever P.36-6). Refer to GROUP 36, Parking Brake Drum P.36-8.
Then go to Step 8.
NO : Go to Step 2. Q: Are the brake shoe springs broken?
YES : Replace the springs. Then go to Step 8.
NO : Go to Step 5.
STEP 2. Check the parking brake pull amount.
Refer to GROUP 36, On-vehicle Service − Parking
Brake Lever Stroke Check and Adjustment P.36-4.
Q: Is the parking brake lever stroke out of
specification?
YES : Adjust it. Then go to Step 8.
NO : Go to Step 3.
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STEP 5. Check the amount of grease at each STEP 7. Inspect the HBB's master cylinder
sliding section. pistons.
Refer to GROUP 36, Parking Brake Drum P.36-8. (1) Remove the HBB (Refer to P.35A-133).
Q: Is the grease amount insufficient?
(2) Inspect the power piston assembly and the
YES : Apply grease. Then go to Step 8. master cylinder piston assembly (Refer to P.35A-
NO : Go to Step 6. 136).
Q: Is there fault?
STEP 6. Check disc brake pistons for sticking. YES : Replace the faulty part. Then go to Step 8.
NO : Go to Step 8.
Depress the brake pedal, then release. Confirm each
wheel spins freely. If any wheel is stuck, inspect that
brake assembly. Then go to Step 8. STEP 8. Retest the system.
Q: Are all wheels stuck? Q: Is the symptom eliminated?
YES : Re-start from Step 1. YES : The procedure is complete.
NO : Go to Step 7. NO : Start over at Step 1. If a new symptom
chart (P.35A-6).
INSPECTION PROCEDURE 5: Scraping or Grinding Noise when Brakes are Applied
DIAGNOSIS STEP 4. Check the brake discs for cracks.

Q: Are there cracks?
STEP 1. Check the front brakes, then rear brakes, YES : Repair or replace the part. Then go to Step
for metal-to-metal condition. 6.
Q: Is the metal-to-metal contact evident? NO : Go to Step 5.
YES : Repair or replace the components. Then go
to Step 6. STEP 5. Check for bent backing plate(s).
NO : Go to Step 2.
Q: Is (Are) the backing plate(s) bent?
YES : Repair or replace the part. Then go to Step
STEP 2. Check for interference between the 6.
caliper and wheel. NO : Go to Step 6.
Q: Is there interference?
YES : Repair or replace the part. Then go to Step STEP 6. Retest the system.
6.
NO : Go to Step 3. Q: Is the symptom eliminated?
STEP 3. Check for interference between the dust appears, refer to the appropriate symptom
cover and brake disc. chart (P.35A-6).
Q: Is there interference?
YES : Repair or replace the part. Then go to Step
6.
NO : Go to Step 4.
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BASIC BRAKE SYSTEM
35A-11
INSPECTION PROCEDURE 6: Squealing, Groaning or Chattering Noise when Brakes are Applied
DIAGNOSIS STEP 3. Check the brake pedal.

Check the brake pedal height, brake pedal free play
STEP 1. Check the brake disc and pads for wear and clearance between brake pedal and floorboard
or cutting. (Refer to P.35A-115).
Q: Is there wear or cutting? Q: Is the brake pedal adjusted correctly?
YES : Repair or replace the part. Then go to Step YES : Go to Step 4.
4. NO : Adjust the brake pedal (Refer to P.35A-
NO : Go to Step 2. 115). Then go to Step 4.
STEP 2. Check the calipers for rust. STEP 4. Retest the system.
Q: Is there rust? Q: Is the symptom eliminated?
YES : Remove the rust. Then go to Step 4. YES : The procedure is complete.
NO : Go to Step 3. NO : Start over at Step 1. If a new symptom
chart (P.35A-6).
INSPECTION PROCEDURE 7: Squealing Noise when Brakes are not Applied
DIAGNOSIS STEP 4. Check the wheel bearings for

deterioration or damage. Also check the grease
STEP 1. Check the brake discs for rust. quality and quantity.
Q: Are the brake discs rusted?
For front wheel, refer to GROUP 26, Hub and
YES : Remove the rust by using sand paper. If still Knuckle Assembly P.26-18. For rear wheel, refer to
rusted, turn the rotors with an on-car brake GROUP 27, Rear Hub Assembly P.27-13.
lathe. Then go to Step 6. Q: Are the wheel bearings damaged or out of grease?
NO : Go to Step 2. YES : Apply grease or replace the wheel bearings.
Then go to Step 6.
NO : Go to Step 5.
STEP 2. Check the brake pads for correct
installation.
Q: Are the pads installed incorrectly?
STEP 5. Check the brake pedal.
YES : Repair the pads. Then go to Step 6. Check the brake pedal height, brake pedal free play,
NO : Go to Step 3. and clearance between brake pedal and floorboard
(Refer to P.35A-115).
STEP 3. Check the calipers for correct Q: Is the brake pedal adjusted correctly?
installation. YES : Go to Step 6.
NO : Adjust the brake pedal (Refer to P.35A-
Q: Are the calipers installed incorrectly? 115). Then go to Step 6.
YES : Repair the calipers. Then go to Step 6.
NO : Go to Step 4.
STEP 6. Retest the system.
Q: Is the symptom eliminated?
chart (P.35A-6).
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INSPECTION PROCEDURE 8: Groaning, Clicking or Rattling Noise when Brakes are not Applied.
DIAGNOSIS STEP 3. Check the wheel bearings for wear,

damage or dryness.
STEP 1. Check for looseness of the wheel nuts. For front wheel, refer to GROUP 26, Hub and
Q: Are the wheel nuts loose?
Knuckle Assembly P.26-18. For rear wheel, refer to
YES : Tighten to 108 ± 10 N⋅m (80 ± 7 ft-lb). Then GROUP 27, Rear Hub Assembly P.27-13.
go to Step 4. Q: Is there fault?
NO : Go to Step 2. YES : Apply grease or replace the wheel bearings.
Then go to Step 4.
NO : Go to Step 4.
STEP 2. Check for looseness of the caliper
installation bolt.
Q: Is the caliper installation bolt loose?
YES : Tighten to 113 ± 9 N⋅m (83 ± 7 ft-lb) for the Q: Is the symptom eliminated?
front caliper, or 100 ± 10 N⋅m (74 ± 7 ft-lb) YES : The procedure is complete.
for the rear caliper. Then go to Step 4. NO : Start over at Step 1. If a new symptom
NO : Go to Step 3. appears, refer to the appropriate symptom
chart (P.35A-6).
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BASIC BRAKE SYSTEM
HYDRAULIC BRAKE BOOSTER (HBB) DIAGNOSIS
35A-13
INTRODUCTION
M1351012800059
The hydraulic brake booster (HBB) accumulates the After erasing an HBB DTC, duplicate the HBB DTC
high-pressure brake fluid in the accumulator by oper- set conditions to see if it resets. Depending on the
ating the pump motor. Even though the working detection timing and set conditions for the specific
sound of the pump motor can be heard during opera- HBB DTC, you must either drive the vehicle or turn
tion, this sound is usually generated at normal opera- the engine off and restart it. To set the proper condi-
tion of the HBB and is not an indication of a tions for that DTC again, refer to "HBB DTC SET
malfunction. CONDITIONS" for each HBB DTC that you are trying
HBB Diagnostic Trouble Code Detection to reset.
Conditions
HBB diagnostic trouble codes (HBB DTCs) are set
under different conditions, depending on the mal-
function detected. Most HBB DTCs will only be set
during vehicle operation. Some HBB DTCs will also
be set during the HBB self-check immediately after
the engine is started.
DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1351012900056
Use these steps to plan your diagnostic strategy. If • If the basic brake system is not operating prop-
you follow them carefully, you will be sure that you erly, refer to "Basic Brake System Diagnosis"
have exhausted most of the possible ways to find an (P.35A-6).
HBB fault. • If the basic brake system is operating properly,
1. Gather information about the problem from the refer to "Symptom Chart" (P.35A-80).
customer. 6. If an HBB DTC sets, record the number of the
2. Verify that the condition described by the DTC, then erase the DTC from the memory using
customer exists. the scan tool.
3. Check the vehicle for any HBB DTC. 7. Duplicate the HBB DTC set conditions to see if
4. If you cannot verify the condition and no HBB the same HBB DTC will set again.
DTC sets, it can be assumed that the malfunction • If the same HBB DTC sets again, perform the
is intermittent. Refer to GROUP 00, How to use diagnostic procedures for the DTC. Refer to
Troubleshooting/Inspection Service Points − How P.35A-15.
to Cope with Intermittent Malfunctions P.00-6. • If you cannot make the same HBB DTC set
5. If you can verify the condition but no HBB DTC again, it can be assumed that the malfunction is
sets, or the system cannot communicate with the intermittent. Refer to GROUP 00, How to use
scan tool, check that the basic brake system is Troubleshooting/Inspection Service Points − How
operating properly. to Cope with Intermittent Malfunctions P.00-6.
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BRAKE WARNING LIGHT CHECK

M1351013000056
Check that the brake warning light illuminates as follows:
1. Check that the brake fluid level in the reservoir is between
BRAKE WARNING LIGHT the "MIN" and the "MAX" lines.
2. Choke the wheels and release the parking brake.
3. When the ignition switch is turned to the "ON" position, the
brake warning light illuminates.
4. When the ignition switch is turned from the "START" position
back to the "ON" position, the brake warning light illuminates
for approximately 3 seconds and then switches off.
5. If the illumination is other than the above, check the
diagnostic trouble codes.
APPROXIMATELY 3S
BRAKE
WARNING ILLUMINATED
LIGHT
NOT
ILLUMINATED
IGNITION START
SWITCH ON
LOCK, ACC
AC000682 AB
TROUBLE CODE DIAGNOSIS

M1351011200054
Retrieving HBB Diagnostic Trouble Codes

Required Special Tool:
• MB991502: Scan Tool (MUT-II)
CAUTION
To prevent damage to scan tool MB991502, always turn the
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting scan tool MB991502.
1. Connect scan tool MB991502 to the data link connector.
MB991502
2. Turn the ignition switch to the "ON" position.
3. Use scan tool MB991502 to check for HBB diagnostic
16-PIN
trouble codes.
4. Turn the ignition switch to the "LOCK" (OFF) position.
5. Disconnect scan tool MB991502.
ACX01539 AC
Erasing HBB Diagnostic Trouble Codes

NOTE: If the M-ASTC-ECU functions have stopped due to the
fail-safe function, the HBB diagnostic trouble code cannot be
erased.
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BASIC BRAKE SYSTEM
35A-15
CAUTION
1. Connect scan tool MB991502 to the data link connector.
MB991502
2. Turn the ignition switch to the "ON" position.
3. Use scan tool MB991502 to erase HBB diagnostic trouble
16-PIN
codes.
4. Turn the ignition switch to the "LOCK" (OFF) position.
5. Disconnect scan tool MB991502.
ACX01539 AC
DIAGNOSTIC TROUBLE CODE CHART

M1351013700066
Follow the inspection chart that is appropriate for the
diagnostic trouble code.
DTC INSPECTION ITEM DIAGNOSTIC CONTENT REFERENCE PAGE
16 Battery positive voltage M-ASTC-ECU power supply voltage is P.35A-16
extremely low or high
31 Ignition switch circuit Open circuit at the HBB power supply P.35A-18
sub circuit
53 Pump motor • Seizure of the pump motor* P.35A-23
• Abnormality at the current detection
circuit of the M-ASTC-ECU
54 Motor relay Open circuit, short circuit or failure of the P.35A-31
motor relay coil
55 Pump motor circuit Pump motor energized abnormally for P.35A-56
long period*
56 Pressure switch • Open circuit at the pressure switch (for P.35A-69
pump motor control)
• Open circuit or short circuit at the
pressure switch (for low-pressure
warning)
57 Accumulator Accumulator low-pressure abnormality* P.35A-77
58 M-ASTC-ECU (Power supply Pump motor drive circuit in the M-ASTC- Replace the M-ASTC-
drive circuit) ECU abnormality ECU (Refer to
GROUP 35C, M-
ASTC-ECU P.35C-
205).
NOTE: If the trouble marked by * has occurred, the M-ASTC-ECU sounds the buzzer continuously to inform
the trouble of the driver and protects the pump motor by activating the pump motor intermittently.
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HBB DIAGNOSTIC TROUBLE CODE PROCEDURES
DTC 16: Battery Positive Voltage (M-ASTC-ECU Power Supply Voltage is Extremely Low or High)
CAUTION
If the battery voltage drops or rises while making this check, DTC 16 is set as an existing problem,
making it impossible to perform correct trouble diagnosis. Before carrying out the following diagno-
sis, test the battery and charge it if necessary.
ASC-ECU Power Supply Circuit
AC204492AC
CONNECTOR: D-116 CONNECTORS: D-208, D-212
D-208
D-212
D-116
JUNCTION BLOCK
AC204688 AB (FRONT VIEW) AC204547AB
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BASIC BRAKE SYSTEM
35A-17
CONNECTOR: E-111 CONNECTORS: E-119, E-120
E-119
E-120
E-111
AC204548 AB AC203901AD
CIRCUIT OPERATION STEP 2. Check the charging system.

The M-ASTC-ECU has two power supply lines. An Refer to GROUP 16, Charging System − Diagnosis
M-ASTC-ECU power is supplied to the M-ASTC- P.16-3.
ECU (terminal 9) from the ignition switch (IG2)
Q: Is the charging system damaged?
through the multi-purpose fuse number 17 in the
YES : Repair the Charging System and then go to
junction block. The other M-ASTC-ECU power is
Step 4.
supplied to the M-ASTC-ECU (terminal 63) from the NO : Go to Step 3.
ignition switch (IG2) through the multi-purpose fuse
number 5 in the junction block and through the joint
connector number 4. STEP 3. Recheck for diagnostic trouble code.
(1) Erase the DTC memory.
(2) Recheck for diagnostic trouble code.
.
HBB DTC SET CONDITIONS

DTC16 is set if the voltage at both of the power line is Q: Is DTC 16 set?
extremely low or high. YES : Replace the M-ASTC-ECU (Refer to
.
GROUP 35C, M-ASTC-ECU P.35C-205).
TROUBLESHOOTING HINTS Then go to Step 4.
• Malfunction of the battery NO : It can be assumed that this malfunction is
• Malfunction of the charging system intermittent. Refer to GROUP 00, How to
• Malfunction of the M-ASTC-ECU Use Troubleshooting/Inspection Service
Points − How to Cope with Intermittent
.
Malfunction P.00-6.
DIAGNOSIS
STEP 4. Recheck for diagnostic trouble code.

STEP 1. Check the battery.
Refer to GROUP 54A, Battery − On-vehicle Service
− Battery Testing Procedure P.54A-6.
Q: Is DTC 16 set?
Q: Is the battery damaged?
YES : Start over at Step 1.
YES : Charge or replace the battery and then go
NO : The procedure is complete.
to Step 4.
NO : Go to Step 2.
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DTC 31: Ignition Switch B Circuit (Open Circuit at the HBB Power Supply Sub Circuit)
HBB Power Supply Sub Circuit
AC204493 AB
CONNECTOR: E-111 CONNECTOR: E-119
E-119
E-111
AC204548 AB AC203901AE

.
CIRCUIT OPERATION
In the ignition switch B circuit, the M-ASTC-ECU DTC31 is set if the ignition switch B circuit is open or
power is supplied to the M-ASTC-ECU (terminal 9) the internal circuit of the M-ASTC-ECU is defective.
from the ignition switch (IG2) through the multi-pur- .
pose fuse number 17 in the junction block. TROUBLESHOOTING HINTS

• Damaged wiring harness or connector
• Malfunction of the M-ASTC-ECU
.
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BASIC BRAKE SYSTEM
35A-19
DIAGNOSIS
• MB991223: Harness Set
STEP 1. Check the following connector.

CONNECTOR: E-119
• M-ASTC-ECU connector E-119
Check connector, for loose, corroded or damaged terminals, or
terminals pushed back in the connector.
Q: Are the connector and terminals in good condition?
YES : Go to Step 2.
E-119 NO : Repair it and then go to Step 5.
AC203901
E-119
M-ASTC-ECU CONNECTOR
AC204627AB
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STEP 2. Check the power supply circuit at M-ASTC-ECU

harness connector E-119.
CONNECTOR: E-119
(1) Disconnect M-ASTC-ECU connector E-119 and measure at
the harness connector (component side).
(2) Start the engine.
E-119
AC203901
E-119
AC204627AB
(3) Measure the voltage between terminal 9 and ground. It

should measure approximately 12 volts (battery positive
voltage).
Q: Is battery positive voltage (approximately 12 volts)
present?
HARNESS CONNECTOR: YES : Go to Step 4.
COMPONENT SIDE NO : Go to Step 3.
E-119
AC204549AC
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BASIC BRAKE SYSTEM
35A-21
STEP 3. Check the following harness wire.

CONNECTOR: E-119
• The wire between M-ASTC-ECU connector E-119 (terminal
9) and multi-purpose fuse number 17 (junction block)
NOTE: Also check intermediate connector E-111 for loose,
corroded, or damaged terminals, or terminals pushed back
in the connector. If intermediate connector E-111 is dam-
E-119 aged, repair or replace the damaged component(s) as
described in GROUP 00E, Harness Connector Inspection
P.00E-2. If the connector has been repaired or replaced, go
to Step 5.
AC203901
E-119
HARNESS CONNECTOR:
COMPONENT SIDE
AC204627AC
MULTIPURPOSE FUSE NO.17
JUNCTION
BLOCK
MULTIPURPOSE
FUSE NO.17
AC203896
AC203896AE
CONNECTOR: E-111 Q: Is the harness wire damaged?

YES : Repair or replace it and then go to Step 5.
NO : Go to Step 5.
E-111
AC204548AK
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Q: Is DTC 31 set?
YES : Replace the M-ASTC-ECU (Refer to GROUP 35C, M-
ASTC-ECU P.35C-205). Then go to Step 5.
NO : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Use Troubleshooting/
Inspection Service Points − How to Cope with
Intermittent Malfunction P.00-6.

Q: Is DTC 31 set?
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BASIC BRAKE SYSTEM
35A-23
DTC 53: Pump Motor (Seizure of the Pump Motor or Abnormality at the Current Detecting Circuit of
the M-ASTC-ECU)
Pump Motor Circuit
AC204494AB
CONNECTORS: B-17, B-18 CONNECTORS: B-53X, B-54X

B-17 (GR)
B-18 (B)
B-54X
B-53X
AC204545 AC AC204329AC
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CONNECTOR: E-119
E-119
AC203901AE

.
CIRCUIT OPERATION
• The pump motor operates if the motor relay A or DTC 53 will be set when the pump motor is locked,
motor relay B turn to ON. two ground lines are open circuit or poorly grounded,
• The M-ASTC-ECU monitors the pump motor (at or the current monitoring circuit is defective. If the
25 terminal). pump motor has been locked, the M-ASTC-ECU
• The M-ASTC-ECU monitors the power supply sounds the buzzer continuously to inform the trouble
current for the pump motor at 14 terminal, and of the driver and protects the pump motor by activat-
ground current at 12 terminal, respectively, to ing it intermittently.
know whether the pump motor is locked or not. .
TROUBLESHOOTING HINTS
• Malfunction of the pump motor [Integrated with
.
the hydraulic brake booster (HBB)]

• Malfunction of the master cylinder and hydraulic
unit assembly [Integrated with the hydraulic brake
booster (HBB)]
.
DIAGNOSIS
STEP 1. Check the sound of the HBB buzzer.

Q: Does the HBB buzzer sound?
YES : Check the pump motor for seizure, and replace the
pump motor if necessary. Then go to Step 10.
NO : Go to Step 2.
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BASIC BRAKE SYSTEM
35A-25
STEP 2. Check the following connectors.

CONNECTORS: B-17, B-18 • HBB connector B-17 and B-18
Check connectors for loose, corroded or damaged terminals, or
B-17 (GR) terminals pushed back in the connector.
Q: Are the connectors and terminals in good condition?
B-18 (B)
YES : Go to Step 3.
NO : Repair the faulty connector or terminal and then go to
Step 10.
B-17 B-18
HBB CONNECTORS
AC204629 AB
STEP 3. Check the HBB ground circuit at HBB harness

connector B-17.
CONNECTOR: B-17 (1) Disconnect HBB connector B-17 and measure at the
harness connector (component side).
B-17 (GR)
B-17
HBB CONNECTOR
AC204629 AC
(2) Measure the resistance between terminal 7 and ground.

HARNESS CONNECTOR:
COMPONENT SIDE
The resistance should measure less than 2 ohms.
3 1
Q: Is the measured resistance less than 2 ohms?
2
B-17 5 4 YES : Go to Step 4.
7
(GR) 8 6 NO : Repair the harness wire between HBB connector B-
17 (terminal 7) and ground. Then go to Step 10.
ACX01937 AC
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STEP 4. Check the HBB ground circuit at HBB harness

connector B-18.
CONNECTOR: B-18 (1) Disconnect HBB connector B-18 and measure at the
B-18 (B)
B-18
HBB CONNECTOR
AC204629 AD

The resistance should measure less than 2 ohms.
YES : Go to Step 5.
HARNESS CONNECTOR:
COMPONENT SIDE
NO : Repair the harness wire between HBB connector B-
18 (terminal 32) and ground. Then go to Step 10.
32 31
B-18 (B)
35 34 33
AC204550 AB
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BASIC BRAKE SYSTEM
35A-27
STEP 5. Check the HBB (continuity and resistance test of

the pump motor).
CONNECTORS: B-17, B-18 (1) Disconnect HBB connectors B-17 and B-18.
B-17 (GR)
B-18 (B)
B-17 B-18
HBB CONNECTORS
AC204629 AB
(2) Check for continuity and measure the resistance between

terminals at the HBB connectors.
TESTER SPECIFIED RESISTANCE Ω
CONNECTION CONDITION (REFERENCE VALUE)
2−7 Continuity 10 or less
2−8 Continuity Approximately 33
2 − 31 Continuity Less than 2
4 − 32 Continuity Approximately 33
B-17
6−7 Continuity Less than 2
B-18
ACX00662AC
31 − 32 Continuity 10 or less
Q: Does continuity exist between above terminals?

YES : Go to Step 7.
NO : Go to Step 6.
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STEP 6. Check the pump motor and lead wire.

(2) Remove the pump motor and the lead wire from the HBB
(3) Check the following items:
• Confirm that the pump motor operates when the battery
voltage is imposed at the pump motor terminal.
• Confirm the continuity of the lead wire.
Q: Are both of the pump motor and the lead wire in good
condition?
YES : Replace the master cylinder and hydraulic unit
assembly (Refer to P.35A-136). Then go to Step 10.
NO : Replace the pump motor or the lead wire (Refer to

CONNECTOR: E-119
Check connector, for loose, corroded or damaged terminals, or
YES : Go to Step 8.
E-119 NO : Repair the faulty connector or terminal and then go to
Step 10.
AC203901
E-119
AC204627AB
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BASIC BRAKE SYSTEM
35A-29
STEP 8. Check the following harness wires.

CONNECTOR: B-17 • The wire between HBB connector B-17 (terminal 4) and M-
ASTC-ECU connector E-119 (terminal 25)
B-17 (GR) • The wire between HBB connector B-17 (terminal 6) and M-
• The wire between HBB connector B-17 (terminal 8) and M-
Q: Is any harness wire damaged?
YES : Repair it and then go to Step 10.
NO : Go to Step 9.
3 2 1
B-17 5 4
8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE
AC204629 AE
CONNECTOR: E-119
E-119
AC203901
E-119
HARNESS CONNECTOR:
COMPONENT SIDE
AC204627AC

Q: Is DTC 53 set?
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Q: Is DTC 53 set?
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BASIC BRAKE SYSTEM
35A-31
DTC 54: Motor Relay (Open Circuit, Short Circuit or Failure of the Motor Relay Coil)
Motor Relay Circuit
AC204495AB
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B-17 (GR)
B-18 (B)
B-54X
B-53X
AC204545 AC AC204329AC
D-208
D-212
D-116
JUNCTION BLOCK
E-119
E-120
E-111
AC204548 AB AC203901AD
HBB DTC SET CONDITION

.
CIRCUIT OPERATION
• The motor relay A and the motor relay B are con- DTC 54 is set if the motor relay circuit is open or
trolled by the M-ASTC-ECU. short, the motor relay A or the motor relay B is defec-
• If the brake fluid pressure in the hydraulic brake tive, or the internal circuit of the M-ASTC-ECU is
booster (HBB) becomes low, the M-ASTC-ECU defective.
outputs the motor relay actuating signal to the .
motor relay A and the motor relay B and then the TROUBLESHOOTING HINTS
pump motor operates. • Malfunction of the motor relay A or the motor
• The M-ASTC-ECU monitors the pump motor (at relay B
25 terminal). • Damaged wiring harness or connector
.
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BASIC BRAKE SYSTEM
35A-33
DIAGNOSIS
STEP 1. Check for any diagnostic trouble code.

(2) Check for any diagnostic trouble code.
Q: Is DTC 55 set?
YES : Carry out the troubleshooting for DTC 55 (Refer to
NO : Go to Step 2.
STEP 2. Check the pump motor operation.

(1) Depress the pedal repeatedly more than 40 times until the
pedal depressing force feels heavy with the ignition switch
at the "LOCK" (OFF) position.
(2) Turn the ignition switch to the "ON" position.
Q: Does the pump motor operate?
YES : Go to Step 22.
NO : Go to Step 3.
STEP 3. Check the motor relay A.

CAUTION
Apply battery voltage according to the table below. Never
confuse the positive and negative battery terminals, or the
diode inside the relay will be damaged.
BATTERY TESTER SPECIFIED

MOTOR CONNECTION CONNECTION CONDITION
RELAY A
− 4−5 Open circuit
• Connect battery 4−5 Less than 2 ohms
terminal (+) to
terminal 3
• Connect battery
AC204329 terminal (−) to
terminal 1
BRAKE FLUID
RESERVOIR
Q: Is the relay damaged?
4 YES : Replace the relay. Then go to Step 25.
5 NO : Go to Step 4.
3 1
ACX01808
AC204381AC
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STEP 4. Check the motor relay B.

CAUTION
MOTOR
BATTERY TESTER SPECIFIED
RELAY B CONNECTION CONNECTION CONDITION
• Connect battery 4−5 Less than 2 ohms
terminal (+) to
terminal 3
• Connect battery
AC204329 terminal (−) to
terminal 1
BRAKE FLUID
RESERVOIR
Q: Is the relay damaged?
4 YES : Replace the relay. Then go to Step 25.
3 1
ACX01808
AC204381AD
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BASIC BRAKE SYSTEM
35A-35

• Motor relay A connector B-53X
CONNECTORS: B-53X, B-54X
• Motor relay B connector B-54X
B-53X B-54X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204551AB
CONNECTORS: B-17, B-18 • HBB connectors B-17 and B-18

Check connectors, for loose, corroded or damaged terminals,
B-17 (GR) or terminals pushed back in the connector.
B-18 (B)
YES : Go to Step 6.
NO : Repair the faulty connector or terminal. Then go to
Step 25.
B-17 B-18
HBB CONNECTORS
AC204629 AB
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STEP 6. Check the power supply circuit at motor relay A

harness connector B-53X.
(1) Remove the motor relay A.
MOTOR
RELAY A
AC204329 AD
(2) Measure the voltage between terminal 5 and ground. The

CONNECTOR: B-53X
voltage should measure approximately 12 volts (battery
positive voltage).
present?
YES : Go to Step 7.
NO : Go to Step 10.
B-53X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204552 AB
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BASIC BRAKE SYSTEM
35A-37
STEP 7. Check the ignition switch (IG2) circuit at motor

relay A harness connector B-53X.
(1) Remove the motor relay A.
MOTOR
RELAY A
AC204329 AD

CONNECTOR: B-53X voltage should measure approximately 12 volts (battery
positive voltage).
present?
YES : Go to Step 8.
NO : Go to Step 11.
B-53X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204552 AC
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STEP 8. Check the power supply circuit at motor relay B

harness connector B-54X.
(1) Remove the motor relay B.
MOTOR
RELAY B
AC204329 AE

CONNECTOR: B-54X
positive voltage).
present?
YES : Go to Step 9.
NO : Go to Step 12.
B-54X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204553 AB
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BASIC BRAKE SYSTEM
35A-39
STEP 9. Check the ignition switch (IG2) circuit at motor

relay B harness connector B-54X.
(1) Remove the motor relay B.
MOTOR
RELAY B
AC204329 AE

CONNECTOR: B-54X
positive voltage).
present?
NO : Go to Step 13.
B-54X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204553 AC
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FUSIBLE LINK No.32 • The wire between fusible link number 32 and motor relay A
BATTERY connector B-53X (terminal 5)
Q: Is the harness wire damaged?
FUSIBLE LINK YES : Repair or replace it and then go to Step 25.
No.32 NO : Go to Step 25.
ACX01501AE
CONNECTOR: B-53X
B-53X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204551 AC
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BASIC BRAKE SYSTEM
35A-41

• The wire between motor relay A connector B-53X (terminal
CONNECTOR: B-53X
3) and junction block connector D-208 (terminal 4)
NOTE: Also check intermediate connectors D-116, D-212 and
E-111 for loose, corroded, or damaged terminals, or terminals
pushed back in the connector. If intermediate connector D-116,
D-212 or E-111 is damaged, repair or replace the damaged
component(s) as described in GROUP 00E, Harness Connec-
tor Inspection P.00E-2. If the connector has been repaired or
replaced, go to Step 25.
B-53X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204551 AC
CONNECTOR: D-208
D-208
JUNCTION BLOCK
(FRONT VIEW)
D-208 JUNCTION BLOCK

CONNECTOR
AC204624 AC
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CONNECTOR: D-116 Q: Is the harness wire damaged?

NO : Go to Step 25.
D-116
D-116
JOINT CONNECTOR (4):

JOINT PIN SIDE
AC204689 AB
CONNECTOR: D-212
D-212
JUNCTION BLOCK
(FRONT VIEW)
4 3 2 1
D-212 11 10 9 8 7 6 5
HARNESS CONNECTOR:
COMPONENT SIDE
AC204624 AD
CONNECTOR: E-111
E-111
AC204548AK
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BASIC BRAKE SYSTEM
35A-43

FUSIBLE LINK No.32 • The wire between fusible link number 32 and motor relay B
BATTERY connector B-54X (terminal 4)
FUSIBLE LINK YES : Repair or replace it and then go to Step 25.
No.32 NO : Go to Step 25.
ACX01501AE
CONNECTOR: B-54X
B-54X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204551 AD
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• The wire between motor relay B connector B-54X (terminal
CONNECTOR: B-54X
3) and multi-purpose fuse number 17 (junction block)
NOTE: Also check intermediate connector E-111 for loose, cor-
roded, or damaged terminals, or terminals pushed back in the
connector. If intermediate connector E-111 is damaged, repair
or replace the damaged component(s) as described in GROUP
00E, Harness Connector Inspection P.00E-2. If the connector
has been repaired or replaced, go to Step 25.
B-54X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204551 AD
MULTIPURPOSE FUSE NO.17
JUNCTION
BLOCK
MULTIPURPOSE
FUSE NO.17
AC203896
AC203896AE

NO : Go to Step 25.
E-111
AC204548AK
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BASIC BRAKE SYSTEM
35A-45

• The wire between HBB connector B-18 (terminal 31) and
CONNECTOR: B-18
motor relay A connector B-53X (terminal 4)
B-18 (B)
B-18
32 31
35 34 33
HARNESS CONNECTOR :
COMPONENT SIDE
AC204626 AB
CONNECTOR: B-53X
B-53X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204551 AC
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CONNECTOR: B-17 • The wire between HBB connector B-17 (terminal 2) and
motor relay B connector B-54X (terminal 5)
B-17 (GR) Q: Is any harness wire damaged?
YES : Repair or replace the faulty harness wire and then go
to Step 25.
NO : Go to Step 15.
3 2 1
B-17 5 4
8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE
AC204629 AE
CONNECTOR: B-54X
B-54X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204551 AD
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BASIC BRAKE SYSTEM
35A-47

CONNECTORS: E-119, E-120
• M-ASTC-ECU connectors E-119 and E-120
or terminals pushed back in the connector.
E-119 NO : Repair the faulty connector or terminal. Then go to
E-120
Step 25.
AC203901
M-ASTC-ECU CONNECTORS
E-119
E-120
AC204627 AD
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STEP 16. Check the ignition switch (IG2) circuit at M-

ASTC-ECU harness connector E-120.
CONNECTOR: E-120
(1) Disconnect M-ASTC-ECU connector E-120.
E-120
AC203901
E-120
AC204627 AE

positive voltage).
E-120 Q: Is battery positive voltage (approximately 12 volts)
present?
HARNESS CONNECTOR: NO : Go to Step 18.
COMPONENT SIDE
AC204729 AB
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BASIC BRAKE SYSTEM
35A-49
STEP 17. Check the ignition switch (IG2) circuit at M-

CONNECTOR: E-119
E-119
AC203901
E-119
AC204627AB

HARNESS CONNECTOR: positive voltage).
COMPONENT SIDE
E-119 present?
NO : Go to Step 19.
AC204631AB
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CONNECTOR: E-120
48) and motor relay A connector B-53X (terminal 1)
NO : Go to Step 25.
E-120
AC203901
E-120
HARNESS CONNECTOR:
COMPONENT SIDE
AC204627AG
CONNECTOR: B-53X
B-53X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204551 AC
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BASIC BRAKE SYSTEM
35A-51

CONNECTOR: E-119
24) and motor relay B connector B-54X (terminal 1)
NO : Go to Step 25.
E-119
AC203901
E-119
HARNESS CONNECTOR:
COMPONENT SIDE
AC204627AC
CONNECTOR: B-54X
B-54X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204551 AD
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STEP 20. Check the HBB (continuity and resistance test of

the pump motor).
CONNECTORS: B-17, B-18 (1) Disconnect HBB connectors B-17 and B-18.
B-17 (GR)
B-18 (B)
B-17 B-18
HBB CONNECTORS
AC204629 AB
(2) Check for continuity and measure the resistance between

terminals at the HBB connectors.
TESTER SPECIFIED RESISTANCE Ω
B-17
B-18 Q: Does continuity exist between above terminals?

NO : Go to Step 21.
ACX00662AC
STEP 21. Check the pump motor and lead wire.

(2) Remove the pump motor and the lead wire from the HBB
(3) Check the following items:
• Confirm that the pump motor operates when the battery
voltage is imposed at the pump motor terminal.
• Confirm the continuity of the lead wire.
Q: Are both of the pump motor and the lead wire in good
condition?
YES : Replace the master cylinder and hydraulic unit
NO : Replace the pump motor or the lead wire (Refer to
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BASIC BRAKE SYSTEM
35A-53

CONNECTOR: B-17 • HBB connector B-17
B-17 (GR)
B-17
HBB CONNECTOR
AC204629 AC
CONNECTOR: E-119
E-119 NO : Repair the faulty connector or terminal. Then go to
Step 25.
AC203901
E-119
AC204627AB
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CONNECTOR: E-119
25) and HBB connector B-17 (terminal 4)
NO : Go to Step 24.
E-119
AC203901
E-119
HARNESS CONNECTOR:
COMPONENT SIDE
AC204627AC
CONNECTOR: B-17
B-17 (GR)
3 2 1
B-17 5 4
8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE
AC204629 AE

Q: Is DTC 54 set?
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BASIC BRAKE SYSTEM
35A-55

Q: Is DTC 54 set?
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DTC 55 : Pump Motor Circuit (Pump Motor Energized Abnormally for Long Period)
Pump Motor Control Circuit
AC204496AB
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BASIC BRAKE SYSTEM
35A-57
B-17 (GR)
B-18 (B)
B-54X
B-53X
AC204545 AC AC204329AC
D-208
D-212
D-116
JUNCTION BLOCK
E-119
E-120
E-111
AC204548 AB AC203901AD
. .
CIRCUIT OPERATION TROUBLESHOOTING HINTS

• The pump motor operates if the motor relay A or • Malfunction of the motor relay A or the motor
motor relay B turn to ON. relay B
• The M-ASTC-ECU monitors the pump motor (at • Malfunction of the pressure switch (for pump
25 terminal). motor control) [Integrated with the hydraulic
.
brake booster (HBB)]
HBB DTC SET CONDITIONS • Damaged wiring harness or connector
DTC 55 will be set when the pump motor has been • Malfunction of the M-ASTC-ECU
energized too long. The M-ASTC-ECU sounds the
buzzer continuously to inform the trouble of the driver
and protects the pump motor by activating the pump
motor intermittently.
.
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DIAGNOSIS

Remove the motor relay A.
Q: Does the pump motor stop?
MOTOR YES : Remove the motor relay A. Then go to Step 15.
RELAY A NO : Go to Step 2.
AC204329 AD

Remove the motor relay B.
Q: Does the pump motor stop?
MOTOR YES : Remove the motor relay B. Then go to Step 15.
RELAY B NO : Go to Step 3.
AC204329 AE
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BASIC BRAKE SYSTEM
35A-59
STEP 3. Check the power supply circuit at HBB harness

connector B-18.
CONNECTOR: B-18 (1) Disconnect HBB connector B-18.
B-18 (B)
B-18
HBB CONNECTOR
AC204629 AD

voltage should measure 0 volt.
Q: Is the measured voltage 0 volt?
B-18 (B)
YES : Go to Step 5.
32 31 NO : Go to Step 4.
35 34 33
HARNESS CONNECTOR:
COMPONENT SIDE
AC204632 AB
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CONNECTOR: B-53X
NO : Go to Step 15.
B-53X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204551 AC
CONNECTOR: B-18
B-18 (B)
B-18
32 31
35 34 33
HARNESS CONNECTOR :
COMPONENT SIDE
AC204626 AB
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BASIC BRAKE SYSTEM
35A-61
STEP 5. Check the power supply circuit at HBB harness

connector B-17.
B-17 (GR)
B-17
HBB CONNECTOR
AC204629 AC

voltage should measure 0 volt.
Q: Is the measured voltage 0 volt?
YES : Go to Step 7.
B-17 3 2 1 NO : Go to Step 6.
(GR) 5 4
8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE
AC204633 AB
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CONNECTOR: B-54X
NO : Go to Step 15.
B-54X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204551 AD
CONNECTOR: B-17
B-17 (GR)
3 2 1
B-17 5 4
8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE
AC204629 AE
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BASIC BRAKE SYSTEM
35A-63

CONNECTOR: B-53X
1) and M-ASTC-ECU connector E-120 (terminal 48)
B-53X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204551 AC
CONNECTOR: E-120
E-120
AC203901
E-120
HARNESS CONNECTOR:
COMPONENT SIDE
AC204627AG
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CONNECTOR: B-54X
1) and M-ASTC-ECU connector E-119 (terminal 24)
NO : Go to Step 8.
B-54X
3 2 1 4 5
5 4 1 2 3
RELAY BOX CONNECTOR
AC204551 AD
CONNECTOR: E-119
E-119
AC203901
E-119
HARNESS CONNECTOR:
COMPONENT SIDE
AC204627AC
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BASIC BRAKE SYSTEM
35A-65
STEP 8. Check the pressure switch (for pump motor

control) circuit at M-ASTC-ECU harness connector E-119.
CONNECTOR: E-119
(1) Disconnect M-ASTC-ECU connector E-119 and measure at
E-119
AC203901
E-119
AC204627AB

The resistance should not measure less than 2 ohms.
HARNESS CONNECTOR:
COMPONENT SIDE
YES : Go to Step 9.
E-119 NO : Go to Step 12.
AC204683AB
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CONNECTOR: B-18
B-18 (B)
NO : Go to Step 10.
B-18
32 31
35 34 33
HARNESS CONNECTOR :
COMPONENT SIDE
AC204626 AB
CONNECTOR: E-119
E-119
AC203901
E-119
HARNESS CONNECTOR:
COMPONENT SIDE
AC204627AC
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BASIC BRAKE SYSTEM
35A-67

control).
at the "LOCK" (OFF) position to release the pressure of
HBB power supply system.
B-18 (B)
B-18
HBB CONNECTOR
AC204629 AD
(3) Measure the resistance between the terminals 33 and 35 at

the HBB. The resistance should measure approximately 1
kilo ohms.
Q: Is the resistance approximately 1 kilo ohms?
NO : Replace the master cylinder and hydraulic unit
HBB
CONNECTOR
B-18
AC204685 AB

Q: Does the pump motor operate?
NO : Go to Step 12.

Q: Is DTC 55 reset?
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B-17 (GR) Q: Is the harness wire damaged?
NO : Go to Step 14.
3 2 1
B-17 5 4
8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE
AC204629 AE
CONNECTOR: E-119
E-119
AC203901
E-119
HARNESS CONNECTOR:
COMPONENT SIDE
AC204627AC

Q: Is DTC 55 set?
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BASIC BRAKE SYSTEM
35A-69

Q: Is DTC 55 set?
DTC 56 : Pressure Switch (Open or Short Circuit at the Pressure Switch)
Pressure Switch Circuit
AC204497AB
CONNECTORS: B-17, B-18 CONNECTORS: E-119, E-120

B-17 (GR)
B-18 (B)
E-119
E-120
AC204545 AC AC203901AD
CIRCUIT OPERATION
.
• The pressure switch (for low-pressure warning)

monitors brake fluid pressure inside of the
hydraulic brake booster (HBB). When the brake
fluid pressure decreases abnormally, the pres-
sure switch (for low-pressure warning) is turned
off and the brake fluid low-pressure warning sig-
nal is output to the M-ASTC-ECU.
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• The pressure switch (for pump motor control) HBB DTC SET CONDITIONS
monitors brake fluid pressure inside of the DTC 56 is set if the pressure switch (for low-pressure
hydraulic brake booster (HBB). When the brake warning) circuit is open or short, or the pressure
fluid pressure decreases lower than the specified switch (for pump motor control) circuit is open.
value, the pressure switch (for pump motor con- NOTE: .
trol) is turned on and outputs the pump motor • DTC 55 will be set if the pressure switch (for
drive signal to the M-ASTC-ECU. pump motor control) is stuck on.
• The M-ASTC-ECU monitors an open circuit of the • DTC 57 will be set if the pressure switch (for low-
pressure switch (for pump motor control) (at 11 pressure warning) is stuck off.
terminal).
• The M-ASTC-ECU monitors an open circuit or
.
short circuit of the pressure switch (for low-pres- • Malfunction of the master cylinder and hydraulic
sure warning) (at 57 terminal). unit assembly [Integrated with the hydraulic brake
.
booster (HBB)]
.
DIAGNOSIS

CONNECTORS: B-17, B-18 • HBB connector B-17 and B-18
B-17 (GR) terminals pushed back in the connector.
B-18 (B)
YES : Go to Step 2.
Step 8.
B-17 B-18
HBB CONNECTORS
AC204629 AB
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BASIC BRAKE SYSTEM
35A-71

control) circuit inside the HBB.
B-18 (B)
B-18
HBB CONNECTOR
AC204629 AD

kilo ohms.
YES : Go to Step 3.
HBB
CONNECTOR
B-18
AC204685 AB
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STEP 3. Check the pressure switch (for low-pressure

warning) circuit inside the HBB.
B-17 (GR)
B-17
HBB CONNECTOR
AC204629 AC

the HBB. The resistance should measure approximately 5.7
kilo ohms.
Q: Is the resistance approximately 5.7 kilo ohms?
YES : Go to Step 4.
B-17
HBB CONNECTOR
AC204686AB
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BASIC BRAKE SYSTEM
35A-73

CONNECTOR: B-17 • The wire between HBB connector B-17 (terminal 1) and
ground
B-17 (GR)
3 2 1
B-17 5 4
8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE
AC204629 AE
• The wire between HBB connector B-18 (terminal 33) and

CONNECTOR: B-18
ground
B-18 (B)
NO : Go to Step 5.
B-18
32 31
35 34 33
HARNESS CONNECTOR :
COMPONENT SIDE
AC204626 AB
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CONNECTORS: E-119, E-120
• M-ASTC-ECU connector E-119 and E-120
YES : Go to Step 6.
E-120
Step 8.
AC203901
E-119
E-120
AC204627 AD
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BASIC BRAKE SYSTEM
35A-75

B-17 (GR)
3 2 1
B-17 5 4
8 7 6
HARNESS CONNECTOR:
COMPONENT SIDE
AC204629 AE
CONNECTOR: E-120
E-120
AC203901
E-120
HARNESS CONNECTOR:
COMPONENT SIDE
AC204627AG
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CONNECTOR: B-18
B-18 (B)
NO : Go to Step 7.
B-18
32 31
35 34 33
HARNESS CONNECTOR :
COMPONENT SIDE
AC204626 AB
CONNECTOR: E-119
E-119
AC203901
E-119
HARNESS CONNECTOR:
COMPONENT SIDE
AC204627AC

Q: Is DTC 56 set?
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BASIC BRAKE SYSTEM
35A-77

Q: Is DTC 56 set?
DTC 57: Accumulator (Accumulator Low-Pressure Abnormality)
Pressure Switch (for Low-Pressure Warning) Circuit
AC204498AB
CONNECTOR: B-17 CONNECTOR: E-120

B-17 (GR)
E-120
AC204545AB AC203901AF
. .
CIRCUIT OPERATION HBB DTC SET CONDITIONS

The pressure switch (for low-pressure warning) mon- DTC 57 is set if the brake fluid pressure decreases,
itors brake fluid pressure inside of the hydraulic or the pressure switch (for low-pressure warning)
brake booster (HBB). When the brake fluid pressure OFF seize-up occurs. In this case, the M-ASTC-ECU
decreases abnormally, the pressure switch (for low- sounds the buzzer continuously to inform the trouble
pressure warning) is turned off and the brake fluid of the driver and protects the pump motor by activat-
low-pressure warning signal is output to the M- ing the pump motor intermittently.
ASTC-ECU. .
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TROUBLESHOOTING HINTS • Malfunction of the pressure switch (for low-pres-

• Brake fluid leakage in the hydraulic brake booster sure warning) [Integrated with the hydraulic brake
(HBB) booster (HBB)]
• Malfunction of the accumulator [Integrated with
the hydraulic brake booster (HBB)]
.
DIAGNOSIS
STEP 1. Check the pressure switch (for low-pressure

warning) circuit inside the HBB.
B-17 (GR)
B-17
HBB CONNECTOR
AC204629 AC

kilo ohms.
YES : Go to Step 2.
B-17
HBB CONNECTOR
AC204686AB
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BASIC BRAKE SYSTEM
35A-79
STEP 2. Check the leakage of brake fluid from the HBB

visually.
Q: Is there leakage of brake fluid from the HBB?
YES : Go to Step 3.
NO : Go to Step 4.
STEP 3. Disassemble and check the HBB.

(2) Disassemble the HBB (Refer to P.35A-136).
(3) Check the HBB for the following points.
• Power piston assembly for rust, damage, wear and
deterioration
• Master cylinder piston assembly for rust, damage, wear
and deterioration
• Inside of the hydraulic unit assembly cylinder for rust
and damage
Q: Are all of the checked items in good condition?
YES : Assemble the HBB (Refer to P.35A-136), install the
HBB (Refer to P.35A-133), refill the brake fluid, and
bleed the brake line (Refer to P.35A-122). Then go to
Step 4.
NO : Replace the deficient parts, assemble the HBB (Refer
to P.35A-136), install the HBB (Refer to P.35A-133),
refill the brake fluid, and bleed the brake line (Refer to

Q: Is DTC 57 set?
YES : Replace the accumulator (Refer to P.35A-134). Then
go to Step 5.

Q: Is DTC 57 set?
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SYMPTOM CHART
M1351013200050
NOTE: The hydraulic brake booster (HBB) accumulates the high-pressure oil in the accumulator by the acti-
vation of the pump motor to assist the brake power. Even though the working sound of the pump motor can
be heard during operation, this sound is usually generated at normal operation of the HBB and is not an indi-
cation of a malfunction.
SYMPTOM INSPECTION REFERENCE

PROCEDURE NO. PAGE
Communication between the scan tool and the whole system is − Refer to GROUP
not possible. 13A, Diagnosis
P.13Ad-2.
Communication between the scan tool and the M-ASTC-ECU is − Refer to GROUP
not possible. 35B, Diagnosis
P.35B-4.
The brake warning light does not illuminate when the ignition 1 P.35A-81
switch is turned to the "ON" position just after the engine start.
The brake warning light remains illuminated after the engine is 2 P.35A-90
started.
DTC 53 <seizure of the pump motor>, DTC 55 or DTC57 is set, 3 P.35A-95
but he buzzer does not sound.
The buzzer does not stop sounding. 4 P.35A-103
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BASIC BRAKE SYSTEM
35A-81
HBB SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: The Brake Warning Light does not Illuminate when the Ignition Switch
is Turned to the "ON" Position just after the Engine Start.
Brake Warning Light Circuit
AC204500AB
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CONNECTORS: D-03, D-30 CONNECTORS: D-208, D-210

D-03 (GR)
D-208
D-210
D-30
JUNCTION BLOCK
AC204687AB (FRONT VIEW) AC204547AC
CONNECTOR: E-111 CONNECTOR: E-121
E-121
E-111
AC204548 AB AC203901AG
. .
CIRCUIT OPERATION TECHNICAL DESCRIPTION (COMMENT)

• The brake warning light power is supplied from The cause is probably an open circuit at the brake
the ignition switch (IG1). The M-ASTC-ECU warning light circuit, or malfunction of the M-ASTC-
grounds the circuit to illuminate the brake warn- ECU.
ing light.
• The M-ASTC-ECU illuminates the brake warning
.
light for 3 seconds while running its self-check. • Damaged wiring harness or connector
The brake warning light can be illuminated for 3 • Blown fuse
seconds upon start-up or with the ignition switch • Malfunction of the combination meter
in the "ON" position, and the engine stopped. • Malfunction of the M-ASTC-ECU
.
DIAGNOSIS
STEP 1. Check whether the brake warning light

illuminates.
Q: Does the brake warning light illuminate at the condition
that the ignition switch is turned to the "ON" position
and the engine is stopped.
YES : Go to Step 2.
NO : Go to Step 5.
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BASIC BRAKE SYSTEM
35A-83
STEP 2. Check the brake warning light circuit at M-ASTC-

ECU connector E-121.
CONNECTOR: E-121
(3) Check whether the brake warning light is illuminated. The
brake warning light should illuminate.
Q: Does the brake warning light illuminate?
E-121
ASTC-ECU P.35C-205.) and then go to Step 9.
NO : Go to Step 3.
AC203901
E-121
AC204627AP
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CONNECTOR: D-03 • Combination meter connector D-03
D-03 (GR)
D-03
COMBINATION METER
CONNECTOR
AC204690 AB
CONNECTOR: E-121
Q: Is any of the connector damaged?
YES : Repair the faulty connector or terminal and then go to
Step 9.
E-121
NO : Go to Step 4.
AC203901
E-121
AC204627AP
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BASIC BRAKE SYSTEM
35A-85

CONNECTOR: D-03 • The wire between combination meter connector D-03 (ter-
D-03 (GR) minal 55) and M-ASTC-ECU connector E-121 (terminal 81)
D-03
HARNESS CONNECTOR:
COMPONENT SIDE
AC204690 AC
CONNECTOR: E-121
E-121
AC203901
E-121
HARNESS CONNECTOR: COMPONE
AC204627AR

NO : Replace the combination meter (Refer to
GROUP54A, Combination Meter and Vehicle Speed
Sensor P.54A-65.) and then go to Step 9.
E-111
AC204548AK
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STEP 5. Check the combination meter power supply circuit

at combination meter harness connector D-03.
CONNECTOR: D-03 (1) Disconnect combination meter connector D-03, and
D-03 (GR) measure at the harness connector (component side).
D-03
COMBINATION METER
CONNECTOR
AC204690 AB

HARNESS CONNECTOR: voltage should measure approximately 12 volts (battery
COMPONENT SIDE positive voltage.)
D-03 58 57 56 55 54 53 52 51 Q: Is battery positive voltage (approximately 12 volts)
(GR) 59 present?
67 66 65 64 63 62 61 60
YES : Replace the combination meter (Refer to
GROUP54A, Combination Meter and Vehicle Speed
Sensor P.54A-65) and then go to Step 9.
NO : Go to Step 6.
AC205296 AB

D-03 (GR) Check connector for loose, corroded or damaged terminals, or
YES : Go to Step 7.
Step 9.
D-03
COMBINATION METER
CONNECTOR
AC204690 AB
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BASIC BRAKE SYSTEM
35A-87

CONNECTOR: D-208 • The wire between junction block connector D-208 (terminal
2) and combination meter connector D-03 (terminal 62)
D-208 NOTE: Also check intermediate connector D-210 for loose, cor-
connector. If intermediate connector D-210 is damaged, repair
JUNCTION BLOCK
(FRONT VIEW)

CONNECTOR
AC204624 AC
CONNECTOR: D-03
D-03 (GR)
D-03
HARNESS CONNECTOR:
COMPONENT SIDE
AC204690 AC
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NO : Go to Step 9.
D-210
JUNCTION BLOCK
(FRONT VIEW)
D-210
HARNESS CONNECTOR:
COMPONENT SIDE
AC204624 AE
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BASIC BRAKE SYSTEM
35A-89

D-03 (GR) minal 57) and ground
NOTE: Also check joint connector (8) D-30 for loose, corroded,
or damaged terminals, or terminals pushed back in the connec-
tor. If joint connector (8) D-30 is damaged, repair or replace the
damaged component(s) as described in GROUP 00E, Harness
Connector Inspection P.00E-2. If the connector has been
repaired or replaced, go to Step 9.
D-03
HARNESS CONNECTOR:
COMPONENT SIDE
AC204690 AC

NO : Go to Step 9.
D-30
D-30

JOINT PIN SIDE
AC204690 AD

Q: Does the brake warning light illuminate for three
seconds when the ignition switch is turned to the "ON"
position with engine stopped?
NO : Start over at Step 1.
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INSPECTION PROCEDURE 2: The Brake Warning Light Remains Illuminated after the Engine is
Started.
CAUTION
First of all, check the parking brake switch circuit
and the brake fluid level switch circuit.
NOTE: This diagnosis procedure is limited to cases
where communication with the scan tool is possible
(M-ASTC-ECU power supply is normal) and no DTC
sets.
AC204501AB
CONNECTOR: D-03 CONNECTOR: E-111

D-03 (GR)
E-111
AC204687AC AC204548 AB
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BASIC BRAKE SYSTEM
35A-91
CONNECTOR: E-121
E-121
AC203901AG
TECHNICAL DESCRIPTION (COMMENT)

.
CIRCUIT OPERATION
When the power transistor in the M-ASTC-ECU is off The cause is probably the M-ASTC-ECU malfunction
or the circuit between the M-ASTC-ECU and the or open circuit at the M-ASTC-ECU’s brake warning
combination meter is open, the power transistor in light drive circuit.
the combination meter will turn on to illuminate the .
brake warning light. TROUBLESHOOTING HINTS

.
• Malfunction of the combination meter

.
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DIAGNOSIS

D-03 (GR)
D-03
COMBINATION METER
CONNECTOR
AC204690 AB
CONNECTOR: E-121
YES : Go to Step 2.
E-121
Step 4.
AC203901
E-121
AC204627AP
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BASIC BRAKE SYSTEM
35A-93
STEP 2. Check the brake warning light drive circuit at M-

CONNECTOR: E-121
(1) Disconnect M-ASTC-ECU connector E-121 and check at
E-121
AC203901
E-121
AC204627AP
(3) Connect terminal 81 to a body ground.

HARNESS CONNECTOR: Q: Does the brake warning light turn off?
COMPONENT SIDE YES : Replace the M-ASTC-ECU (Refer to GROUP 35C, M-
AC204691AB
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D-03 (GR) minal 55) and M-ASTC-ECU connector E-121 (terminal 81)
D-03
HARNESS CONNECTOR:
COMPONENT SIDE
AC204690 AC
CONNECTOR: E-121
E-121
AC203901
E-121
HARNESS CONNECTOR: COMPONE
AC204627AR

NO : Replace the combination meter (Refer to GROUP
54A, Combination Meter and Vehicle Speed Sensor
P.54A-65) and then go to Step 4.
E-111
AC204548AK
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BASIC BRAKE SYSTEM
35A-95

Q: Does the brake warning light turn on for three seconds
and then turn off on start-up?
INSPECTION PROCEDURE 3: DTC 53 <Seizure of the Pump Motor>, DTC55 or DTC57 is set, but the
Buzzer does not Sound.
Buzzer Circuit
AC204502AB
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D-208
D-212
D-116
JUNCTION BLOCK
CONNECTORS: E-107, E-111 CONNECTOR: E-120
E-107
E-120
E-111
AC204548AH AC203901AF
c. When the accumulator pressure is abnormally

.
CIRCUIT OPERATION
• The M-ASTC-ECU controls the buzzer by turning low (DTC 57 is set).
the power transistor in the M-ASTC-ECU ON and d. When the solenoid valve temperature in the
OFF. M-ASTC-ECU is abnormally high (DTC is not
• The M-ASTC-ECU outputs the buzzer-sounding set).
signal at the malfunction of the hydraulic brake .
booster (HBB). (Also the M-ASTC-ECU turns on TECHNICAL DESCRIPTION (COMMENT)

the brake warning light at the same time.) The cause is probably an open circuit at the buzzer
• The buzzer will sound under the following cases: circuit, a malfunction of the buzzer or a failure of
a. When the pump motor is locked (DTC 53 is buzzer drive transistor in the M-ASTC-ECU.
set). .
b. When the pump motor is energized abnor- TROUBLESHOOTING HINTS

mally for long period (DTC 55 is set). • Damaged wiring harness or connector
• Malfunction of the buzzer
.
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BASIC BRAKE SYSTEM
35A-97
DIAGNOSIS

• Buzzer connector E-107
CONNECTOR: E-107
E-107
BUZZER
CONNECTOR
E-107
AC204692 AB
CONNECTOR: E-120
YES : Go to Step 2.
Step 7.
AC203901
E-120
AC204627 AE
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STEP 2. Check the buzzer circuit at M-ASTC-ECU harness

connector E-120.
CONNECTOR: E-120
(1) Disconnect M-ASTC-ECU connector E-120 and check at
E-120
AC203901
E-120
AC204627 AE
(3) Connect terminal 54 to body ground.

HARNESS CONNECTOR: Q: Does the buzzer sound?
COMPONENT SIDE YES : Replace the M-ASTC-ECU (Refer to GROUP 35C, M-
AC204726 AB
STEP 3. Check the buzzer.

(1) Remove the buzzer (Refer to P.35A-139).
(2) Connect the battery to the buzzer as shown on the
illustration.
Q: Does the buzzer sound?
YES : Go to Step 4.
NO : Replace the buzzer (Refer to P.35A-139). Then go to
Step 7.
ACX00680AB
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BASIC BRAKE SYSTEM
35A-99
STEP 4. Check the buzzer power supply circuit at buzzer

harness connector E-107.
(1) Disconnect buzzer connector E-107, and measure at the
CONNECTOR: E-107
E-107
BUZZER
CONNECTOR
E-107
AC204692 AB

positive voltage).
HARNESS CONNECTOR: present?
COMPONENT SIDE YES : Go to Step 5.
2
E-107
ACX01879 AC
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• The wire between buzzer connector E-107 (terminal 2) and
CONNECTOR: E-107
M-ASTC-ECU connector E-120 (terminal 54)
E-107 YES : Repair or replace it and then go to Step 7.
NO : Go to Step 7.
E-107
HARNESS
CONNECTOR:
COMPONENT
SIDE
AC204727AB
CONNECTOR: E-120
E-120
AC203901
E-120
HARNESS CONNECTOR:
COMPONENT SIDE
AC204627AG
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BASIC BRAKE SYSTEM
35A-101

CONNECTOR: E-107
junction block connector D-208 (terminal 4)
NOTE: Also check joint connector D-116, intermediate connec-
E-107 tor E-111 and junction block connector D-212 for loose, cor-
connector. If joint connector D-116, intermediate connector E-
E-107 111 or junction block connector D-212 is damaged, repair or
HARNESS
CONNECTOR:
replace the damaged component(s) as described in GROUP
COMPONENT 00E, Harness Connector Inspection P.00E-2. If the connector
SIDE has been repaired or replaced, go to Step 7.
AC204727AB
CONNECTOR: D-208
D-208
JUNCTION BLOCK
(FRONT VIEW)

CONNECTOR
AC204624 AC
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NO : Go to Step 7.
D-116
D-116

JOINT PIN SIDE
AC204689 AB
CONNECTOR: E-111
E-111
AC204548AK
CONNECTOR: D-212
D-212
JUNCTION BLOCK
(FRONT VIEW)
4 3 2 1
D-212 11 10 9 8 7 6 5
HARNESS CONNECTOR:
COMPONENT SIDE
AC204624 AD
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BASIC BRAKE SYSTEM
35A-103

(1) Apply a chock to the wheel.
(2) Start the engine.
(3) When 120 seconds or more have been elapsed since the
engine was started, release the parking brake lever and
fully depress the brake pedal repeatedly 15 to 20 times
within 10 seconds.
Q: Does the buzzer sound?
INSPECTION PROCEDURE 4: The Buzzer does not Stop Sounding.
NOTE: This diagnosis procedure is limited to cases where communication with the scan tool is possible (M-
ASTC-ECU power supply is normal) and no DTC sets.
AC204503AB
CONNECTORS: E-104, E-107, E-114 CONNECTOR: E-120
E-107
E-120
E-104
E-114
AC204548AI AC203901AF
• The M-ASTC-ECU outputs the buzzer-sounding

.
CIRCUIT OPERATION
• The M-ASTC-ECU and the transfer-ECU controls signal when an abnormality occurs on the
the buzzer by turning the power transistor in the hydraulic brake booster. (And at the same time,
ECU ON and OFF. the M-ASTC-ECU turns on the brake warning
light.)
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• The transfer-ECU outputs the buzzer-sounding

.
signal when an abnormality occurs on the active • Damaged wiring harness or connector
trac 4WD II system. • Malfunction of the M-ASTC-ECU
. • Malfunction of the transfer-ECU
TECHNICAL DESCRIPTION (COMMENT) • Malfunction of the buzzer
The cause is probably an M-ASTC-ECU or transfer-
ECU malfunction.
.
DIAGNOSIS
STEP 1. Check the buzzer circuit at M-ASTC-ECU

connector E-120.
CONNECTOR: E-120
Disconnect M-ASTC-ECU connector E-120.
Q: Does the buzzer still keep on sounding?
YES : Go to Step 2.
NO : Replace the M-ASTC-ECU (Refer to GROUP 35C, M-
E-120
AC203901
E-120
AC204627 AE
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BASIC BRAKE SYSTEM
35A-105
STEP 2. Check the buzzer circuit at transfer-ECU

connector E-104.
CONNECTOR: E-104
Disconnect transfer-ECU connector E-104.
Q: Does the buzzer still keep on sounding?
YES : Go to Step 3.
NO : Replace the transfer-ECU (Refer to GROUP 23A,
Transfer-ECU P.23Aa-45). Then go to Step 5.
E-104
E-104
HARNESS CONNECTOR:
COMPONENT SIDE
AC204728 AB
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• Buzzer connector E-107
CONNECTOR: E-107
E-107
BUZZER
CONNECTOR
E-107
AC204692 AB
CONNECTOR: E-120
E-120
AC203901
E-120
AC204627 AE
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BASIC BRAKE SYSTEM
35A-107
CONNECTOR: E-104
• Transfer-ECU connector E-104
YES : Go to Step 4.
Step 5.
E-104
E-104
TRANSFER-ECU CONNECTOR
AC204728 AC
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CONNECTOR: E-107
M-ASTC-ECU connector E-120 (terminal 54)
E-107
E-107
HARNESS
CONNECTOR:
COMPONENT
SIDE
AC204727AB
CONNECTOR: E-120
E-120
AC203901
E-120
HARNESS CONNECTOR:
COMPONENT SIDE
AC204627AG
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BASIC BRAKE SYSTEM
35A-109
CONNECTOR: E-107
transfer-ECU connector E-104 (terminal 51)
NOTE: Also check intermediate connector E-114 for loose,
E-107 corroded, or damaged terminals, or terminals pushed back in
the connector. If intermediate connector E-114 is damaged,
repair or replace the damaged component(s) as described in
E-107 GROUP 00E, Harness Connector Inspection P.00E-2. If the
HARNESS
CONNECTOR:
connector has been repaired or replaced, go to Step 5.
COMPONENT
SIDE
AC204727AB
CONNECTOR: E-104
E-104
E-104
HARNESS CONNECTOR:
COMPONENT SIDE
AC204728 AB

NO : Replace the buzzer (Refer to P.35A-139). Then go to
Step 5.
E-114
AC204548AN
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CAUTION
(1) Connect scan tool MB991502 to the data link connector.
MB991502
(3) Using scan tool MB991502, check actuator test and sound
the buzzer.
16-PIN
Q: Does the buzzer sound for three seconds and then
stop?
ACX01539 AC
DATA LIST REFERENCE TABLE

M1352011500412
The following items can be read by the scan tool
from the M-ASTC-ECU input data.
MUT-II SCAN ITEM CHECK ITEM CHECKING REQUIREMENT NORMAL
TOOL DISPLAY NO. CONDITION
BATT. 31 M-ASTC-ECU Ignition switch: ON 6.5 − 22.3 V
VOLTAGE power supply
voltage
ACCUM SW 76 Pressure switch (for Ignition switch: ON ON
(PL) low-pressure
warning)
ACCUM SW 77 Pressure switch (for Ignition switch: ON When the pump motor OFF
(PH) pump motor control) is not operating.
When the pump motor ON
is operating.
MOTOR RLY 79 Motor relay A, B Ignition switch: ON When the pump motor OFF
is not operating.
When the pump motor ON
is operating.
ACTUATOR TEST REFERENCE TABLE

M1351013500051
The scan tool activates the following actuators for NOTE: .
testing. • If the M-ASTC-ECU is inoperative, actuator test-
ing cannot be carried out.
• Actuator testing is only possible when the vehicle
is stationary.
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BASIC BRAKE SYSTEM
35A-111
MUT-II SCAN NO. ITEM DRIVE CONTENT Activation when the system fails
TOOL DISPLAY
HBB MOTOR 11 Pump motor Drives the pump motor Disabled
for one second.
HBB BUZZER 12 Buzzer Drives the buzzer for Disabled
three seconds.
BRKE WARN LMP 23 Brake warning Illuminates the brake Enabled (However, disabled when
light warning light. the brake warning light can not be
activated)
CHECK AT M-ASTC-ECU
M1351013600069
Terminal Voltage Check Chart
NOTE: Do not measure terminal voltage during the approxi-
mately three seconds after the ignition switch is turned to the
"ON" position. The M-ASTC-ECU performs the initial check
during that period.
Measure the voltage between terminal (4), (22), (56) or (64)
(ground terminals) and each respective terminal by
backprobing.
M-ASTC-ECU
AC203901
AC204627AT
TERMINAL NO. SIGNAL CHECKING REQUIREMENT NORMAL

CONDITION
9 M-ASTC-ECU Ignition switch: ON Battery positive
power supply voltage
11 Pressure switch Ignition switch: Brake fluid pressure: LOW Approximately 6V
(Pump motor ON (Pump motor operates.)
control)
Brake fluid pressure: HIGH Less than 2V
(Pump motor does not operate.)
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TERMINAL NO. SIGNAL CHECKING REQUIREMENT NORMAL

CONDITION
12 Pump motor Ignition switch: ON Less than 2V
current detection
(−)
14 Pump motor Ignition switch: Pump motor does not operate. Less than 2V
current detection ON
Pump motor operates. Battery positive
(+)
voltage
24 Motor relay B Ignition switch: Pump motor does not operate. Battery positive
ON voltage
Pump motor operates. Less than 2V
25 Pump motor Ignition switch: ON Less than 2V
monitor
48 Motor relay A Ignition switch: Pump motor does not operate. Battery positive
ON voltage
Pump motor operates. Less than 2V
54 Buzzer Ignition switch: Buzzer does not sound. Battery positive
ON voltage
Buzzer sounds. Less than 2V
57 Pressure switch Ignition switch: Brake fluid pressure: EXTRA Approximately 9V
(low-pressure ON LOW
warning) (Buzzer sounds.)
Brake fluid pressure: NORMAL Approximately 4V
(Buzzer does not sound.)
63 M-ASTC-ECU Ignition switch: ON Battery positive
power supply voltage
81 Brake warning Engine: Idling The warning light does not Less than 2V
light illuminate.
The warning light illuminates. Battery positive
voltage
Resistance and Continuity between Harness

Connector Terminals
1. Turn the ignition switch to the "LOCK" (OFF) position and
disconnect the M-ASTC-ECU connectors.
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BASIC BRAKE SYSTEM
35A-113
2. Measure the resistance between the terminals of the
harness connector (component side). The terminals to be
checked are indicated in the table below.
M-ASTC-ECU TERMINAL NO. SIGNAL NORMAL
CONDITION
22 − body ground Ground 1 Less than 2 ohms
AC203901
HARNESS CONNECTORS:
COMPONENT SIDE
AC204627AU
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SPECIAL TOOLS
SPECIAL TOOLS
M1351000600230
TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB991502 MB991496-OD • For checking of HBB
Scan tool (MUT-II) [Diagnostic trouble code
display when using the scan
tool (MUT-II)]
B991502
• Air bleeding of ABS system
in HBB system
MB991529 Tool not necessary For checking of HBB [Diagnostic
Diagnostic trouble code if scan tool (MUT- trouble code display when using
check harness II) is available. the brake warning light]
MB991529
MB991223 MB991223 For hydraulic brake booster

A Harness set MB991709-01 (HBB) diagnosis
A: MB991219
Inspection harness
B
MB991223AB
MB991926 − Accumulator removal and

Accumulator wrench installation
MB991926
MB991620 − Fixing of HBB

Valve spring compressor
adapter
MB991620
MB990964 General service Pushing-in of the disc brake

A Brake tool set tool piston
BB
A: MB990520
Disc brake piston expander
MB990964
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BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
35A-115
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
M1351000900297
Brake Pedal Height

1. Turn up the carpet etc. under the brake pedal.
OPERATING 2. Measure the brake pedal height as illustrated.
ROD LOCK Standard value: 192 − 195 mm (7.6 − 7.7 inches)
NUT STOPLIGHT
SWITCH 3. If the brake pedal height is not within the standard value,
adjust as follows.
(1) Disconnect the stoplight switch connector.
OPERATING
ROD (2) Rotate the stoplight switch 1/4 turn counterclockwise to
loosen.
ACX00657AB
PEDAL (3) Loosen the operating rod jam nut. Turn the serrations of
DOWN the operation rod with pliers to adjust the brake pedal
height to the standard value.
PEDAL UP
JAM NUT
ACX01815AB
(4) Turn the stoplight switch until it contacts the stopper.

During this step, secure the pedal by moving it forward by
STOPPER
hand.
(5) Turn the stoplight switch 1/4 turn clockwise to secure,
and confirm that the clearance between the switch
plunger and the stopper is as shown.
(6) Connect the connector of the stoplight switch.
0.5 - 1.0 mm
(0.02 - 0.04 in)
(7) Check to be sure that the stoplight does not illuminate
with the brake pedal released.
AC101091AB
4. Check the key interlock and shift lock mechanisms (Refer to
GROUP 23A, On-vehicle Service − Key Interlock and Shift
Lock Mechanism Check P.23Aa-24).
5. Return the carpet etc. to its original position.
Brake Pedal Free Play

1. Turn the ignition switch to the "ON" position, and wait until
the HBB pump motor stops.
NOTE: If the brake fluid inside the accumulator is not pres-
surized to a predetermined value, the pump motor will start
to run. Once the pump motor has stopped, the brake fluid
inside the accumulator is pressurized to the predetermined
value. If the brake fluid inside the accumulator is pressurized
to a predetermined value, the pump motor will not start to
run.
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ON-VEHICLE SERVICE
2. Operate the pedal by hand, and check that the pedal stroke
(free play) meets the standard value at the point where
resistance is felt.
Standard value: 3 mm (0.1 inch) or less
3. If the brake pedal play is not within the standard value,
check the following, and adjust or replace if necessary:
• Excessive play between the brake pedal and the clevis pin,
or between the clevis pin and the brake booster operating
rod
ACX00659
• Brake pedal height
• Installation position of the stoplight switch, etc.
Clearance between Brake Pedal and Floorboard

1. Turn up the carpet etc. under the brake pedal.
2. Start the engine, depress the brake pedal with
approximately 500 N (112 pounds) of force, and measure
the clearance between the brake pedal and the floorboard.
Standard value: 90 mm (3.5 inches) or more
3. If the clearance is outside the standard value, check for air
trapped in the brake line and thickness of the disc brake
pad. And then adjust and replace defective parts as
required.
4. Return the carpet etc. to its original position.
ACX00660
STOPLIGHT SWITCH CHECK

M1351008900213
1. Connect an ohmmeter between the stoplight switch
connector terminals.
2. There should be no continuity between the terminals when
the plunger is pushed in as shown. There should be
continuity when it is released.
TESTER PLUNGER SPECIFIED
CONNECTION CONDITION
1−2 IN Open circuit
OUT Less than 2 ohms
NO CONTINUITY CONTINUITY
4 mm
(0.16 in)
ACX00671AB
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BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
35A-117
HBB OPERATING CHECK
M1351010400055
CAUTION
If the diagnostic trouble code is stored in the M-ASTC-ECU
memory, erase it after diagnosis is completed.
Function and Operation Check of Power Supply
System
1. Depress the brake pedal repeatedly more than 40 times until
the pedal depressing force feels heavy with the ignition
switch at the "LOCK" (OFF) position to release the pressure
of HBB power supply system.
2. Check that the fluid level in the reservoir is at the "MAX" line.
3. Chock the wheels and release the parking brake.
4. Turn the ignition switch to the "ON" position and measure
how long it takes for the pump motor to start, then stop.
Standard value: 20 − 80 seconds
5. After the pump motor stops, start the engine to confirm that
the brake warning light does not come on.
6. Stop the engine and turn the ignition switch to the "ON"
position again.
7. Confirm that the pump motor operates, then stops when the
brake pedal is depressed repeatedly 4 to 5 times.
8. Depress the brake pedal repeatedly 4 to 5 times again to
measure how long it takes for the pump motor to start, then
stop.
Standard value: 2 − 11 seconds
9. Check and confirm the following items 120 seconds or more
after turning ON the ignition switch.
CAUTION
Check and confirm the following items 120 seconds or
more after turning the ignition switch to the "ON" position.
10.Confirm that the buzzer sounds and the brake warning light
illuminates when the brake pedal is fully depressed 15 to 20
times within 10 seconds.
HBB Simple Check

1. Depress the brake pedal repeatedly for more than 40 times
until the pedal depressing force feels heavy with the ignition
2. Check the change of pedal height by turning the ignition
switch to the "ON" position while depressing the brake
pedal. It is normal if the pedal is lowered at this time. If it is
not lowered, the system is defective.
Check Using Simple Tester

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ON-VEHICLE SERVICE
2. Connect a pressure gauge and a pedal depression gauge

PEDAL DEPRESSION GAUGE
as shown in the illustration and bleed air from the pressure
gauge.
PRESSURE
GAUGE 3. Perform the operation test without booster according to the
following method.
Depress the brake pedal repeatedly more than 40 times
with the ignition switch at "LOCK" (OFF) position to bleed
pressure from the HBB power supply system. Measure
the relation between the brake pedal depressing force
and the hydraulic pressure.
Standard value:
BRAKE HYDRAULIC PRESSURE kPa (psi)
PEDAL
FRONT BRAKE REAR BRAKE
DEPRESSING
FORCE N (lb)
ACX00661 AB
100 (22) 600 (87) and over 0 (0)
500 (112) 4,500 (653) and 0 (0)
over
4. Perform the operation test with booster according to the

following method.
Turn the ignition switch to the "ON" position and measure
the relation between the brake pedal depressing force
and the hydraulic pressure after pump motor was
stopped.
Standard value:
BRAKE HYDRAULIC PRESSURE kPa (psi)
PEDAL
FRONT BRAKE REAR BRAKE
DEPRESSING
FORCE N (lb)
100 (22) 3,000 − 4,000 3,300 − 4,300
(435 − 580) (479 − 624)
200 (45) 8,000 − 10,000 8,000 − 10,000
(1,160 − 1,450) (1,160 − 1,450)
400 (90) 14,000 − 18,000 14,000 − 18,000
(2,030 − 2,611) (2,030 − 2,611)
500 (112) 15,000 − 19,000 15,000 − 19,000
(2,175 − 2,756) (2,175 − 2,756)
Brake Warning Light and Buzzer Operation Check

1. Chock the wheel and start the engine.
2. Hold the engine at the idling condition for more than 120
seconds.
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BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
35A-119
CAUTION
Perform the check 120 seconds or more after turning the
ignition switch to the "ON" position.
3. Release the parking brake and fully depress the brake pedal
BRAKE WARNING LIGHT repeatedly 15 to 20 times in 10 seconds. Confirm that the
warning light comes on and the buzzer sounds.
BUZZER
ACX01818 AB
HBB CHECK
M1351010500063
Continuity and Resistance Test of Pump Motor
1. Disconnect the HBB connectors.
2. Measure the resistance between the terminals at the HBB.
TESTER SPECIFIED RESISTANCE VALUE Ω
6−7 Continuity Less than 2
ACX00662
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ON-VEHICLE SERVICE
Pressure Switch (for Pump Control) Check

2. Disconnect the HBB connector "A."
3. Measure the resistance between terminals No. 33 and No.
35 at the HBB connector "A."
TESTER SPECIFIED RESISTANCE
CONNECTOR A CONNECTION CONDITION VALUE kΩ
4. If the resistance value exceeds the specified value, replace

ACX01809 AC the HBB master cylinder and hydraulic unit assembly.
5. With the HBB connector "A" disconnected, turn "ON" the
ignition switch to operate the pump motor. Then measure
the resistance between terminals No. 33 and No. 35 at the
HBB connector "A" while the pump motor is operating.
CONNECTION CONDITION VALUE Ω

the HBB master cylinder and hydraulic unit assembly.
7. Connect the HBB connector "A."
8. Erase HBB diagnostic trouble codes (Refer to P.35A-14).
Pressure Switch (for Low-Pressure Warning)

Check
the pedal depressing force is felt heavy with the ignition
2. Disconnect the HBB connector "B."
3. Measure the resistance between terminals No. 1 and No. 5
at the HBB connector "B."
CONNECTOR B TESTER SPECIFIED RESISTANCE
CONNECTION CONDITION VALUE kΩ
1−5 Continuity Approximately 5.7

ACX01810 AC the HBB master cylinder and hydraulic unit assembly.
5. Next, turn the ignition switch to the "ON" position to operate
the pump motor. Then confirm that the pump motor is
stopped.
6. Measure the resistance between terminals No. 1 and No. 5
at the HBB connector "B."
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BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
35A-121

CONNECTION CONDITION VALUE kΩ

the HBB master cylinder and hydraulic unit assembly.
8. Connect the HBB connector "B."
9. Erase HBB diagnostic trouble codes (Refer to P.35A-14).
HBB MOTOR RELAY CHECK

M1351010600059
Motor Relay A, B
CAUTION
MOTOR
BATTERY CONNECTION TESTER SPECIFIED
MOTOR
RELAY B CONNECTION CONDITION
RELAY A
• Connect battery 4−5 Less than 2
terminal (+) to terminal ohms
3
• Connect battery
AC204329 terminal (−) to terminal
1
BRAKE FLUID
RESERVOIR
4
5
3 1
ACX01808
AC204381AB
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ON-VEHICLE SERVICE
BRAKE FLUID LEVEL INSPECTION AND BLEEDING

M1351001400295
CAUTION
• Use only brake fluid DOT3 or DOT4. Never mix the specified brake fluid with other brake fluid, as it
will significantly decrease braking performance.
• Depress the brake pedal slowly. If the brake pedal is pressed too quickly, the pump motor will acti-
vate frequently and a large volume of high-pressure brake fluid may flow from the brake caliper
quickly, depleting the HBB reservoir contents and possibly introducing air into the HBB system.
• Depending upon the quantity of brake fluid in the reservoir, if the brake pedal is pressed with the
reservoir cap removed, the brake fluid in the reservoir may overflow.
• Use suitable protection to prevent brake fluid from contacting underhood components and body
paint.
HBB System Bleeding
WARNING
The HBB system bleeding must be done in the follow-
ing cases.
• If brake fluid is drained after removing or installing
the HBB
• if there is excessive brake fluid loss during normal
brake system bleeding
• if you suspect that air has entered the HBB system
NOTE: The HBB brake system bleeding procedure requires
two persons working together.
HBB system bleeding must be done in the following order:
HBB SYSTEM BLEEDING STEPS
1. FRONT BRAKE LINES (FILLING)
2. ACCUMULATOR (HBB)
3. REAR BRAKE LINES (FILLING)
4. POWER SUPPLY (HBB)
5. ABS (HBB)
6. REAR BRAKE LINES (BLEEDING)
7. FRONT BRAKE LINES (BLEEDING)
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BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
35A-123
CAUTION
• Keep the brake fluid reservoir level just above the
"MIN" line. Monitor the fluid level during this procedure
to ensure the fluid does not reach below the "MIN" line,
to prevent air from entering the system.
• If a large quantity of brake fluid is drained during the
bleeding procedure, the accumulator pressure will
decrease abnormally. Do not bleed more than 0.1 dm3
(0.11quart) from each wheel at a time.
• Confirm that the pump motor stops after each air-bleed-
ing step. If not, proceed to the troubleshooting the HBB
System section.
NOTE: The buzzer may sound during this procedure due to low
pressure in the system. The buzzer will stop when normal HBB
pressure is restored.
1. Fill the front brake system with brake fluid as follows (RH
first, LH second):
(1) Attach a clear hose to the RH caliper bleeder valve. This
helps to monitor air/fluid flow.
(2) Be sure the fluid level is between the "MIN" and "MAX"
lines.
(3) Turn the ignition switch to the "LOCK" (OFF) position.
Pump the brake pedal 3 − 4 times and hold it depressed.
(4) Open the RH caliper bleeder valve 1/4 turn.
(5) With the bleeder valve still open, pump the brake pedal
repeatedly to fill the line with fluid until no obvious air
bubbles are seen. When no more obvious air bubbles are
seen, and while the brake pedal is still being pumped,
close the bleeder valve.
(6) Repeat steps (1) − (5) for the LH caliper.
(7) Release the brake pedal when both sides are filled.
2. Fill the pump motor as follows:
(1) Turn the ignition switch to the "ON" position to operate
the pump motor.
a. If the pump motor operates normally (normal operation
sound), go to step 3.
b. If the pump motor operation sound is dry and high-
pitched, depress the brake pedal 3 or 4 times to
introduce fluid into the pump motor. Then go to step 3.
3. Fill the accumulator system with brake fluid as follows:
(1) Wait for the pump motor to stop from step 2.
(2) Depress the brake pedal slowly 3 or 4 times with the
ignition switch at the "ON" position. Observe the condition
of the brake fluid in the reservoir.
a. If the fluid is cloudy, leave it for 2 or 3 minutes until it
becomes clear.
b. Repeat the above procedure (a) until no bubbles
appear while pumping the brake pedal.
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ON-VEHICLE SERVICE
NOTE: OK to fill the reservoir to the "MAX" line during this

process. Brake fluid level around the "MIN" line may cause
bubbles to appear from the jet flow of brake fluid while
pumping the brake pedal.
4. Fill the rear brake system with brake fluid as follows (RH
first, LH second):
CAUTION
ing step.
NOTE: A high-pressure hydraulic noise (hissing) is normal
during this procedure.
(1) Attach a clear hose to the RH caliper bleeder valve. This
helps to monitor air/fluid flow.
(2) Be sure the fluid level is between the "MIN" and "MAX"
lines.
Pump the brake pedal 3 − 4 times and hold it depressed.
(4) Open the RH caliper bleeder valve 1/4 turn.
(5) With the bleeder valve still open, pump the brake pedal
repeatedly to fill the line with fluid until no obvious air
bubbles are seen. When no more obvious air bubbles are
seen, and while the brake pedal is still being pumped,
close the bleeder valve.
(6) Repeat steps (1) − (5) for the LH caliper.
(7) Release the brake pedal when both sides are filled.
5. Supply brake fluid into the power supply system as follows:
CAUTION
Keep the brake fluid reservoir level just above the "MIN"
line at this time. Monitor the fluid level during this proce-
dure to ensure it does not reach below the "MIN" line.
(1) To release the pressure in the HBB power supply system,
turn the ignition switch to the "LOCK" (OFF) position and
depress the brake pedal repeatedly until its depressing
force suddenly feels heavy (no pedal travel).
(2) Turn the ignition switch to the "ON" position and at the
same time quickly depress the brake pedal approximately
20 times. Then confirm that the pump motor has stopped.
This can take up to 2 minutes.
(3) Turn the ignition switch to the "LOCK" (OFF) position and
depress the brake pedal repeatedly until its depressing
force suddenly feels heavy (no pedal travel).
(4) Turn the ignition switch to the "ON" position to operate
the pump motor. Confirm that the pump motor stops
within 25 seconds. If the pump motor does not stop,
repeat steps (1) through (3) above.
6. Supply fluid into the ABS system as follows:
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BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
35A-125
CAUTION
When connecting or disconnecting the scan tool, ensure
that the ignition switch is at the "LOCK" (OFF) position.
(1) Turn the ignition switch to the "LOCK" (OFF) position and
MB991502
connect scan tool MB991502 to the data link connector.
(2) Turn the ignition switch to the "ON" position. Select from
scan tool menu screen as follows:
16-PIN
[SYSTEM SELECT → ABS → ACTUATOR TEST → AIR
BLEED]
(3) Depress and hold the brake pedal.
(4) Activate the actuator test [AIR BLEED (1)]. When the
scan tool flashes confirmation that the AIR BLEED (1)
ACX01539 AC operation is completed, proceed with AIR BLEED (2).
(5) Depress and hold the brake pedal.
(6) Select and activate [AIR BLEED (2)] on the scan tool
screen. When the scan tool flashes confirmation that the
AIR BLEED (2) operation is completed, go to step 7.
7. Bleed the rear brake system as follows (RH first, LH
second):
CAUTION
"MIN" line at this time. Monitor the fluid level during
this procedure to ensure it does not reach below the
"MIN" line.
ing step.
(1) Attach the clear hose to the RH caliper to monitor air/fluid
flow.
(3) Open bleeder valve 1/4 turn.
(4) With the bleeder valve open, pump the brake pedal 3
times and hold.
(5) Close the bleeder valve.
(6) Pump the brake pedal 3 times and hold.
(7) Open the bleeder valve 1/8 turn briefly to allow any
remaining air to escape, then close the bleeder valve.
(8) Repeat steps (6) and (7) as many times as necessary to
eliminate all air in the line.
(9) Repeat steps (1) − (8) at the LH caliper.
8. Bleed the front brake system as follows (RH first, LH
second):
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ON-VEHICLE SERVICE
CAUTION
"MIN" line at this time. Monitor the fluid level during
this procedure to ensure it does not reach below the
"MIN" line.
ing step.
(1) Attach the clear hose to the RH caliper to monitor air/fluid
flow.
(4) With the bleeder valve open, pump the brake pedal 3
times and hold.
(5) Close the bleeder valve.
(6) Pump the brake pedal 3 times and hold.
(7) Open the bleeder valve 1/8 turn briefly to allow any
remaining air to escape, then close the bleeder valve.
(8) Repeat steps (6) and (7) as many times as necessary to
eliminate all air in the line.
(9) Repeat steps (1) − (8) at the LH caliper.
9. Adjust the brake fluid level as follows:
(2) Depress the brake pedal repeatedly (up to 40 times or
more) until its depressing force suddenly feels very heavy
(no pedal travel).
(3) Release the brake pedal.
(4) Adjust the brake fluid level between the "MIN" and "MAX"
lines on the reservoir.
Normal Brake System Air Bleeding CAUTION

If the brake fluid level in the HBB reservoir is • Keep the brake fluid reservoir level just above
between the "MIN" and "MAX" lines after any brake the "MIN" line at this time. Monitor the fluid
servicing at the wheels (such as calipers, rotors, level during this procedure to ensure it does
etc.), perform the following steps: not reach below the "MIN" line.
1. Bleed the rear brake system as follows (RH first, • If a large quantity of brake fluid is drained
LH second): during the bleeding procedure, the accumula-
tor pressure will decrease abnormally. Do not
bleed more than 0.1 dm3 (0.11quart) from
each wheel at a time.
• Confirm that the pump motor stops after each
air-bleeding step.
(1) Attach the clear hose to the RH caliper to
monitor air/fluid flow.
(4) With the bleeder valve open, pump the brake
pedal 3 times and hold.
TSB Revision
BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
35A-127
(5) Close the bleeder valve. (2) Turn the ignition switch to the "ON" position.
(6) Pump the brake pedal 3 times and hold. (3) Open bleeder valve 1/4 turn.
(7) Open the bleeder valve 1/8 turn briefly to allow (4) With the bleeder valve open, pump the brake
any remaining air to escape, then close the pedal 3 times and hold.
bleeder valve. (5) Close the bleeder valve.
(8) Repeat steps (6) and (7) as many times as (6) Pump the brake pedal 3 times and hold.
necessary to eliminate all air in the line. (7) Open the bleeder valve 1/8 turn briefly to allow
(9) Repeat steps (1) − (8) at the LH caliper. any remaining air to escape, then close the
2. Bleed the front brake system as follows (RH first, bleeder valve.
LH second): (8) Repeat steps (6) and (7) as many times as
CAUTION necessary to eliminate all air in the line.
• Keep the brake fluid reservoir level just above (9) Repeat steps (1) − (8) at the LH caliper.
the "MIN" line at this time. Monitor the fluid 3. Adjust the brake fluid level as follows:
level during this procedure to ensure it does (1) Turn the ignition switch to the "LOCK" (OFF)
not reach below the "MIN" line. position.
• If a large quantity of brake fluid is drained (2) Depress the brake pedal repeatedly (up to 40
during the bleeding procedure, the accumula- times or more) until its depressing force
tor pressure will decrease abnormally. Do not suddenly feels very heavy (no pedal travel).
bleed more than 0.1 dm3 (0.11quart) from (3) Release the brake pedal.
each wheel at a time. (4) Adjust the brake fluid level between the "MIN"
• Confirm that the pump motor stops after each and "MAX" lines on the reservoir.
air-bleeding step.
(1) Attach the clear hose to the RH caliper to
monitor air/fluid flow.
BRAKE FLUID LEVEL SWITCH CHECK

M1351009100254
The brake fluid level switch is in good condition if there is no
MAX continuity when the float surface is above the "MIN" line and if
there is continuity when the float surface is below the "MIN"
line.
MIN
ACX00664 AC
DISC BRAKE PAD CHECK AND REPLACEMENT

M1351002300246
NOTE: The brake pads have indicators that contact the brake
disc when the brake pad thickness becomes 2 mm (0.08 inch),
and emit a squealing sound to warn the driver.
TSB Revision
ON-VEHICLE SERVICE
CAUTION
• Whenever a pad must be replaced, replace both LH and
RH wheel pads as a set to prevent the vehicle from pull-
ing to one side when braking.
CAUTION
If there is a significant difference in the thicknesses of the
pads on the left and right sides, check the sliding condi-
tion of the piston, lock pin and guide pin.
FRONT REAR 1. Check the brake pad thickness through the caliper body
check port.
Standard value: 10.0 mm (0.39 inch)
Minimum limit: 2.0 mm (0.08 inch)
ACX00665AB
2. Remove the guide pin lock bolt. Lift the caliper assembly
and secure it with a wire.
ACX00705
3. Remove the following parts from caliper support.

FRONT (1) Pad and wear indicator assembly <FRONT>
Pad and clip assembly <REAR>
3 (2) Pad assembly
2
4 (3) Clip
1 (4) Shim
(5) Shim B <REAR>
(6) Shim A <REAR>
3
4. Measure the hub torque before and after pad installation.
Follow the procedure:
REAR 3 • FRONT: Refer to P.35A-140.
• REAR: Refer to P.35A-146.
2
5 1
4
6
3
AC204544AB
TSB Revision
BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
35A-129
CAUTION
Do not apply excessive grease. Excessive grease may
cause brake performance to become poor.
5. For rear disc bake, apply brake grease SAE J310, NLGI
number 1 to the following positions before installing the pad.
<REAR> • Pad assembly and shim A contact surface
• Inner shim A and shim B contact surface
SHIM A PAD ASSEMBLY
SHIM B
AC000886 AD
6. Install the pad and caliper assembly, and check the brake
drag force.
• FRONT: Refer to P.35A-140.
• REAR: Refer to P.35A-146.
DISC BRAKE ROTOR CHECK
M1351002900215
CAUTION
Disc brakes must be kept within the allowable
service values in order to maintain normal brake
operation.
Before turning the brake disc, the following condi-
tions should be checked:
INSPECTION ITEM REMARK
Scratches, rust, saturated lining • If the vehicle is not driven for a long period of time, sections of the
materials and wear discs that are not in contact with the pads will become rusty, causing
noise and shuddering.
• If grooves and scratches resulting from excessive disc wear are not
removed prior to installing a new pad assembly, there will be
inadequate contact between the disc and the lining (pad) until the
pads conform to the disc.
Run-out Excessive run-out of the discs will increase the pedal depression
resistance due to piston kickback.
Change in thickness (parallelism) If the thickness of the disc changes, this will cause pedal pulsation,
shuddering and surging.
Warping (flatness) or distortion Overheating and improper handling while servicing will cause warping
or distortion.
TSB Revision
ON-VEHICLE SERVICE
BRAKE DISC THICKNESS CHECK

M1351002400254
1. Remove dirt and rust from the brake disc surface.
2. Using a micrometer, measure disc thickness at eight
positions, approximately 45 degrees apart and 10 mm (0.4
inch) in from the outer edge of the disc.
FRONT BRAKE DISC
REAR BRAKE DISC
ACX00668
NOTE: Thickness variation (at least 8 positions) should not
be more than 0.015 mm (0.0006 inch).
CAUTION
• After a new brake disc is installed, always grind the
brake disc with a on-car type brake lathe. If this step is
not carried out, the brake disc run-out will exceed the
specified value, resulting in judder.
• When the on-car type lathe is used, first install a M12
flat washer on the stud bolt in the brake disc side
according to the figure, and then install the adapter. If
M12 PLANE the adapter is installed without a M12 flat washer, the
WASHER brake disc rotor may be deformed, resulting in inaccu-
rate grinding.
• Grind the brake disc with all wheel nuts diagonally and
equally tightened to the specified torque 100 N⋅m (74 ft-
lb). When all numbers of wheel nuts are not used, or the
tightening torque is excessive or not equal, the brake
disc rotor or drum may be deformed, resulting in
judder.
3. If the disc thickness is less than the limits, replace it with a

M12 PLANE
new one. If thickness variation exceeds the specification,
WASHER
turn rotor with an on-car type brake lathe ("Accuturn-8750"
or equivalent).
If the calculated final thickness after turning the rotor is less
than the standard value, replace the disc.
AC005154 AB
BRAKE DISC RUN-OUT CHECK AND

CORRECTION
M1351009400404
1. Remove the caliper support; then raise the caliper assembly
upward and secure it with a wire.
2. Inspect the disc surface for grooves, cracks and rust. Clean
the disc thoroughly and remove all rust.
3. Fix the disc with a hub nut temporarily.
TSB Revision
BASIC BRAKE SYSTEM
ON-VEHICLE SERVICE
35A-131
4. Place a dial gauge approximately 5 mm (0.2 inch) from the
outer circumference of the brake disc, and measure the run-
out of the disc.
Limit: 0.06 mm (0.002 inch)
5. If the run-out of the brake disc is limit value or more, correct
it as follows:
(1) Place a mating mark on both the wheel stud and disc with
chalk where the run-out is greatest.
ACX00669
(2) Remove the brake disc. Then place a dial gauge as

shown in the illustration, and then move the hub in the
axial direction and measure the play.
Limit: 0 mm (0 inch)
(3) If the play exceeds the limit, disassemble the hub and
knuckle assembly to check each part.
(4) If the play does not exceed the limit, install the brake disc
at a different phase, and then check the run-out of the
brake disc again.
ACX00670
CAUTION
• After a new brake disc is installed, always grind the
brake disc with a on-car type brake lathe. If this step is
not carried out, the brake disc run-out will exceed the
specified value, resulting in judder.
• When the on-car type lathe is used, first install a M12
flat washer on the stud bolt in the brake disc side
according to the figure, and then install the adapter. If
M12 PLANE the adapter is installed without a M12 flat washer, the
WASHER brake disc rotor may be deformed, resulting in inaccu-
rate grinding.
• Grind the brake disc with all wheel nuts diagonally and
equally tightened to the specified torque 100 N⋅m (74 ft-
lb). When all numbers of wheel nuts are not used, or the
tightening torque is excessive or not equal, the brake
disc rotor or drum may be deformed, resulting in
judder.
6. If the run-out cannot be corrected by changing the phase of
the brake disc, replace the brake disc or turn rotor with an
M12 PLANE
on-car type brake lathe ("Accuturn-8750" or equivalent).
WASHER
AC005154 AB
TSB Revision
BRAKE PEDAL
BRAKE PEDAL
REMOVAL AND INSTALLATION
M1351003400257
Post-installation Operation
• Brake Pedal Adjustment (Refer to P.35A-115.)
14 ± 3 N·m
11 124 ± 26 in-lb
12
5
9 4
12 ± 2 N·m 8 6N
107 ± 17 in-lb
10
7
N 2 3
1 ACX01838 AB
REMOVAL STEPS REMOVAL STEPS (Continued)

• INSTRUMENT PANEL LOWER 6. ADJUSTER
PANEL (REFER TO GROUP 52A, 7. PEDAL STOPPER
INSTRUMENT PANEL P.52A-2.) 8. SNAP PIN
1. RETURN SPRING 9. CLEVIS PIN
2. COTTER PIN 10. PEDAL PAD
3. SHIFT LOCK CABLE 11. BRAKE BOOSTER MOUNTING
CONNECTION NUT
4. HARNESS CONNECTOR >>A<< 12. BRAKE PEDAL AND PEDAL
5. STOPLIGHT SWITCH SUPPORT MEMBER ASSEMBLY
INSTALLATION SERVICE POINT

.
>>A<< BRAKE PEDAL AND PEDAL SUPPORT MEMBER

ASSEMBLY INSTALLATION
Tighten the brake booster mounting nut ("A" in the illustration)
first, then tighten the brake pedal mounting bolt ("B" in the illus-
tration).
B NOTE: Because the mounting hole of the pedal mounting bolt
("B" in the illustration) is a slotted hole, if the pedal mounting
A A bolt ("B" in the illustration) is mounted first, positioning
becomes impossible.
ACX01839 AB
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BASIC BRAKE SYSTEM
35A-133
M1351010700056
CAUTION
To prevent damaging the HBB pump motor, do not turn the ignition switch to the "ON" position until
installation is completed and brake fluid is replenished.
Pre-removal Operation Post-installation Operation
• Bleeding of the brake fluid power supply system (Depress • Brake Pedal Adjustment (Refer to P.35A-115.)
the brake pedal repeatedly more than 40 times with the • Brake Fluid Supplying
ignition switch at the LOCK (OFF) position.) • Brake Line Bleeding (Refer to P.35A-122.)
• Brake Fluid Draining • HBB Operating Check (Refer to P.35A-117.)
4
2 7N
15 ± 2 N·m
11 ± 2 ft-lb
3 8 14 ± 3 N·m
7N 124 ± 26 in-lb
2 5
6
1
ACX00672 AB
REMOVAL STEPS REMOVAL STEPS (Continued)

• BATTERY 4. CLEVIS PIN
1. HARNESS CONNECTORS 5. HBB MOUNTING NUT
2. BRAKE TUBE CONNECTION <<A>> >>A<< 6. HBB
3. SNAP PIN 7. SEAL
8. SPACER
TSB Revision
REMOVAL SEVICE POINT

.
<<A>> HBB REMOVAL

CAUTION
Since high-pressure is applied to the tube shown in the
illustration, do not bend it.
AC204332
INSTALLATION SEVICE POINT

.
>>A<< HBB INSTALLATION

CAUTION
Since high-pressure is applied to the tube shown in the
illustration, do not bend it.
AC204332
ACCUMULATOR REPLACEMENT
M1351015800014

• MB991926: Accumulator Wrench
of the HBB power supply system.
CAUTION
To prevent damaging the pump motor, do not turn the igni-
tion switch to the "ON" position until brake fluid is replen-
ished.
2. Drain the brake fluid.
TSB Revision
BASIC BRAKE SYSTEM
35A-135
3. Using special tool MB991926, remove the accumulator.
4. Remove the o-ring installed between the accumulator and
the HBB.
5. Install a new o-ring to a new accumulator.
6. Using special tool MB991926, install the new accumulator to
the HBB. The tightening torque of the accumulator is 54 ± 5
N⋅m (40 ± 4 ft-lb).
MB991926 7. Fill the HBB brake system with brake fluid and bleed the
ACCUMULATOR HBB brake system (Refer to P.35A-122).
AC204060 AB
8. Carry out the function and operation check of power supply
system (Refer to P.35A-117).
9. Erase HBB diagnostic trouble code (Refer to P.35A-14).
10.Dispose of the removed accumulator (Refer to P.35A-135).
ACCUMULATOR DISPOSAL
M1351015900011
WARNING
Do not disassemble, throw into fire, cut, weld, drop,
or shock the accumulator without purging filled gas.
1. Fix the accumulator on a vice as illustrated.
AC204540
2. Punch in the area shown in the illustration to fix the drilling

position.
3. Set a drill [diameter φ 4 mm (φ 0.16 in)] on the drill motor.
Φ50 mm
Φ2.0 in
AC204541AB
TSB Revision
WARNING
Wear protective glasses during drilling to protect you
from scattered chips caused by spouting gas.
4. Using a drill motor, drill a hole on the accumulator to purge
filled gas.
NOTE: .
• There is no danger of accumulator burst due to drilling
work.
• You can hear purging sound of gas as soon as a hole is
made on the accumulator.
• The filled gas is nitrogen, which is colorless, odorless
and harmless.
AC204539 5. Dispose of the accumulator in compliance with Federal,
state, and local laws.
DISASSEMBLY AND ASSEMBLY
M1351010800064
1 1.7 ± 0.3 N•m

15 ± 2.6 in-lb
1.7 ± 0.3 N•m

15 ± 2.6 in-lb 2 25.5 ± 5.1 N•m
19 ± 3 ft-lb
N 21
54 ± 5 N•m
40 ± 4 ft-lb N 22
3
4 N 19
23
20
N 5 BRAKE FLUID: DOT3 OR DOT4
11.8 ± 2.3 N•m

6 104 ± 20 in-lb 24
15
7 11
12
7.8 ± 1.5 N•m
13
69 ± 13 in-lb 14
8 18
17
9 16
15.2 ± 3 N•m
11 ± 2 ft-lb 10
3.0 ± 0.5 N•m

26 ± 4 in-lb
1.7 ± 0.1 N•m 7.8 ± 1.5 N•m
15 ± 1 in-lb 69 ± 13 in-lb AC204377 AC
TSB Revision
BASIC BRAKE SYSTEM
35A-137
DISASSEMBLY STEPS DISASSEMBLY STEPS (Continued)
1. RESERVOIR CAP 17. BUSHING
2. RESERVOIR ASSEMBLY 18. PUMP MOTOR
3. GROMMET 19. CLEVIS
<<A>> 4. ACCUMULATOR 20. BOOT
5. O-RING <> • SECURING THE HBB
6. SPRING <<C>> 21. SNAP RING
7. SILENT TUBE <<C>> 22. POWER PISTON ASSEMBLY
8. HOSE <<C>> 23. MASTER CYLINDER PISTON
9. HBB BRAKE TUBE ASSEMBLY
10. LEAD WIRE 24. MASTER CYLINDER AND
11. WASHER HYDRAULIC UNIT ASSEMBLY
12. BUSHING
Required Special Tools:
13. COLLAR
• MB991926: Accumulator Wrench
14. PIN
15. BRACKET
• MB991620: Valve Spring Compressor Adapter
16. BRACKET
DISASSEMBLY SERVICE POINTS

.
<<A>> ACCUMULATOR REMOVAL

Using special tool MB991926, remove the accumulator. For
disposing of the accumulator, refer to P.35A-135.
MB991926
AC204379AB
<> SECURING THE HBB

MASTER CYLINDER Secure the HBB on a vice as shown in the illustration, using
AND HYDRAULIC UNIT spacers and special tool MB991620.
ASSEMBLY SPACER
MB991620
ACX00675AB
TSB Revision
<<C>> SNAP RING/POWER PISTON ASSEMBLY/MASTER

CYLINDER PISTON ASSEMBLY REMOVAL
1. Press-in the push rod of the power piston assembly, and
remove the snap ring using a precision minus-slot
screwdriver or similar tool.
A
NOTE: If it is difficult to remove the snap ring, push the snap
ring from the hole ("A" in the illustration) on the cylinder
body.
ACX00676AB
CAUTION
Pull out the cylinder carefully so that the inner diameter of
the cylinder is not damaged.
MASTER CYLINDER 2. Pull to remove the power piston assembly and the master
PISTON ASSEMBLY
POWER PISTON cylinder piston assembly straight from the body.
ASSEMBLY
ACX00677AB
TSB Revision
BASIC BRAKE SYSTEM
BUZZER
35A-139
BUZZER
M1351016100018

• Indicator Panel, Lower Center Panel Removal (Refer to • Indicator Panel, Lower Center Panel Installation (Refer to
GROUP 52A, Floor Console P.52A-7.) GROUP 52A, Floor Console P.52A-7.)
• Buzzer Operation Check (Refer to P.35A-117.)
5.0 ± 1.0 N·m

44 ± 9 in-lb
BUZZER
AC204378 AB
BUZZER CHECK
M1351016200015
Check that the buzzer sounds when a battery is connected to
the buzzer as shown in the illustration.
ACX00680AB
TSB Revision
FRONT DISC BRAKE ASSEMBLY

M1351006000269

• Brake Fluid Draining • Brake Fluid Supplying and Air Bleeding (Refer to P.35A-
122.)
1
113 ± 9 N•m 30 ± 4 N•m N 2
83 ± 7 ft-lb 22 ± 3 ft-lb 2N
4
ACX00681AB
REMOVAL STEPS Required Special Tool:

1. BRAKE HOSE CONNECTION • MB990520: Disc Brake Piston Expander
2. GASKET
>>A<< 3. DISC BRAKE ASSEMBLY
4. BRAKE DISC

.
>>A<< DISC BRAKE ASSEMBLY INSTALLATION

1. To check the brake drag force after mounting the pad,
measure the hub torque in the advancing direction using a
spring scale with the pad is removed.
CAUTION
Do not allow any oil, grease or other contamination to con-
tact the friction surfaces of the pads and brake discs.
2. After re-installing the caliper support to the knuckle, install
the pad clips and the pads to the caliper support.
ACX00683
TSB Revision
BASIC BRAKE SYSTEM
35A-141
3. Clean the piston, and insert into cylinder with special tool
MB990520.
MB990520 4. Be careful that the piston boot does not become caught
when lowering the caliper assembly and installing the guide
pin.
5. Check the brake drag force as follows:
(1) Start the engine and hold the brake pedal down for five
seconds. [Pedal depression force: approximately 196 N
(44 pound)]
ACX00684AB
(2) Stop the engine.
(3) Turn the brake disc forward 10 times.
(4) Use a spring scale to measure the hub torque with pads
installed in the same direction as earlier.
(5) Calculate the drag force of the disc brake [difference
between hub torque with pads installed and hub torque
with pads removed].
Standard value: 55 N (12 pound)
6. If the brake drag force exceeds the standard value,
disassemble and clean the piston. Check for corrosion or
worn piston seal, and check the sliding condition of the lock
ACX00685
pin and guide pin.
INSPECTION
M1351006100181
Brake Disc Check

• Disc wear (Refer to P.35A-130.)
• Disc run-out (Refer to P.35A-130.)
TSB Revision

M1351006200285
89 ± 4 N•m
66 ± 3 ft-lb 13 13 13
11
2 7.4 ± 1.4 N•m
65 ± 13 in-lb
10
89 ± 4 N•m
66 ± 3 ft-lb 13 13
1
CLIP KIT
13
12
N 4
9
3
N 8
7
N 6
N 5
2 10
12 8
4 4
1 3
9 6
8 5
7
6
5 11
BRAKE CALIPER KIT PAD SET SHIM KIT SEAL AND BOOT KIT
ACX00686AB

1. GUIDE PIN LOCK BOLT <> 8. PISTON SEAL
2. GUIDE PIN 9. CALIPER BODY
3. CALIPER SUPPORT, PAD, CLIP AND 10. PAD AND WEAR INDICATOR
SHIM ASSEMBLY ASSEMBLY
4. BOOT 11. PAD ASSEMBLY
5. BUSHING 12. SHIM
<<A>> 6. PISTON BOOT 13. CLIP
<<A>> 7. PISTON
TSB Revision
BASIC BRAKE SYSTEM
35A-143
LUBRICATION POINTS
PISTON
SEAL
GREASE: REPAIR KIT GREASE
CAUTION
THE PISTON SEAL INSIDE THE
SEAL AND BOOT KIT IS COATED
WITH SPECIAL GREASE DO NOT
WIPE THIS GREASE OFF.
BRAKE FLUID: DOT3 OR DOT4

ACX00687AC

CAUTION
When disassembling the front disc brakes, disassemble
both sides (left and right wheels) as a set.
.
TSB Revision
<<A>> PISTON BOOT/PISTON REMOVAL

CAUTION
• When removing the pistons, be sure to use the handle
of a plastic hammer and adjust the height of the two
pistons while pumping in air slowly so that the pistons
protrude evenly.
• Do not remove one piston completely before trying to
remove the other piston, because it will become impos-
sible to remove the second piston.
• Blow air little by little to remove the piston. The piston
will rush out if a force of air is applied suddenly.
Blow compressed air slowly from the connecting portion of the
brake hose to pull out the piston and the piston boots.
ACX00688
<> PISTON SEAL REMOVAL

CAUTION
Do not use a flat-tipped screwdriver or similar tool to
remove piston seal. These may damage the inner side of
the cylinder.
1. Remove the piston seal with your finger tip.
2. Clean the piston surface and inner cylinder with alcohol
brake fluid DOT 3 or DOT 4.
ACX00689
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BASIC BRAKE SYSTEM
35A-145
INSPECTION
M1351006300248
• Check the cylinder for wear, damage or rust.
• Check the piston surface for wear, damage or rust.
• Check the caliper body or sleeve for wear.
• Check the pad for damage or adhesion of grease.
• Check the backing metal for damage.
Pad Wear Check

WARNING
• Always replace both brake pads on each wheel as
a set (both front wheels or both rear wheels). Fail-
ure to do so will result in uneven braking, which
may cause unreliable brake operation.
• If there is significant difference in the thickness of
the pads on the left and right sides, check the slid-
ing condition of the piston, lock pin and guide pin.
Measure thickness at the thinnest and most worn area of the
pad. Replace the pad assembly if pad thickness is less than the
limit value.
Standard value: 10 mm (0.39 inch)
ACX00690
TSB Revision
REAR DISC BRAKE ASSEMBLY

M1351007000187

• Brake Fluid Draining • Brake Fluid Supplying and Air Bleeding (Refer to P.35A-
122.)
30 ± 4 N•m
22 ± 3 ft-lb
100 ± 10 N•m
74± 7 ft-lb 3
N 2
4
AC204328AB
REMOVAL STEPS Required Special Tool:

1. BRAKE HOSE CONNECTION • MB990520: Disc Brake Piston Expander
2. GASKET
>>A<< 3. DISC BRAKE ASSEMBLY
4. BRAKE DISC

.
>>A<< DISC BRAKE ASSEMBLY INSTALLATION

1. In order to measure brake drag torque after pad installation,
measure hub torque with the pads removed.
Use a spring scale to measure hub torque in the direction
shown. Record the value.
CAUTION
Do not allow any oil, grease or other contamination to con-
tact the friction surfaces of the pads and brake discs.
2. After re-installing the caliper support, install the pad clips
and pads to the caliper support.
ACX00692
TSB Revision
BASIC BRAKE SYSTEM
35A-147
3. Clean the piston, and insert it into the cylinder with special
tool MB990520.
4. Be careful that the piston boot does not become caught
when lowering the caliper assembly and installing the guide
pin.
5. Check brake drag force as follows:
(1) Start the engine and hold the brake pedal down for five
MB990520 seconds. [Pedal depression force: approximately 196 N
(44 pounds)]
ACX00693AB
(2) Stop the engine.
(3) Turn the brake disc forward ten times.
(4) Use a spring scale to measure the hub torque with pads
installed in the same direction as earlier.
(5) Calculate the drag force of the disc brake [difference
between hub torque with pads installed and hub torque
with pads removed].
Standard value: 55 N (12 pounds)
6. If the drag torque exceeds the standard value, disassemble
and clean the piston. Check for corrosion or worn piston
seal, and check the sliding condition of the lock pin and
ACX00694
guide pin.
INSPECTION
M1351007100184
Brake Disc Check

• Disc wear (Refer to P.35A-130.)
• Disc run-out (Refer to P.35A-130.)
TSB Revision

M1351007200181
7.9 ± 0.9 N•m 8

44 ± 5 N•m
70 ± 8 in-lb 7 6
33 ± 3 ft-lb
1 5
4 2
6 6
17 3
12 N
16
9 6 6
6
10 11 CLIP SET
N 12 15
N 14
N 13
1
17 12
5 5 7 8 3 16 14 12
16
14 11
9
10 7
10
12 15 4 8
3 13
4 12
13
BRAKE CALIPER KIT PAD SET SHIM SET SEAL AND BOOTS KIT
AC204380AB

>>A<< 1. GUIDE PIN 10. BUSHING
2. PAD AND CLIP ASSEMBLY AND SHIM 11. CALIPER SUPPORT
3. SHIM 12. PIN BOOT
4. PAD AND CLIP ASSEMBLY 13. BOOT RING
5. PAD ASSEMBLY <<A>> 14. PISTON BOOT
6. PAD CLIP <<A>> 15. PISTON
7. SHIM B <> 16. PISTON SEAL
8. SHIM A 17. CALIPER BODY
>>A<< 9. LOCK PIN
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BASIC BRAKE SYSTEM
35A-149
LUBRICATION POINTS
SHIM A PAD ASSEMBLY
SHIM B
PISTON
SEAL
GREASE: BRAKE GREASE J310, NLGI NO.1
CAUTION
THE PISTON SEAL INSIDE THE SEAL
AND BOOT KIT IS COATED WITH
SPECIAL GREASE. DO NOT WIPE
THIS GREASE OFF.
BRAKE FLUID: DOT3 OR DOT4
GREASE: REPAIR KIT GREASE AC205297AB

CAUTION
When disassembling the disc brakes, disassemble both
sides (left and right) as a set.
.
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<<A>> PISTON BOOT/PISTON REMOVAL

CAUTION
Blow air little by little to remove the piston. The piston will
rush out if a force of air is applied suddenly.
Place a piece of wood, etc. against the caliper body as shown.
Blow compressed air through the brake hose connection hole
to remove the piston boot and piston.
AC204331
<> PISTON SEAL REMOVAL

CAUTION
Do not use a flat-tipped screwdriver or similar tool to
remove piston seal. These may damage the inner side of
the cylinder.
1. Remove the piston seal with your finger tip.
2. Clean piston surface and inner cylinder with alcohol or brake
fluid DOT 3 or DOT 4.
AC204684
ASSEMBLY SERVICE POINT

.
>>A<< LOCK PIN/GUIDE PIN INSTALLATION

Attach a guide pin at the bleeder nipple side of the caliper body
GUIDE PIN and a lock pin at the opposite side.
BLEEDER
NIPPLE
LOCK PIN
AC204734 AB
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BASIC BRAKE SYSTEM
35A-151
INSPECTION
M1351007300177
• Check the cylinder for wear, damage or rust.
• Check the piston surface for wear, damage or rust.
• Check the caliper body or sleeve for wear.
• Check the pad for damage or adhesion of grease.
• Check the backing metal for damage.
Pad Wear Check

WARNING
• Always replace both brake pads on each wheel as
a set (both front wheels or both rear wheels). Fail-
ure to do so will result in uneven braking, which
may cause unreliable brake operation.
• If there is significant difference in the thickness of
the pads on the left and right sides, check the slid-
ing condition of the piston, lock pin and guide pin.
Measure thickness at the thinnest and most worn area of the
pad. Replace the pad assembly if pad thickness is less than the
limit value.
Standard value: 10 mm (0.39 inch)
AC204733
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SPECIFICATIONS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1351009600260
ITEM SPECIFICATION
Brake line
Brake tube flare nut 15 ± 2 N⋅m (11 ± 2 ft-lb)
Brake pedal
Hydraulic brake booster mounting nut 14 ± 3 N⋅m (124 ± 26 in-lb)
Pedal support member mounting bolt 12 ± 2 N⋅m (107 ± 17 in-lb)
Buzzer
Buzzer mounting nut 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Hydraulic brake booster (HBB)
Accumulator 54 ± 5 N⋅m (40 ± 4 ft-lb)
Brake tube flare nut (between master cylinder and pump motor) 15.2 ± 3 N⋅m (11 ± 2 ft-lb)
Clevis nut 25.5 ± 5.1 N⋅m (19 ± 3 ft-lb)
Hydraulic brake booster mounting nut 14 ± 3 N⋅m (124 ± 26 in-lb)
Lead wire screw (hydraulic unit side) 1.7 ± 0.1 N⋅m (15 ± 1 in-lb)
Lead wire screw (pump motor side) 3.0 ± 0.5 N⋅m (26 ± 4 in-lb)
Pump motor bracket mounting bolt 11.8 ± 2.3 N⋅m (104 ± 20 in-lb)
Pump motor mounting bolt 7.8 ± 1.5 N⋅m (69 ± 13 in-lb)
Reservoir assembly mounting screw 1.7 ± 0.3 N⋅m (15 ± 2.6 in-lb)
Front disc brake
Bleeder screw 7.4 ± 1.4 N⋅m (65 ± 13 in-lb)
Brake hose connector bolt 30 ± 4 N⋅m (22 ± 3 ft-lb)
Front brake assembly mounting bolt 113 ± 9 N⋅m (83 ± 7 ft-lb)
Guide pin 89 ± 4 N⋅m (66 ± 3 ft-lb)
Guide pin lock bolt 89 ± 4 N⋅m (66 ± 3 ft-lb)
Rear disc brake
Bleeder screw 7.9 ± 0.9 N⋅m (70 ± 8 in-lb)
Brake hose connector bolt 30 ± 4 N⋅m (22 ± 3 ft-lb)
Rear disc brake assembly mounting bolt 100 ± 10 N⋅m (74 ± 7 ft-lb)
Guide pin 44 ± 5 N⋅m (33 ± 3 ft-lb)
Lock pin 44 ± 5 N⋅m (33 ± 3 ft-lb)
GENERAL SPECIFICATIONS
M1351000200210
ITEM SPECIFICATION
Hydraulic brake Master cylinder type Single type (with center valve)
booster (HBB) Master cylinder ID mm (in) 22.22 (0.875)
Boosting ratio 5.4
Rear wheel hydraulic pressure control type Electronic brake-force distribution (EBD)
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BASIC BRAKE SYSTEM
SPECIFICATIONS
35A-153
ITEM SPECIFICATION
Front brakes Type Floating caliper, 2 piston, ventilated disc
Disc effective diameter mm (in) 241 (9.5)
Wheel cylinder ID mm (in) 45.4 (1.79)
Pad thickness mm (in) 10.0 (0.40)
Clearance adjustment Automatic
Rear brakes Type Floating caliper, 1 piston, ventilated disc
Disc effective diameter mm (in) 256 (10.0)
Wheel cylinder ID mm (in) 44.5 (1.75)
Pad thickness mm (in) 10.0 (0.40)
Clearance adjustment Automatic
SERVICE SPECIFICATIONS
M1351000300284
ITEM STANDARD VALUE LIMIT

Brake pedal height mm (in) 192 − 195 (7.6 − 7.7) −
Brake pedal play mm (in) 3 (0.1) or less −
Brake pedal to floor board clearance when the brake pedal 90 (3.5) or more −
is depressed mm (in)
<Pedal depression force: Approximately 500 N (112 lb)>
Hydraulic brake Pump motor When brake fluid 20 − 80 −
booster (HBB) operating time: pressure is not
seconds applied to power
supply system
With power assist 2 − 11 −
Hydraulic pressure Depressing Front 600 (87) or more −
generated at test force 100 N
Rear 0 (0) −
without booster: (22 lb)
kPa (psi) Depressing Front 4,500 (653) or more −
force 500 N Rear 0 (0) −
(112 lb)
Hydraulic pressure Depressing Front 3,000 − 4,000 −
generated at test force 100 N (435 − 580)
with booster: kPa (22 lb) Rear 3,300 − 4,300 −
(psi) (479 − 624)
Depressing Front 8,000 − 10,000 −
force 200 N (1,160 − 1,450)
(45 lb) Rear 8,000 − 10,000 −
(1,160 − 1,450)
force 400 N (2,030 − 2,611)
(90 lb) Rear 14,000 − 18,000 −
(2,030 − 2,611)
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SPECIFICATIONS
ITEM STANDARD VALUE LIMIT

force 500 N (2,175 − 2,756)
(112 lb) Rear 15,000 − 19,000 −
(2,175 − 2,756)
Front disc brake Pad thickness mm (in) 10.0 (0.39) Minimum 2.0 (0.08)
Disc thickness mm (in) 26.0 (1.02) Minimum 24.4 (0.96)
Disc run-out mm (in) − 0.06 (0.002)
Drag force N (lb) 55 (12) −
Rear disc brake Pad thickness mm (in) 10.0 (0.39) Minimum 2.0 (0.08)
Disc thickness mm (in) 22.0 (0.87) Minimum 20.4 (0.80)
Disc run-out mm (in) − 0.06 (0.002)
Drag force N (lb) 55 (12) −
Front hub end play mm (in) − 0 (0)
Rear hub end play mm (in) − 0 (0)
LUBRICANTS
M1351000400269
ITEM SPECIFIED LUBRICANT

Brake fluid DOT3 or DOT4
HBB power piston assembly, HBB master cylinder piston assembly
Brake caliper piston, caliper body piston cylinder
Piston boot, piston seal Repair kit grease
Guide pin lock bolt, guide pin, lock pin
Rear disc brake pad assembly and shim A contact surface Brake grease SAE J310, NLGI
Rear disc brake shim A and shim B contact surface No.1
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35A-1

GENERAL DESCRIPTION. . . . . . . . . 35A-3 HBB MOTOR RELAY CHECK . . . . . . . . . . 35A-121

SPECIAL TOOLS. . . . . . . . . . . . . . . . 35A-114 FRONT DISC BRAKE ASSEMBLY . . 35A-140

REAR DISC BRAKE ASSEMBLY . . . 35A-146 SPECIFICATIONS . . . . . . . . . . . . . . . 35A-152

adopted to provide stable braking force and Improved Serviceability

REAR DISC BRAKE

FRONT DISC BRAKE ACX01742 AB

HYDRAULIC BRAKE BOOSTER (HBB)

MASTER CYLINDER AND

SELECT SOLENOID VALVE

CONTROL SOLENOID VALVE

OUT OUT OUT OUT

<When booster is not operating>

LINE A (CLOSED) BOOSTER CHAMBER

REACTION DISC MASTER CYLINDER PISTON

<When booster is operating>

<When a loss of accumulator pressure occurs>

BASIC BRAKE SYSTEM DIAGNOSIS

SYMPTOM INSPECTION REFERENCE

DIAGNOSIS STEP 3. Check brake disc(s) for run-out.

INSPECTION PROCEDURE 2: Insufficient Braking Power

DIAGNOSIS STEP 3. Check the HBB function.

INSPECTION PROCEDURE 3: Increased Pedal Stroke (Reduced Pedal-to-floor Board Clearance)

DIAGNOSIS STEP 3. Check for brake fluid leaks.

INSPECTION PROCEDURE 4: Brake Drag

DIAGNOSIS STEP 3. Inspect the brake pedal return spring for

INSPECTION PROCEDURE 5: Scraping or Grinding Noise when Brakes are Applied

DIAGNOSIS STEP 4. Check the brake discs for cracks.

DIAGNOSIS STEP 3. Check the brake pedal.

INSPECTION PROCEDURE 7: Squealing Noise when Brakes are not Applied

DIAGNOSIS STEP 4. Check the wheel bearings for

DIAGNOSIS STEP 3. Check the wheel bearings for wear,

BRAKE WARNING LIGHT CHECK

TROUBLE CODE DIAGNOSIS

Retrieving HBB Diagnostic Trouble Codes

Erasing HBB Diagnostic Trouble Codes

DIAGNOSTIC TROUBLE CODE CHART

HBB DIAGNOSTIC TROUBLE CODE PROCEDURES

ASC-ECU Power Supply Circuit

CONNECTOR: D-116 CONNECTORS: D-208, D-212

CONNECTOR: E-111 CONNECTORS: E-119, E-120

CIRCUIT OPERATION STEP 2. Check the charging system.

HBB DTC SET CONDITIONS

STEP 4. Recheck for diagnostic trouble code.

HBB Power Supply Sub Circuit

CONNECTOR: E-111 CONNECTOR: E-119

HBB DTC SET CONDITIONS

pose fuse number 17 in the junction block. TROUBLESHOOTING HINTS

STEP 1. Check the following connector.

STEP 2. Check the power supply circuit at M-ASTC-ECU

(3) Measure the voltage between terminal 9 and ground. It

STEP 3. Check the following harness wire.

MULTIPURPOSE FUSE NO.17

CONNECTOR: E-111 Q: Is the harness wire damaged?

STEP 4. Recheck for diagnostic trouble code.

STEP 5. Recheck for diagnostic trouble code.

Pump Motor Circuit

CONNECTORS: B-17, B-18 CONNECTORS: B-53X, B-54X

HBB DTC SET CONDITIONS