BRAKE SYSTEM SECTION BR
Contents
1. 16 BRAKE 17 Removal and Installation 17 17 Metal aO um 18 VACUUM HOSE vUa ER pF SIRE 19 Removal and Installation 19 WIS DC CUOM TM PEE 21 VACUUM PUMP TD27Ti engine model 23 Removal and Installation 23 uu uuu uuu TEE tres 23 VACUUM PUMP ZD30DDTi engine 25 Removal and Installation FRONT DISC BRAKE Pad Replacement mis IOV al NNNM NISC CHO QUERER NT Assembly M CO uuu u T Je ciclo REAR DRUM BRAKE Shoe Replacement luere e ISl PARKING BRAKE CONTROL Removal and Installation p MNT u uu uuu u e ANTI LOCK BRAKE SYSTEM2. ELECTRIC UNIT CONNECTOR BR 69 TROUBLE DIAGNOSES Diagnostic Procedure 2 Warning lamp stays on when ignition switch is turned ON Cont d Replace fuse Does the fuse blow out when ignition switch is turned ON ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR CHECK ABS ACTUATOR AND ELEC Check the following TRIC UNIT POWER SUPPLY CIRCUIT e Harness connector FOR SHORT 1 Disconnect battery cable and ABS e Harness for open or short actuator and electric unit connector between ABS actuator F29 and electric unit and fuse Check continuity between ABS actuator If NG repair harness or and electric unit connector body connector side terminal 45 and ground Continuity should not exist REPLACE ABS actuator and electric unit CHECK ABS WARNING LAMP CON Check the following Y DISCONNECT 5 T S 54 TROL CIRCUIT e Harness connectors ABS ACTUATOR AND 1 Disconnect combination meter connector LHD and F119 or 21 13 F29 14838 Check continuity between ABS actuator Harness for open or and electric unit connector body short between ABS side terminal and combination meter actuator and electric unit connector LHD and 119 or and combination meter RHD and 1838 If NG repair harness or connectors Terminal Combination LHD Terminal meter connector RHD CHECK COMBINATION METER RHD Check combination meter Refer to WARN ING LAMPS in EL s
3. 37 PUMO m 37 per illu u a u uuu nuna m 37 ABS Hydraulic CIRCUIT u u 37 System Description 38 Removal and Installation 42 TROUBLE DIAGNOSES 47 How to Perform Trouble Diagnoses for Quick and Accurate Repalrl 47 Component Parts and Harness Connector Kolectie TR 48 Circuit Diagram for Quick Pinpoint Check 49 Wiring Diagram ABS 50 CONSULT 58 CONSULT II Inspection Procedure 59 Preliminary Check 65 Ground Circuit Check 66 Diagnostic Procedure 1 Not self diagnostic item 67 CONTENTS conto Diagnostic Procedure 2 Warning lamp stays on when ignition switch is turned ON 69 Diagnostic Procedure 3 ABS actuator solenoid valve and solenoid valve relay 71 Diagnostic Procedure 4 Wheel sensor or rotor 73 Diagnostic Procedure 5 Motor Relay or motor 75 Diagnostic Procedure 7 Low voltage 77 Diagnostic Procedure 8 G 78 Diagnostic Procedure 9 Control
4. NG Check the following NG Check the following NG Replace fuse Inspection end NG Replace sensor e Harness connectors 889 LHD GB RHD B67 LHD F66 RHD RHD F136 LHD i787 RHD RHD 1829 205 LHD F RHD and e Harness for open or short between G sensor and ABS actuator and electric unit If NG repair harness or connectors e Harness connectors 889 GH LHD 8 RHD B67 29 LHD and RHD e Harness for open or short between G sensor and ABS actuator and electric unit If NG repair harness or connectors TROUBLE DIAGNOSES Diagnostic Procedure 9 Control unit Malfunctioning code No 71 CHECK CONNECTOR Inspection end 1 Disconnect ABS actuator and electric unit connector ABS control unit Check terminals for damage or loose connections Then reconnect connector Carry out self diagnosis again Does warning lamp activate again CHECK ABS ACTUATOR AND ELEC TRIC UNIT POWER SUPPLY CIRCUIT Check voltage Refer to in Diagnostic Procedure 7 CHECK SELF DIAGNOSTIC RESULTS Does warning lamp indicate code No 71 again Replace ABS actuator and electric unit INSPECTION Inspect the system according to the code No BR 79 TROUBLE DIAGNOSES Diagnostic Procedure 10 Pedal vibration and Brake pedal noise INSPECTION START Yes Carry out self diagnosis 1 Apply brake 2 Start engine
5. Adjust tire pressure or replace tire s 1 Replace sensor rotor CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector ABS actuator and electric unit harness connector Then retest Note Wheel position should be distinguished by code num bers except code No 18 sensor rotor BR 74 TROUBLE DIAGNOSES Diagnostic Procedure 5 Motor Relay or motor Fuse Malfunction code No 61 ABS actuator and electric unit CHECK FUSIBLE LINK Check 40 For fusible link layout refer to POWER SUPPLY ROUTING in EL section Go to next page solenoid valve 1 Disconnect ABS actuator and electric unit connector Check terminals for dam age or loose connection Then recon nect connector Carry out self diagnosis again Does warning lamp activate again CHECK MOTOR RELAY POWER SUP Check the following PLY CIRCUIT e Harness connector 29 1 Disconnect ABS actuator and electric LHD and 1784 or unit connector RHD and Check voltage between ABS actuator Harness for open or and electric unit connector body short between ABS side terminal and ground actuator and electric unit Battery voltage should exist and fusible link If NG repair harness or connector CHECK ABS ACTUATOR AND ELECTRIC NG Repair harness and termi UNIT GROUND nals Refer to ABS
6. NBR269 BR 14 BRAKE PEDAL AND BRACKET Inspection Check brake pedal for following items e Brake pedal bend e pin deformation e Crack of any welded portion e Crack or deformation of clevis pin stopper O 16 22 Adjustment 1 6 2 2 kg m 12 16 ft lb Check brake pedal free height from dash reinforcement panel H Free height Refer to SDS BR 85 Input rod D Full stroke Stop witch ee Refer to SDS 5 C Clearance between pedal stopper and threaded end of stop lamp switch 0 3 1 0 mm 0 012 0 039 in A Pedal free play 1 0 3 0 mm 0 039 0 118 in 4 A 4 f 9 Floor carpet H Floor carpet Dash insulator lt Dash 2 Ac insulator 7777222722 Floor panel Melt sheet EBR200 If necessary adjust brake pedal free height 1 Loosen lock nut and adjust pedal free height by turning brake booster input rod Then tighten lock nut Make sure that tip of input rod stays inside of clevis as shown 2 Loosen lock nut and adjust clearance C with stop lamp switch Then tighten lock nuts 3 Check pedal free play Make sure that stop lamps go off when pedal is released 4 Check brake system for leaks accumulation of air or any dam age to components master cylinder etc then make neces sary repairs 2 mm 0 08 in BR 15 MASTER CYLINDER Reservoir Reservoir tank 07 21 28 Nem 2 1 3 0
7. BR 59 TROUBLE DIAGNOSES CONSULT II Inspection Procedure Cont SELF DIAGNOSTIC RESULTS MODE bears tem T OPEN An abnormally high input voltage is entered OPEN An abnormally high input voltage is entered RR RH SENSOR e Circuit for rear right sensor is open OPEN An abnormally high input voltage is entered HR LH SENSOR e Circuit for rear left sensor is open OPEN An abnormally high input voltage is entered FR RH SENSOR e Circuit for front right wheel sensor is shorted SHORT An abnormally low input voltage is entered FR LH SENSOR e Circuit for front left wheel sensor is shorted SHORT An abnormally low input voltage is entered I SHORT An abnormally low input voltage is entered SHORT An abnormally low input voltage is entered ABS SENSOR e Teeth damage on sensor rotor or misalignment of wheel sensor ABNORMAL SIGNAL Abnormal wheel sensor signal is entered FR RH IN ABS SOL e Circuit for front right inlet solenoid valve is open or shorted OPEN SHORT An abnormally low output voltage is entered FR LH IN ABS SOL e Circuit for front left inlet solenoid valve is open or shorted OPEN SHORT An abnormally low output voltage is entered FR RH OUT ABS SOL e Circuit for front right outlet solenoid valve is open or shorted OPEN SHORT An abnormally low output voltage is entered FR LH OUT ABS SOL e Circuit for front left outlet solenoid valve is open or shorted OPEN SHORT An
8. secondary N Removal i 3 4 Disconnect battery cable Drain brake fluid Refer to 5 Unlock the slider then disconnect the electrical harness con nectors from ABS control unit Identify each brake pipe with corresponding actuator port hole and mark them accordingly Disconnect brake pipes and move them away from actuator Do not force brake pipes so as to kink them or bend them exces sively Ensure that brake fluid does not come into contact with any parts BR 45 ANTI LOCK BRAKE SYSTEM Removal and Installation Cont d 6 Loosen remove mounting nuts between actuator and bracket Installation CAUTION After installation pay attention to the following points e Refill brake fluid and bleed air Refer to CHECK AND ADJUSTMENT and Bleeding Brake System BRAKE HYDRAULIC LINE BR 8 respectively 1 Install actuator on bracket without tightening fixings 2 Assemble brake tubes to actuator without tightening tube nuts Ensure that correct tubes are connected to each port 3 Fully tighten actuator and bracket fixings to ified torque 4 Fully tighten flare nuts to specified torque 5 Secure ABS control unit harness connector and battery cable BR 46 TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair INTRODUCTION The ABS system has an electronic control unit to control major functions The control unit accepts input signals from sensors and use
9. 15 18 N m 1 5 1 8 kg m 11 13 ft Ib Bleed air Refer to Bleeding Brake System BRAKE HYDRAULIC LINE 8 Adjust load sensing valve LSV Refer to Inspection and Adjustment LOAD SENSING VALVE BR 11 LOAD SENSING VALVE Inspection and Adjustment CAUTION 21 Check level in brake fluid reservoir Refill with recommended brake fluid DOT 4 Never reuse drained brake fluid Be careful not to splash brake fluid on painted areas it may cause paint damage If brake fluid is splashed on painted areas wash it away with water immediately DO NOT RUB IT OFF Before adjusting load sensing valve spring length check for proper installation and abnormal wear of brake pads and shoes 2 Remove the air bleeder from the wheel caliper and install a pressure gauge A to the bleed valve hole 3 Bleed the air from the front brake piping 4 Remove the air bleed valve from the rear wheel cylinder and install a pressure gauge B to the bleed valve hole BR 12 LOAD SENSING VALVE Inspection and Adjustment Cont d 5 Bleed the air from the rear brake piping 6 To adjust the LSV correctly proceed as follows a With unladen vehicle 12 liters of fuel radiator coolant and Reference engine oil are full Spare tire hand tools and mats in desig holes nated positions Check the length of LSV spring L b If the spring length is different from that specified move the regulation
10. ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check BR 66 ABS actuator and electric unit connector DISCONNECT ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR REPLACE Replace ABS actuator and electric unit BR 75 TROUBLE DIAGNOSES Diagnostic Procedure 5 Motor Relay or motor Cont d hoe DISCONNECT 5 ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR REPLACE Replace fusible link Does the fusible link blow out when ignition switch is turned ON Inspection end CHECK ABS ACTUATOR MOTOR Check the following POWER SUPPLY CIRCUIT e Harness connector 29 1 Disconnect battery cable and ABS LHD and 1784 or actuator and electric unit connector RHD and E29 Harness for open or Check continuity between ABS actuator short between ABS and electric unit connector body actuator and electric unit side terminal 12 and ground and fusible link Continuity should not exist If NG repair harness or connector CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector ABS actuator and electric unit harness connector Then retest BR 76 TROUBLE DIAGNOSES Malfunction code No 57 CHECK CONNECTOR 1 Disconnect ABS actuator and electric unit connector Check terminals for damage or loose connections Then reconnect connector Carry out self diagnosis aga
11. actuator and electric unit AEQ G sensor connectors 1 51 Usa DISCONNECT SS DISCONNECT Ee ds 4h 899 10 20 ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR YBR278 Diagnostic Procedure 8 sensor Malfunction code No 17 CHECK G SENSOR POWER SUPPLY CIRCUIT Check 10A fuse 19 For fuse layout refer to POWER SUPPLY ROUTING in EL section CHECK CONNECTOR 1 Disconnect ABS actuator and electric unit connector Check terminals for damage or loose connection Then reconnect connector Carry out self diagnosis again Does warning lamp activate again CHECK G SENSOR Refer to G SENSOR in Electrical Compo nents Inspection CHECK G SENSOR POWER SUPPLY CIRCUIT 1 Disconnect G sensor connectors 2 Check voltage between G sensor con nector terminals 859 3 B60 and ground Battery voltage should exist CHECK G SENSOR GROUND 1 Disconnect ABS actuator and electric unit connector and G sensor connec tors Check continuity between ABS actuator and electric unit connector body side terminals 2 G and G sensor connectors body side terminals 2 8595 4 B60 Continuity should exist CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector Reconnect ABS actuator and electric unit harness connector Then retest BR 78 NO
12. bear ing replacer Front sensor rotor Drive shaft Installation Install the sensor rotor For front sensor rotor use hammer and wooden block For rear sensor rotor use suitable drift and press e Always replace sensor rotor with new one BR 43 ANTI LOCK BRAKE SYSTEM Removal and Installation Cont d REAR SENSOR ROTOR Removal e Remove the sensor rotor using Tool 0 HT72480000 M i EN ANA t p n Du gt Installation Install the sensor rotor using suitable drift and press e Always replace sensor rotor with new one e Pay attention to the direction of front sensor rotor as shown in figure lt CONTROL UNIT ABS control unit harness connector Location Built in ABS actuator When disconnecting the harness connector pull the lever as shown in figure SENSOR Rear heater Always replace G sensor if bumped or dropped Otherwise performance characteristics of G sensor will be changed u which in turn alters ABS control performance characteristics G sensor connectors BR 44 ANTI LOCK BRAKE SYSTEM Removal and Installation Cont d ACTUATOR ABS control unit harness connector ko 12 0 9 1 2 80 106 Nem kg m in Ib kg m ft Ib From master cylinder ZZ To front wheel cylinder ABS actuator To front wheel cylinder ZA To rear wheel cylinder From master cylinder
13. harness or REPLACE Replace ABS actuator and electric unit Repair harness and con nector connector BR 71 TROUBLE DIAGNOSES Diagnostic Procedure 3 ABS actuator solenoid valve and solenoid valve relay Cont d REPLACE Replace fusible link Does the fusible link blow out when ignition switch is turned ON Inspection end ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR CHECK SOLENOID VALVE RELAY Check the following POWER SUPPLY CIRCUIT e Harness connector 1 Disconnect battery cable and ABS E29 LHD and actuator and electric unit connector 1784 or RHD and 2 Check continuity between ABS actuator and electric unit connector body e Harness for open or short side terminal ig and ground between ABS actuator Continuity should not exist and electric unit and fus ible link If NG repair harness or connector REPLACE ABS actuator and electric unit REPLACE Check the following Replace fuse e Harness connector F29 Does the fuse blow out when ignition 1822 LHD and switch is turned ON 1787 or RHD F76 and e Harness for open or short between ABS actuator and electric unit and fuse If NG repair harness or connector END Inspection end BR 72 TROUBLE DIAGNOSES Front RH FrontLH RearRH Rear LH Diagnostic Procedure 4 Wheel sensor or rotor Malfunction code No 21 22 25 26 31 32 35 36 or 18 1 Disconnect connect
14. kg m 15 22 ft Ib Cylinder body Protector bushing Removal Direction of rotation CAUTION for REMOVAL Be careful not to splash brake fluid on painted areas it may cause paint damage If brake fluid is splashed on painted areas wash it away with water immediately DO NOT RUB 1 Connect a vinyl tube to air bleeder valve 2 Drain brake fluid from each air bleeder valve depressing brake pedal to empty fluid from master cylinder A 3 Remove brake pipe flare nuts for INSTALLATION 4 Remove master cylinder mounting nuts 5 Remove protector of master cylinder and avoid scratching the surface of master cylinder during removal CAUTION Do not disassemble master cylinder NOTE If it is necessary to change the brake fluid reservoir remove it as shown in the illustration on the left while holding the seals with one hand It is not necessary to replace the seals if they are in a good condition Installation CAUTION e Refill with new brake fluid DOT 4 e Never reuse drained brake fluid 1 Place master cylinder onto brake booster and secure mounting nuts lightly Fit flare nuts to master cylinder Tighten mounting nuts 2 21 29 2 1 3 0 kg m 15 22 ft Ib Tighten flare nuts 15 18 1 5 1 8 kg m 11 13 ft Ib Bleed air Refer to Bleeding Brake System BRAKE HYDRAULIC LINE 8 SI BR 16 BRAKE BOOSTER Removal and Installation 0 17 2
15. lever 2 until the specified value is obtained Move the LSV lever 1 until it contacts the stopper bolt and recheck the spring length Sensor spring length L Hardtop 201 mm 7 913 in Wagon 197 5 mm 7 776 in NOTE Do not disturb stopper bolt Start the engine and run it at idling speed Slowly depress the brake pedal until an input pressure of 4 805 kPa 48 1 bar 49 kg cm 697 psi is obtained at the front axle pressure gauge and an output pressure of 1 736 2 501 kPa 18 26 bar 17 7 25 5 kg cm 252 363 psi is obtained at the rear axle pressure gauge If the output pressure at the rear axle pressure gauge is not within the specified values adjust LSV spring length as described under b until the output pressure measured is within the specified range Unit kPa bar kg cm psi 4 805 48 1 49 0 697 1 736 2 501 18 26 17 7 25 5 252 363 Front axle Rear axle Load conditions as indicated under 6 a driver seat occupied BR 13 BRAKE PEDAL AND BRACKET Removal and Installation LHD gt 0 13 16 1 3 1 6 10 12 Snap ring KAS 7 I X Stop lamp switch 12 15 1 2 1 5 9 11 D 13 16 1 3 1 6 10 12 Clevis SS Pedal bracket 5 13 16 1 3 1 6 10 12 7 Snap ring van A 7 Stop lamp switch x 12 15 1 2 1 5 9 11 L Sess Clevis pin kg m ft Ib
16. 2 0 housing Center plate 9 Do not re use N m kg m ft Ib N m kg m in Ib NBR131 e Drain oil from vacuum pump before removal Manually rotate fan belt clockwise to discharge any oil which may have accumulated in vacuum pump Pump e Install vane so that its round surface faces pump housing mousing e After installing vacuum pump assembly apply 5 m4 0 2 Imp 1 OZ of engine oil into vacuum pump assembly Then make sure that pulley can be smoothly rotated by hand Inspection Clean all parts and check them as follows e Check for wear or scratches on mating surfaces of rotor and vacuum pump housing and on rotor and center plate If wear or scratches are noted replace those parts e Check for wear or scratches on vanes If necessary replace Unit mm in Vane height BR 23 VACUUM PUMP TD27Ti engine model Inspection Cont d e Check inner wall of vacuum pump housing for wear If necessary replace e Check rotor shaft for wear necessary replace e Check valve locations and copper washers for bends or defor mation If necessary replace Inner diameter B mm in 69 5 69 8 2 736 2 748 e Check that valve operates smoothly when slightly pushed Replace if necessary Checking valve operation e Check for air leakage with 98 to 490 kPa 1 0 to 4 9 bar 1 to 5 kg cm 14 to 71 psi of air pressure if necessary Checking air leakage of valve BR 24 VA
17. 3 1 7 2 3 12 17 MM y gt gt 55 Clevis pin pe 20 25 2 1 2 5 15 18 Brake booster O ft lb 21 28 2 1 2 9 15 21 Inspection OPERATING CHECK e Depress brake pedal several times with engine off and check that there is no change in pedal stroke e Depress brake pedal then start engine If pedal goes down slightly operation is normal AIRTIGHT CHECK e Start engine and stop it after one or two minutes Depress brake pedal several times slowly If pedal goes further down the first time and gradually rises after second or third time booster is airtight e Depress brake pedal while engine is running and stop engine with pedal depressed If there is no change in pedal stroke after holding pedal down 30 seconds brake booster is airtight OUTPUT ROD LENGTH CHECK 1 Apply vacuum of 66 7 kPa 667 mbar 500 mmHg 19 69 inHg to brake booster with a manual vacuum pump and check output rod length A Specified length A 22 15 22 45 mm 0 872 0 884 in The length A in this case is the distance from end of output rod to outside of brake booster when the specified vacuum is applied BR 17 BRAKE BOOSTER Inspection Cont d 2 Check output rod length L when brake booster doesn t work Specified length L 129 2 130 2 mm 5 09 5 13 in Installation CAUTION p w
18. 6 GY PRE CEDING lt e IGN MOTOR ACTR MOTOR RELAY RELAY MON ACT ACT Ell M787 eq 8 S To BR ABS 02 FUSE REFER TO EL POWER ED BLOCK J B ic SOLENOID VALVE RELAY ABS ACTUATOR ACTUATOR AND ELECTRIC UN CONTROL UNIT F29 FL IN OUT OUT SOL SOL SOL SOL SOL SOL SOL SOL REFER TO THE FOLLOWING 822 FUSE BLOCK JUNCTION BOX J B YBR246 BR 51 TROUBLE DIAGNOSES Wiring Diagram ABS Cont d BR ABS 03 TD27Ti ENGINE ABS MODELS EID ZDSODDTI ENGINE GROUND GROUND CONTROL UNIT FR FL F29 1 2 FR FL SENSOR SENSOR I coc Er 2 2 ED FRONT WHEEL SENSOR RH E15 FRONT WHEEL SENSOR LH SZ JE REFER TO THE FOLLOWING I up SUPER MULTIPLE GY GY BR B JUNCTION SMJ NO YBR247 BR 52 TROUBLE DIAGNOSES Wiring Diagram ABS Cont d BR ABS 04 TD27Ti ENGINE ABS MODELS ZDSODDTI ENGINE RR GROUND RL GROUND CONTROL UNIT SENSOR RR HL F29 1 L O H O w d L L R G R REAR WHEEL SENSOR RH REAR WHEEL SENSOR LH YBR248 BR 53 TROUBLE DIAGNOSES Wiring Diagram ABS Cont d RHD MODELS IGNITION SWITCH BR ABS 05 FUSE TD27Ti ENGINE MODELS BLOCK REFER TO J B ZD30DDTi ENGINE MODELS M835 109 gt gt NEXT Y COMBINA
19. ABS actuator and electric unit harness connector Reconnect ABS actuator and electric unit harness connector Then retest REPLACE Replace ABS actuator and electric unit BR 68 TROUBLE DIAGNOSES Diagnostic Procedure 2 Warning lamp stays on when ignition switch is turned ON CHECK FUSE Check 10A fuse 19 For fuse layout refer Go to next page to POWER SUPPLY ROUTING in EL sec tion CHECK WARNING LAMP Go to next page 1 Disconnect ABS actuator and electric unit connector 2 Connect suitable wire between ABS actuator and electric unit harness con nector terminals 3 0 and ground Warning lamp should not activate CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector Reconnect ABS actuator and electric unit harness connector Then retest 5G CHECK ABS MOTOR GROUND Check the following Turn ignition switch OFF e Harness connector Disconnect ABS actuator and electric e Harness for open or short unit connector between ABS actuator Check continuity between ABS actuator and electric unit and and electric unit connector body ground side terminal and ground If NG repair harness or Continuity should exist connector REPLACE ABS actuator and electric unit ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR 13 21 5
20. BRAKE SYSTEM SECTION CONTENTS PRECAUTIONS AND 3 Supplement Restraint System SRS AIR and SEAT BELT 5 3 5 sr RENE 3 PO ara PNEU 4 CHECK AND ADJUSTMENT 5 Checking Brake Fluid Level 5 Checking Brake Line 5 Changing Brake Fluid 5 Brake Burnishing Procedure b BRAKE HYDRAULIC 6 Bleeding Brake System 8 L ROT TT 9 NTSC COIN NNNM 9 uuu uuu u ul l u uu EE M ee 9 LOAD SENSING VALVE 10 Removal and Installation 10 mister IT 11 DEus uuu u u RM M MEER ETE 11 Inspection and Adjustment 12 BRAKE PEDAL AND 14 Removal and Installation 14 APECU N uuu u ua 15 PGI ES 15 MASTER 16 u u n 16 uuu
21. CUUM PUMP ZD30DDTi engine model Removal and Installation Refer to EM section VACUUM PUMP Removal and Installa tion BR 25 FRONT DISC BRAKE Bleed valve 7 9 0 7 0 9 61 78 Brake hose e o Bleed valve cover Cylinder body Piston seals e3 amp 31 38 3 2 3 9 23 o 2 no ES Pin boot dt Nem kg m in Ib Torque member fixing bolts D 98 118 10 12 78 87 kg m ft Ib Rubber grease point Slide pin B Brake fluid point Torque member PRECAUTION Clean all brake assembly parts with a vacuum dust collector to prevent particles from spreading through work area Pad Replacement 1 Loosen brake fluid reservoir cap 2 Remove lower pin bolt BR 26 FRONT DISC BRAKE Pad Replacement Cont d 3 Swing cylinder body upward Then remove pad and anti noise shims CAUTION e When cylinder body is swung up do not depress brake pedal because piston will pop out e Ensure that brake fluid does not come into contact with dustcover and rotor e Becareful not to twist brake hoses Brake pad thickness new 10 mm 0 39 in Wear limit min thickness 2 mm 0 08 in e After installing new brake pads check brake fluid level at brake fluid reservoir Removal Remove torque member fixing bolts and union bolt SBRO12C Disassembly Push out piston with dust cover with compressed air Use a wooden block so th
22. DE SELECT TEST ITEM FR RH SOL FR LH SOL RR SOL ABS MOTOR FR RH SOL SELECT MONITOR ITEM MAIN SIGNALS SELECTION FROM MENU TROUBLE DIAGNOSES CONSULT II Inspection Procedure ACTIVE TEST PROCEDURE e When conducting Active test vehicle must be stationary e When ABS warning lamp stays on never conduct Active test 1 Turn ignition switch to the LOCK position 2 Connect CONSULT II to Data Link Connector 3 Start engine 1 Touch START CONSULT II screen 2 Touch ABS 3 Touch ACTIVE TEST 1 Select active test item by touching screen 2 Touch START Carry out the active test by touching screen key BR 63 TROUBLE DIAGNOSES CONSULT II Inspection Procedure Cont ACTIVE TEST MODE TEST ITEM CONDITION JUDGEMENT Brake fluid pressure control operation FR RH SOLENOID IN SOL OUT SOL Ald UP Increase OFF OFF KEEP Hold ON OFF DOWN Decrease ON ON Engine is running ABS actuator motor ABS MOTOR ON Motor runs ABS motor relay ON OFF Motor stops ABS motor relay OFF Check G switch circuit OFF G switch OFF ON G switch ON Note Active test will automatically stop ten seconds after the test starts LIMIT SIGNAL monitor shows ON Ignition switch is ON or G SWITCH Ma engine is running BR 64 TROUBLE DIAGNOSES Preliminary Check Max line Check brake fluid level in reservoir tank Min line
23. Flare nut m Flare nut D 15 18 1 5 1 8 11 13 15 18 1 5 1 8 11 13 f m 9 Three way connector Mounting bolt 5 7 0 5 0 7 43 61 Flare nut C x 15 18 1 5 1 8 11 13 Front Load sensing valve LSV m Mounting bolt 17 21 1 7 2 1 12 15 m Flare nut Brake booster 15 18 1 5 1 8 11 13 Master cylinder Flare nut D 15 18 1 5 1 8 11 13 oa O Primary line s Secondary line O kg m ft Ib Nem kg m in Ib YBR256 BR 6 BRAKE HYDRAULIC LINE WITH ABS Three way connector Mounting bolt Ero brska 8 11 0 8 1 1 69 95 Flare nut 2 Flare nut 0 15 18 1 5 1 8 11 13 15 18 1 5 1 8 11 13 Hear brake emm Brake booster Master cylinder ABS actuator and electric unit with Electronic Brake Distribution EBD Flare nut 0 15 18 1 5 1 8 11 13 Primary line Note without load sensing valve m Secondary line CAUTION O Nem kg m ft Ib When Brake and ABS warning lights come on simultaneously with an audible sound drive at low speed and brake smoothly to prevent rear wheel locking Nem kg m in Ib YBR257 BR 7 BRAKE HYDRAULIC LINE QU ELA eh Bleeding Brake System CAUTION Carefully monitor brake fluid level at master cylinder dur ing bleedi
24. Hefer to 1 3 Does the symptom appear only when engine is started CHECK IF SYMPTOM APPEARS No Go to 8 in Diagnostic Does the symptom appear when electrical Procedure 12 equipment switches such as headlamp are operated Yes CHECK WHEEL SENSOR NG Repair wheel sensor Check wheel sensor shield ground For location of shield ground refer to wiring diagram and HARNESS LAYOUT in EL section CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector Heconnect ABS actuator and electric unit harness connector Then retest Note ABS may operate and cause vibration under any of the following conditions Diagnostic Procedure 11 Long stopping distance CHECK ABS PERFORMANCE Go to z in D Disconnect ABS actuator and electric unit Procedure 12 connector and check whether stopping distance is still long ls Perform Preliminary Check and air bleed ing Note Stopping distance may be larger than vehicles without ABS when road condition is slippery BR 80 TROUBLE DIAGNOSES Diagnostic Procedure 12 Unexpected pedal action CHECK BRAKE PEDAL STROKE Perform Preliminar Check brake pedal stroke Is stroke exces Check refer to BRAA sively large CHECK BRAKE PERFORMANCE Perform Preliminary Check Disconnect ABS actuator and electric unit refer to BR 65 c
25. LECT SYSTEM 1 Select SELECT MONITOR ITEM Carry out the monitor test under the condition as described in page 62 SELECT DIAG MODE SELECT MONITOR ITEM ALL SIGNALS SELECTION FROM MENU BR 61 TROUBLE DIAGNOSES CONSULT II Inspection Procedure Cont DATA MONITOR MODE MONITOR ITEM CONDITION SPECIFICATION FR RH SENSOR FR LH SENSOR Drive vehicle Wheel speed signal REAR RH SENSOR Each wheel is rotating Almost the same speed as speedometer REAR LH SENSOR Depress the pedal ON STOP LAMP SW Brake is depressed Release die pedak OFF When driving or stopping vehicle with a force of less than 0 3G ON When driving or stopping vehicle with a force of 0 3G or more OFF Vehicle is driven G SWITCH Vehicle is stopped Brake is applied FR RH IN SOL FR RH OUT SOL FR LH IN SOL Drive vehicle at speeds over Operating conditions for each solenoid valve are indicated FR LH OUT SOL 30 km h 19 MPH for at ABS is not operating OFF RR IN SOL least one minute RR OUT SOL Engine is running ABS is not operating OFF eee ABS is operating ON ACTUATOR RELAY switch e ON position Engine stops OFF Ignition switch is set to the WARNING LAMP ON position or engine is run Warning lamp 5 turned on ON ning Warning lamp is turned off OFF BATTERY VOLT Power supply voltage for control unit BR 62 CONSULT II AED99A START SUB MODE SELECT SYSTEM AIR BAG SELECT DIAG MO
26. Low fluid level may indicate brake pad wear or leakage from brake line Check brake booster for operation and air tightness Refer to BR 14 NG Check brake pads rotor and drums NG Check brake fluid level in reservoir tank NG Fill up brake fluid OK Check warning lamp s or warning sound activation When ignition switch is turned on warning lamp s turn s on Check fuse warning lamp bulb and warning lamp cir cuit OK Check warning lamp s for deactivation NG Goto Self diagnosis after engine is started BR 59 OK Drive vehicle at speeds over 30 km h 19 MPH for at least one minute Ensure warning lamp s remain s off NG Go to Self diagnosis while driving BR 59 OK END BR 65 TROUBLE DIAGNOSES Ground Circuit Check W DISCONNECT ABS CONTROL UNIT GROUND AEGRO ORAE e Check resistance between ABS actuator and electric unit con ELECTRIC UNIT CONNECTOR nector terminals and ground Resistance approximately 00 16 19 F29 BR 66 TROUBLE DIAGNOSES Diagnostic Procedure 1 Not self diagnostic item Warning lamp does not come on when ignition switch is turned ON CHECK FUSE NG Replace fuse Check 10A fuse 12 For fuse layout refer to POWER SUPPLY ROUTING EL sec tion Yes CHECK ABS and BRAKE WARNING 8 to next page LAMP S ACTIVATE Disconnect ABS actuator and electric unit connector Does the
27. TION METER GY i837 1838 B67 STOP DEPRESSED ewrrcy mm s mn mn ABS ACTUATOR AND ELECTRIC UNIT NI CONTROL UNIT 9 o ch 43 42 2 6 DATA LINK 9 M832 REFER TO THE FOLLOWING 9000 8 76 15 14 13 t2 11 10 9 71510617 2 M743 M829 ee 1811515141312 JUNCTION BOX J B 1 2131415 6 7 8 9 10 14 44 5272 4 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 yE 3 17 GY W AI 15 YBR249 BR 54 TROUBLE DIAGNOSES Wiring Diagram ABS Cont d BR ABS 06 TD27Ti ENGINE MODELS IGNITION SWITCH ON OR START REFER TO ZD30DDTi ENGINE MODELS FUSE EL POWER FE 8 5 BR Y GY lt TD gt 11 D m m 8 d E 76 lt TD gt F79 Y BR Y 2 PRE CEDING lt PAGE I GY BR Y SOLENOID VALVE RELAY ABS ACTUATOR ACTUATOR AND ELECTRIC IGN MOTOR ACTR MOTOR FL FL FR FR R RL RR RELAY RELAY MON IN OUT OUT OUT OUT CONTROL ACT ACT SOL SOL SOL SOL SOL SOL SOL 501 REFER TO THE FOLLOWING a M822 FUSE BLOCK 4 2 3 4 5 744 11213145 ez GID 6 7 8 9110 Gv GY 5 61 7 8 cv JUNCTION BOX J B YBR250 BR 55 TROUBLE DIAGNOSES Wiring Diag
28. WHEEL SENSOR ona Y SIDE Check resistance for each sensor Resistance Front 0 9 1 1 kO Rear 1 44 1 76 G SENSOR Vehicle front Resistance between ter gt Condition minas 9 Continuity x 4 Installed in vehicle Approx 1 5 Yes F Tilted as shown in figure Approx 5 1 KQ No BR 83 SERVICE DATA AND SPECIFICATIONS SDS General Specifications Wagon LWB Hard Top SWB Wagon LWB Hard Top SWB Front brake LD28VA Brake model Cylinder bore diameter 43 1 69 mm in Pad mm in 144 85 x 48 5 x 15 5 length x width x thickness 5 70 x 1 90 x 0 61 Rotor outer mm in 27 7 x 26 1 diameter x thickness 10 91 x 1 02 Drum brake LT28 Brake model 23 8 0 94 22 0 0 87 20 6 0 81 mm Lining mm in ua 111 x 55x 8 95 4 37 x 2 17 x 0 35 Trailing 114 x 55 x 3 95 4 49 x 2 17 x 0 16 Drum inner mm in Diameter 280 11 02 Master cylinder mm in Cylinder bore diameter 25 4 1 0 Control valve Valve model Load Sensing Valve 2 1 Split point kPa bar kg cm psi x Variable x 093 Variable x 0 15 reducing ratio Brake booster Booster model Lucas LSC 115 8 9 Diaphragm diameter Primary 203 2 8 mm in Secondary 228 6 9 Specified brake fluid DOT 4 BR 84 SERVICE DATA AND SPECIFICATIONS SDS Inspection and Adjustment DISC BRAKE BRAKE PEDAL Unit mm in Unit mm in Brake model LD28VA HHD LHD Pad we
29. abnormally low output voltage is entered 4 4 4 4 4 4 4 4 4 3 3 3 3 RR IN ABS SOL e Circuit for rear right outlet solenoid valve is open or shorted OPEN SHORT An abnormally high output voltage is entered OPEN SHORT An abnormally high output voltage is entered e Actuator solenoid valve relay is ON even if control unit sends OFF signal e Actuator solenoid valve relay is OFF even if control unit sends ON signal ABS ACTUATOR RELAY ABNORMAL e Circuit for ABS motor relay is open or shorted 2 EE e Circuit for actuator motor is open or shorted e Actuator motor relay is stuck EM et e Power source voltage supplied to ABS control unit is abnormally low 7 CONTROL UNIT e Function of calculation in ABS control unit has failed e G sensor is open If a tire slips on rough roads for more than 10 seconds the ABS warning lamp may come on In this case the malfunctioning code regarding the wheel sensors may be memorized Turn off the ignition switch restart the engine and drive the vehicle at speeds above 30 km h 19 MPH BR 60 TROUBLE DIAGNOSES CONSULT II Inspection Procedure DATA MONITOR PROCEDURE 1 Turn ignition switch to the OFF position 2 Connect CONSULT II to Data Link Connector 3 Turn ignition switch to the ON position CONSULT II AED99A START SUB MODE 1 Touch START on CONSULT II screen 2 Touch ABS 3 Touch DATA MONITOR SE
30. ar limit Free pedal height H 196 206 210 220 7 7 8 1 8 3 8 7 Minimum thickness 2 0 0 079 137 7 148 7 142 5 152 5 Rotor repair limit Full stroke D 5 42 5 85 5 61 6 0 Minimum thickness 24 0 0 94 Clearance between pedal stopper and threaded end of 0 3 1 0 0 012 0 039 stop lamp switch C DRUM BRAKE Pedal free play at clevis A 1 0 039 0 118 Unit mm in Lining wear limit Minimum thickness 1 52 0 06 PARKING BRAKE Control type Drum repair limit Center lever Item Maximum inner diameter 280 5 11 04 Number of notches 9 10 under force of 196 N 20 kg 44 Ib Number of notches 1 when warning switch comes on BR 85 NOTES
31. at the 2 pistons come out evenly CAUTION e Wear protecting clothes and safety goggles e Do not hold your fingers in front of the pistons e Be careful not to scratch piston and or cylinder faces Inspection INSPECTION OF BRAKE DRAG FORCE Residual pair describes the friction pressure of the disc brake shoes against the disc when the brake pedal is not applied 1 Swing cylinder body upward 2 Make sure that wheel bearing is adjusted properly Refer to section FA Measure rotating force F4 BR 27 FRONT DISC BRAKE Inspection Cont d Install caliper with pads to the original position Depress brake pedal for 5 seconds Release brake pedal rotate disc rotor 10 revolutions Measure rotating force Calculate brake drag force by subtracting from Maximum brake drag force F5 F 103 0 N 10 5 kg 23 2 Ib Ol If it is not within specification check pins and pin boots in caliper e Make sure that wheel bearing is adjusted properly e Disc pads and disc rotor must be dry Pin cover DISC PAD Check disc pad for wear or damage Pad wear limit A 2 0 mm 0 079 in Assembly Fit new piston seals Lightly apply clean brake fluid DOT 4 to piston outer face 1 Insert piston seal into groove on cylinder body 2 Install piston into cylinder body 3 Install piston boot and secure properly Inspection CYLINDER BODY e Check inside surface of cylinder for score
32. e and optimal utilisation of the rear brakes under many different circumstances Operation ABS with EBD has self test capabilities The ABS warning lamp is illuminated for 1 second each time the ignition switch is turned ON After the engine is started the ABS warning lamp turns off An ABS self test is performed the first time the vehicle reaches 6 km h 4 MPH to ensure the system is operational A mechanical noise may be heard as the ABS performs this self test and is a normal part of the self test feature If a malfunction is detected during this check the ABS warning lamp will stay on During the self test it also performs a EBD check when it detects a failure the ABS warning light will go on simultaneously with the brake warning light and an audible sound will sound constantly EBD system will only operate when the ABS is not in active status and it uses the inlet valves of ABS con trol unit to limit the pressure to the rear wheels when they tend to go into slip When the vehicle speed is less than 10 km h 6 MPH the ABS system does not operate While driving a mechanical noise may be heard during ABS operation this is a normal system condition ABS Hydraulic Circuit I HE 2 T Front LH Front RH Rear LH T Rear RH wheel wheel wheel wheel Inlet solenoid valve Pump pass check valve Outlet solenoid valve 5 Motor 7 Damper Reservoir BR 37 ANTI LOCK BRAKE SYSTEM ABS war
33. e drum cannot be removed after carrying out this operation refer to Inspection PARKING BRAKE CONTROL Bolts M8 x 1 25 SBR093A BR 32 REAR DRUM BRAKE Shoe Replacement When installing new shoes springs should be changed as well Check lining thickness Standard lining thickness Trailing 3 95 mm 0 156 in Leading 8 95 mm 0 352 in Lining wear limit A 1 52 mm 0 05968 in Inspection WHEEL CYLINDER e Check wheel cylinder for leakage e Check for wear damage and loose conditions Replace if any such condition exists DRUM Maximum inner diameter 282 mm 11 10 in Out of roundness 0 05 mm 0 019 in or less e Contact surface should be fine finished with No 120 to 150 emery paper e f any scratches or wear are detected adjust the alignment of the drum e After brake drum has been completely reconditioned or replaced check drum and shoes for proper contact pattern Installation Always perform shoe clearance adjustment Refer to Adjustment PARKING BRAKE CONTROL 1 Fit adjuster assembly Left wheel cylinder BR 33 REAR DRUM BRAKE Installation Cont d 2 Apply brake grease to the contact areas shown at left Shorten adjuster by rotating it so that shoe outer diameter is 2 9 279 5 mm 10 98 11 in e Pay attention to direction of adjuster assembly DIRECTION OF FORWARD ROTATION DIRECTION OF FORWARD ROTATION Connect parking brake cable to toggle
34. ection Combination LHD meter connector BR 70 TROUBLE DIAGNOSES Diagnostic Procedure 3 ABS actuator solenoid valve and solenoid valve relay ABS actuator Malfunction code Nos 41 42 45 46 55 56 63 and electric unit CHECK FUSIBLE LINK Check 40A For fusible link layout refer to 9 Go to next page POWER SUPPLY ROUTING in EL section CHECK FUSE Check 10A fuse 19 For fuse layout refer to POWER SUPPLY ROUTING in EL sec tion Go to next page CHECK CONNECTOR ABS control unit 1 Disconnect ABS actuator and electric unit connector Check terminals for damage or loose connection Then reconnect connector Inspection end 27 28 abra i n INTs Carry out self diagnosis again Cee Hn 1 2 5 1213415 Does warning lamp activate again connector CHECK ABS ACTUATOR AND ELECTRIC DISCONNECT UNIT GROUND CIRCUIT Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit Check 66 ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR CHECK SOLENOID VALVE RELAY Check the following POWER SUPPLY CIRCUIT e Harness connector F29 1 Disconnect ABS actuator and electric LHD and 1784 unit connector RHD and Check voltage between ABS actuator Harness for open or and electric unit connector body short between ABS side terminal ig and ground actuator and electric unit Battery voltage should exist and fusible link If NG repair
35. gnal x gt x gt x gt x gt X X Applicable Not applicable ECU ABS control unit part number mode Ignore the ECU part number displayed in the ECU PART NUMBER MODE Refer to parts catalog to order the ECU TROUBLE DIAGNOSES Data link connector CONSULT II Inspection Procedure SELF DIAGNOSIS PROCEDURE 1 Turn ignition switch to OFF position 2 Connect CONSULT II to Data Link Con nector 1 Start engine 2 Drive vehicle over 30 km h 19 MPH for at least one minute CONSULT II 1 Stop vehicle with engine running and touch START on CON SULT II screen 2 Touch ABS 3 Touch SELF DIAG RESULTS e The screen shows the detected malfunc tion and how many times the ignition switch has been turned since the mal function AED99A SUB MODE SELECT SYSTEM AIR BAG Make the necessary repairs following the diagnostic procedures After the malfunctions are repaired erase the self diagnostic results stored in the control unit by touching ERASE SELECT DIAG MODE 22277 Test the ABS system in a safe area to MERE verify that it functions properly SELF DIAG RESULTS END DTC RESULTS FR RH SENSOR Check warning lamp s for deactivation after driving vehicle over 30 km h 19 MPH for at least one minute Note SELF DIAG RESULTS screen shows the detected malfunction and how many times the ignition switch has been turned since the mal function
36. id from each air bleeder valve by depressing brake pedal 3 Remove flare nut securing brake tube to hose then withdraw lock spring 4 Cover openings to prevent entrance of dirt whenever discon necting hydraulic line Inspection Check brake lines tubes and hoses for cracks deterioration or other damage Replace any damaged parts Installation CAUTION Refill with new brake fluid DOT 4 Never reuse drained brake fluid Tighten all flare nuts and connecting bolts Flare nut 9 9 11 0 9 1 1 kg m 78 95 in Ib Connecting bolt 17 20 N m 1 7 2 0 kg m 12 14 ft Ib 2 Refill until new brake fluid comes out of each air bleeder valve 3 Bleed air Refer to Bleeding Brake System BR 9 LOAD SENSING VALVE Removal and Installation 20 24 2 0 2 4 14 17 kg m Ib ft i9 N m kg m 16 NBR312 BR 10 LOAD SENSING VALVE Removal CAUTION Be careful not to splash brake fluid on painted areas it may cause paint damage If brake fluid is splashed on painted areas wash it away with water immediately DO NOT RUB IT OFF Remove flare nuts and LSV bolts Installation CAUTION Refill with new brake fluid DOT 4 Never reuse drained brake fluid Check level in brake fluid reservoir Tighten provisionally flare nuts Tighten LSV bolts 2 20 24 2 0 2 4 kg m 14 17 ft lb Tighten flare nuts
37. ignal from the deceleration sensor to compensate for road surface conditions when controlling the braking operation Rear heater Glass tube E NN H MIS AF e av y em duct lt Y lt e d ON ON ort Braking low p road surface Braking high road surface ON OFF BR 39 ANTI LOCK BRAKE SYSTEM System Description Cont d ACTUATOR AND ELECTRIC UNIT ABS actuator ABS control unit harness connector ko 9 12 0 9 1 2 80 106 Nem kg m in Ib kg m ft Ib From master cylinder 2 To front wheel cylinder To front wheel cylinder C From master cylinder secondary gt s S The actuator and electric unit contains e electric motor and pump e Iwo relays e Six solenoid valves each inlet and outlet for LH front RH front Rear e ABS control unit These components control the hydraulic circuit The ABS control unit directs the actuator to increase hold or decrease hydraulic pressure to all or individual wheels The ABS actuator and electric unit cannot be disassembled and has to be serviced as an assem bly BR 40 ANTI LOCK BRAKE SYSTEM System Description Cont d ABS actuator operation Inlet solenoid Outlet solenoid valve valve M li ke flui is directl Normal brake operation OFF Open OFF Closed aster Cy Inder ora e uid pressure is directly trans mitted to caliper via the i
38. in Does warning lamp activate again CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT eee 1 Disconnect ABS actuator and electric UATOR AND i unit connector ELECTRIC UNIT CONN 2 Check voltage between ABS actuator and electric unit connector termi nal 9 and ground Battery voltage should exist when ignition switch is turned ON CHECK ABS CONTROL UNIT GROUND Refer to ABS ACTUATOR AND ELEC TRIC UNIT GROUND in Ground Circuit Check 66 CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector Reconnect ABS actuator and electric unit harness connector Then retest CHECK FUSE Check 10A fuse 19 For fuse layout refer to POWER SUPPLY ROUTING in EL sec tion CHECK ABS CONTROL UNIT POWER SUPPLY CIRCUIT Check continuity between fuse and ABS actuator and electric unit connector body side terminal 19 Check battery Refer to BATTERY in EL section BR 77 Replace fuse Diagnostic Procedure 7 Low voltage Inspection end See below Repair harness and con nector Replace Replace ABS actuator and electric unit Check the following e Harness connector F29 822 LHD and 1787 or RHD F76 and 4 e Harness for open or short between ABS actuator and electric unit and fuse If NG repair harness or connector TROUBLE DIAGNOSES Fuse 19 ABS
39. l injury or death in the event of a collision which would result in air bag inflation all maintenance must be per formed by an authorized NISSAN dealer Improper maintenance including incorrect removal and installation of the SRS can lead to per sonal injury caused by unintentional activation of the system Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual SRS wiring harnesses except SEAT BELT TENSIONER connector can be iden tified with yellow harness connector and with yellow harness protector or yellow insulation tape before the harness connectors Precautions e Useonly DOT 4 fluid from a sealed container e Never reuse drained brake fluid e Be careful not to splash brake fluid on painted areas it may cause paint damage If brake fluid is splashed on painted areas wash it away with water immediately e To clean master cylinder parts disc brake caliper parts or wheel cylinder parts use clean brake fluid e Never use mineral oils such as Petrol or kerosene They will ruin rubber parts of hydraulic system e Use flare nut wrench when removing and installing brake tubes e Always torque brake lines when installing e Burnish the brake contact surfaces after refinishing or replacing drums or rotors after replacing pads or linings or if a soft pedal occurs at very low speed Refer to Brake Burnishing Procedure Check and Adjustment WARNING e Clea
40. lever Install all parts Check all parts are installed properly ay attention to direction of adjuster assembly Install brake drum When installing new wheel cylinder or overhauling wheel cylinder bleed air Refer to Bleeding Brake System BRAKE HYDRAULIC LINE BR 8 9 At completion apply brake pressure by pressing the brake pedal approximately 20 times at half stroke DOM BR 34 PARKING BRAKE CONTROL 3 8 4 5 0 39 0 46 33 9 39 9 EN N 25 32 2 6 3 3 19 24 C 25 32 2 6 3 3 19 24 3 8 0 39 0 46 3 8 4 5 33 9 39 9 0 39 0 46 Nm ft lb 33 9 39 9 5 in Ib 0 39 0 46 33 9 39 9 3 8 4 5 0 39 0 46 33 9 39 9 Grease point Removal and Installation 1 remove parking brake cable first remove center console 2 Disconnect warning lamp connector 3 bolts slacken off and remove adjusting nut Warning lamp connector SBR101B Inspection 1 Check control lever for wear or other damage Replace if nec essary 2 Check wires for discontinuity or deterioration Replace if nec essary 3 Check warning lamp and switch Replace if necessary 4 Check parts at each connecting portion and if deformed or damaged replace Adjustment 1 Adjust clearance between shoe and drum as follows a Helease parking brake lever and loosen adjusting nut b Depress brake pedal fully at least 10
41. n brakes with a vacuum dust collector to minimize risk of health hazard from airborne materials e Avoid prolonged and repeated skin contact with brake fluid e Wear protective clothing including impervious gloves e Where there is a risk of eye contact eye protection should be worn for example chemical goggles or face shield BR 3 Tool number Tool name 9694310000 Flare nut torque wrench KV991V0010 Brake fluid pressure gauge HT 72480000 Rear axle shaft bearing puller PRECAUTIONS AND PREPARATION Preparation SPECIAL SERVICE TOOLS Description Removing and installing each brake pip ing Measuring brake fluid pressure Removing rear wheel sensor rotor BR 4 CHECK AND ADJUSTMENT Max line Min line Checking Brake Fluid Level e Check fluid level in reservoir tank It should be between Max and Min lines on reservoir tank e lf fluid level is extremely low check brake system for leaks e When brake warning lamp comes on even when parking brake lever is released check brake system for leaks Checking Brake Line CAUTION If leakage occurs around joints retighten or if necessary replace damaged parts 1 Check brake lines tubes and hoses for cracks deterioration or other damage Replace any damaged parts 2 Check for oil leakage by fully depressing brake pedal while engine is running Changing Brake Fluid CAUTION e Refill with new brake fluid DOT 4 e Never reu
42. nd 4 f the runout is still out of specification turn rotor with on car brake lathe Thickness Standard thickness 26 0 mm 1 02 in Minimum thickness 24 0 mm 0 94 in BR 29 25 014 FRONT DISC BRAKE Installation CAUTION e Refill with new brake fluid DOT 4 e Never reuse drained brake fluid 1 Install caliper assembly 2 Install brake hose to caliper securely taking care that brake hose is not trapped between any suspension part and that hoses are not twisted 3 Bleed air Refer to Bleeding Brake System BRAKE HYDRAULIC LINE 8 BR 30 9 Nem in Ib D kg m ft Ib Brake grease point Rubber grease point Wheel cylinder assembly Boot Piston Piston cup Cylinder body Spring Retaining shoe spring REAR DRUM BRAKE amp Hold down retainer Shoe hold down spring Shoe hold down pin Pawl Adjuster assembly Trailing shoe Leading shoe BR 31 6 6 ko 6 11 0 6 1 1 52 95 YBR298 Back plate Plug Shoe return spring Toggle lever Pin Dust cap REAR DRUM BRAKE Removal WARNING Clean brake lining with a vacuum dust collector CAUTION Make sure parking brake lever is released completely 1 Release parking brake lever fully then remove drum If drum is hard to remove screw two bolts in the provided holes of the drum and tighten them gradually If th
43. ng operation If master cylinder is suspected to have air inside bleed air from master cylinder first Refer to Installation MAS TER CYLINDER Fill reservoir with recommended brake fluid DOT 4 Make sure it is full at all the times while bleeding air out of sys tem Place a container under master cylinder to avoid spillage of brake fluid For models with ABS turn ignition switch to the OFF posi tion and disconnect ABS fuse or battery cable Bleed air in the following order Load Sensing Valve air bleeder Models equipped with LSV Left rear brake Right rear brake Left front brake Right front brake Connect a transparent vinyl tube to air bleeder valve Fully depress brake pedal several times With brake pedal depressed open air bleeder valve to release air Close air bleeder valve Release brake pedal slowly Repeat steps 2 through 5 until clear brake fluid comes out of air bleeder valve Tighten air bleeder valve 9 7 9 Nm 0 7 0 9 kg m 61 78 in Ib BR 8 BRAKE HYDRAULIC LINE YBR293 Removal CAUTION e Use suitable tool for assembly and disassembly of brake lines and hoses e Be careful not to splash brake fluid on painted areas it may cause paint damage If brake fluid is splashed on painted areas wash it away with water immediately DO NOT RUB IT OFF e All hoses must be free from excessive bending twisting and pulling 1 Connect a vinyl tube to air bleeder valve 2 Drain brake flu
44. ning lamp ABS actuator and Z _ NY E ULT electric unit control unit m N IN ya JL C2 Rear wheel sensor Front wheel sensor Control unit System Description Sensor The sensor unit consists of a gear shaped sensor rotor and a sen sor element The element contains a bar magnet around which a coil is wound The sensor is installed on the back of the brake rotor A of one tooth and the rear brake drum As the wheel rotates the sensor generates a sine wave pattern AAJN The frequency and voltage increase s as the rotating speed increases V Induced electromotive force SBR124B Control unit The control unit computes the wheel rotating speed by the signal current sent from the sensor Then it supplies a DC current to the actuator solenoid valve It also controls ON OFF operation of the valve relay and rotor relay If any electrical malfunction should be detected in the ABS or EBD system the control unit causes the warning lamp s to light up combined with an audible sound In this condition the ABS or EBD will be deactivated by the control unit and the vehicle s brake system reverts to normal operation Fail safe mode BR 38 ANTI LOCK BRAKE SYSTEM System Description Cont d G SENSOR The G sensor analyses deceleration during braking to determine whether the vehicle is being driven on a road with low surface resistance u snow covered road etc The ABS control unit uses the s
45. nlet solenoid valve Hydraulic circuit is shut off to hold the cali ON Closed OFF Closed ydrau ic circuit is shut off to hold the caliper brake fluid pressure ABS operation Pesse Caliper brake fluid is sent to reservoir via the outlet ON Closed ON Open solenoid valve Then it is pushed up to the master decrease cylinder by pump OFF Open OFF Closed Master cylinder brake fluid pressure is transmitted to increase caliper BR 41 ANTI LOCK BRAKE SYSTEM Removal and Installation CAUTION Be careful not to damage sensor edge and sensor rotor teeth When removing the front or rear wheel hub assembly discon nect the ABS wheel sensor from the assembly and move it away FRONT WHEEL SENSOR QW UC H E Z ff n Front w sensor connector LH di 4 N m kg m ft Ib 1 REAR WHEEL SENSOR SEC 476 Hear wheel sensor connector LH 27 17 7 23 5 1 8 2 4 13 0 17 4 0 13 16 1 3 1 6 9 12 4 4 5 8 0 45 0 59 39 1 51 2 Nem kg m in Ib 4 4 5 8 0 45 0 59 39 1 51 2 3 kg m ft Ib SBR399D BR 42 ANTI LOCK BRAKE SYSTEM Removal and Installation Cont d FRONT SENSOR ROTOR Removal 1 Remove the drive shaft and rear wheel hub Refer to Front axle drive shaft in FA section and Rear axle in RA section 2 Remove the sensor rotor using suitable puller drift and
46. nts e Do not apply any oil or lubricants to vacuum hose and check valve e Insert vacuum tube into vacuum hose over a length of min 24 mm 0 94 in as shown Take care to main vacuum hoses in their original direction and position BR 20 VACUUM HOSE Rubber joint Brake booster side Vacuum hose Inspection HOSES AND CONNECTORS e Check condition of vacuum hoses and connectors e Check vacuum hoses and check valve for air tightness CHECK VALVE e Check vacuum with a manual vacuum pump nn r es eer toned Vacuum should exist side Connect to engine I Vacuum should not exist side VACUUM WARNING SWITCH Test continuity though vacuum warning switch with an ohmmeter and vacuum pump Less than 26 7 kPa 267 mbar 200 mmHg 00 7 87 inHg Vacuum 33 3 kPa 333 mbar 250 mmHg 9 84 inHg or more BR 21 VACUUM HOSE Inspection Cont d VACUUM PUMP TD27Ti ENGINE 1 Install vacuum gauge 2 Run engine at 1 000 rpm or more 3 Check vacuum Specified vacuum 93 3 kPa 933 mbar 700 mmHg 27 56 inHg or more VACUUM PUMP ZD30DDTi ENGINE Hefer to EM section INSPECTION in VACUUM PUMP Removal and Installation BR 22 VACUUM PUMP TD27Ti engine model Removal and Installation 29 34 3 0 3 5 21 4 AN 2 29 3 0 3 5 21 4 25 1 e 29 34 3 0 3 5 21 4 25 1 pL Ce a S 9 6 7 0 61 0 71 53 1 6
47. onnector and check whether brake is effective CHECK WARNING LAMP ACTIVATE NG Carry out self diagnosis Ensure warning lamp remains off while Refer to BR 59l driving NG CHECK WHEEL SENSOR Repair 1 Check wheel sensor connector for ter minal damage or loose connection 2 Perform wheel sensor mechanical check Refer to Diagnostic Procedure 4 CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector Heconnect ABS actuator and electric unit harness connector Then retest CAUTION Drive at low speed and brake smoothly to prevent rear wheels locking BR 81 TROUBLE DIAGNOSES Diagnostic Procedure 13 SYMPTOM ABS does not work Does the ABS warning lamp activate Carry out self diagnosis Hefer to 59 Go to Diagnostic Procedure 12 Note ABS does work when vehicle speed is under 10 km h 6 MPH Diagnostic Procedure 14 SYMPTOM ABS works frequently CHECK WHEEL SENSOR 1 Check wheel sensor connector for ter minal damage or loose connections 2 Perform wheel sensor mechanical check Refer to Diagnostic Procedure 4 CHECK FRONT AXLES Check front axles for excessive loose ness Refer to FA section Front Wheel Bearing ON VEHICLE SERVICE OK Go to in Diagnostic Procedure 12 BR 82 TROUBLE DIAGNOSES Electrical Components Inspection
48. or Front wheel sensors e Rear right wheel sensor connector e Front left wheel sensor connector 5 Front right wheel sensor connector Under the LH seat Hear left wheel Hear heater sensor connector pee Rear right wheel Air duct sensor connector 2 KE SR G sensor f 860 Sensor YBR264 BR 48 TROUBLE DIAGNOSES Circuit Diagram for Quick Pinpoint Check H MOSNJS 33HM LINA 218412414 YOLVNLOV Sav HOSN3S TS3SHM H 5 45 33HM LINOJ 31 NOILWNIEGWOO HH 5 35 33HM LINOJ YOLOANNOOD ANIT VIVO zig na 14415 29 NO HOLIMS YBR244 BR 49 TROUBLE DIAGNOSES Wiring Diagram ABS LHD MODELS IGNITION SWITCH BR ABS 01 585 BLOCK J B REFER TO EL POWER F48 H B Y COMBINATION lt NEXT METER GY PAGE e c I R B GY F45 B73 STOP LAMP F69 gt BH LAU Y B L R mai Li OO pe d E m 2 amp 0 ABS ACTUATOR AND ELECTRIC DATA LINK CONNECTOR REFER TO THE FOLLOWING FUSE BLOCK JUNCTION BOX J B 16 15114113112 11110 9 18 7161514 3 2 1 _ BR GY YBR245 TROUBLE DIAGNOSES Wiring Diagram ABS Cont d IGNITION SWITCH ON OR START M787 F6
49. ors from ABS actua tor and electric unit and wheel sensor of malfunction code No Check termi nals for damage or loose connections Then reconnect connectors Carry out self diagnosis again Does warning lamp activate again Front LH Rear LH Front M 2 65 Hear RH 420 DISCONNECT Go to next page 1 Disconnect ABS actuator and electric page 1 4 6 1 468 2 5 7 2 579 unit connector Check resistance between ABS actua tor and electric unit connector body side terminals Code No 21 or 22 Front RH wheel Terminals 5 4 Code No 25 or 26 Front LH wheel Yn Terminals 2 and 6 LES Code No 31 or 32 Rear RH wheel Front sensor Rear sensor Terminals 2 and D Code No 35 36 Rear LH wheel Es 558 Terminals 9 and E Resistance Front 0 9 1 1 gt gt Rear 1 44 1 76 kQ CHECK WHEEL SENSOR Check the following Check each sensor for resistance e Harness connectors Resistance Front 0 9 1 1 29 B57 858 E15 Rear 1 44 1 76 205 and Harness for open short between wheel sensor connectors and ABS actuator and elec tric unit If NG repair harness or connectors REPLACE Replace wheel sensor BR 73 TROUBLE DIAGNOSES Diagnostic Procedure 4 Wheel sensor or rotor Cont d 9 Note Note CHECK TIRE NG Check for inflation pressure wear and size of each tire
50. r mc Be careful not to deform or bend brake pipes during instal lation of booster Replace clevis pin if damaged Refill with new brake fluid DOT 4 Never reuse drained brake fluid Take care not to damage brake booster mounting bolt thread when installing Due to the acute angle of installation the threads can be damaged on the metal sur rounding the dash panel holes Before fitting booster temporarily adjust clevis to dimension shown Fit booster then secure mounting nuts brake pedal bracket to brake booster lightly Join brake booster and brake pedal bracket to the front end of the vehicle interior Connect brake pedal and booster input rod with clevis pin Secure mounting nuts 20 25 1 3 1 6 kg m 10 12 ft Ib Install master cylinder Refer to Installation MASTER CYLINDER BR 16 Bleed air Refer to Bleeding Brake System BRAKE HYDRAULIC LINE 8 BR 18 VACUUM HOSE Removal and Installation TD27Ti Engine RHD x VA Y No 4 sx C 1 2 Solenoid valves ABS models 2 VAC switch 2 T 58 S 2 Solenoid valves ABS models kas L VAC switch YBR260 BR 19 ZD30DDTi Engine RHD LHD VACUUM HOSE Removal and Installation Cont d C 4 More than 24 mm 0 94 in Connect hose until it contacts protrusion on vacuum tube YBR292 CAUTION When installing vacuum hoses pay attention to the following poi
51. ram ABS Cont d BR ABS 07 S TD27Ti ENGINE ACTUATOR AND MODELS FH GROUND FL GROUND SENSOR FR SENSOR p ELECTRIC UNIT 705 ZD30DDTi ENGINE CONTROL UNIT e MODELS FL F29 FRONT WHEEL SENSOR RH E15 20 FRONT WHEEL SENSOR LH REFER TO THE FOLLOWING AEEA M743 AT 8 M745 E211 F108 SUPER MULTIPLE 1 2 58171819197 Gy 51617182 JUNCTION SMW YBR251 BR 56 TROUBLE DIAGNOSES Wiring Diagram ABS Cont d TD27Ti ENGINE ABS MODELS ACTUATOR AND ELECTRIC UNIT CEL RR GROUND RL GROUND CONTROL UNIT SENSOR RR RL Fg EE x2 UR B 1 2 G H xa RR T r2 1 B67 L L R G R REAR WHEEL REAR WHEEL SENSOR RH SENSOR LH 112 314 BR BR W YBR252 BR 57 TROUBLE DIAGNOSES CONSULT II CONSULT II APPLICATION TO ABS SELF DIAGNOSTIC RESULTS DATA MONITOR ACTIVE TEST Front right wheel sensor Front left wheel sensor Rear right wheel sensor Rear left wheel sensor G switch G sensor Stop lamp switch Front right inlet solenoid valve Front right outlet solenoid valve Front left inlet solenoid valve Front left outlet solenoid valve Rear inlet solenoid valve Rear outlet solenoid valve Actuator solenoid valve relay Actuator motor relay ABS MOTOR is shown on the Data Monitor screen ABS warning lamp Brake warning lamp Battery voltage ABS Operating Si
52. rust wear damage or presence of foreign materials If any of the above conditions Piston seal are observed replace cylinder body Piston Minor damage from rust or foreign materials may be eliminated by polishing the surface with a fine emery paper Replace inder body if necessary CAUTION Use brake fluid to clean Never use mineral oil Cylinder body BR 28 FRONT DISC BRAKE Inspection Cont d PISTON Check outside surface of piston for score rust wear damage or presence of foreign materials Replace if any of the above condi tions are observed CAUTION Piston sliding surface is plated Do not polish with emery paper even if rust or foreign materials are stuck to sliding surface PIN PIN BOLT AND PIN BOLT Check for wear cracks or other damage if any of the above conditions are observed ROTOR Rubbing surface Check rotor for roughness cracks or chips Runout 1 Secure rotor to wheel hub with at least two nuts 2 Check runout using a dial indicator Make sure that wheel bearing axial end play is within the specifications before measuring Refer to section FA Maximum runout 0 07 mm 0 0028 in 3 If the runout is out of specification find minimum runout posi tion as follows a Remove nuts and rotor from wheel hub b Shift the rotor one hole and secure rotor to wheel hub with nuts c Measure runout d Repeat steps a to c so that minimum runout position can be fou
53. s this data to compute control characteristics to instantly drive the actuators It is essential that both kinds of signal are accurate and stable It is also important to check for conventional brake system problems such as air leaks in booster lines lack of brake fluid or other problems with the brake system Itis much more difficult to diagnose a problem that occurs intermit tently rather than catastrophically Most intermittent problems are caused by poor electric connections or faulty wiring In this case careful checking of suspicious circuits may help prevent the replacement of good parts A visual check may not be sufficient to determine the cause of the problems so a road test should also be conducted Before undertaking actual checks take a few minutes to talk with a customer who approaches with an ABS complaint The customer is a very good source of information on such problems especially intermittent ones Through the talks with the customer find out what symptoms are present and under what conditions they occur Start your diagnosis by looking for conventional problems first This is one of the best ways to troubleshoot brake problems on an ABS controlled vehicle BR 47 TROUBLE DIAGNOSES Component Parts and Harness Connector Location ABS warning light me e ABS actuator and electric unit control unit Rear wheel sensors Rear left wheel sensor connect
54. se drained brake fluid e Be careful not to splash brake fluid on painted areas it may cause paint damage If brake fluid is splashed on painted areas wash it away with water immediately DO NOT RUB IT OFF 1 Connect a vinyl tube to each air bleeder valve 2 Drain brake fluid from each air bleeder valve by depressing brake pedal 3 Refill until new brake fluid comes out of each air bleeder valve Use same procedure as in bleeding hydraulic system to refill brake fluid Refer to Bleeding Brake System BRAKE HYDRAULIC LINE 8 Brake Burnishing Procedure Burnish the brake contact surfaces according to the following pro cedure after refinishing or replacing rotors or drums after replac ing pads or linings or if a soft pedal occurs at very low mileage CAUTION Only perform this procedure under safe road and traffic con ditions Use extreme caution 1 Drive the vehicle on a straight smooth road at 50 km h 31 MPH 2 Use medium brake pedal foot to bring the vehicle to a com plete stop from 50 km h 31 MPH Adjust brake pedal foot pressure such that vehicle stopping time equals 3 to 5 seconds 3 To cool the brake system drive the vehicle at 50 km h 31 MPH for 1 minute without stopping 4 Repeat steps 1 to 3 for 10 times or more to complete the burnishing procedure BR 5 BRAKE HYDRAULIC LINE W O ABS Three way connector Mounting bolt Rear brake Front brake 8 11 0 8 1 1 69 95
55. times with engine running 2 Apply the handbrake allowing the handbrake grip to move 6 notches You can adjust the handbrake travel by using the adjusting nut To complete this adjustment you will need a dynamo meter to check the amount of load required to move from 9 to 10 notches If the load exceeds 20 kg the cable will have to be loosened with the help of the adjusting nut Number of notches 9 10 If the load is less than 20 kg the cable should be tightened v TN lt SOL CONDES Adjusting nut BR 35 PARKING BRAKE CONTROL Adjustment Cont d 3 Apply the handbrake using the specified pressure Check the 196 N 20 kg 44 Ib travel to see that the handbrake is working smoothly 4 Bend parking brake warning lamp switch plate so that brake warning lamp comes on when parking brake lever is pulled A notches Number of A notches 1 or less BR 36 ANTI LOCK BRAKE SYSTEM Purpose The Anti lock Brake System ABS with an integrated Electronic Brake force Distribution EBD system con sists of electronic and hydraulic components It allows you to control the braking force so that wheel lock can be avoided during braking The advantages of ABS with EBD Q N Better tracking performance through improved steering wheel control Improved maneuverability and safer vehicle control Improved vehicle stability by preventing flat spins Shorter stopping distanc
56. unit 79 Diagnostic Procedure 10 Pedal vibration and 1911 3 eme E 80 BR 2 Diagnostic Procedure 11 Long stopping distance nennen nnns 80 Diagnostic Procedure 12 Unexpected pedal RO 81 Diagnostic Procedure 13 82 Diagnostic Procedure 14 82 Electrical Components Inspection 83 SERVICE DATA AND SPECIFICATIONS SDS 84 General Specifications 84 Inspection and Adjustment 85 PRECAUTIONS AND PREPARATION Supplement Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER The Supplemental Restraint System Air Bag and Seat Belt Pre tensioner used along with a seat belt help to reduce the risk or severity or injury to the driver and front passenger in a collision The Supplemental Restraint System consists of air bag module located in the center of the steering wheel and on the instru ment panel on the passenger side where fitted seat belt pre tensioners a diagnosis sensor unit warning lamp wiring harness and spiral cable Information necessary to service the system safely is included in the BT section of this Service Manual WARNING To avoid rendering the SRS inoperative which could increase the risk of persona
57. warning lamp s activate CHECK HARNESS FOR SHORT Repair harness or connec 1 Disconnect ABS connector and electric unit connector 2 Check voltage between ABS actuator and electric unit connector body side terminals Gp 13 and ground Battery voltage should not exist Replace harness or con nector Check voltage between combination con LHD 918 RHD terminal and ground Battery Voltage should exist F E CHECK WARNING LAMP S NG Replace bulb s 1 Turn ignition switch to OFF position 2 Check ABS and Brake warning lamp s gt DISCONNECT IEA ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR 21 13 F29 AEA Combination meter connector BR 67 TROUBLE DIAGNOSES Diagnostic Procedure 1 Not self diagnostic item Cont d 44 9 ABS ACTUATOR AND D ELECTRIC UNIT CONNECTOR CHECK HARNESS FOR SHORT NG Replace harness or con 21 13 E25 1 Disconnect combination meter connec nector s tor LHD and 19 or RHD and 1838 2 Check continuity between ABS actuator and electric unit connector and combination meter connector LHD and 19 or RHD and 1838 Combination LHD meter connector RHD 837 Terminal Terminal Check combination meter CHECK HARNESS CONNECTOR OK Check ABS actuator and electric unit pin terminals for damage or connection of pes SEES PET lll Combination LHD meter connector RHD
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