Sec5a4 Abs Asr

ABS/ASR 5A4-56 Step

17

Action Check the FL wheel speed sensor circuit. (Refer to the check flow B-13.)

Value

18

19

21

Replace the EHCU. Is this step completed? 1. Instal Installl all the the compon components ents,, and check check that that those are installed properly. 2. Clea Clearr the the DTC DTC. Is this step completed?

—

Go to Step21

—

Go to Step21

Go to Step21

Go to Step21

—

Go to “Diagnostic basic flow”.

Go to Step21

—

Is this step completed? 20

Check the repair.

—

Is this step completed? Repair the circuit for open/short circuit, and the connector for improper connection between the EHCU connector and the speed sensor connector.

NO

—

Is this step completed? Check the circuit for open circuit, and the connector for improper connection between the EHCU and the speed sensor sen sor connector. Refer to “Intermittent trouble”.

YES

—

—

5A4-57 ABS/ASR DTC:C0262 (Flash Code 62) Speed Sensor Signal Fault/Wrong Tire Size; FR Check flow B-18 Step

Action

Value

YES

NO

Go to Step2

Replace with the specified tire without wear.Go wear.Go to Step21

DTC may be set if certain tire is rotated alone. Go to Step21

Go to Step3

Go to Step12

Go to Step4

Go to Step13

Go to Step5

Go to Step14

Go to Step6

Go to Step7

Go to Step10

Go to Step15

Go to Step8

Go to Step9

Go to Step11

Go to Step20

Go to Step18

Go to Step16

Go to Step17

Go to Step19

Go to Step16

Go to Step21

—

Go to Step21

—

Go to Step21

—

Go to Step21

—

Go to Step21

—

Check the tire. 1

2

Is the tire specification correct? Is abnormal wear found in the outer surface? Has certain tire been rotated alone by perfuming for jack-up or roller tester?

—

—

3

Is the FR wheel bearing rattling?

—

4

Is the FR wheel speed sensor/sensor rotor rattling?

—

5

Is iron powder attached to the FR wheel speed sensor/sensor rotor?

—

6

Check the FR wheel speed sensor. (Refer to the check flow C-1-2 or TC-1.)

—

Is the FR sensor output normal? 7

8

Does the sensor rotor have missing tooth or saw-toothed? Measure the resistance between the B-177 connector terminal 11 and the ground. Is the value within specified value?

9

1. Clea Clearr the the DTC DTC. 2. Test Test run the the vehic vehicle, le, and and perfo perform rm the self self-diagnosis.

— 1000kΩ or more

—

Is DTC displayed repeatedly? 10

Is the speed sensor damaged or sawtoothed?

—

1. Discon Disconnec nectt the FR sens sensor or conne connecto ctor. r. 11

2. Measure Measure the the resis resistanc tance e betwee between n the J-74 J-74 connector terminal 2 (sensor side) and the ground.

1000kΩ or more

Is the value within specified value? 12

13

Adjust the preload of the wheel bearing. Is this step completed? Repair or replace the speed sensor/sensor rotor.

—

—


15

Repair the speed sensor/sensor rotor. Is this step completed? Replace the sensor rotor. Is this step completed?

—

—

Replace the FR wheel speed sensor. 16

Is this step completed?

—

ABS/ASR 5A4-58 Step

17

Action Check the FR wheel speed sensor circuit. (Refer to the check flow B-14.)

Value

18

19

21

Replace the EHCU. Is this step completed? 1. Instal Installl all the the compon components ents,, and check check that that those are installed properly. 2. Clea Clearr the the DTC DTC. Is this step completed?

—

Go to Step21

—

Go to Step21

Go to Step21

Go to Step21

—


Go to Step21

—


Check the repair.

—

Is this step completed? Repair the circuit for open/short circuit, and the connector for improper connection between the EHCU connector and the speed sensor connector.

NO

—

Is this step completed? Check the circuit for open circuit, and the connector for improper connection between the EHCU and the speed sensor sen sor connector. Refer to “Intermittent trouble”.

YES

—

—

5A4-59 ABS/ASR DTC:C0263 (Flash Code 63) Speed Sensor Signal Fault/Wrong Tire Size; RL Check flow B-19 Step

Action

Value

YES

NO

Go to Step2



Go to Step3

Go to Step10

Go to Step4

Go to Step11

Go to Step5

Go to Step12

Go to Step6

Go to Step7

Go to Step9

Go to Step13

Go to Step8

Go to Step17

Go to Step16

Go to Step14

Go to Step15

Go to Step18

—

Go to Step18

—

Go to Step18

—

Go to Step18

—

Go to Step18

—

Check the repair.

—

Go to Step18

—

Check the tire. 1

2

Is the tire specification correct? Is abnormal wear found in the outer surface? Has certain tire been rotated alone by perfuming for jack-up or roller tester?

—

—

3

Is the FL wheel bearing rattling?

—

4

Is the FL wheel speed sensor/sensor rotor rattling?

—

5

Is iron powder attached to the FL wheel speed sensor/sensor rotor?

—

6

Check the RL wheel speed sensor. (Refer to the check flow C-1-3.)

—

Is the RL sensor output normal? 7

8

Does the sensor rotor have missing tooth or saw-toothed? 1. Clea Clearr the the DTC DTC. 2. Test Test run the the vehic vehicle, le, and and perfo perform rm the self self-diagnosis.

—

—

Is DTC displayed repeatedly? 9 10

11

Is the speed sensor damaged or sawtoothed? Adjust the preload of the wheel bearing. Is this step completed? Repair or replace the speed sensor/sensor rotor.

— —

—


13


—

—

Replace the RL wheel speed sensor. 14

15

Is this step completed? Check the RL wheel speed sensor circuit. (Refer to the check flow B-15.)

—

—


16

Check the circuit for open circuit, and the connector for improper connection the EHCU connector and the speed sensor connector. Refer to “Intermittent trouble”. Is this step completed?

—

ABS/ASR 5A4-60 Step 17

Action Replace the EHCU. Is this step completed?

Value —

YES

NO

Go to Step18

—


Go to Step18

1. Instal Installl all the the compon components ents,, and check check that that those are installed properly. 18

2. Clea Clearr the the DTC DTC. Is this step completed?

—

5A4-61 ABS/ASR DTCC0264 (Flash Code 64) Speed Sensor Signal Fault/Wrong Tire Size; RR Check flow B-20 Step

Action

Value

YES

NO

Go to Step2



Go to Step3

Go to Step10

Go to Step4

Go to Step11

Go to Step5

Go to Step12

Go to Step6

Go to Step7

Go to Step9

Go to Step13

Go to Step8

Go to Step17

Go to Step16

Go to Step14

Go to Step15

Go to Step18

—

Go to Step18

—

Go to Step18

—

Go to Step18

—

Go to Step18

—

Check the repair.

—

Go to Step18

—

Check the tire. 1

2

Is the tire specification correct? Is abnormal wear found in the outer surface?

—

Has certain tire been rotated alone by perfuming for jack-up or roller tester?

3

Is the RR wheel bearing rattling?

—

4

Is the RR wheel speed sensor/sensor rotor rattling?

—

5

Is iron powder attached to the RR wheel speed sensor/sensor rotor?

—

6

Check the RR wheel speed sensor. (Refer to the check flow C-1-4.)

—

Is the RR sensor output normal? 7

8

Does the sensor rotor have missing tooth or saw-toothed? 1. Clea Clearr the the DTC DTC. 2. Test Test run the the vehic vehicle, le, and and perfo perform rm the self self-diagnosis.

—

—

Is DTC displayed repeatedly? 9 10

11

Is the speed sensor damaged or sawtoothed? Adjust the preload of the wheel bearing. Is this step completed? Repair or replace the speed sensor/sensor rotor.

— —

—


13


—

—

Replace the RR wheel speed sensor. 14

15

Is this step completed? Check the RR wheel speed sensor circuit. (Refer to the check flow B-16.)

—

—


16

Check the circuit for open circuit, and the connector for improper connection the EHCU connector and the speed sensor connector. Refer to “Intermittent trouble”. Is this step completed?

—

ABS/ASR 5A4-62 Step 17

Action

Value

Replace the EHCU.

—


YES

NO

Go to Step18

—


Go to Step18

1. Instal Installl all the the compon components ents,, and check check that that those are installed properly. 18

—

2. Clea Clearr the the DTC DTC. Is this step completed?

List of Trouble Symptom Troubles not appeared as warning lamp indication can be classified into the following five categories. 1. The ABS opera operates tes frequ frequentl ently y but brake brake force force is is insufficient, or the ASR operates frequently. 2. The ABS ABS operate operates s but pullin pulling g to one one side. side. 3. Wheels Wheels are are locked locked duri during ng brake brake operati operation. on. 4. Feeling Feeling of brake brake pedal pedal is faulty faulty..

No.

5. Brake Brake operat operating ing nois noise e comes comes from from the the EHCU EHCU though the brake pedal is not depressed. Self-diagnosis function is unable to detect these symptoms. Check the trouble symptom by reproducing the condition through interviewing customer with the test run, and perform the diagnosis according to each trouble symptom.

Trouble symptom

Diagnostic check flow Without Tech 2

With Tech 2

1

The ABS operates frequently but brake force is insufficient, or the ASR operates frequently.

Check flow A-1

Check flow TA-1

2

The ABS operates but pulling to one side.

Check flow A-2

Check flow TA-2

3

Wheels are locked during brake operation.

Check flow A-3

Check flow TA-3

4

Feeling of brake pedal is faulty.

Check flow A-4

5

Brake operating noise comes from the hydraulic unit though the brake pedal is not depressed.

Check flow A-5

— Check flow TA-5

5A4-63 ABS/ASR Symptom: [The ABS Operates Frequently but Brake Force is Insufficient, or the ASR Operates Frequently.] (Check Flow A-1) Check flow A-1 Step

Action

Value

YES

NO

Go to Step2


Go to Step3

Repair the brake components.Go components.Go to Step7

Go to Step4

Repair the parts.Go parts.Go to Step7

Go to Step5

Repair the wheel speed sensor.Go sensor.Go to Step7

Go to Step6

Replace the sensor or sensor rotor. Go to Step7

—

Replace the control unit.Go unit.Go to Step7

Replace the wheel speed sensor, or repair the circuit. Go to Step7

—

Repeat “Diagnostic basic flow”.

Go to Step7

Check the tire. 1

2

3

Is the tire specification correct? Is abnormal wear found in the outer surface? Is the brake balance between front and rear wheels correct? Are the axle-related parts correctly assembled?

—

—

—

Is the speed sensor installation normal? 4

5

— Is the speed sensor/sensor rotor damaged? Or iron powder attached?

—

Are all the wheel speed sensor outputs normal? 6

7

Install all the components, and check that those are installed p roperly. Is this step completed?

ABS/ASR 5A4-64 Symptom: [The ABS Operates Frequently but Brake Force is Insufficient, or the ASR Operates Frequently.] (Check Flow TA-1) Check flow TA-1 Step

Action

Value

YES

NO

Go to Step2

Replace the wheel speed sensor.Go sor.Go to Step3

Go to Step3

Go to Step2


Go to Step3

1. Conn Connec ectt the the Tech Tech 2.

1

2. Check Check each each sensor sensor output output from the “Wheel sensor”.

—

Is the lowest value of each wheel sensor reading 4 km/h (2 mph) or less? And is the value stable? 2

Go back to the check flow A-1.

—

Is the check flow A-1 completed? 3

Assemble all the components, a nd check that those are installed p roperly. roperly. Is this step completed?

CAUTION: On the vehicle that the rear tires have smaller diameter, the rear wheel speed may be indicated a little higher than the front wheel speed. Check the speed after driving a while at a constant speed.

—

5A4-65 ABS/ASR Symptom: [The ABS Operates but Pulling to One Side.] (Check Flow A-2) Check flow A-2 Step 1 2

3

Action Is the speed sensor installation normal? Is the wheel speed sensor/sensor rotor damaged? Or iron powder attached? Are the wheel speed sensor outputs normal? no rmal? (Refer to the check flow C-1 or TC-1)

Value — —

5

— Assemble all the components, a nd check that those are installed p roperly. roperly. Is this step completed?

NO

Go to Step2

Repair.Go Repair. Go to Step5

Go to Step3

Repair or replace it.Go it.Go to Step5

Go to Step4

Replace the sensor or repair the circuit. Go to Step5

Replace the control unit.Go unit.Go to Step5

Correct the connection.Go nection.Go to Step5


Go to Step5

—

Is the brake pipe connection correct? 4

YES

—

ABS/ASR 5A4-66 Symptom: [The ABS Operates but Pulling to One Side.] (Check Flow TA-2) Check flow TA-2 Step

Action

Value

1

1. Conn Connec ectt the the Tech Tech 2. 2. Check Check each each wheel wheel spee speed d sensor sensor output. output.

—

2

3

YES

NO

Is each sensor output normal?

Go to Step2

Go to Step3

Check the brake pipe.

Replace the EHCU.Go EHCU.Go to Step4

Repair the pipe.Go pipe.Go to Step4

Go to Step4

Go to Step3


Go to Step4

Is the pipe normal? Repair and check the wheel speed sensor. (Refer to the check flow C-1 or TC-1.)

—

—



CAUTION: On the vehicle that the rear tires have smaller diameter, the rear wheel speed may be indicated a little higher than the front wheel speed. Check the speed after driving a while at a constant speed.

—

5A4-67 ABS/ASR Symptom: [Wheels are Locked During Brake Operation.] (Check Flow A-3, TA-3) Check flow A-3, TA-3 Step

Action

Value

YES

NO

1

Does the ABS operate?

—

Go to Step2

Go to Step4

2

Is the vehicle speed 10km/h (6 mph) or less?

—

Go to Step3

Normal

Go to Step4

Replace the sensor or repair the circuit. Go to Step5

Replace the EHCU.Go EHCU.Go to Step5



Go to Step5

3

Are the wheel speed sensor outputs normal? no rmal? (Refer to the check flow C-1 or TC-1)

—

Is the EHCU grounded properly? 4

5

— Assemble all the components, a nd check that those are installed p roperly. roperly. Is this step completed?

—

ABS/ASR 5A4-68 Symptom: [Feeling of Brake Pedal is Faulty.] (Check Flow A-4) Check flow A-4 Step

Action

Value

YES

NO

1

Does the stop lamp come on when depressing the brake pedal?

—

Go to Step2

Go to Step3

Go to Step4

Repair the circuit between the stop lamp switch and the control unit.Go unit. Go to Step7

Go to Step5

Replace the fuse.Go fuse.Go to Step7

Go to Step6

Repair the body ground circuit.Go circuit.Go to Step7

—

Repair the stop lamp circuit.Go circuit.Go to Step7

Replace the stop lamp switch.Go switch.Go to Step7

—

Brake fluid line is leaked or air mixed. (Refer to Section 5A.)Go 5A.)Go to Step7

Repair the circuit.Go cuit.Go to Step7


Go to Step7

1. Turn Turn the sta start rter er swi switc tch h OFF. OFF. 2. Discon Disconnec nectt the conne connector ctor of the the EHCU. EHCU. 2

3. Measure Measure the volt voltage age betwee between n the the J-177 J-177 connector terminal 16 and the J-177 connector terminal 1,23 with the brake pedal depressed.

—

Is the power supply voltage supplied to it? 3

4

Is the stop lamp fuse F-5 normal? Check for continuity between the J-177 connector terminal 1,23 and the body ground. Is there continuity?

—

—

Is the stop lamp switch normal? 5

6

7

Check the suspicious circuit/connector for improper connection. Is there improper connection?

Assemble all the components, a nd check that those are assembled properly. Is this step completed?

—

5A4-69 ABS/ASR Symptom: [Brake Operating Noise Comes from the Hydraulic Unit Though t he Brake Pedal is not Depressed.] (Check Flow A-5, TA-5) Check flow A-5, TA-5 Step

Action

Value

YES

NO

—

Normal (It is a motor check operation noise of selfdiagnosis function.)

Go to Step2

Normal (It is a motor check operation noise of selfdiagnosis function.)

Go to Step3

Normal (ABS may operate without depressing the brake pedal.)

Go to Step4

Go to Step5

Repair.Go Repair.Go to Step7

Go to Step7

Repair or replace it.Go it.Go to Step6

Check the suspicious circuit/connector for improper connection. If the connection is normal, replace the EHCU.Go EHCU.Go to Step7



Go to Step7

Is this the first time operation since the engine is started? 1

Is the vehicle speed 10km/h (6 mph) or less? 2

—

1. Check Check for for noise noise in in the follow following ing condiconditions: • When When shifti shifting ng down down,, or when when operat operat-ing the clutch • When When driving driving a slippe slippery ry low-t low-temp empera era-ture road (iced or snow-covered), or when driving a rough road 3

• While While turnin turning g with with high high speed speed

—

• When When drivi driving ng over over a bump bump (suc (such h as curbstone) • When When opera operating ting electr electrica icall switch switches es • When When runnin running g the the engin engine e high high speed speed Is noise generated in any of the above conditions? 4

Do all the speed sensor/sensor rotor operate normally?

—

5

Is the wheel speed sensor/sensor rotor damaged? Or iron powder attached?

—

Are all the sensor outputs normal? (Refer to the check flow C-1 or TC-1)

6

7

—


—

ABS/ASR 5A4-70

Electronic Hydraulic Control Unit (EHCU) Components

N5A2039E

Legend 1. Pipe 2. EHCU 3. Connector

4. Bracket 5. Cover

Removal

• Do not not pour pour water water to the the EHCU EHCU direct directly. ly.

CAUTION: • When performi performing ng electri electric-arc c-arc welding welding on the vehivehicle, remove the EHCU before starting welding work. • When remov removing ing the the EHCU EHCU from from the vehi vehicle cle,, disconnect the battery cable first, and then disconnect the connector. Connect in the reverse order of disconnection.

• Never Never loosen loosen the the screw screw of the EHCU EHCU body. body. Nor Nor apply paint to the EHCU body.

• Do not plac place e intense intense radio radio emis emissio sion n equipme equipment nt such as radio device near the EHCU.

• Do not not let metal products products directly directly contact contact with with the connector pin terminals, including screwdriver and or tester probe. • Use spec special ial care for elec electro trosta static tic.. • Do not not directly directly apply external external voltage voltage to the the termiterminals.

5A4-71 ABS/ASR • When hand handling ling,, do not not hold hold the pipe pipe of of the upper upper EHCU. 1

• Never Never loosen loosen the the bolts bolts and nuts nuts of the EHCU EHCU body. body. If loosened, that EHCU must not be used anymore. 1. Cover • Remo Remove ve the the cov cover er.. 2. Harn Harnes ess s conn connec ecto tor r 2

• If the harne harness ss is fixe fixed d to the the EHCU EHCU bracket bracket,, loosen the fixing clip.

3

1 4 N5A2041E

2

Legend 1. Lever lo lock

3

2. Lever 3. Lock Lock port portio ion n (A porti portion) on) 4. Housing • Oper Operat ate e the the leve lever. r.

4 N5A2040E

Legend 1. Lever 2. Lever lo lock

Notice: Operate the lever till the lever becomes heavy. Then change the force direction to the downward of the connector. (See illustration.) Applying force to the EHCUside may damage the connector.

3. Clip 4. Fixe Fixed d to to EHC EHCU U bra brack cket et..

1

• Unlock Unlock the the connect connector. or. Pull Pull down down the lever lever lock lock to the unlock position.

2

Notice: Make sure the lock portion (A portion) is in the unlock position.

3 N5A2042E

Legend 1. Lever 2. Lever Lever opera operatio tion n (rotati (rotation on direc direction tion)) 3. Force Force applied applied direc directio tion n when oper operati ating ng lever lever

ABS/ASR 5A4-72 • Move Move the conne connecto ctorr to the oppos opposite ite side side of the the EHCU to remove. Notice: With the lever in stop position, make sure that the lever surface (lock portion side) is almost perpendicular to the connector before removing the connector.

1. Bracket • Instal Installl the brack bracket et to the the frame frame if it has has been reremoved. 2. EHCU • Instal Installl the the EHCU EHCU to the the brac bracket ket.. 3. EHCU EHCU fixin ixing g nut nut • Instal Installl the the EHCU EHCU fixi fixing ng nuts nuts..

1 3

Tighten: Nut to 22 N ⋅m (2.2 kg⋅m / 16.2 lb ⋅ft)

2

4. Brake pi pipe • Inst Instal alll the the brak brake e pipe pipe.. Tighten: Brake pipe to 16 N ⋅m (1.6 kg⋅m / 11.8 lb ⋅ft) 5. Harn Harnes ess s conn connec ecto tor r

3

• Align Align the harne harnessss-sid side e connect connector or with with the EHCU-side connector. EHCU

Harness

N5A2043E

1

Legend

2

1. Lever 2. Connector 3. Lever lo lock

3

3. Brake pi pipe

5

• Disconn Disconnect ect the six brake brake pipes. pipes. 4. EHC EHCU fix fixin ing g nut nut • Disconn Disconnect ect the the three three nuts nuts fixing fixing the the EHCU. EHCU. 5. EHCU

4

• Remo Remove ve the the EHCU EHCU.. 6. Bracket

N5A2044E

• Remo Remove ve the the bra brack cket et..

Installation CAUTION: • Be sure sure to use use ground ground bolt bolt to inst install all the the ground ground.. • Make Make sure ther there e is no dust dust or foreig foreign n materia materials ls in and around the pipe connection. • Be careful careful that that the pipe pipe is connec connectt to correc correctly tly.. • After After EHCU inst install allati ation, on, bleed bleed air air from the the brake brake system completely. Remove the fuse (FL-9 (40A)) of ABS to deactivate the ABS before air bleeding operation. • Be sure sure to use use fresh fresh specif specified ied brak brake e fluid. fluid.

Legend 1. EHCU EHCU-s -sid ide e conne connect ctor or 2. 3. 4. 5.

Lever Housing Harness Lever lo lock • Insert the harness-side harness-side connector connector to to the the EHCUEHCUside connector.

Notice: The lever moves approx. 30° when the connector is inserted.

5A4-73 ABS/ASR

1

2 1 3

30

EHCU

Harness 4 2

N5A2045E

Legend 1. Push Pushin ing g dir direc ecti tion on

N5A2040E

Legend 1. Lever

2. Harne Harness ss-si -side de conn connec ecto tor r

2. Lever lo lock 3. Clip

• Operate Operate the the lever lever to lock lock the the lever lever lock lock to to the housing.

4. Fixe Fixed d to to EHC EHCU U bra brack cket et..

6. Cover • Inst Instal alll the the cove cover. r.

1

N5A2046E

Legend 1. Lever • If the harne harness ss was was fixed fixed to the the EHCU EHCU bracket bracket,, fix the harness with the fixing clip.

N5A2047E

Legend 1. Master Master cylind cylinder er (front (front wheel) wheel) 2. Master Master cylind cylinder er (rear (rear wheel) wheel) 3. RR whee wheell mast master er cyl cylin inder der 4. RL whee wheell mast master er cyl cylin inde der r 5. FR whee wheell mas maste terr cyl cylin inder der 6. FL wheel wheel mas master ter cyli cylind nder er

ABS/ASR 5A4-74

Speed Sensor (Front) Components

N5A2048E

Legend 1. Speed Speed sensor sensor (mode (modell with with rigid rigid suspens suspension ion)) 2. Hub cap 3. Split pin 4. Hub nut 5. Thru Thrust st washe asher r

Removal 1. Harn Harnes ess s conn connec ecto tor r • Disconn Disconnect ect the harn harness ess conn connecto ector. r. 2. Harn Harnes ess s fixi fixing ng bol boltt • Remove Remove the harness harness fixing fixing bolt. bolt. 3. Sens Sensor or fixi fixing ng bolt bolt • Remove Remove the sensor sensor fixing fixing bolt bolt.. 4. Spee Speed d sens sensor or (fr (fron ont) t)

6. Oute Outerr bear bearin ing g 7. Hub Hub & rot rotor or asse assemb mbly ly 8. Inne Innerr bea beari ring ng 9. Sens ensor rot roto or 10. Disc Disc calip caliper er asse assembl mbly y

Installation CAUTION: • Do not let let the spee speed d sensor sensor body body contac contactt with with the sensor rotor during hub assembly. Otherwise the parts will be damaged. • The speed speed sens sensor or body body has has a built-i built-in n magnet. magnet. Be careful not to allow metallic materials attached to it.

5A4-75 ABS/ASR • Remove Remove the spee speed d sensor sensor before before removi removing ng the the hub & rotor assembly or the hub & drum assembly.

• Instal Installl the the harne harness ss fixi fixing ng bolt bolt.. Frame side

• Remove Remove the speed speed sens sensor or before before hamme hammerin ring g to remove the knuckle etc.

Tighten: Bolt to 22 N ⋅m (2.2 kg⋅m / 16.2 lb⋅ft)

• Use the the harness harness line as as a referen reference ce to avoi avoid d the harness from twisting, when installing the sensor harness.

Tighten together with the dust cover (model with dram brake)

• To install install the sensor, sensor, press-fit press-fit the the sensor sensor until until the sensor flange contacts closely with the installing surface by your hand, and then tighten with the bolt.

Tighten: Bolt to 15 N ⋅m (1.5 kg⋅m / 11.1 lb⋅ft) Tighten together with the brake support (model with rigid disc brake) Tighten: Bolt to 45 N ⋅m (4.6 kg⋅m / 33.2 lb⋅ft)

1. Spee Speed d sens sensor or (fr (fron ont) t) • Inst Instal alll the the spee speed d sens sensor or.. 2. Sens Sensor or fixi fixing ng bolt bolt

4. Harn Harnes ess s conn connec ecto tor r • Connec Connectt the the harne harness ss conne connecto ctor. r.

• Instal Installl the the senso sensorr fixin fixing g bolt. bolt. Tighten: Bolt to 22 N⋅m (2.2 kg⋅m / 16.2 lb ⋅ft)

Inspection This section explores inspection procedures as the reference to perform “Diagnostics with symptom” and “Diagnosis with illumination pattern”.

3. Harn Harnes ess s fixi fixing ng bol boltt

Without Tech 2 Speed sensor output check

With Tech 2

Check flow C-1-1 — C-1-4

Check flow TC-1

FL Wheel Speed Sensor Output Check Procedure Check flow C-1-1 Step

1

Action 1. Turn Turn the sta start rter er swi switc tch h OFF. OFF. 2. Discon Disconnec nectt the the EHCU EHCU connec connector tor.. 3. Jack-u Jack-up p the vehi vehicle cle to to lift lift the front front wheel wheels s off the floor. 4. Measure Measure the the AC voltag voltage e betwee between n the J177 connector terminals 32 and 33 while turning the FL wheel half turn/sec.

Value

YES

NO

Go to Step5

Go to Step2

Go to Step4

Go to Step3

Go to Step5

—

Go to Step5

—

200mV or more

Is the value within specified value? 1. Discon Disconnec nectt the FL sensor sensor connec connector tor JJ75. 2

2. Measure Measure the the resis resistanc tance e betwee between n the J-75 J-75 connector terminals 1 and 2 (sensor side).

1 — 2kΩ

Is the value within specified value? Replace the FL sensor. 3

4

Is this step completed? Repair the circuit for open/short circuit, and the connector for improper connection between the connector of EHCU and the sensor connector. Is this step completed?

—

—

ABS/ASR 5A4-76 Step

5

Action

Value

1. Instal Installl all the the compon components ents,, and check check that that those are installed properly. 2. Clea Clearr the the DTC DTC.

YES

NO


Go to Step5

YES

NO

Go to Step5

Go to Step2

Go to Step4

Go to Step3

Go to Step5

—

Go to Step5

—


Go to Step5

YES

NO

Go to Step2

Go to Step6

Replace the speed sensor.Go sensor.Go to Step3

Repair.Go Repair.Go to Step3

—


FR Wheel Speed Sensor Output Check Procedure Check flow C-1-2 Step

Action

Value

1. Turn Turn the sta start rter er swi switc tch h OFF. OFF. 2. Discon Disconnec nectt the the EHCU EHCU connec connector tor..

1

3. Jack-u Jack-up p the vehi vehicle cle to to lift lift the front front wheel wheels s off the floor. 4. Measure Measure the AC volt voltage age betwee between n the the J177 connector terminals 10 and 11 while turning the FR wheel half turn/sec.

200mV or more

Is the value within specified value?

2

1. Discon Disconnec nectt the FR FR sensor sensor conn connect ector or J74. 2. Measure Measure the the resis resistanc tance e betwee between n the J-74 J-74 connector terminals 1 and 2 (sensor side).

1 — 2kΩ

Is the value within specified value? 3

Replace the FR sensor.

—


4

Repair the circuit for open/short circuit, and the connector for improper connection between the connector of EHCU and the sensor connector.

—


5

1. Instal Installl all the the compon components ents,, and check check that that those are installed properly. 2. Clea Clearr the the DTC DTC.

—


Speed Sensor Output Check Procedure (With Tech 2) Check flow TC-1 Step

1

Action 1. Conn Connec ectt the the Tech Tech 2. 2. Check Check each each sens sensor or lowes lowestt speed speed from the “Wheel sensor”.

Value

—

Is the sensor speed 4km/h (2mph) or more?

2

Check the suspicious sensor circuit for open circuit. (Check with shaking the wire and the connector.) Is the sensor circuit connection normal?

—

5A4-77 ABS/ASR Step

Action

Value

3

Check each sensor lowest speed from the “Wheel sensor”.

—

Is the sensor speed 4km/h (2mph) or more?

YES

NO

Go to Step4

Go to Step6

Go to Step5

Replace the sensor rotor.Go rotor.Go to Step5

Repair the circuit or circuit between the EHCU and the speed sensor. Go to Step6

Go to Step6


Go to Step6

Check the sensor rotor. 4

Is the sensor rotor normal?

—

Check each sensor lowest speed from the “Wheel sensor”. 5

6

Is the sensor speed 4km/h (2mph) or more? Install all the components, and check that those are installed p roperly. roperly. Is this step completed?

Used for checking the front speed sensor, or the rear speed sensor when no DTC is set. CAUTION: On the vehicle that the rear tires have smaller diameter, the rear wheel speed may be indicated a little higher than the front wheel speed. Check the speed after driving a while at a constant speed.

—

—

ABS/ASR 5A4-78

Sensor Rotor (Front Wheel) Components

N5A2048E

Legend 1. Speed Speed sensor sensor (mode (modell with with rigid rigid suspens suspension ion)) 2. Hub cap 3. Split pin 4. Hub nut 5. Thru Thrust st washe asher r

Removal CAUTION: • Hold Hold the brake brake hose hose and the the calipe caliperr assembl assembly y with with wire or the like to prevent them from dropping, to stand clear from the service work. Do not bend the hose sharply or stretch it to the limit. Remove the brake hose if necessary. If to be removed, be careful to prevent the brake fluid from

6. Oute Outerr bear bearin ing g 7. Hub Hub & rot rotor or asse assemb mbly ly 8. Inne Innerr bea beari ring ng 9. Sens ensor rot roto or 10. Disc Disc calip caliper er asse assembl mbly y flowing out and protect it from intrusion of foreign materials. 1. Remove Remove the the disc brake brake cali caliper per.. (Model (Model with disc disc brake)

5A4-79 ABS/ASR 11. Oute Outerr bear bearin ing g inner inner race race 12. Senso Sensorr rotor rotor (fro (front nt whe wheel el)) • Use a puller puller to to take take out the sens sensor or rotor rotor..

N5A2049E

2. Guard Guard (NPR (NPR wit with h disc disc bra brake ke)) • Remo Remove ve the the gua guard rd.. 3. Spee Speed d sen senso sorr (NP (NPS) S)

N5A2051E

• Remove Remove the the head head section section of of the speed speed senso sensor r from the knuckle. 4. Hub cap cap (NPR (NPR)) • Remo Remove ve the the hub hub cap. cap. 5. Free Free wheel wheel hub asse assembl mbly y (NPS) (NPS) • Remove Remove the free wheel wheel hub hub assem assembly. bly. 6. Spli Splitt pi pin (NP (NPR R)

Installation 1. Senso Sensorr roto rotorr (fro (front nt whe wheel el)) • PressPress-fit fit the the new new sensor sensor roto rotorr with with a bench bench press around the circumference until it contacts. 2. Hub Hub & rot rotor or asse assemb mbly ly • Fill Fill the outer outer beari bearing ng with with grease grease (Besco (Besco L-2), L-2), and install it to the hub.

• Remo Remove ve the the spl split it pin. pin. 7. Lock Lock wash washer er (NPS (NPS)) • Remove Remove the the lock lock washer washer and and the fixi fixing ng screw screw.. 8. Hub nut

CAUTION: Use new oil seal.

• Remo Remove ve the the hub hub nut. nut. 9. Trus Trustt was washe herr (NP (NPR) R) • Remo Remove ve the the thr thrus ustt wash washer er.. 10. 10. Hub Hub & roto rotorr asse assemb mbly ly

N5A2052E

3. Oute Outerr bear bearin ing g inn inner er race race 4. Trus Trustt was washe herr (NP (NPR) R) N5A2050E

• Inst Install all the the thr thrust ust wash washer er.. 5. Hub nut • Inst Install all the the hub nut. nut.

ABS/ASR 5A4-80 CAUTION: After installing the thrust washer and the hub nut, adjust the hub bearing preload.

N5A2054E

8. Hub cap

N5A2053E

• Fill Fill the hub hub cap cap with with grease grease (Besc (Besco o L-2), L-2), and drive it in to the hub.

Hub bearing preload adjustment • Tighten the hub hub nut till the hub no longer longer be turned, turned, and then loosen it completely. • Turn the hub hub to make make the beari bearing ng seate seated. d. • Attach Attach a spring spring bala balance nce to to the wheel wheel pin. pin. While While pulling the it tangentially, tighten the hub nut so that the hub rotates with the specified value. • For hub hub bearing bearing prelo preload, ad, refer refer to “FRO “FRONT NT AXLE” AXLE” in Section 4C. 6. Spli Splitt pi pin (NP (NPR R) • After preload adjustment, adjustment, install the split split pin. If the pin hole does not match the groove on the nut, adjust them by turning minimum to the tightening direction. 7. Lock Lock wash washer er (NPS (NPS)) • Instal Installl the pawl pawl to the the cutout cutout of the the spind spindle le securely, and tighten with the screw. Tighten: Lock washer to 10 N ⋅m (1.0 kg⋅m / 7.4 lb ⋅ft)

9. Free Free whee wheell hub hub assem assembl bly y (NPS) (NPS) • Instal Installl the the free free wheel wheel hub assembl assembly. y. CAUTION: Be sure to adjust the drive shaft axial play. 10. 10. Spee Speed d sens sensor or (NP (NPS) S) • Instal Installl the head head sectio section n of the speed speed senso sensorr to the knuckle and tighten the bolt to the specified torque. Tighten: Speed sensor to 22 N ⋅m (2.2 kg⋅m / 16.2 lb ⋅ft) 11. Guard Guard (NPR (NPR wit with h disc disc brak brake) e) • Inst Instal alll the the guar guard. d. Tighten: Guard to 37 N ⋅m (3.7 kg⋅m / 27.3 lb⋅ft) 12. Disc Disc brake brake caliper caliper assemb assembly ly (Model (Model with with disc disc brake) • Instal Installl the disc disc brake brake calip caliper er assemb assembly. ly. Tighten: Disc brake calper to 220 N ⋅m (22.5 kg⋅m / 162.3 lb ⋅ft)

5A4-81 ABS/ASR

N5A2055E

ABS/ASR 5A4-82

Sensor Harness (Rear Axle) Components

N5A2056E

Legend 1. Harn Harnes ess s conn connec ecto tor r 2. Harnes Harness s brack bracket et fixi fixing ng bolt bolt

Removal 1. Harn Harnes ess s conn connec ecto tor r • Disconn Disconnect ect the harn harness ess conn connecto ector. r. 2. Harnes Harness s brack bracket et fixi fixing ng bolt bolt • Remove Remove the the harnes harness s bracket bracket fixing fixing bolt. bolt. 3. Sens Sensor or har harne ness ss • Remo Remove ve the the sens sensor or harn harnes ess. s.

3. Sens Sensor or harn harnes ess s

Installation CAUTION: Take care not to twist the harness during installation. 1. Sens Sensor or harn harnes ess s • Instal Installl the the sensor sensor harnes harness. s. 2. Harne Harness ss bra bracke ckett fixi fixing ng bolt bolt • Instal Installl the harne harness ss bracke brackett fixing fixing bolt. bolt.

5A4-83 ABS/ASR Tighten: • Flange Flange bolt bolt (excep (exceptt below below)) to 22 22 N⋅m (2.2 kg⋅m / 16.2 lb⋅ft) • SEMS bolt bolt (2 point points s on the axle axle case case upper upper face) face) to 13 N⋅m (1.3 kg⋅m / 9.6 lb ⋅ft) 3. Harn Harnes ess s conn connec ecto tor r • Connec Connectt the the harness harness connec connector. tor.

ABS/ASR 5A4-84

Rear Speed Sensor Components

N5A2057E

Legend 1. Axle Axle shaf shaft, t, out outer er oil oil sea seall 2. Bearing Bearing lock lock wash washer, er, lock nut 3. Outer Outer bear bearing ing,, beari bearing ng lock lock nut 4. Hub and drum

6. 7. 8. 9.

Inne Innerr bea beari ring ng Inne Innerr oil oil seal seal Rear Rear spee speed d sen senso sor r Harn Harnes ess s conn connec ecto tor r

5. Sensor ro rotor

Removal 1. Rear Rear axle axle shaft, shaft, outer outer oil oil seal, seal, lock lock washer washer • Remove Remove the the axle shaft shaft inst install alling ing nut, nut, and reremove the rear axle shaft. Special tool: Universal Universal puller: 5-8840-2027-0 5-8840-2027-0 Slid Slide e ham hammer mer:: 5-884 5-88400-008 0084-0 4-0

N5A2058E

5A4-85 ABS/ASR • Remo Remove ve the the out outer er oil oil seal seal..

N5A2061E N5A2059E

• Remove Remove the the lock lock washe washerr install installing ing bolt bolt..

3. Hub Hub and and drum drum ass assem embl bly y • Remove Remove the hub and drum assemb assembly. ly.

N5A2062E

N5A2060E

2. Bearing Bearing lock lock nut, nut, outer outer bearing bearing,, hub hub • Remo Remove ve the the bear bearin ing g nut. nut. Special tool: Wrench: 9-8522-1188-0 • Remo Remove ve the the out outer er bea bearin ring. g.

4. Inne Innerr oil oil seal seal • Remo Remove ve the the inn inner er oil oil sea seal. l. 5. Inne Innerr bea beari ring ng • Remo Remove ve the the inn inner er bea beari ring. ng. 6. Harn Harnes ess s conn connec ecto tor r • Discon Disconnec nectt the connec connectio tion n of the harne harness ss conconnector.

ABS/ASR 5A4-86 4. Inne Innerr oil oil seal seal • Inst Instal alll the the inner inner oil oil seal seal.. 5. Hub Hub and and drum drum ass assem embl bly y • Instal Installl the the hub and drum drum asse assembly mbly.. 6. Outer Outer beari bearing, ng, hub, hub, bearin bearing g lock lock nut nut • Instal Installl the outer outer bearin bearing, g, hub, hub, and bearin bearing g lock nut.

N5A2063E

7. Rear Rear spee speed d sen senso sor r • Remove Remove the the speed speed sensor sensor instal installin ling g bolt, bolt, and take out from the sensor bracket.

N5A2065E

Rear hub bearing preload adjustment • Rotate Rotate the the hub to the the left and and right right severa severall times times to make it seated. • Tighte Tighten n the beari bearing ng lock lock nut till till the hub hub no longlonger be turned. Then, back off to a degree that the hub rotates easily. Special tool: Wrench: 9-8522-1180-0

N5A2064E

Installation CAUTION: • Grommet Grommet in in the back back plate plate must must be instal installed led sesecurely. • Bearing lock nut nut must must be installe installed d with with its slit surface facing outside. 1. Rear Rear spee speed d sen senso sor r • Tighten Tighten the speed speed sens sensor or insta installi lling ng bolt. bolt. Tighten: Bolt to 22 N⋅m (2.2 kg⋅m / 16.2 lb ⋅ft) 2. Harn Harnes ess s conn connec ecto tor r • Connec Connectt the the harness harness connec connector. tor. 3. Inne Innerr bea bearing ring • Inst Instal alll the the inner inner bear bearing ing..

N5A2066E

• Attach Attach a sprin spring g balance balance to to the wheel wheel pin. pin. Whil While e pulling it tangentially, tighten the bearing nut so that the spring balance reading shows the specified value when the hub starts rotation.

5A4-87 ABS/ASR Tighten: Starting to 42 — 52 N (4.3 — 5.3 kg / 9.4 — 11.7 lb)

• Inst Install all the the axl axle e sha shaft ft.. Install to the rear hub stud part through the special washer with the flange nut. Tighten: Flarge nut to 49 N ⋅m (5.0 kg⋅m / 36.1 lb ⋅ft)

N5A2067E

• After After adjusti adjusting ng the start starting ing torqu torque, e, move move the hub to the right and left side several times to make sure the value is correct. • With With the prelo preload ad adjust adjusted, ed, match match the the lock cutcutout center point of the axle case screw part with nearest ruling of the bearing lock nut. If it does not, rotate the nut in the tightening direction to match.

N5A2068E

7. Lock washer, washer, outer outer oil oil seal, seal, axle axle shaft shaft • Instal Installl the pawl pawl of the the lock lock washer washer to the the lock lock cutout of the axle case screw part securely, and tighten the bearing nut and the lock washer with the lock bolt. • Apply Apply grease grease to the the circum circumfere ference nce of the the outer outer oil seal inner lip, and install the outer oil seal.

N5A2069E

ABS/ASR 5A4-88 Inspection RL Wheel Speed Sensor Output Check Procedure Check flow C-1-3 Step

Action

Value

YES

NO

Go to Step5

Go to Step2

Go to Step3

Go to Step4

Go to Step5

—

Go to Step5

—


Go to Step5

1. Turn Turn the sta start rter er swi switc tch h OFF. OFF. 2. Discon Disconnec nectt the conne connector ctor of the the EHCU. EHCU.

1

3. Jack-u Jack-up p the vehi vehicle cle to to lift lift the front front wheel wheels s off the floor. 4. Conn Connec ectt a 120 120 Ω resistance between the J-177 connector terminal 34 and the ground. 5. Apply Apply a 9 — 16V 16V voltag voltage e to the J-177 J-177 connector terminal 22. 6. Measure Measure the DC DC volta voltage ge betwe between en the the B177 connector terminal 34 and the ground while turning the RL wheel half turn/sec.

0.2 — 4.5V


2

1. Turn Turn the sta start rter er swi switc tch h OFF. OFF. 2. Discon Disconnec nectt the RL wheel wheel speed speed sensor sensor connector J-149. 3. Conn Connec ectt a 120 120 Ω resistance between the J-149 connector terminal 2 and the ground. 4. Apply Apply a 9 — 16V 16V voltag voltage e to the J-149 J-149 connector terminal 1 (sensor side). 5. Measure Measure the DC DC volta voltage ge betwe between en the the J149 connector terminal 2 and the ground while turning the RL wheel half turn/sec.

0.2 — 4.5V


3


—


5

Replace the RL wheel speed sensor. Is this step completed? 1. Instal Installl all the the compon components ents,, and check check that that those are installed properly. 2. Clea Clearr the the DTC DTC. Is this step completed?

—

—

5A4-89 ABS/ASR

N5A2070E

Legend 1. Batt Batter ery y (12V (12V)) 2. Tester 3. Resi esistance 4. Spe Speed se sensor sor

ABS/ASR 5A4-90 RR Wheel Speed Sensor Output Check Procedure Check flow C-1-4 Step

1

Action 1. Turn Turn the sta start rter er swi switc tch h OFF. OFF. 2. Discon Disconnec nectt the conne connector ctor of the the EHCU. EHCU. 3. Jack-u Jack-up p the vehi vehicle cle to to lift lift the front front wheel wheels s off the floor. 4. Conn Connec ectt a 120 120 Ω resistance between the J-177 connector terminal 12 and the ground. 5. Apply Apply a 9 — 16V 16V voltag voltage e to the J-177 J-177 connector terminal 21. 6. Measure Measure the DC DC volta voltage ge betwe between en the the J177 connector terminal 1 and the ground while turning the RR wheel half turn/sec.

Value

YES

NO

Go to Step5

Go to Step2

Go to Step3

Go to Step4

Go to Step5

—

Go to Step5

—


Go to Step5

0.2 — 4.5V

Is the value within specified value? 1. Turn Turn the sta start rter er swi switc tch h OFF. OFF.

2

2. Discon Disconnect nect the RR RR wheel wheel speed speed sensor sensor connector J-148. 3. Conn Connec ectt a 120 120 Ω resistance between the J-148 connector terminal 2 and the ground. 4. Apply Apply a 9 — 16V 16V voltag voltage e to the J-148 J-148 connector terminal 1 (sensor side). 5. Measure Measure the DC DC volta voltage ge betwe between en the the J148 connector terminal 2 and the ground while turning the RR wheel half turn/sec.

0.2 — 4.5V


3


—


5

Replace the RR wheel speed sensor. Is this step completed? 1. Instal Installl all the the compon components ents,, and check check that that those are installed properly. 2. Clea Clearr the the DTC DTC. Is this step completed?

—

—

5A4-91 ABS/ASR

N5A2070E

Legend 1. Batt Batter ery y (12V (12V)) 2. Tester 3. Resi esistance 4. Spe Speed se sensor sor

ABS/ASR 5A4-92 Speed Sensor Output Check Procedure Check flow TC-1 Step

1

Action 1. Conn Connec ectt the the Tech Tech 2. 2. Check Check each each sensor sensor lowes lowestt speed speed from the “Wheel sensor”.

Value

2

—

Is the sensor circuit connection normal? 3

Check each sensor lowest speed from the “Wheel sensor”.

NO

Go to Step2

Go to Step6

Replace the speed sensor.Go sensor.Go to Step3


Go to Step4

Go to Step6

Go to Step5

Replace the sensor rotor. Go to Step5

Repair the circuit or connector between the EHCU and the speed sensor. Go to Step6

Go to Step6


Go to Step6

—

Is the sensor speed 4km/h (2 mph) or more? Check the suspicious sensor circuit for open circuit. (Check with shaking the wire and the connector.)

YES

—

Is the sensor speed 4km/h (2 mph) or more? Check the sensor rotor. 4

Is the sensor rotor normal?

—

Check each sensor lowest speed from the “Wheel sensor”. 5

6

Is the sensor speed 4km/h (2 mph) or more?

Install all the components, and check that those are installed p roperly. roperly. Is this step completed?

Used for checking the front speed sensor, or the rear speed sensor when no DTC is set. CAUTION: On the vehicle that the rear tires have smaller diameter, the rear wheel speed may be indicated a little higher than the front wheel speed. Check the speed after driving a while at a constant speed.

—

—

5A4-93 ABS/ASR

Rear Sensor Rotor Components

N5A2057E

Legend 1. Axle Axle shaf shaft, t, out outer er oil oil sea seall 2. Bearing Bearing lock lock wash washer, er, lock nut 3. Outer Outer bear bearing ing,, beari bearing ng lock lock nut 4. Hub and drum

6. 7. 8. 9.

Inne Innerr bea beari ring ng Inne Innerr oil oil seal seal Rear Rear spee speed d sen senso sor r Harn Harnes ess s conn connec ecto tor r

5. Sensor ro rotor

Removal • Refer Refer to the the rear rear speed speed senso sensorr removal removal proce proce-dure. 1. Rear Rear sens sensor or roto rotor r • Use a puller puller to to take take out the the senso sensorr rotor. rotor. 2. Inne Innerr oil oil seal seal • Remo Remove ve the the inn inner er oil oil sea seal. l. 3. Inne Innerr bea bearing ring • Remo Remove ve the the inn inner er bear bearin ing. g. • Roto Rotorr runo runout ut must must be ±0.1 mm (0.004 in) or less with the rotor installed.

N5A2071E

ABS/ASR 5A4-94 Installation 1. Install Install the the inne innerr bearin bearing g to the the hub. hub. 2. Install Install the the inne innerr oil oil seal seal to the hub. hub. 3. Instal Installl the new rear rear sens sensor or rotor rotor to to the hub. hub. • Press-f Press-fit it with with a bench bench press press around around the the circumcircumference until it contacts. • Refer Refer to the the rear speed speed sens sensor or instal installat lation ion proprocedure step. 5 — 7.

N5A2072E

Sec5a4 Abs Asr

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