35B ABS General Information

GENERAL INFORMATION
The ABS consists of wheel speed sensors, brake pedal switch, integral hydraulic unit and ABS-ECU. If a problem occurs in the system, the malfunctioning system can be identified by means of the diagnosis function. The diagnosis codes recorded in the memory will not be erased even if the ignition switch
Items Speed sensor Front rotor teeth Rear rotor teeth

Main Index
is turned to OFF. In addition, reading of diagnosis codes, service data and actuator testing are possible using the MUT-II. Electronic Brake-Force Distribution (EBD) uses the ABS Hydraulic Unit to control rear brake pressures, hence deleting the need for a proportioning valve.
Specifications Magnet coil type 48 48

35 Index

CONSTRUCTION DIAGRAM
3 4 5

3 4 5

5 6

1. Stop lamp switch 2. Data link connector 3. ABS warning light

4. Rotor 5. Wheel speed sensor 6. ABS-ECU/Hydraulic unit

35B ABS Service Specifications/Sealant/Special Tools

SERVICE SPECIFICATIONS
Items Speed sensors internal resistance k Clearance between the wheel speed sensor mounting surface and the toothed rotor mm. Standard value 1.4 1.8 28.228.5

Main Index 35 Index

SEALANT
Items Thread part fitting Vacuum switch Specified sealant Loctite 577 Remarks Semi-drying sealant

SPECIAL TOOLS
Tool Tool number and name MB991502 MUT II Supersession Application For checking ABS

ROM pack

35B ABS Troubleshooting

TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
Refer Group 00. NOTES WITH REGARD TO DIAGNOSIS The conditions listed in the following table are considered normal.
Condition System check sound Explanation of condition When starting the engine, a thudding sound can sometimes be heard coming from inside the engine compartment, but this is because the system operation check is being performed. This is considered normal. 1. Sound of the motor inside the ABS hydraulic unit operating (whine) 2. Sound is generated along with vibration of the brake pedal. (scraping) 3. When ABS operates, sound is generated from the vehicle chassis due to repeated brake application and release. (Thump: suspension; squeak: tyres) For road surfaces such as snow-covered roads and gravel roads, the braking distance for vehicles with ABS can sometimes be longer than that for other vehicles. Accordingly, advise the customer to drive safely on such roads by lowering the vehicle speed and not being overconfident.

Main Index 35 Index

ABS operation sound

ABS operation (Long braking distance)

Diagnosis detection condition depends on the diagnosis code. When checking to see if the trouble symptom reoccurs after the diagnosis code has been erased, check the detection conditions column in the inspection chart for diagnosis codes (refer on vehicle service) and the memorise conditions recorded in the Comments column of the inspection procedure chart for diagnosis codes in order to carry out testing under driving conditions which satisfy each of the given conditions.

DIAGNOSIS FUNCTION
DIAGNOSIS CODES CHECK Read the diagnosis codes by the MUT-II or ABS warning lamp. (Refer Group 00.)

ERASING DIAGNOSIS CODES

WITH MUT-II Read the diagnosis codes by the MUT-II or ABS warning lamp. (Refer Group 00.)

WITHOUT MUT-II 1. Press on the brake pedal so that the brake pedal switch is on. 2. Switch the ignition ON. 3. Wait until the ABS warning lamp goes out, then release the brake pedal. 4. Toggle the brake pedal so that the ABSECU receives a brake pedal switch on signal 9 times in 20 seconds. 5. The warning lamp will illuminate for 1 second to confirm code erasure.

35B ABS Troubleshooting

INSPECTION CHART FOR DIAGNOSIS CODES

Inspect according to the inspection chart that is appropriate for the diagnosis code.
Diagnosis code no. 11 12 13 14 15 16 21 22 23 24 38 41 42 43 44 45 46 47 48 51 53 63 Inspection item Front right wheel speed sensor Front left wheel speed sensor Rear right wheel speed sensor Rear left wheel speed sensor Wheel speed sensor output signal abnormal Power supply system Front right wheel speed sensor Front left wheel speed sensor Rear right wheel speed sensor Rear left wheel speed sensor Stop light switch system Front right solenoid valve (inlet) Front left solenoid valve (inlet) Rear right solenoid valve (inlet) Rear left solenoid valve (inlet) Front right solenoid valve (outlet) Front left solenoid valve (outlet) Rear right solenoid valve (outlet) Rear left solenoid valve (outlet) Valve relay Motor relay ABSECU Detection conditions

Main Index 35 Index

Open circuit

B, C

A, B A, B, C

Short circuit

B, C

B, C

B, C

B, C

A, B, C B A, B, C

Detection conditions A: During system check immediately after starting B: While ABS control is not operating while driving C: While ABS control is operating

35B ABS Troubleshooting

INSPECTION PROCEDURE FOR DIAGNOSIS CODES

Code No. 11, 12, 13, 14 Wheel speed sensor open circuit
[Comment] These codes are displayed when the sensor with the open circuit can be distinguished.

Main Index 35 Index

Probable cause
D Malfunction of wheel speed sensor (Open circuit) D Malfunction of wiring harness or connector D Malfunction of ABS-ECU

Wheel speed sensor inspection (Refer On vehicle service.)

OK
Measure at the ABS-ECU connector A115. D Disconnect the connector and measure from the harness side. D Resistance values between 1-2, 45, 67, 89. D OK: 1.41.8 k

NG

Check the following connectors. D A05, A14, B42, B51, B57, B74, H03, H08.

NG

Repair

OK
Check trouble symptoms.

NG

OK
Check the following connectors D A115

Check the harness wire between each wheel speed sensor and ABS-ECU, and repair if necessary.

NG

Repair

OK
Check trouble symptoms.

NG

Replace the Hydraulic unit

Code No. 15 Wheel speed sensor (Abnormal output signal)

[Comment] A wheel speed sensor outputs an abnormal signal (other than an open or short circuit)

Probable cause
D D D D D D Improper installation of wheel speed sensor Malfunction of wheel speed sensor Damaged rotor Wheel bearing worn or loose Malfunction of wiring harness or connector Malfunction of ABSECU

Wheel speed sensor installation inspection

NG

Repair

OK
Wheel speed sensor output voltage inspection (Refer On vehicle service.)

NG

Wheel speed sensor inspection (Refer On vehicle service.)

NG

Replace the wheel speed sensor

OK
Rotor inspection (Refer On vehicle service.)

NG

Replace the rotor

OK
Check the following connector A-115

NG

Repair

OK
Check the trouble symptoms

OK
Wheel bearing inspection (refer to Group 26 and Group 27.)

OK

NG
Replace the Hydraulic unit

Check the harness wire between each wheel speed sensor and ABSECU and repair if necessary

35B ABS Troubleshooting Code No. 16 Power supply system

[Comment] This diagnosis code is output when the ABS-ECU power voltage is outside the standard value. Furthermore, if the voltage returns to normal, this diagnosis code will not be output.

Probable cause
D Malfunction of wiring harness or connector. D Malfunction of battery or alternator D Malfunction of ABS-ECU

Main Index 35 Index

Caution If the battery voltage drops during inspection, this code will be output as a current problem, and correct diagnosis of the problem cannot be made. Before carrying out the following inspection, check the battery condition, and recharge it if necessary.
Measure at the ABS-ECU connector A115 D Disconnect the connector and measure from the harness side. D Start the engine. Voltage between 15 Body ground D OK: 1017 V

NG

Check the following connectors D B42, B76, B77

NG

Repair

OK
Check trouble symptoms

NG

OK
Check the battery or the alternator.

Check the harness wire between the ignition switch and the ABS-ECU, and repair if necessary.

OK
Check the following connector D A115

NG

Repair

OK
Check trouble symptoms

NG

Replace the Hydraulic unit

Code No. 21, 22, 23, 24 Wheel speed sensor short circuit
[Comment] These codes are displayed when the sensor with the short circuited can be distinguished.

Probable cause
D Malfunction of wheel speed sensor D Malfunction of wiring harness D Malfunction of ABS-ECU

NOTE Short circuit is not detected when IG power voltage drops.

Wheel speed sensor inspection (Refer On vehicle service.)

NG

Replace the wheel speed sensor.

OK
Measure at ABS-ECU connectors A115 D Disconnect the connectors and measure at the harness side. D Continuity between the terminals 1, 4, 6, 8 and body ground. OK: No continuity

NG

Repair the harness wire between the wheel speed sensor and ABS-ECU.

OK
Replace the Hydraulic unit

35B ABS Troubleshooting Code No. 38 Stop light switch system

[Comment] This diagnosis code is output if it is judged to be a short circuit when the stop light switch is ON for a continuous period of 15 minutes or more.

Probable cause
D Malfunction of wiring harness or connector D Malfunction of stop light switch D Malfunction of ABS-ECU

Main Index 35 Index

Does the stop light illuminate and switch off normally

No

Repair

Yes
Measure at ABS-ECU connector A115. D Disconnect the connector and measure at the harness side. D Stop light switch on. NG D Voltage between terminal (14) and ground. OK: Battery positive voltage

NG

Stop light switch inspection (Refer On vehicle service.)

NG

Replace the stop light switch

OK
Check the following connectors. B18, B-42, B76, B85

NG

Repair

OK
Check the following connector. D A115

NG

OK
Repair Check trouble symptoms

OK
Check trouble symptoms

NG
Check the harness between dedicated fuse No. 3 and the ABS-ECU, and repair if necessary

NG
Replace the Hydraulic unit

35B ABS Troubleshooting Code No. 41, 42, 43, 44 Solenoid valve (inlet)
[Comment] The ABS-ECU normally monitors the solenoid valve drive circuit. and determines if there is an open circuit or short circuit in the solenoid coil or in the harness, i.e. no current flows in the solenoid even though the ABSECU turns it on, and vice versa.

Probable cause
D Malfunction of wiring harness D Malfunction of hydraulic unit D Malfunction of ABS-ECU

Main Index 35 Index

Refer to Troubleshooting procedure for DTC No.16.

Code No. 45, 46, 47, 48 Solenoid valve (outlet)

[Comment] The ABS-ECU normally monitors the solenoid valve drive circuit. and determines if there is an open circuit or short circuit in the solenoid coil or in the harness, i.e. no current flows in the solenoid even though the ABSECU turns it on, and vice versa.

Probable cause
D Malfunction of wiring harness D Malfunction of hydraulic unit D Malfunction of ABS-ECU

Refer to Troubleshooting procedure for DTC No.16.

Code No. 51 Valve relay

[Comment] When the ignition switch is turned to ON, the ABSECU switches the valve relay off and on during the initial check to check if the valve relay is operating normally.

Probable cause
D D D D Malfunction of Malfunction of Malfunction of Malfunction of ABS valve relay wiring harness or connector ABS-ECU hydraulic unit

Refer to Troubleshooting procedure for DTC No.16.

Code No. 53 Motor relay, motor

[Comment] The code is output at the following times: D When the motor relay is on but no signal is input to the motor monitor line (motor is not operating etc.). D When the motor relay is off but a signal is input to the motor monitor line (motor continues operating etc.).

Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of ABS motor relay wiring harness or connector hydraulic unit ABS-ECU

Refer to Troubleshooting procedure for DTC No.16.

Code No. 63 ABS-ECU

[Comment] The code is output at the following times: D During diagnosis output test or flash code output test.

Probable cause
D Malfunction of wiring harness or connector D Malfunction of ABS-ECU

Refer to Troubleshooting procedure for DTC No.16.

35B ABS Troubleshooting

ABS warning light

ABS WARNING LIGHT INSPECTION

Check that the ABS warning light illuminates as follows. 1. When the ignition key is turned to ON, the ABS warning light illuminates for approximately 3 seconds and then 35 switches off. Index 2. When the ignition key is turned to START, the ABS warning light remains illuminated. 3. When the ignition key is turned from START back to ON, the ABS warning light illuminates for approximately 3 seconds and then switches off. 4. If the illumination is other than the above, check the diagnosis trouble codes.

Main Index

Approx. 3s Approx. 3s Illuminated ABS warning Not light illuminated Ignition switch START ON ACC, LOCK

INSPECTION CHART FOR TROUBLE SYMPTOMS

Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Trouble symptom Communication with MUT-II is not possible. Communication with all systems is not possible. Communication with ABS only is not possible. Inspection procedure No. 1 2 3 4 5

When the ignition key is turned to ON (engine stopped), the ABS warning light does not illuminate. After the engine starts, the light remains illuminated. After the engine started, the ABS warning light and the Brake warning light remains illuminated. Unequal braking power on both sides Insufficient braking power ABS operates under normal braking conditions Faulty ABS operation ABS operates before vehicle stops under normal braking conditions Large brake pedal vibration when ABS operates Large brake pedal vibration (Caution 2.)

Caution 2

Caution 1. If steering movements are made when driving at high speed, or when driving on road surfaces with low frictional resistance, or when passing over bumps, the ABS may operate even though sudden braking is not being applied. Because of this, when getting information from the customer, check if the problem occurred while driving under such conditions as these. 2. During ABS operation, changes in the feeling of the brake pedal (vibration may occur or pedal may not be able to be depressed). Such changes are due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking, and is considered normal.

35B ABS Troubleshooting

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1 Communication with MUT-II is not possible. (Communication with all systems is not possible.)
[Comment] The reason is probably a defect in the power supply system (including ground) for the diagnosis line.

Main Index 35 Index

Probable cause
D Malfunction of connector D Malfunction of harness

Refer Group 13A. INSPECTION PROCEDURE 2 Communication with MUT-II is not possible. (Communication with ABS only is not possible.)
[Comment] When communication with the MUT-II is not possible, the cause is probably an open circuit in the ABS-ECU power circuit or an open circuit in the diagnostic output circuit.

Probable cause
D D D D Blown fuse Malfunction of wiring harness or connector Malfunction of ABS power relay Malfunction of ABS-ECU

Measure at diagnosis connector B-37 and ABS-ECU connector A-115. D Disconnect the connector and measure at the harness side. Continuity between the following terminals. OK: Continuity 11 ABS-ECU side Diagnosis connector side 7

NG

Check the following connector D A-115, B-37, B-42

NG

Repair

OK
Check trouble symptoms

NG
Check the harness between the ABS-ECU and diagnosis connector, and repair if necessary.

OK
Measure at ABS-ECU connector A-115. D Disconnect the connector and measure at the harness side. D Ignition switch ON D Voltage between terminal (15) and body ground. OK: Battery positive voltage

NG

Check the following connector D A-115, B-42, B-76, B-77

NG

Repair

OK
Check trouble symptoms

NG
Check the harness between fuse No. 9 inside the junction block and ABSECU, and repair if necessary.

OK
Measure at ABS-ECU connector A-115. D Disconnect the connector and measure at the harness side. D Continuity between terminals (16), (19), and body ground. OK: Continuity

NG

Repair

OK
Check the following connector. D A-115

NG

Repair

OK
Check trouble symptoms

NG

Replace the Hydraulic unit.

35B ABS Troubleshooting INSPECTION PROCEDURE 3 When ignition key is turned to ON (engine stopped), ABS warning light does not illuminate
[Comment] The cause may be an open circuit in the lamp power supply circuit, a blown light bulb, an open circuit in both the circuit between the ABS warning light and the ABS-ECU.

Main Index
Probable cause
D Blown fuse D Burnt out ABS warning light bulb D Malfunction of wiring harness or connector

35 Index

Fuse inspection, Multipurpose fuse No. 13

NG

Refer Group 00 - Inspection service points for a blown fuse

NG

Replace

OK
Measure at connector C-05 D Disconnect the connector and NG measure at the male pin. D Turn ignition switch to ON position D Does the ABS warning lamp illuminate when terminal 21 is grounded OK: illuminates

Check whether the ABS warning lamp bulb is burnt out

NG

Replace the ABS warning lamp bulb

OK
Check the following connectors: B-80, C-03, C-05

NG

Repair

OK
Check the harness wire between the ABS-ECU and connector C-05, repair if necessary

OK
Check the trouble symptoms

NG

Replace the combination meter

35B ABS Troubleshooting INSPECTION PROCEDURE 4 Even after the engine is started, the ABS warning light remains illuminated.
[Comment] The cause may be a short circuit in the ABS warning light illumination circuit or an incorrectly secured connector at the ABS-ECU.

Main Index
Probable cause
D Combination meter fault D ABS-ECU fault D Harness fault (short)

35 Index

This breakdown phenomenon is restricted to circumstances where communication with the MUT-II is possible (ABS-ECU power supply normal), and when the diagnosis code is normal.
Yes

D Disconnect connector C-05 and turn the ignition switch ON D Does the ABS warning lamp remain illuminated ?

Replace the combination meter

No
D Check that the ABS-ECU connector A-115 is correctly connected D Ignition switch: ON D Does the ABS warning lamp switch off ?

No
Check harness between the combination meter and the and the ABSECU, repair as necessary Check trouble symptom

NG
Replace Hydraulic unit

INSPECTION PROCEDURE 5 Even after the engine is started, the ABS warning light and the Brake warning light remains illuminated.
[Comment] The cause may be an ABS/EBD system fault or an ABS combined with a brake system fault.

Probable cause
D D D D D D ABS-ECU fault Valve relay interruption Solenoid valve actuation fault Brake failure Parkbrake switch failure Harness fault (short)

D Check ABS diagnosis codes

Yes

No
D Check brake fluid level

Inspection chart codes

for

diagnosis

NG NG

Top up brake fluid reservoir Adjust or replace park brake switch

OK
D Check park brake switch and adjustment

OK
D Check harness between park brake switch and ABS-ECU and repair as necessary

35B ABS Troubleshooting INSPECTION PROCEDURE 6 Brake operation is abnormal

[Comment] This varies depending on the driving conditions and the road surface conditions, so problem diagnosis is difficult. However, if a normal diagnosis code is displayed, carry out the following inspection.

Probable cause
D D D D D D D Improper installation of wheel speed sensor Incorrect sensor harness contact Malfunction of wheel speed sensor Malfunction of rotor Malfunction of wheel bearing Malfunction of hydraulic unit Malfunction of ABS-ECU

Main Index 35 Index

Wheel speed sensor installation (Refer On vehicle service.)

NG

Repair

OK
Wheel speed sensor output voltage inspection (Refer On vehicle service.)

NG

Wheel speed sensor inspection (Refer On vehicle service.)

NG

Replace the wheel speed sensor.

OK
Rotor inspection (Refer On vehicle service.)

OK
Hydraulic unit inspection (Refer On vehicle service.)

NG NG

Replace the rotor.

OK
Wheel bearing inspection Refer Group 26 On-vehicle Service Refer Group 27 On-vehicle Service

Repair

OK
Check the following connectors. D A-05, A-14, B-42, B-57, B-74, H-03, H-08, B-51

NG

Repair

OK
Check trouble symptoms

NG
Measure at ABS-ECU connector A-115. D Disconnect the connector and measure at the harness side. D Resistance values between terminals (1) and (2), (4) and (5), (6) and (7), and (8) and (9). OK: 1.41.8 k The sensor harness and connector should be moved while these inspections are carried out.

NG

Repair

OK
Check the following connectors D A-115

NG

Repair

OK
Check trouble symptoms

NG

Replace the Hydraulic unit.

35B ABS Troubleshooting

DATA LIST REFERENCE TABLE

With the MUT-II, check the data list for the items listed.
Item No. 11 12 13 14 16 Check point Front right wheel speed sensor Front left wheel speed sensor Rear right wheel speed sensor Rear left wheel speed sensor Battery positive voltage IG power voltage and valve monitor voltage Depress brake pedal. 33 Stop lamp switch Release brake pedal. OFF 916 V ON Check by actually operating vehicle. Speedometer indication and MUT-II indication are the same. Check condition Normal condition

Main Index 35 Index

ACTUATOR TEST REFERENCE TABLE

The MUT-II activates the following actuators for testing. NOTE 1. If the ABS-ECU is not functional, actuator testing cannot be carried out. 2. Actuator testing is only possible when the vehicle is stationary. If the vehicle speed during actuator testing exceeds 10 km/h, forced actuation will be cancelled. 3. During the actuator test, the ABS warning lamp will illuminate and the anti-skid control will be cancelled.

ACTUATOR TEST SPECIFICATIONS

Start of forced action 1s 2 ms 8 ms End of forced action

No. 01 02 03 04

Item Solenoid valve for front-left wheel Solenoid valve for front-right wheel Solenoid valve for rear-left wheel Solenoid valve for rear-right wheel Solenoid valves and pump motors in the hydraulic unit (simple inspection mode)

Solenoid valve

A B C
48 ms ON

Pump motor

OFF

NOTE A: Hydraulic pressure increase B: Hydraulic pressure holds C: Hydraulic pressure decrease

35B ABS Troubleshooting

CHECK AT THE ABS-ECU

TERMINAL VOLTAGE CHECK CHART 1. Turn the ignition switch to OFF. 35 2. Disconnect the ABS-ECU connector. 3. Measure the voltage at the terminals of the ABS-ECU Index harness-side connector while referring to the check chart. NOTE 1. When measuring voltage, a harness for checking contact pin pressure should be used instead of inserting a test probe. 2. Checks do not have to be carried out in the order given in this chart. Caution Short-circuiting the positive (+) probe between a connector terminal and ground could damage the vehicle wiring, the sensor, ABS-ECU, or all three. Use care to prevent this! 4. If voltmeter shows any deviation from standard value, check the corresponding sensor, actuator and related electrical wiring, then repair or replace. 5. After repair or replacement, recheck with the voltmeter to confirm that the repair has corrected the problem.

Main Index

Terminal No.

Name of circuit

Check requirements Ignition switch: ON (Stop light switch ON)

Normal condition Battery positive voltage 1.0 V or less Battery positive voltage Battery positive voltage When light is switched off Battery positive voltage 02 V Battery positive voltage 02 V

14

Stop light switch (Input) Ignition switch: ON (Stop light switch OFF)

17, 18 15

Memory power supply ECU power supply

At all times Ignition switch: ON

20

ABS warning light (Output)

Ignition switch: ON When light is illuminated When light is switched off Ignition switch: ON When light is illuminated

21

Brake warning light (EBD) (Output)

35B ABS Troubleshooting

Main TERMINAL RESISTANCE AND CONTINUITY CHECKS Index 1. Turn the ignition switch to OFF. 2. Disconnect the ABS-ECU connector. 3. Measure the resistance and check for continuity between 35 the terminals of the ABS-ECU harness-side connector Index while referring to the check chart.
NOTE 1. When measuring resistance and checking continuity, a harness for checking contact pin pressure should be used instead of inserting a test probe. 2. Checks do not have to be carried out in the order given in this chart. Caution If resistance or continuity checks are performed on the wrong terminals, damage to the vehicle wiring, sensors, ABS-ECU, and/or ohmmeter may occur. Use care to prevent this! 4. If ohmmeter shows any deviation from the normal condition, check the corresponding sensor, actuator and related electrical wiring, then repair or replace. 5. After repair or replacement, recheck with the ohmmeter to confirm that the repair or replacement has corrected the problem.

Terminal No. 12 67 16ground 19ground 89 45

Name of circuit Rear right wheel speed sensor Front left wheel speed sensor ABS-ECU ground ABS-ECU ground Rear left wheel speed sensor Front right wheel speed sensor

Check requirements Ignition switch: OFF Ignition switch: OFF Ignition switch: OFF Ignition switch: OFF

Terminal voltage 1.41.8 k 1.41.8 k Continuity Continuity 1.41.8 k 1.41.8 k

35B ABS On-vehicle Service

ON-VEHICLE SERVICE
BLEEDING

Main Index

Caution 35 Use the specified brake fluid. Avoid using a mixture of Index the specified brake fluid and other fluid. Specified brake fluid: DOT4 MASTER CYLINDER BLEEDING Refer Group 35 - On vehicle service. BRAKE LINE BLEEDING Start the engine and bleed the air in the sequence shown in the figure. Caution For vehicles with ABS, be sure to filter/strain the brake fluid being added to the master cylinder reservoir tank. Debris may damage the Hydraulic Unit.
2 3

ABS OPERATION CHECK

WHEEL SPEED SENSOR OUTPUT VOLTAGE CHECK 1. Lift up the vehicle and release the parking brake. 2. Disconnect the ABS-ECU harness connector and measure from the harness side connector. Caution Use a special tool (inspection harness for connector pin contact pressure) to measure the output voltage at the harness side connector to prevent damaging the connector terminals. 3. Rotate the wheel to be measured at approximately 1/21 rotation per second, and check the output voltage using a circuit tester or an oscilloscope.
Wheel speed sensor Terminal No. Front left 6 7 Front right 4 5 Rear left 8 9 Rear right 1 2

Output voltage When measuring with a circuit tester: 50 mV or more When measuring with an oscilloscope: 20 mV p-p or more 4. If the output voltage is lower than the above values, the reason could be as follow: D Faulty wheel speed sensor replace the wheel speed sensor.

35B ABS On-vehicle Service

When turning by hand

Main Inspecting Wave Forms With An Oscilloscope Index Use the following method to observe the output voltage wave form from each wheel sensor with an oscilloscope:D Start the engine, and rotate the front wheels by engaging 35 D range. Turn the rear wheels manually so that they Index rotate at a constant speed.
NOTE 1. Check the connection of the sensor harness and connector before using the oscilloscope. 2. The wave form measurements can also be taken while the vehicle is actually moving. 3. The output voltage will be low when the wheel speed is low, and similarly it will be higher as the wheel speed increases.

When idling (56 km/h)

10.0 ms/DIV 1 V/DIV

Points In Waveform Measurement

Symptom Too small or zero waveform amplitude Waveform amplitude fluctuates excessively (this is no problem if the minimum amplitude is 100 mV or more) Noisy or disturbed waveform Probable causes Faulty wheel speed sensor Axle hub eccentric or with large runout Remedy Replace sensor Replace hub

Open circuit in sensor Open circuit in harness Incorrectly mounted wheel speed sensor Rotor with missing or damaged teeth

Replace sensor Correct harness Mount correctly Replace rotor

NOTE The wheel speed sensor cable moves following motion of the front or rear suspension. Therefore, it is likely that it has an open circuit only when driving on rough roads and it functions normally on ordinary roads. It is, therefore, recommended to observe sensor output voltage waveform also under special conditions, such as rough road driving.

35B ABS On-vehicle Service

Main HYDRAULIC UNIT (HU) INSPECTION Index Caution Connection and disconnection of the MUT-II should always be made with the ignition switch in the OFF position. 35

1. Jack up the vehicle and support the vehicle with rigid Index racks placed at the specified jack-up points or place the wheels which are checked on the rollers of the braking force tester. Caution 1. The roller of the braking force tester and the tyre should be dry during testing. 2. When testing the front brakes, apply the parking brake, and when testing the rear brakes, stop the front wheels by chocking them.

2. Release the parking brake, and feel the drag force (drag torque) on each road wheel. When using the braking force tester, take a reading of the brake drag force. 3. Turn the ignition key to the OFF position and set the MUT-II as shown in the diagram. 4. After checking that the selector lever is in neutral, start the engine. NOTE 1. At this time, the ABS system will switch to the MUT-II mode and the ABS warning light will illuminate. 2. When the ABS has been interrupted by the fail-safe function, the MUT-II actuator testing cannot be used. 5. Use the MUT-II to force-drive the actuator. 6. Turn the wheel by hand and check the change in braking force when the brake pedal is depressed. When using the braking force tester, depress the brake pedal until the braking force is at the following values, and check to be sure that the braking force changes to the brake drag force inspected in step 2 when the actuator is force-driven.
N Front wheel Rear wheel 785981 294490

The result should be as shown in the following diagram.

35B ABS On-vehicle Service

Main Index
Depressed Pedal operation Released Increase in pressure Steady pressure Reduction in pressure (when not working) Lock Checking the brake force Drag force when the pedal is free 3 seconds MUT-II actuator test (Item Nos. 01, 02, 03, 04) start 2 seconds

35 Index

Solenoid valve position

1 second

7. If the result of inspection is abnormal, correct according to the Diagnosis Table. Diagnosis Table
No. Operation (1) Depress brake pedal to lock wheel. (2) Using the MUT-II, select the wheel to be checked and force the actuator to operate. (3) Turn the selected wheel manually to check the change of brake force. JudgementNormal Brake force released for 3 seconds after locking. JudgementAbnormal Wheel does not lock when brake pedal is depressed. Probable cause Clogged brake line other than HU Clogged hydraulic circuit in HU Brake force is not released Incorrect HU brake tube connection HU solenoid valve not functioning correctly Remedy Check and clean brake line Replace HU assembly Connect correctly

01

02

03

04

Replace HU assembly

8. After inspection, disconnect the MUT-II immediately after turning the ignition switch to OFF.

35B ABS On-vehicle Service

Fusible link

Main REMEDY FOR A FLAT BATTERY Index When booster cables are used to start the engine when the battery is completely discharged and then the vehicle is immediately driven without waiting for the battery to recharge 35 itself to some extent, the engine may misfire or stall, making Index driving difficult. This happens because ABS consumes a great amount of current for its self-check function. The remedy is to either allow the battery to recharge sufficiently, or to remove the fusible link for ABS circuit, thus disabling the anti-lock brake system. The ABS warning light will illuminate when the fusible link (for ABS) is removed. After the battery has sufficiently charged, install the fusible link (for ABS) and restart the engine; then check to be sure the ABS warning light is not illuminated.

35B ABS Master Cylinder and Brake Booster

MASTER CYLINDER AND BRAKE BOOSTER

REMOVAL AND INSTALLATION
(Refer Group 35 - Master Cylinder )

Main Index 35 Index

MASTER CYLINDER DISASSEMBLY AND REASSEMBLY

1 2

Master cylinder kit

5 4 3 9

8 7 6 10

10

Brake fluid: DOT4

Disassembly steps 1. Reservoir cap assembly 2. Diaphragm 3. Brake fluid level sensor 4. Reservoir bolt 5. Reservoir

AA"

6. 7. 8. 9. 10.

Reservoir seals Piston stopper pin Primary piston assembly Secondary piston assembly Master cylinder body

Caution Do not disassemble the primary and secondary piston assemblies.

35B ABS Master Cylinder and Brake Booster

DISASSEMBLY SERVICE POINTS

AA" PISTON STOPPER PIN DISASSEMBLY Remove the piston stopper pin, while depressing the piston.

Main Index 35 Index

INSPECTION
D D D Check the inner surface of master cylinder body for corrosion or pitting. Check the primary and secondary pistons for corrosion, scoring, damage or wear. Check the diaphragm for cracks and wear.

35B ABS Hydraulic Unit

HYDRAULIC UNIT
REMOVAL AND INSTALLATION
Pre-removal Operation D Brake Fluid Draining D Air Intake Hose Removal Post-installation Operation D Installation of the Air Intake Hose Removal D Brake Fluid Supplying D Brake Line Bleeding (Refer On vehicle service.) D Hydraulic Unit Checking (Refer On vehicle service.)

Main Index 35 Index

Flared brake line nuts

1 3
15 Nm

2 1

Removal steps "AA 1. Connection for brake pipe 2. Connection for harness connector

AA"

3. Hydraulic unit 4. Hydraulic unit bracket

35B ABS Hydraulic Unit

REMOVAL SERVICE POINT

AA" HYDRAULIC UNIT REMOVAL

Main Index

Caution 35 1. The hydraulic unit is heavy, and so care should be Index taken when removing it. 2. The hydraulic unit is not to be disassembled; its nuts and bolts must not be loosened. 3. The hydraulic unit must not be dropped or otherwise subjected to impact shocks. 4. The hydraulic unit must not be turned upside down or laid on its side.

4 3 2 1

INSTALLATION SERVICE POINT

"AA BRAKE PIPE CONNECTION Connect the pipes to the hydraulic unit as shown in the illustration. 1. To the rear brake (LH) 2. To the rear brake (RH) 3. From the master cylinder (primary) 4. From the master cylinder (secondary) 5. To the front brake (LH) 6. To the front brake (RH)

35B ABS Wheel Speed Sensor

WHEEL SPEED SENSOR

REMOVAL AND INSTALLATION
Post-installation Operation D Wheel Speed Sensor Output Voltage Checking (Refer On vehicle service.)

Main Index 35 Index

<FRONT>
25 Nm

<SEDAN REAR>

25 Nm

25 Nm

1 4

25 Nm 25 Nm

2 4 <WAGON REAR>
25 Nm

5
200260 Nm

25 Nm

Front speed sensor removal steps 1. Front speed sensor 2. Front rotor (Refer Group 26 -Driveshaft.) Rear speed sensor removal<Sedan> 3. Rear rotor (Refer Group 27 - Rear Axle hub.) 4. Rear speed sensor

Rear speed sensor removal <Wagon> 3. Rear rotor (Refer Group 27A - Rear Axle hub.) 4. Rear speed sensor 5. Hub
NOTE The front rotor is integrated with the drive shaft and is not disassembled.

35B ABS Wheel Speed Sensor

Front Rear

INSPECTION

Magnetic parts

SPEED SENSOR 1. Check whether any metallic foreign material has adhered 35 to the parts shown in the illustration at the speed sensor tip, and if so, remove it. Index NOTE The section shown in the illustration can become magnetised because of the magnet built into the speed sensor, with the result that foreign metallic material is attached to it. 2. Measure the resistance between the speed sensor terminals. Standard value: 1.41.8 k If the internal resistance of the speed sensor is not within the standard value, replace with a new speed sensor.

Main Index

3. Check the speed sensor cable for breakage, damage or disconnection; replace with a new one if a problem is found. NOTE When checking for cable damage, remove the cable clamp part from the body and then bend and pull the cable near the clamp to check whether or not an intermittent contact results. Check the connector connection and the terminal insertion.

SPEED SENSOR INSULATION INSPECTION 1. Remove all connections from the speed sensor, and then measure the resistance between terminals (1) and (2) and the body of the speed sensor. Standard value: 100 k or more 2. If the speed sensor insulation resistance is outside the standard value range, replace with a new speed sensor.

TOOTHED ROTOR Check whether rotor teeth are broken or deformed, and, if so, replace the rotor.