HF35

35A-1
SERVICE BRAKES
CONTENTS
BASIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A

ANTI-SKID BRAKING SYSTEM (ABS) <4WD> . . . . . . . . . . . . . . . . . . . . . . 35B
35A-2
BASIC BRAKE
SYSTEM
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 4
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Fluid Level Sensor Check . . . . . . . . . . . . . 10

Disc Brake Pad Check and Replacement . . . . . . 11
Disc Brake Rotor Check . . . . . . . . . . . . . . . . . . . . . 12
Brake Disc Thickness Check . . . . . . . . . . . . . . . . . 12
Brake Disc Run-out Check and Correction . . . . 13
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6
MASTER CYLINDER AND BRAKE

BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Brake Pedal Check and Adjustment . . . . . . . . . . . . 6
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Brake Booster Operating Test . . . . . . . . . . . . . . . . . . 7

Check Valve Operation Check . . . . . . . . . . . . . . . . . 8
FRONT DISC BRAKE . . . . . . . . . . . . . . . . . . . . . 20
Load Sensing Spring Length Check and

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REAR DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . 25
Load Sensing Proportioning Valve Function

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LOAD SENSING PROPORTIONING

VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
35A-3
BASIC BRAKE SYSTEM General Information
GENERAL INFORMATION
The brake system offers high dependability and durability along with improved braking performance and
brake sensitivity.
Items
Specifications
Master cylinder
Brake booster
Load sensing proportioning

valve
Front disc brakes
Rear disc brakes
Type
Tandem type
I.D. mm
22.2
Type
Vacuum type, single
Effective dia. of power cylinder mm
230
Boosting ratio
4.5
Type
Dual type
Decompression ratio
0.25
Type
Floating caliper, 1-piston, ventilated disc
Disc effective dia. thickness mm
236 22
Wheel cylinder I.D. mm
57.2
Pad thickness mm
10.0
Clearance adjustment
Automatic
Type
Floating caliper,1-piston, solid disc
Disc effective dia. thickness
222 9.4
Wheel cylinder I.D. mm
34.93
Pad thickness mm
10.0
Clearance adjustment
Automatic
Brake fluid
DOT3 or DOT4
CONSTRUCTION DIAGRAM
Load sensing
proportioning
valve
Hydraulic unit
Brake booster
Master cylinder
35A-4
BASIC BRAKE SYSTEM Service Specifications
SERVICE SPECIFICATIONS
Items
Standard value
Limit
L.H. drive vehicles
201 204
R.H. drive vehicles
201.7 204.7
Brake pedal play mm
3 8
Brake pedal to floorboard clearance when the brake pedal is depressed mm
105 or more
Brake booster push rod protrusion amount mm
L.H. drive vehicles with ABS
22.7 22.9
L.H. drive vehicles without

ABS and R.H. drive vehicles
23.93 24.18
When load sensing spring length is 199 mm (when

unladen)
4.2 6.0 (9.8)
When load sensing spring length is 217 mm (when

laden)
9.7 10.5 (9.8)
14.5 16.3 (16.7)
0.39
Load sensing spring length <Distance between spring ends> mm
194 198
Front disc brake
Pad thickness mm
10.0
2.0
Disc thickness mm
22 0
22.0
20 4
20.4
Disc runout mm
0.06
Drag force N
69
Pad thickness mm
10.0
2.0
Disc thickness mm
9.4
7.8
Disc runout mm
0.08
Drag force N
34
Front hub end play mm
0.2
Rear hub end play mm
0.025
Brake pedal height mm
Load sensing proportioning valve output fluid

pressure (Input fluid pressure) MPa
Output fluid pressure difference between left and right

MPa
Rear disc brake
BASIC BRAKE SYSTEM Lubricants/Sealant/Special Tools
35A-5
LUBRICANTS
Items
Specified Lubricant
Quantity
Brake fluid
DOT3 or DOT4
As required
Vacuum sensor grommet
Silicone grease
Brake booster seal

Repair kit grease
Piston boot, piston seal

Guide pin, lock pin
Piston, wheel cylinder body
DOT3 or DOT4
SEALANT
Items
Specified sealant
Remarks
Fitting
3M ATD Part No. 8661 or equivalent
Semi-drying sealant
SPECIAL TOOLS
Tool
A
Number
Name
Use
MB990964
A: MB990520
Brake tool set
Pushing-in of the disc brake piston
A: MB990998
B: MB991000
A: Front hub remover and installer

B: Spacer
When bearing provisional holding

MB991000, which belongs to MB990998,
should be used as a spacer.
MB991568
Push rod adjusting

socket
Adjustment of the brake booster push rod

protrusion amount
A
B
35A-6
BASIC BRAKE SYSTEM On-vehicle Service
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
Operating rod
Stop lamp switch

Operating
rod lock nut
BRAKE PEDAL HEIGHT

1. Turn up the carpet, etc. under the brake pedal.
2. Measure the brake pedal height as illustrated.
Standard value (A):
<L.H. drive vehicles> 201 204 mm
<R.H. drive vehicles> 201.7 204.7 mm
3. If the brake pedal height is not within the standard value,

follow the procedure below.
(1) Disconnect the stop lamp switch connector.
(2) Loosen the stop lamp switch by turning it approx.
1/4 turns anticlockwise.
(3) Remove the pin, and then adjust so that the brake
pedal height meets the standard value by turning the
clevis.
NOTE
When the clevis is turned 180, the pedal height is
changed approximately 2.3 mm.
(4) Screw in the stop lamp switch until it touches the
stopper. At this time, support the brake pedal to the
highest position by hand.
(5) Lock the stop lamp switch by turning it approx. 1/4
turns clockwise, and confirm that the clearance
between the switch plunger and the stopper is as
shown.
(6) Connect the connector at the stop lamp switch.
Stopper
0.5 1.0 mm
Caution
Check that the stop lamp does not illuminate when
the brake pedal is not depressed.
4. For A/T, check the key interlock and shift lock mechanisms.
(Refer to GROUP 23 On-vehicle Service.)
5. Return the carpet, etc.
BRAKE PEDAL FREE PLAY

1. With the engine stopped, depress the brake pedal two
or three times. After eliminating the vacuum in the power
brake booster, press the pedal down by hand, and confirm
that the amount of movement before resistance is met
(the free play) is within the standard value range.
Standard value (B): 3 8 mm
B
35A-7
2. If the brake pedal play is not within the standard value,

check the following, and adjust or replace if necessary:
D Excessive play between the brake pedal and the clevis
pin, or between the clevis pin and the brake booster
operating rod
D Brake pedal height
D Installation position of the stop lamp switch, etc.
CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR

BOARD
1. Turn up the carpet etc. under the brake pedal.
2. Start the engine, depress the brake pedal with
approximately 490 N of force, and measure the clearance
between the brake pedal and the floorboard.
Standard value (C): 105 mm or more
3. If the clearance is outside the standard value, check for
air trapped in the brake line, thickness of the disc brake
pad or the drum brake lining and dragging in the parking
brake.
Adjust and replace defective parts as required.
4. Return the carpet, etc.
Good
No good
BRAKE BOOSTER OPERATING TEST

For simple checking of the brake booster operation, carry
out the following tests:
1. Run the engine for one or two minutes, and then stop
it.
If the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the
booster is operating properly. If the pedal height remains
unchanged, the booster is defective.
When engine is
stopped
When engine is
started
2. With the engine stopped, step on the brake pedal several

times.
Then start the engine while the brake pedal is stepped
on.
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is
defective.
35A-8

No good
Good
3. With the engine running, step on the brake pedal and

then stop the engine.
Hold the pedal depressed for 30 seconds. If the pedal
height does not change, the booster is in good condition.
If the pedal rises, the booster is defective.
If the above three tests are okay, the booster performance
can be determined as good.
If one of the above three tests is not okay at least, the check
valve, vacuum hose, or booster will be defective.
CHECK VALVE OPERATION CHECK

1. Remove the vacuum hose. (Refer to P.35A-15, 16.)
Caution
The check valve should not be disassembled from
the vacuum hose as they are united as one part.
2. Check the operation of the check valve by using a vacuum
pump.
Spring
Valve
Booster A
side
Intake
manifold
side
Vacuum pump
connection
Accept/reject criteria
Connection at the brake

booster side (A)
A negative pressure (vacuum) is

created and held.
Connection at the intake

manifold side (B)
A negative pressure (vacuum) is

not created.
Caution
If the check valve is defective, always replace it as
an assembly unit together with the vacuum hose.
LOAD SENSING SPRING LENGTH CHECK

AND ADJUSTMENT
1. Park the vehicle on a level ground. The vehicle should
be unloaded and supported only by wheels.
Caution
Never support the vehicle with jacks or other similar
means.
Load sensing spring

Lever
Spring support
2. With the lever pressed all the way to the load sensing
proportioning valve side, check whether or not the length
(shown in the figure) of the spring (the length between
its ends) is the standard value.
Standard value (A): 194 198 mm
3. If the spring length is not within the standard value, loosen

the bolt attaching the support and adjust the distance by
moving the support.
35A-9

Pressure gauge
LOAD SENSING PROPORTIONING VALVE

FUNCTION TEST
1. Connect pressure gauges to the input and output ports
of the load sensing proportioning valve.
2. Bleed the system. (Refer to P.35A-10.)
3. Disconnect the spring at the support side.
Load sensing proportioning valve
Load sensing proportioning valve
Load sensing spring

A
Parallel
4. Place the spring so that it is in parallel with the load sensing

proportioning valve, and then pull in the direction indicated
by arrow A so that its length H shown in the figure (the
length between its ends) is as noted below.
NOTE
At this time the lever is pressed all the way to the load
sensing proportioning valve side.
Lever
5. Check at this time whether or not the output fluids pressure,

relative to the load sensing proportioning valves input fluid
pressure, is within the standard value.
Standard value:
Spring length
H mm
Input fluid
pressure MPa
Output fluid pressure

MPa
199*1
9.8
4.2 6.0
217*2
9.8
9.7 10.5
16.7
14.5 16.3
NOTE
*1 and *2
indicate the applicable lengths for unladen
and laden vehicles respectively.
6. Measure each output fluid pressure at both valves, and
check that the difference between the two is at the limit
value or less.
Limit: 0.39 MPa
7. After making the check, install the spring. Disconnect the
pressure gauges from the load sensing proportioning valve
and bleed air.
35A-10

BLEEDING
Caution
Specified brake fluid: DOT3 or DOT4
Always use the specified brake fluid. Avoid using a mixture
of the specified brake fluid and other fluid.
MASTER CYLINDER BLEEDING

The master cylinder used has no check valve, so if bleeding
is carried out by the following procedure, bleeding of air from
the brake pipeline will become easier. (When brake fluid is
not contained in the master cylinder.)
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylinder outlet with
a finger.
4. With the outlet still closed, release the brake pedal.
5. Repeat steps 2 4 three or four times to fill the inside
of the master cylinder with brake fluid.
4 (2)
1 (3)
2 (4)
3 (1)
BRAKE PIPE LINE BLEEDING

Bleed the air in the sequence shown in the figure.
( ): R.H. drive vehicles
BRAKE FLUID LEVEL SENSOR CHECK

MAX
MIN
The brake fluid level sensor is in good condition if there is

no continuity when the float surface is above MIN and if
there is continuity when the float surface is below MIN.
35A-11
DISC BRAKE PAD CHECK AND REPLACEMENT

NOTE
The brake pads have wear indicators that contact the brake
disc when the brake pad thickness reaches approximately
2 mm and emit a squealing sound to warn the driver.
1. Check the brake pad thickness through the caliper body

check port.
REAR
FRONT
Standard value: 10.0 mm

Limit: 2.0 mm
2. When the thickness is less than the limit, always replace
the pads at an axle set.
3. Remove the guide lock pin bolt. Pivot the caliper assembly
and hold it with wires.
FRONT
REAR
3
1
2
4
3
2
4. Remove the following parts from the caliper support.

1. Pad and wear indicator assembly
2. Pad assembly
3. Clip
4. Inner shim
5. Outer shim
1
3
5. In order to measure the brake drag force after pad

installation, measure the rotary-sliding resistance of the
hub with the pads removed. (Refer to P.35A-20, 25.)
6. Install the pads and caliper assembly, and then check
the brake drag force. (Refer to P.35A-21, 26.)
35A-12
DISC BRAKE ROTOR CHECK

Caution
When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within
the allowable service values in order to maintain normal brake operation.
Before re-finishing or re-processing the brake disc surface, the following conditions should be checked.
Inspection items
Remarks
Scratches, rust, saturated lining materials

and wear
D
D
If the vehicle is not driven for a certain period, the sections of

the discs that are not in contact with lining will become rusty, causing
noise and shuddering.
If grooves resulting from excessive disc wear and scratches are
not removed prior to installing a new pad assembly, there will
momentarily be inappropriate contact between the disc and the
lining (pad).
Run-out or drift
Excessive run-out or drift of the discs will increase the pedal depression
resistance due to piston knock-back.
Change in thickness (parallelism)
If the thickness of the disc changes, this will cause pedal pulsation,
shuddering and surging.
Inset or warping (flatness)
Overheating and improper handling while servicing will cause inset or

warping.
BRAKE DISC THICKNESS CHECK

1. Using a micrometer, measure disc thickness at eight
positions, approximately 45_ apart and 10 mm in from
the outer edge of the disc.
Brake disc thickness
Item
Standard value
Limit
Front
22.0
20.4
Rear
9.4
7.8
Thickness variation (at least 8 positions)

The difference between any thickness measurements
should not be more than 0.015 mm.
2. If the disc is beyond the limits for thickness, remove it
and install a new one. If thickness variation exceeds the
specification, replace the brake disc or grind it with
on-the-car type brake lathe (MAD, DL-8700PF or
equivalent).
35A-13
BRAKE DISC RUN-OUT CHECK AND

CORRECTION
1. Remove the brake assembly, and then hold it with wire.
2. Place a dial gauge approximately 5 mm from the outer
circumference of the brake disc, and measure the run-out
of the disc.
Limit: <Front> 0.06 mm or less,
<Rear> 0.08 mm or less
3. If the brake disc run-out exceeds the limit, correct it as
follows:
Chalk marks
(1) Chalk phase marks on the wheel stud and the brake
disc, which run-out is excessive as shown.
(2) Remove the brake disc. Then place a dial gauge as

shown, and measure the end play by pushing and
pulling the wheel hub.
Limit: <Front> 0.2 mm, <Rear> 0.025 mm
(3) If the end play exceeds the limit, disassemble the
hub and knuckle assembly to check each part.
(4) If the end play does not exceed the limit, dephase
the brake disc and secure it. Then recheck the brake
disc run-out.
4. If the run-out cannot be corrected by changing the phase

of the brake disc, replace the brake disc or grind it with
the on-the-car type brake lathe (MAD, DL-8700PF or
equivalent).
35A-14
BASIC BRAKE SYSTEM Brake Pedal
BRAKE PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
Brake Pedal Adjustment (Refer to P.35A-6.)
14 Nm
10
5
3
7
4
9
12 Nm
Removal steps
1. Harness connector
2. Stop lamp switch
3. Adjuster
4. Pedal stopper
5. Snap pin
6. Pin assembly
7.
8.
9.
10.
Split pin <A/T>

Shift lock cable connection <A/T>
Pedal pad
Brake pedal and pedal support
member
INSPECTION
No continuity
Continuity
4 mm
STOP LAMP SWITCH CHECK

1. Connect an ohmmeter between the stop lamp 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.
BASIC BRAKE SYSTEM Master Cylinder and Brake Booster
35A-15
MASTER CYLINDER AND BRAKE BOOSTER

<L.H. drive vehicles with ABS>
Pre-removal Operation
Brake Fluid Draining
D Brake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)
D Brake Pedal Adjustment (Refer to P.35A-6.)
10
14
11
12
14
14.7 17.7 Nm
Specified Sealant: 3M ATD

Part No.8661 or equivalent
Grease: Silicone grease
9
15 Nm
10
4
11
12 Nm
13
1
2
14 Nm
15 Nm
12
3
Silicon grease
35A-16
<L.H. drive vehicles without ABS and R.H. drive vehicles>

D Brake Fluid Supplying and Air Bleeding
D Brake Pedal Adjustment (Refer to P.35A-6.)
10
12
11
14
Specified Sealant: 3M ATD

Part No.8661 or equivalent
12
9
10
15 Nm
11
2
5
12 Nm
13
7
1
4
14 Nm
15 Nm
12
3
<L.H. drive vehicles>
<R.H. drive vehicles>
14.7 17.7 Nm
14
6
14
14.7 17.7 Nm

Master cylinder removal steps
1. Brake pipe connection
2. Brake fluid level sensor connector
3. Bracket <L.H. drive vehicles>
4. Master cylinder
"CA 5. Seal
Brake booster removal steps
2. Brake fluid level sensor connector
3. Bracket <L.H. drive vehicles>
4. Master cylinder
"CA 5. Seal
"BA D Push rod protrusion amount check and
adjustment
35A-17
"AA 6. Vacuum hose

(With built-in check valve)
7. Snap pin
8. Pin assembly
9. Vacuum sensor connector
10. Vacuum sensor
11. Grommet
12. Brake booster
13. Sealer
Fitting removal
14. Fitting
INSTALLATION SERVICE POINTS

"AA VACUUM HOSE CONNECTION
Insert the vacuum hose to the fitting with its paint mark facing
forward <L.H. drive vehicles>/upward <R.H. drive vehicles>
until the hose end reaches the edge of the hexagonal part
of the fitting, and then secure the hose by using the hose
clip.
"BA PUSH ROD PROTRUSION AMOUNT CHECK AND

ADJUSTMENT
1. Measure dimension (A).
Measuring distance A
Block gauge
Standard value (A) :

<L.H. drive vehicles with ABS> 22.7 22.9 mm
<L.H. drive vehicles without ABS and R.H. drive
vehicles> 23.93 24.18 mm
NOTE
When a negative pressure of 66.7 kPa is applied to the
brake booster, the push rod should protrude 22.2 22.4
mm <L.H. drive vehicles with ABS>/23.48 23.73 mm
<L.H. drive vehicles without ABS and R.H. drive vehicles>.
35A-18

2. If the protrusion amount is not within the standard value
range, adjust the push rod length by turning the push
rod. Use the special tool to turn the push rod while holding
the rod spline with angle-nose pliers.
Angle-nose pliers
MB991568
<L.H. drive vehicles with ABS>

Master cylinder
"CA SEAL INSTALLATION

1. Apply silicone grease to the seal.
2. Install the seal to the master cylinder as shown.
Seal
<L.H. drive vehicles without ABS and R.H.

drive vehicles>
Master cylinder
Seal
INSPECTION
VACUUM SENSOR CHECK
Refer to GROUP 13A Troubleshooting.
NOTE
The vacuum sensor is monitored by the engine-ECU. Diagnosis
code is output when the vacuum sensor has a malfunction.
35A-19
MASTER CYLINDER <L.H. drive vehicles without ABS and R.H. drive vehicles>
DISASSEMBLY AND REASSEMBLY
1
3
4
2
5
7
10
11
12
12
10
11
11
12
8 7
10
Brake fluid: DOT3 or DOT4
Master cylinder kit
AA"
Disassembly steps
1. Reservoir cap
2. Pin
3. Reservoir tank
4. Brake fluid level sensor
5. Reservoir seal
6. Stopper ring
7.
8.
9.
10.
11.
12.
Piston guide
Cylinder cup
Plate
Primary piston assembly
Secondary piston assembly
Master cylinder body
DISASSEMBLY SERVICE POINT

AA" STOPPER RING REMOVAL
Push the primary piston assembly and remove the stopper
ring.
35A-20
BASIC BRAKE SYSTEM Front Disc Brake
FRONT DISC BRAKE

Brake Fluid Supplying and Air Bleeding
49 Nm
90 110 Nm
1
2
3
4
Removal steps
1. Brake hose connection
2. Gasket
"AA 3. Disc brake assembly
4. Brake disc
INSTALLATION SERVICE POINT
MB991000
(MB990998)
Bolt
"AA DISC BRAKE ASSEMBLY INSTALLATION

installation, measure the rotary-sliding resistance of the
hub by the following procedure with the pads removed.
(1) Withdraw the drive shaft. (Refer to GROUP 26 Front
Axle.)
(2) Attach the special tool to the front hub assembly as
shown in the illustration, and tighten it to the specified
torque.
Tightening torque: 196 255 Nm
(3) Use a spring balance to measure the rotary-sliding
resistance of the hub in the forward direction.
2. Install the caliper support to the knuckle, and then assemble
the pad clip and the pad to the caliper support.
Caution
Do not contaminate the friction surfaces of the pads
and brake discs by any oil or grease.
35A-21
3. Clean the piston and insert it into the cylinder with the
special tool.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin to the caliper.
5. Start the engine, and then depress the brake pedal two
or three times strongly. Then stop the engine.
6. Turn the brake disc forward 10 times.
MB990520
7. Use a spring balance to measure the rotary-sliding

resistance of the hub.
8. Calculate the drag force of the disc brake [difference
between the values measured at steps 1 and 7].
Standard value: 69 N
9. If that drag force exceeds the standard value, disassemble
the piston assembly. Then check the piston for
contamination or rust, and confirm if the piston or the
piston seal is deteriorated, and if the lock pin and the
guide pin slide smoothly.
35A-22
15
15
12
13
26 Nm
15
11
Clip kit
26 Nm
15
14
8
10
6
2
3
5
4
3
9
8
7
10
13
11
9
3
2
3
5
Brake caliper kit
AA"
14
4
5
4
12
Pad set
Disassembly steps
1. Guide pin lock bolt
2. Guide pin
3. Boot
4. Bushing
5. Bushing retainer
6. Caliper support (including pad, clip,
and shim)
7. Piston boot
Shim kit
AA"
AB"
8.
9.
10.
11.
12.
13.
14.
15.
Seal and boot kit
Piston
Piston seal
Caliper body
Pad and wear indicator assembly
Pad assembly
Inner shim
Outer shim
Clip

LUBRICATION POINTS
Piston seal
Grease: Repair kit grease
Caution
The piston seal inside the
seal and boot kit is coated
with special grease, so do
not wipe this grease off.

35A-23
35A-24

DISASSEMBLY SERVICE POINTS
AA" PISTON BOOT/PISTON REMOVAL
Use a piece of wood to protect the caliper body outer side,
and then apply compressed air through the brake hose
connection hole to withdraw the piston and piston boot.
Caution
If air is blown into the caliper body suddenly, the piston
will pop out, causing damage to the caliper body. Be sure
to apply compressed air gradually.
AB" PISTON SEAL REMOVAL
1. Remove the piston seal with finger tip.
Caution
Do not use a flat-tipped screwdriver or other tool to
prevent damage to inner cylinder.
2. Clean piston surface and inner bore with trichloroethylene,
alcohol or the specified brake fluid.
INSPECTION
D
D
D
D
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 pad for damage or adhesion of grease, check the
backing metal for damage.
PAD WEAR CHECK

Measure thickness at the thinnest and worn area of the pad.
Replace the pad assembly if the pad thickness is less than
the limit value.
Standard value: 10 mm
Limit: 2.0 mm
Caution
1. Always replace the brake pads as an axle set.
2. If an excessive difference is found in the thickness
between the right and left brake pads, check moving
parts.
BASIC BRAKE SYSTEM Rear Disc Brake
35A-25
REAR DISC BRAKE

D Brake Fluid Draining
D Brake Fluid Supplying and Air Bleeding (Refer to
P.35A-10.)
55 65 Nm
1
15 Nm
3
Removal steps
1. Brake hose connection
"AA 2. Disc brake assembly
3. Brake disc

"AA DISC BRAKE ASSEMBLY INSTALLATION
installation, use a spring balance to measure the
rotary-sliding resistance of the hub with the pads removed.
2. Install the caliper support to the backing plate, and then
assemble the pad clip and the pad to the caliper support.
Caution
Do not contaminate the friction surfaces of the pads
and brake discs by any oil or grease.
35A-26

3. Clean the piston and insert it into the cylinder with the
special tool.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin to the caliper.
5. Start the engine, and then depress the brake pedal two
or three times strongly. Then stop the engine.
6. Turn the brake disc forward 10 times.
MB990520
7. Use a spring balance to measure the rotary-sliding

resistance of the hub.
8. Calculate the drag force of the disc brake [difference
between the values measured at steps 1 and 7].
Standard value: 34 N
9. If that drag force exceeds the standard value, disassemble
the piston assembly. Then check the piston for
contamination or rust, and confirm if the piston or the
piston seal is deteriorated, and if the lock pin and the
guide pin slide smoothly.
35A-27

15
15
43 Nm
8 Nm
11
12
13
14
15
9
Clip set
7
6
15
3
10
5
5
1
14
11
10
2
3
Grease
12
Pad set
Disassembly steps
"AA 1. Guide pin
"AA 2. Lock pin
3. Bushing
4. Caliper support (pad, clip, shim)
5. Pin boot
6. Boot ring
AA"
7. Piston boot
AA"
8. Piston
Shim set
AB"
9.
10.
11.
12.
13.
14.
15.
13
7
6
Brake caliper kit
Seal and boots kit
Piston seal
Caliper body
Pad and wear indicator assembly
Pad assembly
Inner shim
Outer shim
Clip
35A-28
LUBRICATION POINTS
Piston
seal
Caution
The piston seal inside the seal
and boot kit is coated with
special grease, so do not wipe
this grease off.

35A-29
DISASSEMBLY SERVICE POINTS

AA" PISTON BOOT/PISTON REMOVAL
Use a piece of wood to protect the caliper body outer side,
and then apply compressed air through the brake hose
connection hole to withdraw the piston and piston boot.
Caution
If air is blown into the caliper body suddenly, the piston
will pop out, causing damage to the caliper body. Be sure
to apply compressed air gradually.
AB" PISTON SEAL REMOVAL
1. Remove the piston seal with finger tip.
Caution
Do not use a flat-tipped screwdriver or other tool to
prevent damage to inner cylinder.
2. Clean piston surface and inner bore with trichloroethylene,
alcohol or the specified brake fluid.
REASSEMBLY SERVICE POINT

Lock pin
L
Front
"AA LOCK PIN/GUIDE PIN INSTALLATION

Install the guide pin and lock pin as illustrated that each head
mark of the guide pin and the lock pin matches the indication
mark (G or L) located on the caliper body.
Guide pin
G
INSPECTION
D
D
D
D
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 pad for damage or adhesion of grease, check the
backing metal for damage.
35A-30

PAD WEAR CHECK
Measure thickness at the thinnest and worn area of the pad.
Replace the pad assembly if the pad thickness is less than
the limit value.
Standard value: 10 mm
Limit: 2.0 mm
Caution
1. Always replace the brake pads as an axle set.
2. If an excessive difference is found in the thickness
between the right and left brake pads, check moving
parts.
35A-31
BASIC BRAKE SYSTEM Load Sensing Proportioning Valve
LOAD SENSING PROPORTIONING VALVE

Caution
Do not disassemble the load sensing proportioning valve.
D Brake Fluid Supplying
D Brake Line Bleeding (Refer to P.35A-10.)
2
5
1
3
15 Nm
15 Nm
Removal steps
"AA 1. Spring support
2. Load sensing spring
4. Load sensing proportioning valve

5. Bracket

Load sensing spring
Lever
Spring
support
"AA SPRING SUPPORT INSTALLATION

1. Install the load sensing spring, and then tighten the spring
support to the axle assembly temporarily.
2. Insert the lever of the load sensing proportioning valve
fully into the valve side and hold it. Then adjust the spring
support so that the spring length (the distance between
the two ends of the spring) is at the standard value.
Standard value (A): 194 198 mm
NOTES
35B-1
ANTI-SKID
BRAKING SYSTEM
(ABS) <4WD>
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3
Brake Fluid Level Sensor Check

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
Bleeding . . . . . . . . . . . . . . . . . Refer to GROUP 35A
LUBRICANTS . . . . . . . . . . Refer to GROUP 35A
Disc Brake Pad Check and Replacement

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
SEALANTS . . . . . . . . . . . . Refer to GROUP 35A
Disc Brake Rotor Check . . . Refer to GROUP 35A
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake Disc Thickness Check

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Disc Run-out Check and Correction

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 22
Wheel Speed Sensor Output Voltage Check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Brake Pedal Check and Adjustment

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
ABS Warning Lamp Relay Continuity Check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake Booster Operating Test

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Hydraulic Unit Check . . . . . . . . . . . . . . . . . . . . . . . . 24
Check Valve Operation Check

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Load Sensing Spring Length Check and
Adjustment . . . . . . . . . . . . . . . Refer to GROUP 35A
Load Sensing Proportioning Valve Function
Test . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Remedy for a Flat Battery . . . . . . . . . . . . . . . . . . . 25
BRAKE PEDAL . . . . . . . . Refer to GROUP 35A

MASTER CYLINDER AND BRAKE
BOOSTER . . . . . . . . . . . . Refer to GROUP 35A
CONTINUED ON NEXT PAGE
35B-2
FRONT DISC BRAKE . . Refer to GROUP 35A
HYDRAULIC UNIT AND ABS-ECU . . . . . . . . . 26
REAR DISC BRAKE . . . . Refer to GROUP 35A
WHEEL SPEED SENSOR . . . . . . . . . . . . . . . . . . 29
LOAD SENSING PROPORTIONING

VALVE . . . . . . . . . . . . . . . . . Refer to GROUP 35A
G SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ABS <4WD> General Information/Service Specifications
35B-3
GENERAL INFORMATION
The ABS consists of components such as the wheel
speed sensors, stop lamp switch, hydraulic unit
assembly (integrated with the ABS-ECU) and the
ABS warning lamp. If a problem occurs in the
system, the malfunctioning components can be
identified and the trouble symptoms will be

memorized by the diagnosis function.
In addition, reading of diagnosis codes and service
data and actuator testing are possible by using the
MUT-II.
WHEEL SPEED SENSOR

Type
Magnet coil type
ABS rotor teeth
43
CONSTRUCTION DIAGRAM
ABS warning
lamp
Hydraulic unit
assembly
(integrated with
the ABS-ECU)
Diagnosis
connector
G-sensor
Wheel speed sensor
Stop lamp switch
Wheel speed sensor
SERVICE SPECIFICATIONS
Items
Standard value
Wheel speed sensor internal resistance k
1.30 1.58
Wheel speed sensor insulation resistance k
100 or more
G sensor output voltage V
When labeled surface is faced to vertical direction
2.4 2.6
When labeled surface is faced straight down
3.3 3.7
35B-4
ABS <4WD> Special Tools
SPECIAL TOOLS
Tool
Number
Name
Use
MB991502
MUT-II sub
assembly
For checking of ABS

(Diagnosis code display when using the
MUT-II)
MB991529
Diagnosis code
check harness
For checking of ABS

(Diagnosis code display when using the ABS
warning lamp)
MB991547
ABS check
harness
For measuring of ABS-ECU terminal voltage
MB991348
Test harness set
For checking of G sensor
ABS <4WD> Troubleshooting
35B-5
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Refer to GROUP 00 How to Use Troubleshooting/Inspection Service Points.
NOTES WITH REGARD TO DIAGNOSIS

1. The phenomena listed in the following table are not abnormal.
Phenomenon
Explanation of phenomenon
System check sound
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,
and is not an abnormality.
ABS operation sound
1.
2.
3.
System check sound
When depressing the brake pedal during driving, a shock is sometime felt.
Sound of the motor inside the ABS hydraulic unit operation. (whine)
Sound is the generated along with vibration of the brake pedal. (scraping)
When ABS operates, sound is generated from the vehicle chassis due to repeated
brake application and release.
(Thump: suspension; squeak: tyres)
2. 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 too overconfident.
3. Diagnosis detection condition can vary depending on the diagnosis code.
Make sure that checking requirements listed in the Comment are satisfied when checking the trouble
symptom again.
Caution
Use the special tool (MB991547) when checking the terminal voltage and resistance of ABS-ECU.
35B-6

ABS WARNING LAMP INSPECTION
Check that the ABS warning lamp illuminates as follows.
1. When the ignition key is turned to ON, the ABS warning
lamp illuminates for approximately 3 seconds and then
switches off.
2. When the ignition key is turned to START, the ABS
warning lamp remains illuminated.
3. When the ignition key is turned from START back to
ON, the ABS warning lamp illuminates for approximately
3 seconds and then switches off.
ABS warning lamp
Approx. 3 s
ABS
warn- Illuminated
Not illumiing
lamp nated
START
Ignition
ON
switch
ACC,
LOCK
Approx. 3 s
NOTE
The ABS warning lamp may remain on until the vehicle
reaches a speed of several km/h. This is limited to cases
where diagnosis code Nos.21 to 24, 53 or 55 have been
recorded because of a previous problem occurring. In
this case, the ABS-ECU keeps the warning lamp
illuminated until the problem corresponding to that
diagnosis code can be detected.
4. If the illumination is other than the above, check the
diagnosis codes.
DIAGNOSIS FUNCTION
READING DIAGNOSIS CODES
Read a diagnosis code by the MUT-II or ABS warning lamp.
(Refer to GROUP 00 How to Use Troubleshooting/Inspection
Service Points.)
NOTE
Connect the MUT-II to the diagnosis connector (16-pin).
ERASING DIAGNOSIS CODES
When using the MUT-II
Connect the MUT-II to the diagnosis connector (16-pin) and
erase the diagnosis code.
Caution
Turn the ignition key to the LOCK (OFF) position before
connecting or disconnecting the MUT-II.
35B-7
When not using the MUT-II

1. Stop the engine.
2. Use the special tool to earth terminal (1) (diagnosis control
terminal) of the diagnosis connector.
3. Turn on the stop lamp switch. (Depress the brake pedal.)
4. After carrying out steps 1. to 3., turn the ignition switch
to ON. Within 3 seconds after turning the ignition switch
to ON, turn off the stop lamp switch (release the brake
pedal). Then, turn the stop lamp switch on and off a total
of 10 times.
MB991529
NOTE
If the ABS-ECU function has been stopped because of
fail-safe operation, it will not be possible to erase the
diagnosis codes.
ON
Ignition switch
LOCK (OFF)
Stop lamp switch
ON
OFF
1 second
ABS warning lamp
ON
OFF
ABS-ECU memory
Within 3
seconds
Within
1
second
1st
Within
1
second
Within Within
1
1
second second
Within Within Within Within

1
1
1
1
second second second second
Within Within
1
1
second second
2nd 3rd 4th 5th 6th 7th 8th 9th 10th
Erasing of
ABS-ECU
diagnosis
codes
complete.
35B-8
INSPECTION CHART FOR DIAGNOSIS CODES

Diagnosis code No.
Inspection item
Reference page
11
Front right wheel speed sensor (Open circuit or short circuit)
35B-9
12
Front left wheel speed sensor (Open circuit or short circuit)
35B-9
13
Rear right wheel speed sensor (Open circuit or short circuit)
35B-9
14
Rear left wheel speed sensor (Open circuit or short circuit)
35B-9
15
Wheel speed sensor (Abnormal output signal)
35B-10
16*
ABS-ECU power supply system (Abnormal voltage drop or rise)
35B-11
21
Front right wheel speed sensor
35B-9
22
Front left wheel speed sensor
35B-9
23
Rear right wheel speed sensor
35B-9
24
Rear left wheel speed sensor
35B-9
32
G sensor system
35B-12
33
Stop lamp switch system
35B-13
41
Front right solenoid valve
42
Front left solenoid valve
43
Rear right solenoid valve
44
Rear left solenoid valve
51
Valve relay problem (stays on)
35B-26, 27
(Replace the
hydraulic unit and
ABS-ECU.)
52
Valve relay problem (stays off) or ABS-ECU power supply system

problem
35B-13
53
Motor relay problem (stays off) or ABS-ECU power supply system

problem
54
Motor relay problem (stays on)
35B-26, 27
(Replace the
hydraulic unit and
ABS-ECU.)
55
Motor system (seized pump motor) or ABS-ECU power supply system

problem
35B-13
63
ABS-ECU
35B-26, 27
(Replace the
hydraulic unit and
ABS-ECU.)
The diagnosis codes are output

when there is no response to the
drive signals for respective solenoid
ECU power
valves or the ABS
ABS-ECU
supply system is defective.
NOTE
*: Turning the ignition switch to ACC will erase the diagnosis code No.16.
35B-13
35B-9

INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code Nos.11, 12, 13 and 14 Wheel speed sensor
(open circuit or short circuit)
Probable cause
Code Nos.21, 22, 23 and 24 Wheel speed sensor

Code Nos. 11, 12, 13 and 14 are output if the ABS-ECU detects an open circuit
or short-circuit in the (+) wire or () wire in any one of the four wheel speed sensors.
D Malfunction of wheel speed sensor

D Malfunction of wiring harness or connector
D Malfunction of hydraulic unit and ABS-ECU
Code Nos. 21, 22, 23 and 24 are output in the following cases.
D When there is no input from any one of the four wheel speed sensors when
travelling at several km/h or more, even though open circuit can not be verified.
D When a chipped or blocked-up ABS rotor is detected and if the anti-lock system
operates continuously because a malfunctioning sensor or a warped ABS rotor
is causing sensor output to drop.
D
D
D
D
D
D
NG
Wheel speed sensor installation check
OK
NG
Measure at the ABS-ECU connector A-58.
D Disconnect the connector, and measure at the harness side
connector.
D Resistances between 17 and 18, 15 and 14, 2 and 1, 4 and
5
OK: 1.30 1.58 k
OK
Wheel bearing check

(Refer to GROUP 26 and
GROUP 27 On-vehicle
Service.)
Check the following connector: A-58

OK
Check the trouble symptom.
NG
Replace the hydraulic unit and ABS-ECU.
NG
Repair
Replace
NG
Repair
NG
NG
ABS rotor check

(Refer to P.35B-30.)
OK
NG
Check the following connectors:

A-58, C-25<L.H. drive vehicles>, C-24<R.H. drive vehicles>, A-24,
A-85, D-24, D-28
NG
Wheel speed sensor
check
OK
Wheel speed sensor check (Refer to P.35B-30.)
Replace
Wheel speed sensor output voltage check (Refer to P.35B-22.)

NG
Repair
OK
OK
OK
Malfunction of wheel speed sensor

Malfunction of wiring harness or connector
Malfunction of ABS rotor
Too much gap between the sensor and the ABS rotor
Malfunction of hydraulic unit and ABS-ECU
Malfunction of wheel bearing
Replace
Check the harness wire, and repair if necessary.

D Between each wheel speed sensor and ABS-ECU
35B-10
Code No.15 Wheel speed sensor (Abnormal output signal)
Probable cause
This code is output if the output signal of any wheel speed sensor is abnormal
(other than an open circuit or short circuit).
D
D
D
D
D
D
D
NO
Are four tyres equal in size?
Unequal tyre size

Improper installation of wheel speed sensor
Equalize sizes on all tyres.
YES
NG
Check the wheel speed sensor installation condition.
NG
Repair
OK
Check the wheel speed sensor output voltage. (Refer to P.35B-22.)
NG
Check the wheel speed sensor. (Refer to P.35B-30.)

OK
OK
Replace

OK
NG
NG
Repair
Check the ABS rotor. (Refer to P.35B-30.)

OK
NG
Replace
NG
Check the wheel bearing. (Refer to GROUP 26 and GROUP

27 On-vehicle Service.)
OK
NG
Replace
NG
35B-11

Code No.16 ABS-ECU power supply system (abnormal
voltage drop or rise)
Probable cause
This code is output if the ABS-ECU power supply voltage drops below or rises
above the rated values.
Furthermore, turning the ignition switch to ACC will erase this code.
D Malfunction of battery
Caution
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage
returns to standard value, this code is no longer output.
Before carrying out the following inspection, check the battery level, and refill it if necessary.
NG
connector.
D Start the engine. Voltage between 10 and body earth
OK: System voltage
Check the following connectors: A-58, C-40 <R.H. drive

vehicles>, C-02 <R.H. drive vehicles>, C-78 <L.H. drive vehicles>,
C-76 <R.H. drive vehicles>, C-74
OK
NG
OK

OK
NG
NG
Repair
NG
Repair
D Between ignition switch and ABS-ECU
35B-12
Code No.32 G sensor system
Probable cause
This code is output in the following cases.

D G sensor output voltage is less than 0.5 V or more than 4.5 V. (An open or
short circuit is present in the G sensor circuit.)
D G sensor output voltage does not change. (G sensor output voltage is abnormal.)
D Malfunction of G sensor
NG
G sensor check (Refer to P.35B-31.)
Replace
OK
Measure at the G sensor connector D-29.
connector.
D Ignition switch: ON
D Voltage between 1 and body earth
OK: System voltage
NG
Check the following connector: D-29

OK
NG
Repair
NG
OK

D Between ignition switch and G sensor

connector.
D Voltage between 7 and 20
OK: 2.4 2.6 V (When labeled surface is faced to vertical
direction)
Check the following connectors: A-58, C-25 <L.H. drive

vehicles>, D-29
OK
NG
Repair
NG
OK
OK
NG
NG
Repair
NG

D Between G sensor and ABS-ECU
35B-13

Code No.33 Stop lamp switch system
Probable cause
This code is output in the following cases.

D If the stop lamp switch is continuously on for 15 minutes or more even though
the ABS system is not operating.
D If there is an open circuit in the stop lamp switch input circuit harness.
D Malfunction of stop lamp switch

NO
Does the stop lamp turn on and off normally?
Check the stop lamp switch installation condition.

(Refer to GROUP 35A On-vehicle Service.)
YES
OK

connector.
D Stop lamp switch: ON
OK: System voltage
OK
Repair
Check the stop lamp switch. (Refer to GROUP 35A Brake Pedal.)
OK
NG
NG
Check the following

connector: A-58
OK
NG
Replace
Check the following

connectors:
A-58, C-28 <L.H. drive
vehicles>, C-41 <R.H.
drive vehicles>
NG
Repair
OK
Check the following connectors: C-28 <L.H. drive vehicles>,

C-41 <R.H. drive vehicles>, C-02, C-04, C-29
NG
Repair
Replace the hydraulic

unit and ABS-ECU.
Repair
NG
NG
NG
OK

D Between battery and stop lamp switch
D Between stop lamp switch and ABS-ECU
NG
Check the harness wire,
and repair if necessary.
D Between stop lamp
switch and ABS-ECU
Probable cause
Code Nos.41, 42, 43 and 44 Solenoid valve

Code No.52 Valve relay problem (stays off)
Code No.53 Motor relay problem (stays off)
Code No.55 Motor system (seized pump motor)
These codes are output if there is an open circuit or short-circuit in the ABS-ECU
power supply circuit (power supply circuit for solenoid valve and motor), or the internal
circuit in the hydraulic unit and ABS-ECU is defective.

NG
connector.
D Voltage between 22 and body earth, and between 24 and
body earth
OK: System voltage
OK

NG
OK
NG
Repair
NG

OK

vehicles>
NG
Repair

D Between fusible link No.1 and ABS-ECU
35B-14
INSPECTION CHART FOR TROUBLE SYMPTOMS

Trouble symptoms
Inspection procedure
No.
Reference page
Communication between the MUT-II and the whole system is not

possible.
35B-14
Communication between the MUT-II and the ABS-ECU is not possible.
35B-15
When the ignition key is turned to ON (engine stopped), the ABS warning
lamp does not illuminate.
35B-16
Even after the engine is started, the ABS warning lamp remains
illuminated.
35B-17
Faulty ABS operation
35B-18
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, the brake pedal may vibrate or may not be able to be depressed. Such
phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent
the wheels from locking and is not an abnormality.
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

Inspection Procedure 1
Communication between the MUT-II and the whole system
is not possible.
Probable cause
The cause may be a malfunction of the power supply circuit or the earth circuit
of the diagnosis connector.
D Malfunction of diagnosis connector

NG
Measure at the diagnosis connector C-35.
OK: System voltage
Check the following connectors: C-35, C-76, C-77

OK
OK
NG
Repair
NG
D Between fusible link No.2 and diagnosis connector
NG
Measure at the diagnosis connector C-35.
D Continuity between 4 and body earth, and between 5 and
body earth
OK: Continuity
OK
NG
Replace the MUT-II.
Check the following connector: C-35

OK
NG
NG
Repair

D Between diagnosis connector and earth
35B-15

Communication between MUT-II and the ABS-ECU is not
possible.
Probable cause
The cause may be an open circuit in the ABS-ECU power supply circuit or an open
circuit in the diagnosis output circuit.
D Blown fuse
NG
Measure at the diagnosis connector C-35 and the ABS-ECU connector A-58.
D Disconnect the connectors, and measure at the harness side
connectors.
D Continuity between the following terminals
ABS-ECU side Diagnosis connector side
19 1
9 7
OK: Continuity
Check the following connectors: A-58, C-28 <L.H. drive

vehicles>, C-40 <R.H. drive vehicles>, C-70, C-35
OK
NG
Repair
NG
D Between ABS-ECU and diagnosis connector
OK
NG
connector.
OK: System voltage

vehicles>, C-02 <R.H. drive vehicles>, C-78 <L.H. drive vehicles>,
C-76 <R.H. drive vehicles>, C-74
OK
OK
NG
Repair
NG
D Between ignition switch and ABS-ECU
connector.
D Continuity between 21 and body earth, and between 23 and
body earth
OK: Continuity
OK
OK
NG
NG
Repair
NG

OK
NG
NG
Repair

D Between ABS-ECU and earth
35B-16
When the ignition key is turned to ON (engine stopped),
the ABS warning lamp does not illuminate.
Probable cause
The cause may be an open circuit in the lamp power supply circuit, a blown lamp,
a malfunction of the ABS warning lamp relay or an open circuit between the ABS
warning lamp and the earth.
D
D
D
D
D
Blown fuse
Burn out ABS
Malfunction of
Malfunction of
Malfunction of
warning lamp bulb

ABS warning lamp relay
wiring harness or connector
hydraulic unit and ABS-ECU
NG
Refer to GROUP 00 Inspection Service Points for Blown Fuse.
Fuse check
Multi-purpose fuse No.6
OK
NG
Measure at the ABS warning lamp relay connector A-57.
connector.
D ABS warning lamp condition when terminal 3 is earthed.
OK: Illuminates
Check whether the ABS warning lamp bulb is burnt out.
Replace the ABS warning

lamp bulb.
OK
Check the following connectors: A-57,

C-27 <L.H. drive vehicles>, C-40 <R.H. drive vehicles>,
C-07, C-06, C-02 <L.H. drive vehicles>, C-76, C-74
ABS warning lamp relay check (Refer to P.35B-23.)

NG
OK
NG
OK
OK
Replace the ABS warning
lamp relay.
NG
Repair
NG
Check the harness wire.
D Between ignition switch and combination meter
D Between combination meter and ABS warning lamp relay
OK
NG
Repair
Replace the combination meter.

NG
connector.
D Continuity between 1 and body earth
OK: Continuity
OK

OK
NG
Repair
NG
D Between ABS warning lamp relay and earth
35B-17

Even after the engine is started, the ABS warning lamp
remains illuminated.
Probable cause
The cause is probably a short-circuit in the ABS warning lamp illumination circuit.
D
D
D
D
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
combination meter
ABS warning lamp relay
wiring harness (short circuit)
hydraulic unit and ABS-ECU
NOTE
This trouble symptom is limited to cases where communication with the MUT-II is possible (ABS-ECU
power supply is normal) and the diagnosis code is a normal diagnosis code.
YES
Replace the combination meter.
Does the ABS warning lamp stay illuminated when the combination
meter connector C-07 is disconnected and the ignition switch
is turned to ON?
NO
NG
ABS warning lamp relay check (Refer to P.35B-23.)
Replace the ABS warning lamp relay.
OK
YES
D Between combination meter and ABS warning lamp relay
Does the ABS warning lamp stay illuminated when the ABS warning
lamp relay connector A-57 is disconnected and the ignition switch
is turned to ON?
NO
NG
connector.
OK: System voltage

OK
NG
Repair
NG
OK

D Between ignition switch and ABS warning lamp relay
NG
OK: System voltage
OK
Check the following connectors: A-58, A-57

OK
NG
Repair
NG
D Between ABS warning lamp relay and ABS-ECU
35B-18
Faulty ABS operation
Probable cause
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.
D
D
D
D
D
D
D
NG
Wheel speed sensor installation check
Improper installation of wheel speed sensor

Foreign material adhering to wheel speed sensor
Repair
OK
OK
Wheel speed sensor output voltage check (Refer to P.35B-22.)
Hydraulic unit check (Refer to P.35B-24.)
NG
NG
Wheel speed sensor check (Refer to P.35B-30.)
Replace the wheel speed sensor.
OK
ABS rotor check (Refer to P.35B-30.)
NG
Repair
OK
Wheel bearing check (Refer to GROUP 26 and GROUP 27
On-vehicle Service.)
NG
Repair
OK
Check the following connectors:
A-58, C-25 <L.H. drive vehicles>, C-24 <R.H. drive vehicles>,
A-24, A-85, D-24, D-28
NG
Repair
OK
NG
connector.
D Resistances between 17 and 18, 15 and 14, 4 and 5, 2 and
1
OK: 1.30 1.58 k
(The sensor harness and connector should be moved while
these inspections are carried out.)
OK
OK
NG
NG
NG
Check the harness wire.

Repair
35B-19

DATA LIST REFERENCE TABLE
The following items can be read by the MUT-II from the ABS-ECU input data.
1. When the system is normal
Item No.
Check item
Checking requirements
Normal value
11
Front-right wheel speed sensor
Perform a test run
12
Front-left wheel speed sensor
13
Rear-right wheel speed sensor
Vehicle speeds
displayed on the
speedometer
MUT II are
and MUT-II
identical.
14
Rear-left wheel speed sensor
16
ABS-ECU power supply

voltage
Ignition switch: ON
9.2 17.5 V
32
G sensor
Vehicle is stopped.
2.4 2.6 V
Vehicle is running.
0.5 4.5 V
Depress the brake pedal.
ON
Release the brake pedal.
OFF
33
Stop lamp switch
2. When the ABS-ECU shut off ABS operation.

When the diagnosis system stops the ABS-ECU, the MUT-II display data will be unreliable.
ACTUATOR TEST REFERENCE TABLE

The MUT-II activates the following actuators for testing.
NOTE
1. If the ABS-ECU runs down, actuator testing cannot be carried out.
2. Actuator testing is only possible when the vehicle is stationary.
ACTUATOR TEST SPECIFICATIONS

Activation pattern
A
Solenoid
B
valve
C
0.05 s
ON
Pump
motor
OFF
Start of
forced
action
1s
End of forced
action
2s
0.01 s
NOTE
A: Hydraulic pressure increase
B: Hydraulic pressure holds
C: Hydraulic pressure decrease
No.
Item
01
Solenoid valve for

front-right wheel
02
Solenoid valve for front-left

wheel
03
Solenoid valve for rear-right

wheel
04
Solenoid valve for rear-left

wheel
Solenoid valves and pump

motors in the hydraulic unit
(simple inspection mode)
35B-20

CHECK AT ABS-ECU
TERMINAL VOLTAGE CHECK CHART
1. Disconnect the ABS-ECU connector. (Refer to P. 35B-27.)
2. Use the special tool to measure the voltage between each
terminal and earth (terminal No.23).
3. The terminal layout is shown in the illustration.
Earth terminal
Check connector
MB991547
Body side harness

ABS-ECU
Terminal No.
Check item
Checking requirements
Stop lamp switch input
Ignition switch: ON
Input
In
ut from G sensor
Ignition switch: ON
Vehicle is horizontal
ABS warning lamp

relay transistor output
Ignition switch: ON
Normal condition
Stop lamp switch: ON
System voltage
Stop lamp switch: OFF
1 V or less
2.4 2.6 V
When the lamp

switched off
is
When the lamp is illuminated

9
10
19
MUT-II
ABS-ECU power
supply
Diagnosis changeover
input
2 V or less
System voltage
When the MUT-II is connected
Serial communication
with MUT-II
When the MUT-II is not connected
1 V or less
Ignition switch: ON
System voltage
Ignition switch: START
0V
When the MUT-II is connected
0V
When the MUT-II is not connected
Approx. 12 V
20
G sensor earth
Always
0V
22
Solenoid valve power

supply
Always
System voltage
24
Motor power supply
Always
System voltage
35B-21
RESISTANCE AND CONTINUITY BETWEEN

HARNESS-SIDE CONNECTOR TERMINALS
1. Turn the ignition key to the LOCK (OFF) position.
2. Disconnect the ABS-ECU connector. (Refer to P. 35B-27.)
3. Use the special tool to check the resistance and continuity
between the terminals indicated in the table below.
4. The terminal layout is shown in the illustration.
Check connector
MB991547
Body side harness
ABS-ECU
ABSECU terminal No.
Signal
Normal condition
12
Wheel speed sensor (rear left)
1.30 1.58 k
45
Wheel speed sensor (rear right)
14 15
Wheel speed sensor (front left)
17 18
Wheel speed sensor (front right)
21 Body earth
Earth
23 Body earth
Earth
Continuity
35B-22
ABS <4WD> On-vehicle Service
ON-VEHICLE SERVICE
WHEEL SPEED SENSOR OUTPUT VOLTAGE
CHECK
Check connector
MB991547
Body side harness
1. Lift up the vehicle and release the parking brake.

2. Disconnect the ABS-ECU connector and then connect
the special tool to the harness side connector. (Refer to
P. 35B-27.)
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
Front
left
Front
right
Rear left
Rear
right
Terminal No.
15
17
14
18
Output voltage
ABS-ECU
When measuring with a circuit tester:

42 mV or more
When measuring with an oscilloscope:
120 mV p-p or more
4. The followings are suspected if the output voltage is lower
than the value described above. Check the wheel speed
sensor, and replace if necessary.
D Too large clearance between the pole piece of the
wheel speed sensor and ABS rotor
D Faulty wheel speed sensor
When turning by hand
When idling (5 6 km/h), 1st gear (M/T)

or D range (A/T)
10.0 ms/DIV 1
V/DIV
Inspecting Waveforms With An Oscilloscope

Use the following method to observe the output voltage
waveform from each wheel speed sensor with an oscilloscope.
D Start the engine, and rotate the rear wheels by engaging
1st gear (vehicles with manual transmission) or D range
(vehicles with automatic transmission). Turn the front
wheels manually so that they rotate at a constant speed.
NOTE
1. The waveform measurements can also be taken while
the vehicle is actually moving.
2. The output voltage will be small when the wheel speed
is low, and similarly it will be large when the wheel speed
is high.
35B-23

Points In Waveform Measurement
Symptom
Probable causes
Remedy
Too small or zero waveform

amplitude
Faulty wheel speed sensor
Replace sensor
Waveform amplitude fluctuates

excessively (this is no problem
roblem if
the minimum amplitude is 100 mV
or more)
Axle hub eccentric or with large runout
Replace hub
Faulty ABS-ECU earth
Repair
Noisy or disturbed waveform
Open circuit in sensor
Replace sensor
Open circuit in harness
Correct harness
Incorrectly mounted wheel speed sensor
Mount correctly
ABS rotor with missing or damaged teeth
Replace ABS rotor
Caution
Because the wheel speed sensor cables move together with the front and rear suspension, they vibrate
greatly when driving over poor road surfaces. As a result, the sensor harnesses should also be shaken
when monitoring of output waveforms of the wheel speed sensors in order to simulate conditions such
as driving over poor road surfaces.
Hydraulic unit
and ABS-ECU
ABS WARNING LAMP RELAY CONTINUITY

CHECK
Battery voltage
Terminal No.
1
Power is not
supplied
Power is supplied
Hydraulic unit
and ABS-ECU
35B-24
HYDRAULIC UNIT CHECK

1. Jack up the vehicle and support the vehicle with rigid 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. Turn the ignition key to the LOCK (OFF) position and set the MUT-II.
Caution
Turn the ignition key to the LOCK (OFF) position before connecting or disconnecting the MUT-II.
3. After checking that the shift lever <M/T> or the selector lever <A/T> is in neutral, start the engine.
4. Use the MUT-II to force-drive the actuator.
NOTE
(1) During the actuator test, the ABS warning lamp will illuminate and the anti-skid control will be
cancelled.
(2) When the ABS has been interrupted by the fail-safe function, the MUT-II actuator testing cannot
be used.
5. 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 that the braking force decreases when the actuator is force-driven.
Front wheel
785 981 N
Rear wheel
588 784 N
The result should be as shown in the following diagram.

Pedal operation
Depressed
Released
Increase in pressure
Solenoid valve
position
Steady pressure
Reduction in pressure
Checking the
brake force
MUT-II actuator test

(Item No. 01, 02, 03, 04) start
Lock
Drag force when the pedal is free
2 seconds
1 seconds
Approx. 0.05 seconds
35B-25
6. If the result of inspection is abnormal, correct according to the Diagnosis Table.

Diagnosis Table
No.
Operation
Judgement
Normal
Judgement
Abnormal
Probable cause
Remedy
01
(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.
Brake force
released for 3
seconds after
locking
locking.
Wheel does not

lock when brake
pedal is depressed
pressed.
Clogged brake
line other than
hydraulic unit
Check and clean

brake line
Clogged hydraulic circuit in

hydraulic unit
Replace hydraulic unit assembly
Incorrect hydraulic unit brake

tube connection
Connect correctly
Hydraulic unit
solenoid valve
not functioning
correctly
Replace hydraulic unit assembly
02
03
04
Brake force is
not released
7. After inspection, disconnect the MUT-II immediately after turning the ignition switch to OFF.
REMEDY FOR A FLAT BATTERY

When booster cables are used to start the engine when the
battery is completely flat and then the vehicle is immediately
driven without waiting for the battery to recharge itself to some
extent, the engine may misfire, and driving might not be
possible.
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 disconnect the
ABS-ECU connector, thus disabling the anti-skid brake system.
The ABS warning lamp will illuminate when the ABS-ECU
connector is disconnected.
After the battery has sufficiently recharged, connect the
ABS-ECU connector and restart the engine; then check to
be sure the ABS warning lamp is not illuminated.
Lock lever
Hydraulic unit and

ABS-ECU
DISCONNECTING ABS-ECU CONNECTOR

Move the lock lever of the ABS-ECU connector as shown
in the illustration, and then disconnect the ABS-ECU connector.
35B-26
ABS <4WD> Hydraulic Unit and ABS-ECU
HYDRAULIC UNIT AND ABS-ECU

D Brake Fluid Draining
D Air Cleaner Removal (Refer to GROUP 15.)
D Brake Fluid Supplying and Brake Line Bleeding
(Refer to GROUP 35A On-vehicle Service.)
D Hydraulic Unit Inspection (Refer to P.35B-24.)
D Air Cleaner Installation (Refer to GROUP 15.)

3
3
4
15 Nm
35B-27

3
4
15 Nm
Removal steps
1. ABS warning lamp relay
AA"
2. Harness connector
"AA 3. Brake pipe connection
AB"
4. Hydraulic unit and ABS-ECU

5. Hydraulic unit bracket assembly
REMOVAL SERVICE POINTS

Lock lever
Hydraulic unit
and ABS-ECU
AA" HARNESS CONNECTOR DISCONNECTION

Move the lock lever of the ABS-ECU connector as shown
in the illustration, and then disconnect the harness connector.
35B-28

AB" HYDRAULIC UNIT AND ABS-ECU REMOVAL
Caution
1. The hydraulic unit assembly is heavy, and so care
should be taken when removing it.
2. The hydraulic unit assembly is not to be disassembled;
its nuts and bolts should absolutely not be loosened.
3. The hydraulic unit assembly must not be dropped
or otherwise subjected to impact shocks.
4. The hydraulic unit assembly must not be turned upside
down or laid on its side.

6
3
4
"AA BRAKE PIPE CONNECTION

Connect the pipes to the hydraulic unit assembly as shown
in the illustration.
1. To the proportioning valve (Rear brake, LH)
2. To the proportioning valve (Rear brake, RH)
3. From the master cylinder (Primary)
4. From the master cylinder (Secondary)
5. To the front brake (RH)
6. To the front brake (LH)
35B-29
ABS <4WD> Wheel Speed Sensor
WHEEL SPEED SENSOR

Wheel Speed Sensor Output Voltage Check
<FRONT>
<REAR>
1
4
AA"
AA"
1. Front wheel speed sensor

2. Front ABS rotor (Refer to GROUP
26 Drive Shaft.)
3. Rear wheel speed sensor
4. Rear ABS rotor (Refer to GROUP
27 Axle Shaft.)
NOTE
The front ABS rotor is integrated with the drive shaft. Do
not disassemble it.
REMOVAL SERVICE POINT

AA" FRONT WHEEL SPEED SENSOR/REAR WHEEL
SPEED SENSOR REMOVAL
Pole piece
Caution
Do not strike the pole piece at the tip of the wheel speed
sensor against the ABS rotor tooth surface or other parts
when removing the wheel speed sensor.
35B-30
ABS <4WD> Wheel Speed Sensor

INSPECTION
CHECK OF RESISTANCE BETWEEN WHEEL SPEED
SENSOR TERMINALS
Caution
The pole piece can become magnetized because of the
magnet built into the wheel speed sensor, with the result
that metallic foreign material easily adheres to it. Moreover,
the pole piece may not be able to function to correctly
sense the wheel rotation speed if it is damaged.
1. Measure the resistance between the wheel speed sensor

terminals.
Standard value: 1.30 1.58 k
If the internal resistance of the wheel speed sensor is
not within the standard value, replace with a new wheel
speed sensor.
2. Check the wheel 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 temporary disconnection
occurs.
WHEEL SPEED SENSOR INSULATION INSPECTION

1. Remove all connections from the wheel speed sensor,
and then measure the resistance between terminals 1
and 2 and the body of the wheel 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.
ABS ROTOR CHECK

Check whether ABS rotor teeth are broken or deformed, and,
if so, replace the B.J. assembly or the ABS rotor.
ABS <4WD> G Sensor
35B-31
G SENSOR
Caution
Do not drop the G sensor or subject it to any shocks.
Pre-removal and Post-installation Operation
Rear floor console removal and installation
(Refer to Group 52A.)
5 Nm
G sensor
INSPECTION
Label
1. Remove the G sensor.

2. Connect the special tool between the disconnected
connectors, and then place the G sensor horizontally as
shown in the illustration.
3. Turn on the ignition switch, and then measure the voltage
between terminal No.2 and body earth.
Standard value: 2.4 2.6 V
MB991348
Label
4. Face the labeled surface straight down with the special

tool still connected. Measure the voltage between terminal
No.2 and body earth with the labeled surface faced straight
down.
Standard value: 3.3 3.7 V
5. If not within the standard value, check the power supply
line and earth condition, and then replace the G sensor.
NOTES

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35A-1

BASIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A

Brake Fluid Level Sensor Check . . . . . . . . . . . . . 10

MASTER CYLINDER AND BRAKE

Brake Pedal Check and Adjustment . . . . . . . . . . . . 6

Brake Booster Operating Test . . . . . . . . . . . . . . . . . . 7

FRONT DISC BRAKE . . . . . . . . . . . . . . . . . . . . . 20

Load Sensing Spring Length Check and

REAR DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . 25

Load Sensing Proportioning Valve Function

LOAD SENSING PROPORTIONING

BASIC BRAKE SYSTEM General Information

Load sensing proportioning

Rear disc brakes

Vacuum type, single

Effective dia. of power cylinder mm

Floating caliper, 1-piston, ventilated disc

Disc effective dia. thickness mm

Wheel cylinder I.D. mm

Floating caliper,1-piston, solid disc

Disc effective dia. thickness

Wheel cylinder I.D. mm

BASIC BRAKE SYSTEM Service Specifications

L.H. drive vehicles

R.H. drive vehicles

Brake pedal play mm

Brake pedal to floorboard clearance when the brake pedal is depressed mm

Brake booster push rod protrusion amount mm

L.H. drive vehicles with ABS

L.H. drive vehicles without

When load sensing spring length is 199 mm (when

4.2 6.0 (9.8)

When load sensing spring length is 217 mm (when

9.7 10.5 (9.8)

14.5 16.3 (16.7)

Load sensing spring length <Distance between spring ends> mm

Front disc brake

Front hub end play mm

Rear hub end play mm

Brake pedal height mm

Load sensing proportioning valve output fluid

Output fluid pressure difference between left and right

Rear disc brake

BASIC BRAKE SYSTEM Lubricants/Sealant/Special Tools

Vacuum sensor grommet

Brake booster seal

Piston boot, piston seal

3M ATD Part No. 8661 or equivalent

Brake tool set

Pushing-in of the disc brake piston

A: Front hub remover and installer

When bearing provisional holding

Push rod adjusting

Adjustment of the brake booster push rod

BASIC BRAKE SYSTEM On-vehicle Service

Stop lamp switch

BRAKE PEDAL HEIGHT

3. If the brake pedal height is not within the standard value,

BRAKE PEDAL FREE PLAY