SECTION

BRAKE SYSTEM
BR
CONTENTS
SPECIAL SERVICING TOOLS ................................... 3 FRONT DISC BRAKES ............................................ 32
PRECAUTIONS .......................................................... 4 Replacing pads ....................................................... 32
Supplement Restraint System (SRS) “AIRBAG” Calliper and cylinder body ...................................... 36
and“ SEATBELT PRE-TENSIONER” ........................ 4 REAR DRUM BRAKES ............................................ 38
Precautions related to the brake system .................. 4 Fitting ...................................................................... 39
Precautions related to the ABS ................................ 4 Brake drum ............................................................. 41
CHECKING AND ADJUSTMENT ............................... 5 PARKING BRAKE ..................................................... 42
Checking brake and clutch fluid level ....................... 5 TECHNICAL DATA AND CHARACTERISTICS ........ 45
Checking the state of the braking system pipes ....... 5 Technical data ......................................................... 45
Changing the brake and clutch fluid ......................... 5 DESCRIPTION / ABS BD-30 TI/BD-30 T ................. 48
HYDRAULIC BRAKING SYSTEM .............................. 6 Purpose .................................................................. 48
System diagram ....................................................... 6 ABS (Anti-Lock Brake System) Operation .............. 48
Description and operation ........................................ 7 ABS Hydraulic Circuit ............................................. 48
Leaks in the hydraulic system .................................. 8 System Components .............................................. 48
Bleeding ................................................................... 8 System Description ................................................ 49
Front brakes ........................................................... 11 Component Parts and Harness Connector Location... 50
Hoses on front wheels ............................................ 15 TROUBLE DIAGNOSIS / ABS BD-30 TI/BD-30 T ... 51
Rear brakes ............................................................ 16 Circuit diagram for a quick check ............................ 51
BRAKING REGULATOR VALVE (BRV) ................... 17 Wiring Diagram ....................................................... 52
Valve ....................................................................... 17 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Pressure connectors .............................................. 18 / ABS BD-30 TI/BD-30 T ........................................... 56 BR
Cut-off pressures .................................................... 18 Self-diagnosis ......................................................... 56
Valve adjustment .................................................... 19 CONSULT-II ............................................................ 58
Checking the cut-off pressures .............................. 20 CONSULT-II Inspection Procedure ......................... 59
BRAKE PEDAL AND BRACKET ............................. 23 TROUBLE DIAGNOSIS - INTRODUCTION / ABS
BRAKE SERVO ........................................................ 25 BD-30 TI/BD-30 T ..................................................... 64
In-vehicle servicing ................................................. 25 How to Perform Trouble Diagnoses for Quick and
Removal ................................................................. 25 Accurate Repair ...................................................... 64
Inspection ............................................................... 26 TROUBLE DIAGNOSIS - BASIC INSPECTION /
Fitting ..................................................................... 26 ABS BD-30 TI/BD-30 T ............................................. 65
BRAKE PUMP .......................................................... 27 Preliminary Check .................................................. 65
Master cylinder ....................................................... 27 Ground Circuit Check ............................................. 67
DEPRESSOR ............................................................ 28 TROUBLE DIAGNOSIS - GENERAL DESCRIP-
Removal ................................................................. 28 TION / ABS BD-30 TI/BD-30 T ................................. 68
Disassembly ........................................................... 28 Malfunction Code/Symptom Chart ......................... 68
Inspection ............................................................... 29 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
Assembly ................................................................ 30 ITEMS / ABS BD-30 TI/BD-30 T ............................... 69
Fitting ..................................................................... 31 Wheel Sensor or Rotor ........................................... 69
ABS Actuator Solenoid Valve or Solenoid Valve

BR-1
 Relay ....................................................................... 72 Is Turned On ...........................................................86
Motor Relay or Motor .............................................. 75 REMOVAL AND INSTALLATION / ABS BD-30T /
Low Voltage ............................................................ 77 BD-30 TI ....................................................................87
Control Unit ............................................................. 79 Wheel Sensors ........................................................87
TROUBLE DIAGNOSES FOR SYMPTOMS / ABS ABS Actuator and Electric Unit ...............................90
BD-30 TI/BD-30 T ...................................................... 81 Sensor Rotor ...........................................................91
ABS Works Frequently ............................................ 81 SERVICE DATA AND SPECIFICATIONS (SDS) /
Unexpected Pedal Action ........................................ 81 ABS BD-30 T / BD-30 TI ...........................................92
Long Stopping Distance ......................................... 82 General Specifications ............................................92
ABS Does Not Work ............................................... 82 Disc Brake ...............................................................92
Pedal Vibration and Noise ...................................... 83 Brake Pedal .............................................................92
ABS Warning Lamp Does Not Come On when Igni- Parking Brake ..........................................................92
tion Switch Is Turned On ......................................... 84
ABS Warning Lamp Stays On When Ignition Switch

When you use the connection diagrams:

• See Section GI, GI-11, "INTERPRETATION OF ELECTRICAL DIAGRAMS". When trouble-
shooting, see Section GI, GI-41, "FAULT-FINDING PROCEDURE" and GI-29, "QUICK TROU-
BLESHOOTING OF ELECTRICAL FAULTS".
• See Section EL, EL-8, "POWER SUPPLY ROUTING" for issues regarding the power distribu-
tion system.
• Consult the section EC for more information on the ENGINE BRAKE and connection dia-
gram.

BR-2
 SPECIAL SERVICING TOOLS

SPECIAL SERVICING TOOLS PFP:00070

EFS002F9

REFERENCE
NAME
NUMBER

GG94310000 Removal and fitting of brake pipes.

NIE-66A Braking system pressure gauge.

(A-860-ECCF)

BR-3
 PRECAUTIONS

PRECAUTIONS PFP:00071

Supplement Restraint System (SRS) “AIRBAG” and“ SEATBELT 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 an 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.
CAUTION:
● To avoid rendering the SRS inoperative (which could increase the risk of personal 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 related to the brake system EBS00B01

● Use recommended brake fluid only.

See MA-11, "RECOMMENDED FUEL, LUBRICANTS AND
FLUIDS" in section MA of this manual.
● Never reuse the brake fluid obtained from bleeding or drain-
ing the brake or clutch system.
● Never mix two different brands of brake fluid.
● Take care to avoid spilling brake fluid onto painted surfaces
since it will damage the paintwork. Wash immediately with
plenty of water if this happens.
● Use clean, new brake fluid to clean or wash the parts of the 0294BR
master cylinder, disc brake calliper and slave cylinder.
● Never use mineral oils or petrol to clean or lubricate the braking system. These materials will dam-
age the rubber parts in the hydraulic system.
● Use a suitable tool to remove and refit the brake system pipes.
● CLEAN THE BRAKE PADS AND LININGS WITH A VACUUM CLEANER, to reduce the production of
dust.

Precautions related to the ABS EBS00B02

● Use the recommended tyres with ABS.

● The used tyres must be of the same size.
● If tyres are fitted of different sizes, the braking distance will increase and the stability may be
negatively affected.
● On replacing the brake components, use NISSAN originals.
● On fitting radio stations, etc., do not place the radio, the aerial or the cables under 10 mm from the
control unit.
● When doing welding work, disconnect the control unit and suitably protect its connector.
● If it is necessary to take current to supply any electrical component, never do so from the ABS
installation.

BR-4
 CHECKING AND ADJUSTMENT

CHECKING AND ADJUSTMENT PFP:00072

Checking brake and clutch fluid level EBS00C01

● Check the level of the brake and clutch fluid by observing

the marks on the fluid reservoir. The level must be between
the maximum and minimum marks on the reservoir.
● If the fluid level is too low, check both the brake and clutch
systems for leaks.
● If the fluid level warning light on the instrument panel
comes on, check for leaks in the system. Check the wear of
the brake pads if no leaks are found.

0295BR

Checking the state of the braking system pipes EBS00C02

● If leaks are found in the connections, tighten them or replace the damaged parts if necessary.
1. Trace the pipes and hoses in the system, checking for cracks, bending or any other irregularity in the sys-
tem. Change the damaged parts.
2. Check for fluid leaks by pressing the brake pedal fully down with the engine running.

Changing the brake and clutch fluid EBS00C03

● Use only recommended brake fluids. See MA-11, "RECOM-

MENDED FUEL, LUBRICANTS AND FLUIDS" in section MA
of this manual.
● Never reuse the brake fluid obtained from bleeding or
draining the brake or clutch system.
● Take care to avoid spilling brake fluid onto painted surfaces
since it will damage the paintwork. Wash immediately with
plenty of water if this happens.
● Never mix two different brands of brake fluid.
● Carefully check that the fluid level in the reservoir does not 0296BR
drop below the minimum level during this operation.
1. Fill the reservoir to the correct level. Always use new fluid.
2. Fit a clear vinyl tube on each bleeding valve and place the other end of the tube in a clean container with
sufficient capacity.
3. Open the bleed nipple on one wheel.
4. Depress the brake pedal slowly and repeatedly to the end of its travel until new fluid comes out of the
bleed nipple.
5. Close the bleed nipple.
6. Repeat this operation on each wheel.
7. Fill the reservoir up to the “MAX” level.

BR-5
 HYDRAULIC BRAKING SYSTEM

HYDRAULIC BRAKING SYSTEM PFP:00073

System diagram EBS00D01

MODELS WITHOUT ABS

0652BR

MODELS WITH ABS

0653BR

COMPONENTS
1. Vacuum pump 7. Front disc brake 13. Rear brake circuit
2. Brake pump 8. Piloted braking regulator valve 14. Rear drum brake (parking)
3. Brake master cylinder 9. Rear drum brake 15. ABS actuator
4. Brake liquid tank 10. Front pistons Hydraulic service circuit
5. Vacuum tank (optional) 11. Rear cylinders Hydraulic piloting circuit
6. Pressure connector 12. Front brake circuit Emptying circuit

BR-6
 HYDRAULIC BRAKING SYSTEM

Description and operation EBS00D02

The service brake system comprises two independent systems, one for the front axle and one for the rear axle.
The emergency brake operates on either system independently of the service brake.
The front brakes have ventilated disks. The rear brakes have “Simplex” drums that are adjusted automatically.
The actuation system is by direct controlled vacuum servobrake. The circuit includes a regulating valve piloted
depending on the load.
The parking brake is mechanical, on the rear wheels.

SERVICE BRAKE
On using the brake pedal the servobrake is worked mechanically (3), which drives the brake pump (2) that
sends brake fluid under pressure to the front pistons (10) and rear cylinders (11), which, by extension, drive
the brake pads and shoes against the front disks and rear drums, thus stopping the vehicle.

EMERGENCY BRAKE
If a fault or leak occurs in one of the independent systems (of the service brake), the remaining intact system
acts as an emergency brake.

PARKING BRAKE
When the hand brake is set to “Braked” a cable is pulled that works the brake shoes, which, by dragging on the
rear drums, hold the vehicle stationary.
The brakes are released by setting the hand brake to “Unbraked”.

PILOTED BRAKE REGULATING VALVE

This valve regulates the outlet or cutting pressure of the rear circuit depending on the load.
As well as the working in itself, the valve is piloted by the pressure from the front brake circuit. In this way, we
can differentiate two different behaviours:
● Normal working conditions:
The BRV is reached, on the one hand, by the pressure sent by the brake pump to the rear axle, and on the
other, the piloting pressure (which comes from the front axle). In this case, the pressures that reach the
valve are equal, and its working is standard.
● Extreme working conditions:
If there should be a break in the front brake circuit, the BRV is not reached by the piloting pressure. At this
time, a “bridge” is made on the BRV, that is, its function is annulled and all the pressure the brake pump
sends to the rear axle is what is transmitted to the rear wheels. The braking efficacy is thus maintained on
the rear axle, compensating the loss caused in the front axle.

BR-7
 HYDRAULIC BRAKING SYSTEM

Leaks in the hydraulic system EBS00D03

● When the level in the brake fluid reservoir is seen to drop, visually check the entire system from
the brake fluid reservoir, to the servo, the brake discs and the brake discs. Clean any grease stains
from the engine, springs, front and rear axles to avoid confusion with brake fluid and check all the
joints and metallic pipes as well as the hoses and their connections. Check that there are no signs
of damage, scrapes or cracks. Re-tighten and replace parts if necessary. Top up the brake fluid
level. After several hours of operation and on successive days, check that the fluid level in the res-
ervoir has not dropped and that there are no signs of leaks.

Bleeding EBS00D04

The hydraulic system must be bled whenever any pipe has been disconnected or air has entered the system.
The presence of air in the system can be noticed by the “spongy” feel of the pedal.
● It is very important to maintain absolute cleanliness during the bleed operation.
● Use only recommended brake fluids. See MA-11, "RECOMMENDED FUEL, LUBRICANTS AND FLUIDS"
in section MA of this manual.
● Never reuse the brake fluid obtained from bleeding or draining the brake or clutch system.
● Never mix two different brands of brake fluid.
● Carefully check that the fluid level in the reservoir does not drop
below the minimum level during this operation.
● Take care to avoid spilling brake fluid onto painted surfaces
since it will damage the paintwork. Wash immediately with
plenty of water if this happens.

1. Top up when little fluid is left

2. Depress slowly 0275MA

● Before starting bleeding, press the brake pedal several times to use up the vacuum in the brake
servo, in order to work under purely mechanical conditions. Thus, high pressures will not be
created in the system that could cause turbulence between the fluid and the air in the system.
● In vehicles fitted with ABS, make sure the engine has stopped and disconnect the connectors of
the ABS or the ground cable from the battery.
Purge the air in the following order:
– Left front brake
– Right front brake
– Left rear brake
– Right rear brake
– Braking regulator valve

BR-8
 HYDRAULIC BRAKING SYSTEM

1. Open the cover, unscrew the plug (1) and add recommended
fluid. See MA-11, "RECOMMENDED FUEL, LUBRICANTS AND
FLUIDS" in section MA of this manual, up to the “Max” mark in
the reservoir.

0412BR

2. Fit a vinyl tube to each bleed nipple and place the other end of
the tube in a clean container with sufficient capacity.
3. Press the brake pedal fully several times.
4. With the pedal pressed, open the purger screw of the rear right
brake to expel the air inside the circuit.
5. Close the bleed nipple.
Brake purging valve:
7 ÷ 9 N-m (0.7 ÷ 0.9 kgm; 5.2 ÷ 6.6 ft-lb)
0186BR
1. Top up until fluid without bubbles appears
6. Release the brake pedal slowly.
7. Repeat steps 3 to 6 above until fluid without bubbles exits from
the bleed nipple.
● Brake fluid containing air is white and bubbles can be
seen in the plastic tube.
Close the bleed nipple.

NBR529
2. Top bleed nipple on front wheel

8. Repeat steps 4 to 7 on all wheels.

9. Bleed the braking regulator valve using the bleed nipple (3).

0149RA

BR-9
 HYDRAULIC BRAKING SYSTEM

INSPECTION
1. Follow the system’s pipes and hoses, checking for cracks, bending or any other fault in the system.
Change any damaged parts.
2. Check the state of the threads on the connectors, hoses and control valves.
Change any defective part.
3. Check the state of the studs fixing the hoses. Change them if they are bent or otherwise faulty.
4. Check for fluid leaks by fully depressing the pedal with the engine running.

FITTING
● Use only recommended brake fluids. See MA-11, "RECOMMENDED FUEL, LUBRICANTS AND
FLUIDS" in section MA of this manual.
● Never mix two different brands of brake fluid.
● Never reuse the brake fluid obtained from bleeding or draining the brake or clutch system.
● Use clean, new brake fluid to clean or wash the parts of the master cylinder, disc brake calliper
and slave cylinder.
● Take care to avoid spilling brake fluid onto painted surfaces since it will damage the paintwork.
Wash immediately with plenty of water if this happens.
● Avoid excess bending, deforming or stretching hoses.
● Leave sufficient space between the brake pipes and adjacent parts to prevent the transmission of
vibrations when the engine is running.
● Do not over-tighten the connectors.
● Use a suitable tool to remove and refit the brake system pipes.
1. Hand fit the nuts and hoses removed and then fully tighten them.

Brake pipe connectors:

10 N-m (1 kgm; 7.4 ft-lb)
2. Fill the reservoir to the correct level.
3. After fitting, bleed the air from the system. See BR-8, "Bleeding"
in this section.

0294BR

BR-10
 HYDRAULIC BRAKING SYSTEM

Front brakes EBS00D05

Models with fixed cab Models with tilt cab

VIEW “A”
Left
side

Left
right side right
side side

TL 45 WITHOUT ABS

NBR530

BR-11
 HYDRAULIC BRAKING SYSTEM

TL 45 WITH ABS

NBR531

TL 28 / 32 / 34 / 35 WITHOUT ABS

NBR532

BR-12
 HYDRAULIC BRAKING SYSTEM

TL 28 / 32 / 34 / 35 WITH ABS

NBR533

BR-13
 HYDRAULIC BRAKING SYSTEM

NOTE:

BR-14
 HYDRAULIC BRAKING SYSTEM

ROUTE OF BRAKE AND CLUTCH PIPES IN THE CHASSIS

There are two pipes: the one closer to the centre of the unit (2) is for the front brakes and the one more on the
outside (1) in the braking regulator valve (BRV), rear brakes.
The pipe closer to the centre of the unit (2) is the connection from the distributor (A) to the front right brake.
From the distributor (A) there is another connection to its distributor (B), another to the front left brake and
another to the pilot regulator valve (BRV).
From the pipe at the end of the unit (1) there is a connection to the distributor (A) and from here, another con-
nection to the distributor (B).
From the distributor (B) there is another pipe to the braking regulator valve (BRV).
From the BRV there is a stay that connects with the rear brakes.

Hoses on front wheels EBS00D06

1. Remove the sleeve of the metal pipe of the longitudinal beam.

NBR534

2. Remove the fixing clip.

3. Loosen and remove the connection (1) and withdraw the sleeve.

BR-15
 HYDRAULIC BRAKING SYSTEM

Rear brakes EBS00D07

0339BR

COMPONENTS
1. BRV connector a. To BRV
2. Left rear drum DT. Direction of travel
3. Rear control valve
4. Right rear drum

BR-16
 BRAKING REGULATOR VALVE (BRV)

BRAKING REGULATOR VALVE (BRV) PFP:00074

Valve EBS00E01

NOTE:
Vehicles in this range have a BRV (piloted brake regulator valve) depending on the load, which may be
regulated in the workshop if necessary.

The unit comprises the valve itself (1), a traction spring (2) and its support (3), with a variable position with
respect to the valve in order to regulate the cutting pressure of the BRV. To do this, it is only necessary to
loosen bolts (4) and (5) and articulate the support with respect to the bolt (5) to modify the cutting pressures.
By turning the support (3) in direction (A), greater cutting pressure is
achieved, whereas if it is turned to side (B), the opposite effect is
achieved.

NOTE:
Do not swap the springs of the BRV as those in the CABSTAR.E
100 (28/32) 120 (35) are different to those fitted for the
CABSTAR.E 120 (45HD/45), CABSTAR.E 100 (45 GE).

0149RA

REMOVAL
1. Release the piloting pipe (1), the pipe (2) bringing brake fluid to
the rear circuit and the outlet pipe (3) to the rear wheels. Collect
the brake fluid in a suitable manner.
2. Release the piloting pipe (1), the pipe (2) bringing brake fluid to
the rear circuit and the outlet pipe (3) to the rear wheels. Collect
the brake fluid in a suitable manner.
3. Remove the bolts (5) fixing the BRV to its support.

0149RA

REFITTING
Proceed in reverse order to Removal, bearing in mind the following points:
Nut fixing the lever to the BRV:
59 ÷ 76 N-m (6.0 ÷ 7.8 kgm; 43.5 ÷ 56.1 ft-lb)
Bolts fixing the BRV to its support:
21 ÷ 31 N-m (2.1 ÷ 3.2 kgm; 15.5 ÷ 22.9 ft-lb)
NOTE:
Apply sealant to the threaded area of the bolts.

1. Apply grease to the pivoting area of the lever with the BRV and to the area of the lever where the spring is
fixed.
2. Purge the brake circuit. Consult the aside BR-6, "HYDRAULIC BRAKING SYSTEM" in this same Section.

BR-17
 BRAKING REGULATOR VALVE (BRV)

Pressure connectors EBS00E02

The hydraulic braking system is equipped with a pressure connection of the plug-in type; it is not necessary to
bleed the system after it has been used to check or adjust the pressure.
HYDRAULIC BRAKING SYSTEM DIAGRAM

0181BR

COMPONENTS
1-2-3. Plug-in type pressure connections
4. Brake regulator valve (BRV)
5. Brake servo
A-B-C. Pressure gauges with plug-in connectors.

As shown in the figure, the pressure connections are located in the following three points:
● In the front braking system (1).
● In the rear braking system (2), BEFORE the BRV.
● In the rear system (3), AFTER the BRV.
Thus, a plug-in pressure gauge may be used to check the pressure at the points in the system at which these
connections are located.

Cut-off pressures EBS00E03

The pressures shown in table are those that should exist in the rear system AFTER the BRV (3) when there is
a pressure of 14,270 kPa (140 bar; 143 kg/cm2; 2033 lb-inches2) in the rear system BEFORE the BRV (2).In
order to check the correct adjustment of the BRV, it is necessary to know the tare of the rear axle according to
the vehicle model.
In order to check the correct adjustment of the BRV, it is necessary to know the weight of the rear axle on the
ground and the vehicle model.
In the front bonnet, all vehicles have see GI-51, "ADHESIVE LABELS" in section GI in this Manual the BRV
plate giving details of all the technical details of the model, valve reference, cutting or outlet pressure (PS) and
the weight of the rear axle on the ground.

BR-18
 BRAKING REGULATOR VALVE (BRV)

Valve adjustment EBS00E04

0181BR

To carry out this regulation, the unit must be in the same conditions as those described in the aside below,
“Checking the cutting pressure”, and the pressure obtained in the manometer (C) on making the check must
have been noted, either in default or in excess.

Proceed as follows to adjust:

1. Loosen bolts (1) and (2).
2. If the pressure shown on the manometer (C) is below that stipu-
lated in table 1, tension the spring. To do this, direct support (3)
the spring to (+). If, on the other hand, the value measured is
below what is stipulated, proceed to detension the spring by
turning support (3) of the spring in the direction (–). Then tighten
bolts (1) and (2).
Bolts fixing the lever of the spring (3) to its support:
21 ÷ 31 N-m (2.1 ÷ 3.2 kgm; 15.5 ÷ 23.6 ft-lb)
0149RA

NOTE:
It is best to adjust the BRV with the vehicle in CONFIGURE and on NOMINAL LOAD.
In this way, the dispersions on the specified pressure are smaller in each of the loads. However,
adjustment may be performed at half load, refining the cutting pressure as far as possible to avoid
differences between the states of maximum and minimum charge.

BR-19
 BRAKING REGULATOR VALVE (BRV)

Checking the cut-off pressures EBS00E05

1. Use details of the weight of the rear axle on the ground and the vehicle model, to refer to the plate ot table
1 and note the pressure for pressure gauge (C) when pressure gauge (B) shows 14,270 kPa (140 bar;
143 kg/cm2; 2033 ft-lb2).
Example: In an CABSTAR.E-120 (35/45) vehicle with a rear axle weight of 1,200 kg, the pressure to
be noted will be 3.300 kPa (33 bar; 33.66 kg/cm2; 478.5 ft-lb2).
2. Connect the plug-in pressure gauges (2) and (3) to the pressure connectors.
3. To carry out the test, the vehicle must be stationary, the brakes released, and the engine running to
ensure a supply of vacuum for braking.
4. With the vehicle as described in points 1 and 2. and with the pressure gauges connected, press the brake
pedal until the pressure gauge (B) for the rear system before the BRV, shows a pressure of 14,270 kPa
(140 bar; 143 kg/cm2; 2033 ft-lb2).
5. Keep the pedal depressed to maintain a pressure reading of 14.270 kPa (140 bar; 143 kg/cm2; 2033 ft-
lb2) at the pressure gauge (B); check that the pressure shown by pressure gauge (C) for the rear system
after the BRV, matches that noted in point 1, ± 204 kPa (2 bar; 2.04 kg/cm2; 29 ft-lb2). bar. If not, the brak-
ing regulator valve must be adjusted as described in the section BR-19, "Valve adjustment".
Pressure connector at fitting or connector:
8 ÷ 15 N-m (0.8 ÷ 1.5 kgm; 5.9 ÷ 11.1 ft-lb)

TABLE OF CUT-OFF PRESSURES

CABSTAR.E 100 (28)
Load Pressure
kg lb kPa bar kg/cm2 lb/in2
600 1323 1200 12 12.24 174.0
700 1544 1600 16 16.32 232.0
Weight of rear axle on the ground

800 1764 2000 20 20.40 290.0

900 1985 2400 24 24.48 348.0
1000 2205 2700 27 27.50 391.0
1100 2426 3000 30 30.60 435.0
1200 2646 3300 33 33.66 478.5
1300 2867 3500 35 35.70 507.5
1400 3087 3800 38 38.76 551.0
1500 3308 4000 40 40.80 580.0
1600 3528 4300 43 43.86 623.5
1700 3749 4600 46 46.92 667.0

BR-20
 BRAKING REGULATOR VALVE (BRV)

CABSTAR.E 100 (32) (34) (35)

Load Pressure
kg lb kPa bar kg/cm2 lb/in2
600 1323 1500 15 15.30 217.5
700 1544 1800 18 18.36 261.0
800 1764 2100 21 21.42 304.5
900 1985 2400 24 24.48 348.0
1000 2205 2700 27 27.54 391.5
Weight of rear axle on the ground

1100 2426 3000 30 30.60 435.0

1200 2646 3300 33 33.66 478.5
1300 2867 3500 35 35.70 507.5
1400 3087 3700 37 37.74 536.5
1500 3308 3900 39 39.78 565.5
1600 3528 4000 40 40.80 580.0
1700 3749 4200 42 42.84 609.0
1800 3969 4400 44 44.88 638.0
1900 4190 4600 46 46.92 667.0
2000 4410 4800 48 48.96 696.0
2100 4631 5000 50 51.0 725.0
2200 4851 5200 52 53.04 754.0

BR-21
 BRAKING REGULATOR VALVE (BRV)

CABSTAR.E 120 (45/35)

Load Pressure
kg lb kPa bar kg/cm2 lb/in2
700 1544 2200 22 22.44 319.0
800 1764 2600 26 26.52 377.0
900 1985 2900 29 29.58 420.5
1000 2205 3300 33 33.66 478.5
1100 2426 3600 36 36.72 522.0
1200 2646 4000 40 40.80 580.0
1300 2867 4400 44 44.88 638.0
1400 3087 4800 48 48.96 696.0
1500 3308 5300 53 54.00 765.5
1600 3528 5700 57 58.14 826.5
Weight of rear axle on the ground

1700 3749 6000 60 61.20 870.5

1800 3969 6300 63 64.26 913.5
1900 4190 6600 66 67.32 957.0
2000 4410 6900 69 70.38 1000.5
2100 4631 7200 72 73.44 1044.0
2200 4851 7500 75 76.50 1087.5
2300 5072 7800 78 79.56 1131.0
2400 5292 8100 81 82.62 1174.5
2500 5513 8400 84 85.68 1218.0
2600 5733 8700 87 88.74 1261.5
2700 5954 9000 90 91.80 1305.0
2800 6174 9300 93 94.86 1348.5
2900 6395 9600 96 97.92 1392.0
3000 6615 9900 99 100.98 1435.5
3100 6836 10200 102 104.04 1479.0
3200 7056 10500 105 107.10 1522.5
3300 7277 10800 108 110.16 1566.0

BR-22
 BRAKE PEDAL AND BRACKET

BRAKE PEDAL AND BRACKET PFP:00075

EBS00F01

0656BR

COMPONENTS
1. Return spring
2. Fork pin
3. Brake pedal
4. Brake pedal position switch
5. Pedal shaft bolt
6. Pedal and brake servo bracket
7. Circlip
8. Brake light contact switch

INSPECTION
Check the following points on the brake pedal:
● Deformation of the brake pedal.
● Deformation of the fork pin.
● Cracking of welded parts.
● Cracks or deformation in the fork pin stop.
● Fatigue in the return spring.

1. Stop 0300BR

BR-23
 BRAKE PEDAL AND BRACKET

ADJUSTMENT
Check the free height of the brake pedal to the cab floor.
H. Free height = 169 - 174 mm (6.65 - 6.85 inches)
D. Pedal stroke = 140 mm (5.51 inches)
C. Clearance between pedal and braking switch:
maximum 7 mm (0.28 inches)
A. Free play of pedal: 1.0 - 5.0 mm (0.039 - 0.196 inches)
R. 302 (11.89 inches)
Adjust the free height of the brake pedal if necessary.
1. Loosen the lock nut and adjust the free height of the pedal by
turning the primary brake servo rod. Then re-tighten the lock nut.
Ensure that the end of the primary rod (4) projects within the
fork.
2. Loosen the lock nut and adjust the clearance “C” of the brake
light switch. Then re-tighten the lock nut.
3. Check the pedal’s free play.
Check that the brake lights go out when the pedal is released.
4. Check the height “H” of the pedal by depressing it with the
engine running. If the height when depressed is less than the
specified value, check the brake system for leaks, accumulated 0301BR
air or damaged parts (master cylinder, etc) and make the neces-
sary repairs.

1. Primary rod
2. Lock nut
3. Fork
4. End of primary rod 0302BR

BR-24
 BRAKE SERVO

BRAKE SERVO PFP:00076

In-vehicle servicing EBS00G01

CHECKING OPERATION
● Depress the brake pedal several times with the engine
stopped and then check that the pedal’s travel has not
changed.
● Depress the brake pedal and then start the engine. If the
pedal lowers slightly, operation is normal.

0311BR

LEAK TEST
● Start the engine and then stop it after a couple of minutes.
Depress the brake pedal several times, little by little. If the pedal
can be depressed more the fist time and then gradually less at
the second or third try, the brake servo has no leaks.
● Depress the brake pedal with the engine running and then stop
the engine while continuing to press the pedal. If there is no
change in the pedal’s stroke after keeping it depressed for 30
seconds, the brake servo has no leaks.

0312BR

Removal EBS00G02

0313BR

COMPONENTS
1. Pedal support and servobrake 3. Fork pin 5. Brake pump
2. Brake pedal 4. Servobrake

BR-25
 BRAKE SERVO

Inspection EBS00G03

CHECKING THE LENGTH OF THE SECONDARY ROD

1. Apply a vacuum of approximately 66.7 kPa (667 mbar, 500 mm
Hg) to the servobrake with a manual vacuum pump.
2. Check the length (1) of the secondary rod.
Length of secondary rod:
10.4 ± 0.125 mm (0.409 ± 0.0050 inches)

0314BR

Fitting EBS00G04

WARNING:
● Take care not to deform or bend the brake system pipes
when fitting the brake servo.
● Change the fork pin if it is damaged.
● Fill with new “DOT 4” brake fluid.
● Never re-use the brake fluid that was drained from the
system.
● Take care not to damage the threads of the brake servo
when fitting it. Because of the small space available, the
threads may be damaged by contact with other parts.
1. Before adjusting the servo, temporarily adjust the fork (2) to the 0315BR
dimension shown.
2. Adjust the servo and lightly tighten the fixing nuts (pedal bracket on brake servo).
3. Connect the brake pedal and the primary link of the servo with the fork pin.
4. Fit the fixing nuts.
Servobrake to brake pedal support:
15 ÷ 21 N-m (1.5 ÷ 2.1 kgm; 11.1 ÷ 15.5 ft-lb)
5. Fit the main braking pump. Consult BR-27, "BRAKE PUMP" in this same section.
6. Bleed the air from the system. See BR-8, "Bleeding" in this section.

BR-26
 BRAKE PUMP

BRAKE PUMP PFP:00077

Master cylinder EBS00H01

REMOVAL
1. Loosen the nuts fixing the master cylinder to the brake servo.
2. Remove the master cylinder from the brake servo.

0171BR

FITTING
Fill the reservoir with new brake fluid before fitting it to the vehicle in order to prevent all the air in the master
cylinder from entering the system during bleeding.
The brake pump must be cleaned quickly, making use of the protection stoppers of the brake pump.
Reverse the removal operations, taking the following into account:
Fix the master cylinder to the brake servo.
Nuts fixing the pump to servobrake:
39 N-m (4 kgm; 28.8 ft-lb)
Connect the brake pipes from the tank. When the fluid begins to flow through the outlets, stop them.

BR-27
 DEPRESSOR

DEPRESSOR PFP:00078

Removal EBS00I01

1. Release the pipes from the depressor and the engine brake.
2. Remove the lubrication pipe (1) of the depressor.
3. Remove the bolts (2) fixing the depressor to the distribution
cover.

0575BR

4. Extract the depressor (3) together with the two o-rings (4) that
join them to the distribution cover.

0576BR

Disassembly EBS00I02

1. Separate the rear housing (1) from the front (2).

0577BR

2. Extract the rotor (3) together with the blades (4).

3. Extract the o-rings (5) from the front body (2).

0578BR

BR-28
 DEPRESSOR

Inspection EBS00I03

Clean and check all the parts of the depressor.

● Make sure that the interior of the body of the depressor is not scratched or excessively worn,
above all the rear housing.
● Make sure that the axial face of the rear housing is not deeply scratched.
● Make sure that the blades are not scratched on the three faces that contact the body and the rear
housing, and that there is not excessive play in the housing in the rotor grooves.
● Check the rotor for wear in the grooves of the blades and the central streaks for the axle.
● With the depressor fitted on the vehicle, check the vacuum generated. Proceed as follows:
– Remove the vacuum tube from the depressor and stop the one going to the engine brake.
– Insert a three way pipe in the area where there is negative pressure, that is, on the outlet of the
depressor, and connect it to a vacuum pistol.
– Start the engine and make sure the following values are attained:
Engine speed at 900 rpm:
-90 kPa (-676 mmHg; -900 mbar)
Engine speed at 3,000 rpm:
-93.3 kPa (-701 mmHg; -933 mbar).
– If the data found do not lie within the specified values, make sure there is air suction in the centre
of the supply.
● If after this check, the values are still off the specified limits, replace the depressor.
● Replace the o-rings and the seal washers for new ones on each assembly.

BR-29
 DEPRESSOR

Assembly EBS00I04

Proceed in the reverse order to that of disassembly, taking the following into account:
● Lubricate the O-rings with clean oil.
● Change the sealing washers for the vacuum and greasing
connectors.

1. Vane
2. Flat side
3. Rounded side
4. Fit this way round 0179BR

BR-30
 DEPRESSOR

Fitting EBS00I05

Proceed in the reverse order to that of removal, taking the following into account:
● When fitting the rotor vanes, take care to fit the rounded sides so that they make contact with the depres-
sor body.
● Start the engine and check for oil leaks in the lubrication system.
● Operate the brakes to monitor the behaviour of the vacuum pump and its capacity for creating a vacuum.
● Tighten all components to the correct torques.
Bolts fixing the depressor to distribution cover:
17 ÷ 23 N-m (1.7 ÷ 2.3 kgm; 12.5 ÷ 17.0 ft-lb)
Vacuum socket to depressor:
29 ÷ 34 N-m (3.0 ÷ 3.5 kgm; 21.4 ÷ 25.1 ft-lb)
Connector bolt fixing the grease nozzle to the
depressor and engine block:
19 ÷ 27 N-m (1.9 ÷ 2.8 kgm; 14.0 ÷ 19.9 ft-lb)

BR-31
 FRONT DISC BRAKES

FRONT DISC BRAKES PFP:00079

Replacing pads EBS00J01

The brakes on these vehicles carry a brake pad wear indicator. This is connected to a warning light that is
common with the minimum brake fluid level and is located on the instrument panel.
Brake pad wear makes the pistons in the calliper move. The volume created by this movement is filled with
fluid from the brake and clutch fluid reservoir.
● If there is an important drop in the brake and clutch fluid level, check the brake pad wear. (Before-
hand, check the free play in the hub bearings.)
● When the brake pads are thinner than the specified limit (see BR-45, "TECHNICAL DATA AND
CHARACTERISTICS"), they must be changed. This thickness must be measured on the most worn
pad.
● If the pads in one calliper are changed, the pads on the opposite side of the same axle must also
be changed.

REMOVAL
1. Stop the rear wheel by applying the parking brake and blocking.
2. Loosen the nuts (1) fixing the wheel to the front axle.
3. Use a hydraulic jack to raise the front axle until the wheels are free for removal.
● Place safety trestles in position.

4. Unscrew the front wheel nuts (1) and remove the wheel.

0107BR

BR-32
 FRONT DISC BRAKES

5. Without removing the pads, measure their wear (on the disks),
which will be:
Wear limit of the brake pads (minimum thickness):
E = 9 mm (0,35 inches) : 6 mm (0,23 inches) plate + 3
mm (0,12 inches) lining
The inner side of the pad can be measured through the windows
of the clip (2).
The outer side of the pad can be measured vext to the clip on
the exterior face of the disk (3).
NBR535
● If the thickness is more than specified, check the wear
warning light and/or for possible leaks in the circuit.
6. Unscrew the bolt (4) of the upper fixture.
7. Immobilize the guide bolt (5) with a spanner.

NBR536

8. Rock the clip (6) downwards and support it so that it does not
pull on the flexible pipe.
● From here on, the brake pedal must not be pushed.

9. Disconnect the connector of the wear indicator (if there is one).

10. Unscrew the guide bolt from the clip support.
11. Remove the pads (7) from their housings.

NBR537

INSPECTION
● When the brake pads are very dirty with oil or grease, or
when they are damaged or deformed, replace them.
Wear limit of the brake pads (minimum thickness):
E = 9 mm (0,35 inches): 6 mm (0,23 inches)
plate + 3 mm (0,12 inches) lining
● If the pads are worn to below the specified limit, replace
them.
● This thickness must be measured on the most worn pad.
● If the pad is worn very unevenly, check the fork fixture for NBR538
looseness and if the disk has worn in a conic fashion,
change it.
Always replace the pads in a set of four.
● Check the disc. See BR-35, "Brake disc" in this section.
● Changing the pads on a clip automatically means those on the other end of the same axle must
also be changed.

BR-33
 FRONT DISC BRAKES

REFITTING
1. Remove the dustcovers from their housing on the pistons. Clean the piston heads with brake liquid and
grease the protruding surfaces of the pistons with LOCKHEED grease ref. 911001.
2. Check whether the dustcovers (1), after being cleaned with
denaturalised alcohol, are in a perfect state. Otherwise, replace
them.
3. Push back the pistons (2) with the tool (3).
Avoid damaging the dustcovers.

0262BR

4. Present the exterior pad (4) and fix it.

5. Present the interior pad (5) and fix it in the clip support (6).
6. Connect the cable of the wear indicator (if there is one).
7. Fit the clip (7) in its position.

NBR539

8. Fit the bolts and immobilize the lock nuts (8) with a spanner:

Guide-bolt:
30 N-m (3.1 kgm; 22.1 ft-lb)
9. Fit the wheels.
Guide-bolt:
30 N-m (3.1 kgm; 22,1 ft-lb)

Tighten the wheel nuts diametrally to a torque of: NBR540

CABSTAR. E-
120 and 100
100 35 45 / GE and GE HD
N-m 181 ÷ 216 265 ÷ 324
FRONT kgm 18,5 ÷ 22 27 ÷ 33
lb-In 133,5 ÷ 159,3 195,5 ÷ 239

10. After doing this, apply the brake several times and make sure the wheels turn freely. (See BR-36, "Calliper
and cylinder body" in this same Section.)

BR-34
 FRONT DISC BRAKES

REMOVAL
To remove the brake assembly from the vehicle, see FA-19, "FRONT
AXLE - FRONT INDEPENDENT SUSPENSION (F.I.S) / ASSEM-
BLY" in section FA.

INSPECTION
Clean all the parts and make the following checks:
Brake disc
● Disc grinding must never exceed the wear limit. Wear limit =
24 mm (0.94 inches) 0316BR
● If there is light scratching, it may be rectified on the condi-
tion that both faces are parallel and that there is not a difference in the thickness of more than 0,01
mm (0,003 inches).
(See BR-45, "TECHNICAL DATA AND CHARACTERISTICS".)
● The warping of the fitted disk must not be more than 0,07
mm (0,003 inches).
● The disc warp must be checked with a dial gauge fixed to
the calliper. Place the pointer on the ground surfaces of the
disc and spin the disc to check its warp.
Brake pads
Brake pad wear makes the pistons in the calliper move. The volume
created by this movement is filled with fluid from the brake and clutch
fluid reservoir.
0133BR
● If there is an important drop in the brake and clutch fluid
level, check the brake pad wear.
(Beforehand, check the free play in the hub bearings.)
● When the brake pads are thinner than 3 mm (0.12 inches),
they must be changed. This thickness must be measured
on the most worn pad.
● If the pads in one calliper are changed, the pads on the
opposite side of the same axle must also be changed.

FITTING
See FA-19, "FRONT AXLE - FRONT INDEPENDENT SUSPEN-
SION (F.I.S) / ASSEMBLY" in section FA.
0317BR

BR-35
 FRONT DISC BRAKES

Calliper and cylinder body EBS00J02

DISASSEMBLY
1. Drain the brake fluid from the calliper.
2. Clean any dust and mud from the calliper assembly.
3. Remove the dust guards from the pistons and use compressed
air to remove the pistons.

0318BR

4. Use a punch (1) to remove the seals (2) and (3).

5. Carefully clean the pistons and the interior of the calliper with
denatured alcohol or clean brake fluid.
● Take special care not to damage or scratch the inside of the
calliper body or the pistons.

INSPECTION
Calliper body
● Check the interior surface of the cylinder for scratches, 0319BR
rust, wear, damage or foreign bodies. Change the body of
the clip if there is any fault on the surface.
● Damage of little importance, such as rust and the presence of foreign bodies, can be removed by
filing the surface with fine grain emery cloth. Change the calliper body if the damage is important.
Pistons
● Check the piston for scratches, rust, wear or the presence of foreign bodies. Change the piston if
any fault is found.
● The sliding surface of the piston is chromed. Do not file it with emery cloth even if it is rusty or
foreign bodies are stuck to it.
O-ring
● Change the O-ring and the dust guard whenever these are removed.

BR-36
 FRONT DISC BRAKES

ASSEMBLY
Proceed in the reverse order to that of disassembly, taking the following into account:
● Lubricate the O-rings with brake fluid.
● Use clean brake fluid to lubricate the parts. Do not use mineral oil or solvents.
1. Offer up the new O-rings (1) and (2) into their housings in the
calliper (3), taking special care not to damage them.
2. Offer up the pistons, lubricating them with brake fluid, into their
housings in the calliper body.

0352BR

● The pistons must be fitted by hand. ON NO ACCOUNT

SHALL THE PISTONS BE FORCED OR HIT TO MAKE
THEM ENTER INTO THEIR HOUSINGS.
● Grease the dust guards to facilitate their fitting in the
housing in the calliper. With the dust guard fitted into the
calliper, insert it into the slot in the piston.
● Fit the protective bushes.

3. See section FA for the installation of the calliper in the vehicle.

0353BR

BR-37
 REAR DRUM BRAKES

REAR DRUM BRAKES PFP:00080

EBS00K01

0673BR

COMPONENTS
1. Wheel cylinder unit 8. Lower recovery seal 15. Brake plate
2. Cover 9. Shoe retention spring 16. Stopper
3. Piston 10. Shoe retention pin 17. Shoe return spring
4. Piston bushing 11. Hook 18. Elbowed lever
5. Cylinder body 12. Adjuster 19. Pin
6. Spring 13. Secondary pad 20. Dust cover stopper
7. Shoe retention spring 14. Primary pad

BR-38
 REAR DRUM BRAKES

REPLACING THE SHOE

Normal thickness of the lining:
Secondary: 3,95 mm (0,155 inches)
Primary: 8,95 mm (0,352 inches)
Lining wear limit (A):
1,5 mm (0,059 inches.)

0678BR

DRUM

Maximum interior diameter: 280 mm (11,02 inches)

Ovalling: 0,05 mm (0,001 inches) or less

0676BR

Fitting EBS00K02

Always adjust the play in the shoes. (See BR-43, "Adjustment".)

1. Fix the adjuster.

0675BR

2. Apply brake grease to the contact areas indicated on the left.

0679BR

BR-39
 REAR DRUM BRAKES

3. Shortern the adjuster by turning it until the exterior diameter of

the shoe is 279 ÷ 279,5 mm (10,98 ÷ 11,00 inches).
● Take care of the direction of the adjuster.

0677BR

4. Connect the parking brake cable to the elbowed lever.

5. Fit all the parts.
6. Make sure all the parts are correctly fitted.
● Take care of the direction of the adjuster.

7. Fit the brake drum.

8. When the new wheel cylinder is fitted or generally serviced,
purge the air. (See BR-8, "Bleeding" in "HYDRAULIC BRAKING
SYSTEM".)
9. Having finished, apply pressure to the brake by pressing the
pedal half way down approximately 20 times. 0674BR

BR-40
 REAR DRUM BRAKES

Brake drum EBS00K03

INSPECTION
● Check the inner diameter of the brake drum to ensure that it is perfectly circular and cylindrical.
Repair or change the drum if it does not meet the specifications.
Nominal diameter = 280 mm (11.02 inches)
Maximum allowed ovalling limit: 0.05 mm (0.002 inches)
Maximum allowed eccentricity (total gauge reading)
= 0.06 mm (0.002 inches)
● The surface of the drum with which the brake shoes enter into contact must be finished using
emery cloth of Nß 120 to 150.
● Use a drum grinder to finish the brake drum if it is scratched, partially worn or is stepped at its
contact surface between the linings and the drum.
● After the drum has been completely reconditioned or changed, check that the shoes and drum
make contact correctly.

FITTING
● Remove the drum. See the corresponding section in section RA.
● Remove the wheel. See the corresponding section in section RA.
● Wheel fixing nuts.
Tighten the wheel nuts diametrally and give a torque according to the table.
CABSTAR. E-
100 100 and 120
28 / 32 / 34 35* 35* 45* / GE* and GE HD*
N-m 184 ÷ 220 144 ÷ 216 273
REAR kgm 18,8 ÷ 22,4 14,7 ÷ 22 27,8
lb-In 135,7 ÷ 162,3 106,2 ÷ 159,3 201,4
* Twin wheels
● Adjust the parking brake cable. See BR-43, "Adjustment" in this manual.
● After fitting, bleed the braking system. See BR-8, "Bleeding" in this section.

BR-41
 PARKING BRAKE

PARKING BRAKE PFP:00081

EBS00L01

0329BR

COMPONENTS
1. Parking brake assembly 5. Rear cable tensioner
2. Parking brake switch 6. RH rear cable
3. Front cable 7. LH rear cable
4. Rocker

REMOVAL AND FITTING

1. Loosen and remove the rear LH cable from the tensioner.
2. Remove the drum, the brake shoe and the front cable.

1. Tensioner 0330BR

3. Remove the cable tightening nut and the cable.

0331BR

BR-42
 PARKING BRAKE

INSPECTION
1. Check the following points. Change any defective parts.
● Drive lever, for deformation and wear

● Parking brake cables

Check whether they are bent, worn or frayed

● Operation of the warning light and switch

● Cable joints

Adjustment
1. With the brake lever released, turn the nut (1) until the rocker is
at 230 mm (9.055 inches) from the cross-member.
2. Tighten the lock nut (2) to the specified torque.
Tightening torque of lock nut (2) for adjusting rocker
9.2 ÷ 13.8 N-m (0.94 ÷ 1.41 kgm; 6.79 ÷ 10.19 ft-lb)

0332BR

0334BR

3. With the diameter of the linings “D” at 279 ÷ 279.5 mm (10.98 ÷

11.00 inches), turn the tensioner (3) until the rear cables are
tense and the wheels spin freely (a slight rubbing of the lining is
permissible for this type of dual servo).
4. Tighten the nut (4) to the specified torque.
Tightening torque for the tensioner adjustment nut (3).
9.2 ÷ 13.8 N-m (0.94 ÷ 1.41 kgm; 6.79 ÷ 10.19 ft-lb)

0684BR

BR-43
 PARKING BRAKE

NOTE:

BR-44
 TECHNICAL DATA AND CHARACTERISTICS

TECHNICAL DATA AND CHARACTERISTICS PFP:00082

Technical data EBS00LL01

FRONT DISC BRAKE

Unit:mm (inches)
CABSTAR
CABSTAR 100
100 (45 GE / 45 GEHD)
Brake model 120 (35)
120 (45 / 45HD)
VD PF 2x48 VD PF 2x52
Pad wear limit
Maximum permissible warp 9 mm (0.35 inches) : 6 mm (0.23 inches) plate + 3 mm (0.12 inches) lining
Limit of disc repair
Maximum permitted warp 0.07 (0.003)
Minimum permissible thickness 24 (0.944)

REAR DRUM BRAKE

Unit:mm (inches)
Type LT-28 SIMPLEX
Lining wear limit
Minimum permissible thickness mm (inch) 1.5 (0.059)
Drum wear limit
Maximum inner diameter mm (inch) 280 (11.02)
Maximum permitted eccentricity mm (inch) 0.06 (0.002)
Maximum permitted ovalling mm (inch) 0.05 (0.001)

PARKING BRAKE
Number of teeth in the rachet when the
1
warning light of the instrument panel lights
Number of teeth
9 - 10
(Applying a force of 196 N (20 kg; 44 lb)

BRAKE PEDAL
Unit: mm (inches)
Free height “H” 169 ÷ 174 (6.65 ÷ 6.85)
Clearance between pedal stop and switch 7 (0.28)
Pedal free play 1 ÷ 5 (0.039 ÷ 0.196)
Pedal travel “D” 140 (5.51)

BR-45
 TECHNICAL DATA AND CHARACTERISTICS

FRONT BRAKES
Type Discs, ventilated
CABSTAR 100 CABSTAR100 (45 GE / 45
Model 120 (35) GEHD)120 (45 / 45HD)
VD PF 2X48 VD PF 2X52
Drive system
Number of pistons per calliper 2
Diameter mm (inches) 48 (1.89) 52 (2.04)
Brake pads
Thickness standard mm (inches) 18 mm (0.70 inch): 6 mm (0.23 inch) plate + 12 mm (0.47 inch) lining
Friction surface area
(per pad) cm2(sq. inch) 68.5 (10.616)
Disc
Diameter mm (inches) 276 (10.86)
Diameter mm (inches) 26 (1.023)
REAR BRAKES
Type Drum
Model LT 28
Adjustment Automatic
Operation piston
Diameter mm (inches) 25.4 (1)
Drum Diameter mm (inches) 280 (11.02)
Shoes Diameter mm (inches) 279 ÷ 279.5 (10.98 ÷ 11.00)
Friction surface area cm2 (p.s.i.) 304.5 (11.988)
BRAKE SERVO
Model MVT 8 inches (203,2 mm) + 9 inches (228,6 mm)
BRAKE CYLINDER
Diameter mm (inches) 27 (1.06)
RECOMMENDED BRAKE FLUID DOT 4

BR-46
 TECHNICAL DATA AND CHARACTERISTICS

TIGHTENING TORQUES N-m kgm ft lbs

Brake purging valve 7÷9 0,7 ÷ 0,9 5,2 - 6,6
Brake pipe connectors 10 1 7,4
BRV inlet connector nut 17,0 ÷ 21,0 1,7 ÷ 2,1 12,5 ÷ 15,5
BRV outlet connector nut 17,0 ÷ 21,0 1,7 ÷ 2,1 12,5 ÷ 15,5
Bolt fixing BRV to bracket: 59 ÷ 76 6,0 ÷ 7,8 43,5 ÷ 56,1
Nut fixing brake servo to bracket 9,3 ÷ 10,8 0,95 ÷ 1,1 6,9 ÷ 8
Nut fixing pedal shaft bolt 20 ÷ 23 2 ÷ 2,3 14 ÷ 17
Bolts fixing brake pedal bracket to cab floor 9,3 ÷ 10,8 0,95 ÷ 1,1 6,9 ÷ 8
Brake light switch regulator nut 12 ÷ 15 1,2 ÷ 1,5 9 ÷ 11
Bolts fixing upper pedal bracket and brake servo 9,3 ÷ 10,8 0,95 ÷ 1,1 6,9 ÷ 8
Nuts fixing master cylinder to brake servo 39 4,0 28,8
Bolt fixing the grease nozzle to the depressor and
19 ÷ 27 1,9 ÷ 2,8 14 ÷ 19,9
engine block
Bolts fixing the depressor to the distribution cover 17 ÷ 23 1,7 ÷ 2,3 12,5 ÷ 17
Drain socketto depressor 29 ÷ 34 3,0 ÷ 3,5 21,4 ÷ 25,1
Guidebolt 30 3,1 22,1
Bolts fixing brake plate 68 ÷ 102 6,9 ÷ 10,4 50,2 ÷ 75,2
Bolts fixing cylinder to brake plate 6 ÷ 11 0,6 ÷ 1,1 4,4 ÷ 8,1
Bolt fixing hand brake column 8,7 ÷ 12 0,89 ÷ 1,2 6,4 ÷ 8,9
Hand brake to tensioner support regulation nut 9,2 ÷ 11,7 0,94 ÷ 1,41 6,7 ÷ 10,1
Bolt fixing the spring lever to its support 21 ÷ 31 2,1 ÷ 3,2 15,5 ÷ 22,9
Servobrakenut to brake pedal support 15 ÷ 21 1,5 ÷ 2,1 11,1 ÷ 15,5

BR-47
 DESCRIPTION / ABS BD-30 TI/BD-30 T

DESCRIPTION / ABS BD-30 TI/BD-30 T PFP:00083

Purpose EBS00M01

The anti-lock braking system (ABS) includes electronic and hydraulic components. It allows to control the
braking force so that locking of the wheels can be avoided.
The ABS:
1. Ensures proper tracking performance through steering wheel operation.
2. Enables obstacles to be avoided through steering wheel operation.
3. Ensures vehicle stability by preventing flat spins.
ABS (Anti-Lock Brake System) Operation EBS00M02

● When the vehicle speed is less than 10 km/h (6 mph) this system does not work.
● The Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS warning lamp
for 1 second after turning the ignition switch ON. The system performs another test the first time the
vehicle reaches 6 km/h (4 mph).
A mechanical noise may be heard as the ABS performs a self-test. This is a normal part of the self-test
feature. If a malfunction is found during this check, the ABS warning lamp will come on.
● During ABS operation, a mechanical noise may be heard. This is a normal condition.
ABS Hydraulic Circuit EBS00M03

See BR-6, "HYDRAULIC BRAKING SYSTEM" of this manual.

0682BR

COMPONENTS
1. Intake solenoid valve 4. Pump 6. Derivation retention valve
2. Outlet solenoid valve 5. Engine 7. Damper
3. Tank

System Components EBS00M04

See the section BR-50, "Component Parts and Harness Connector Location" in this section.

BR-48
 DESCRIPTION / ABS BD-30 TI/BD-30 T

System Description EBS00M05

SENSOR
The sensor unit consists of a gear-shaped sensor rotor and a sensor
element. The element contains a bar magnet around which a coil is
wound. The sensor is installed on the back side of the brake rotor
and the snubber. Sine-wave current is generated by the sensor as
the wheel rotates. The frequency and voltage increase(s) as the
rotating speed increases.

0592BR

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 motor relay. If any electrical malfunction should be
detected in the system, the control unit causes the warning lamp to
light up. In this condition, the ABS will be deactivated by the control
unit, and the vehicle’s brake system reverts to normal operation.
NOTE:
In certain conditions, the ECM in vehicles with a BD-30 Ti motor
may believe there is an error in the system and so illuminate the 0593BR
ABS light.
These conditions are: the vehicle is stationary, but the parking
brake is not ON, minimum box configuration in empty and vehicle operating at over 4000 rpm.
To eliminate the error stored in the ECM’s memory, just drive at 15 Km/h (9.32 mph) and the light goes
out, this shows that the supposed error does not fact exist.
ABS ACTUATOR AND ELECTRIC UNIT
The ABS actuator and electric unit contains:
● An electric motor and pump.
● Two relays.
● Six solenoid valves, each inlet and outlet for
– Part left front
– Part right front
– Part rear
● ABS control unit
This components controls the hydraulic circuit and increases, 0594BR
holdsor decreases hydraulic pressure to all or individual wheels. The
ABS actuator and electric unit can not be disassembled and will be serviced as an assembly.
ABS ACTUATOR OPERATION
Intake solenoid Exhaust solenoid
valve valve
Master cylinder brake fluid pressure is directly transmitted
Normal brake operation OFF (Open) OFF (Closed)
to caliper via the inlet solenoid valve.
Hydraulic circuit is shut off to hold the caliper brake fluid
Pressure hold ON (Closed) OFF (Closed)
pressure.
Pressure Caliper brake fluid is sent to reservoir via the outlet solenoid
ABS operation ON (Closed) ON (Open)
decrease [Link] it is pushed up to the master cylinder by pump.
Pressure Master cylinder brake fluid pressure is transmitted to
OFF (Open) OFF (Closed)
increase caliper.

BR-49
 DESCRIPTION / ABS BD-30 TI/BD-30 T

Component Parts and Harness Connector Location EBS00M06

0683BR

A FRONT SENSOR B DATA LINK CONNECTOR

NBR541 NEF465A

C CONTROL UNIT AND ACTUATOR D REAR SENSOR

0655BR 0681BR

BR-50
 TROUBLE DIAGNOSIS / ABS BD-30 TI/BD-30 T

TROUBLE DIAGNOSIS / ABS BD-30 TI/BD-30 T PFP:00084

Circuit diagram for a quick check EBS00N01

IGNITION BATTERY
SWITCH
ON O START

FUSE FUSE LINK

COMBINATION
METER

STOP LAMP
SWITCH
ABS

15 14

21 18

17

SFL 2 7
R27
LH FRONT
1 6 ENGINE BRAKE
13 DISCONNECTING
RELAY

T11
SFR 2 5
ABS ACTUATOR
RH FRONT AND
1 4 ELECTRIC UNIT

SRL 1 9

LH REAR K60
2 8
DATA LINK
CONNECTOR

11
SRR 1 2
22
RH REAR 2 1 12
SENSOR

16 19

NBR542

BR-51
 TROUBLE DIAGNOSIS / ABS BD-30 TI/BD-30 T

Wiring Diagram EBS00N02

IGNITION
SWITCH BR-ABS-01
ON O START
BATTERY B/W
17
C08
Refer to 15A FUSE AND
17 RELAY BOX
EL-POWER-01
F37
65A 30A 39
FUSE LINK
BOX G/B

R/W
W R/Y R/W G/B
TO
W 1 W 3 IBC
EL-START-01

B01 COMBINATION
ABS
W METER

R/Y

12 IAC 1 IBC

R/W PU B
B01 1 10

W R/Y R/W PU B

17 18 15 21

T11
ABS ACTUATOR AND
ELECTRIC UNIT

19 16

B/Y B
B

B/Y B
B
B B
1 B01 B

B
B B B B

T11 IBC Refer to the last page

IAC
"Section EL"
B01
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
6 7 5 6
26 25 24 23 22 21 20 C08
19 18 17 16 5 8 4 7
31 30 29 28 27 3 8
4 9

3 10 2 9
2 11 1 10
1 12

NBR543

BR-52
 TROUBLE DIAGNOSIS / ABS BD-30 TI/BD-30 T

BR-ABS-02

TO
R R C
EC-INJPMP-01
R
TO
Ti L/R
EC-EXH/BRAKE-01
K60 R L/R
DATA LINK
2 5 3
CONNECTOR
R27

12 13 15 EXHAUST BRAKE
RELAY

4 1

R/Y G BR L/R BR/B TO

Ti BR/B
EC-EXH/BRAKE-01

R/Y G BR L/R

B01 9 11 2 8

R/Y G BR L/R

R/Y G BR L/R

11 22 12 13

T11
ABS ACTUATOR AND
ELECTRIC UNIT

Ti : VEHICLES WITH BD-30 Ti ENGINE

Refer to the last page

"Section EL"
T11 K60
B01

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8

26 25 24 23 22 21 20 9 10 11 12 13 14 15 16
19 18 17 16
31 30 29 28 27
R27

1
4 3 2
5
NBR544

BR-53
 TROUBLE DIAGNOSIS / ABS BD-30 TI/BD-30 T

BR-ABS-03

T11

ABS ACTUATOR AND

ELECTRIC UNIT

6 7 4 5

W B W B

W B W B

1 2 1 2

SFL SFR

FRONT ABS FRONT ABS

SENSOR LH SENSOR RH

SFL SFR T11

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

2 1 2 1 26 25 24 23 22 21 20
19 18 17 16
31 30 29 28 27

NBR545

BR-54
 TROUBLE DIAGNOSIS / ABS BD-30 TI/BD-30 T

BR-ABS-04

T11
ABS ACTUATOR AND
ELECTRIC UNIT

14 8 9 1 2

G/Y B/R W/R L/B L/W

TO
A G/Y
EL-STOP-01

B25 9 10 11 12

W B W B

2 1 2 1

SRL SRR
REAR ABS REAR ABS
SENSOR LH SENSOR RH

T11 SRL SRR

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

26 25 24 23 22 21 20 1 2 1 2
19 18 17 16
31 30 29 28 27

4 3 2 1
8 7 6 5 B25
12 11 10 9

NBR546

BR-55
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION / ABS BD-30 TI/BD-30 T

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION / ABS BD-30 TI/BD-30 T PFP:00085

Self-diagnosis EBS00P01

FUNCTION
● When a problem occurs in the ABS, the ABS warning lamp on the instrument panel comes on. To start the
self-diagnostic results mode, ground the self-diagnostic (check) terminal located on “Data link connector”.
The location of the malfunction is indicated by the ABS warning lamp flashing.

SELF-DIAGNOSIS PROCEDURE
1. Drive vehicle over 30 km/h (18.64 mph) for at least one minute.
2. Turn ignition switch “OFF”.
3. Ground terminal 15 of “Data link connector” with a suitable
harness.
4. Turn ignition switch “ON” while grounding terminal 15 .
Do not depress brake pedal.
Do not start engine.

NEF465A

5. After 3 seconds, the ABS warning lamp starts flashing to

indicate the malfunction code No. (See NOTE.)
6. Verify the location of the malfunction with the malfunction code
chart.
Refer to BR-68, "Malfunction Code/Symptom Chart". Then make
the necessary repairs following the diagnostic procedures.
7. After the malfunctions are repaired, erase the malfunction codes
stored in the control unit. Refer to BR-57, "HOW TO ERASE
SELF-DIAGNOSTIC RESULTS".
8. Return the self-diagnostic results mode to verify that the 0593BR
malfunction codes have been erased.

9. Disconnect the check terminal from the ground. The self-diagnostic results mode is now complete.
10. Check ABS warning lamp for deactivation after driving vehicle over 30 km/h (18.64 mph) for at least one
minute.
11. After making certain that ABS warning lamp does not come on, test the ABS SELF-DIAGNOSIS in a safe
area to verify that it functions properly.

NOTE:
The indication terminates after five minutes.
However, when the ignition switch is turned from “OFF” to “ON”, the indication starts flashing again.

BR-56
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION / ABS BD-30 TI/BD-30 T

HOW TO READ SELF-DIAGNOSTIC RESULTS

(MALFUNCTION CODES)
1. Determine the code No. by counting the number of times the ABS warning lamp flashes on and off.
2. When several malfunctions occur at one time, up to three code numbers can be stored; the latest
malfunction will be indicated first.
3. The indication begins with the start code 12. After that a maximum of three code numbers appear in the
order of the latest one first.
The indication then returns to the start code 12 to repeat (the indication will stay on for five minutes at the
most).
4. The malfunction code chart is given in BR-68, "Malfunction Code/Symptom Chart".

Example: Code No. 32 REAR SENSOR SHORT-CIRCUIT

0595BR

HOW TO ERASE SELF-DIAGNOSTIC RESULTS

(MALFUNCTION CODES)
1. Disconnect the check terminal from ground (ABS warning lamp
will stay lit).
2. For a 12,5 seconds, ground the check terminal 3 times. Each
terminal ground must last more than 1 second.
The ABS warning lamp goes out after the erase operation has
been completed.
3. Perform self-diagnosis again. Refer to last page. Only the start
code should appear, (no malfunction codes).

0596BR

BR-57
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION / ABS BD-30 TI/BD-30 T

CONSULT-II EBS00P02

CONSULT-II APPLICATION TO ABS

SELF-DIAGNOSTIC
ITEM DATA MONITOR ACTIVE TEST
RESULTS
Front right wheel sensor X X —
Front left wheel sensor X X —
Rear right wheel sensor X X —
Rear left wheel sensor X X —
Stop lamp switch — X —
Front right inlet solenoid valve X X X
Front right outlet solenoid valve X X X
Front left inlet solenoid valve X X X
Front left outlet solenoid valve X X X
Rear inlet solenoid valve X X X
Rear outlet solenoid valve X X X
Actuator solenoid valve relay X X —
Actuator motor relay (ABS MOTOR is shown on the
X X X
ACTIVE TEST screen.)
ABS warning lamp — X —
Battery voltage X X —
Brake warning lamp — X —
Signal operation of the ABS — — —
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 ECU.

BR-58
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION / ABS BD-30 TI/BD-30 T

CONSULT-II Inspection Procedure EBS00P03

SELF-DIAGNOSIS PROCEDURE
1. Turn ignition switch OFF.
2. Connect CONSULT-II to data link connector.
3. Start engine.
4. Drive vehicle over 30 km/h (18.64 mph) for at least one minute.

NEF465A

5. Stop vehicle with engine running and touch “START” on

CONSULT-II screen.

0602BR

6. Touch “ABS”.

NBR547

7. Touch “SELF-DIAG RESULTS”.

● The screen shows the detected malfunction and how many
times the ignition switch has been turned since the malfunc-
tion.
8. Make the necessary repairs following the diagnostic procedures.

0604BR

BR-59
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION / ABS BD-30 TI/BD-30 T

9. After the malfunctions are repaired, erase the self-diagnostic

results stored in the control unit by touching “ERASE”.
10. Check ABS warning lamp for deactivation after driving vehicle
over 30 km/h (18.64 mph) for at least one minute.
11. Test the ABS system in a safe area to verify that it functions
properly.
NOTE:
“SELF-DIAG RESULTS” screen shows the detected malfunction
and how many times the ignition switch has been turned since
the malfunction.
0605BR

SELF-DIAGNOSTIC RESULTS MODE

Reference
Diagnostic item Diagnostic item is detected when ...
page
FR RH SENSOR ● Circuit for front right wheel sensor is open.
BR-69
[OPEN]*1 (An abnormally high input voltage is entered).
FR LH SENSOR ● Circuit for front left wheel sensor is open.
BR-69
[OPEN]*1 (An abnormally high input voltage is entered).
RR RH SENSOR ● Circuit for rear right sensor is open.
BR-69
[OPEN]*1 (An abnormally high input voltage is entered).
RR LH SENSOR ● Circuit for rear left sensor is open.
BR-69
[OPEN]*1 (An abnormally high input voltage is entered).
FR RH SENSOR ● Circuit for front right wheel sensor is shorted.
BR-69
[SHORT]*1 (An abnormally low input voltage is entered).
FR LH SENSOR ● Circuit for front left wheel sensor is shorted.
BR-69
[SHORT]*1 (An abnormally low input voltage is entered).
RR RH SENSOR ● Circuit for rear right sensor is shorted.
BR-69
[SHORT]*1 (An abnormally low input voltage is entered).
RR LH SENSOR ● Circuit for rear left sensor is shorted.
BR-69
[SHORT]*1 (An abnormally low input voltage is entered).
ABS SENSOR ● Teeth damage on sensor rotor or improper installation of wheel sensor.
BR-72
[ABNORMAL SIGNAL] (Abnormal wheel sensor signal is entered).
FR RH IN ABS SOL ● Circuit for front right inlet solenoid valve is open.
BR-72
[OPEN] (An abnormally low output voltage is entered).
FR LH IN ABS SOL ● Circuit for front left inlet solenoid valve is open.
BR-72
[OPEN] (An abnormally low output voltage is entered).
RR IN ABS SOL ● Circuit for rear inlet solenoid valve is open.
BR-72
[OPEN] (An abnormally low output voltage is entered).
FR RH IN ABS SOL ● Circuit for front right inlet solenoid valve is shorted.
BR-72
[SHORT] (An abnormally high output voltage is entered).
FR LH IN ABS SOL ● Circuit for front left inlet solenoid valve is shorted.
BR-72
[SHORT] (An abnormally high output voltage is entered).
RR IN ABS SOL ● Circuit for rear inlet solenoid valve is shorted.
BR-72
[SHORT] (An abnormally high output voltage is entered).
FR RH OUT ABS SOL ● Circuit for front right outlet solenoid valve is open.
BR-72
[OPEN] (An abnormally low output voltage is entered).
FR LH OUT ABS SOL ● Circuit for front left outlet solenoid valve is open.
BR-72
[OPEN] (An abnormally low output voltage is entered).
RR OUT ABS SOL ● Circuit for rear outlet solenoid valve is open.
BR-72
[OPEN] (An abnormally low output voltage is entered).
FR RH OUT ABS SOL ● Circuit for front right outlet solenoid valve is shorted.
BR-72
[SHORT] (An abnormally high output voltage is entered).
FR LH OUT ABS SOL ● Circuit for front left outlet solenoid valve is shorted.
BR-72
[SHORT] (An abnormally high output voltage is entered).

BR-60
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION / ABS BD-30 TI/BD-30 T

Reference
Diagnostic item Diagnostic item is detected when ...
page
RR OUT ABS SOL ● Circuit for rear outlet solenoid valve is shorted.
BR-72
[SHORT] (An abnormally high output voltage is entered).

ABS ACTUATOR RELAY ● Actuator solenoid valve relay is ON, even control unit sends off signal.
BR-72
[ABNORMAL] ● Actuator solenoid valve relay is OFF, even control unit sends on signal.

ABS MOTOR RELAY ● Circuit for actuator motor is open or shorted.

BR-75
[ABNORMAL] ● Actuator motor relay is stuck.
BATTERY VOLT
● Power source voltage supplied to ABS control unit is abnormally low. BR-77
[ABNORMAL]
CONTROL UNIT ● Function of calculation in ABS control unit has failed. BR-79
*1 If one or more of the wheels skinds on roads with an uneven surface for more than 10 seconds, the ABS indicator may light up. In
such a case, the fault code refering to the wheel sensors may be memorized. Turn the engine OFF, turn it on again and drive the vehi-
cle at speeds above 30 km/h (18.64 mph) for approximately 1 minute, as indicated in BR-59, "SELF-DIAGNOSIS PROCEDURE".
Check that the ABS indicator goes off while the vehicle is being driven.

DATA MONITOR PROCEDURE

1. Turn ignition switch OFF.
2. Connect CONSULT-II to data link connector.
3. Turn ignition switch ON.
4. Touch “START” on CONSULT-II screen.

0602BR

5. Touch “ABS”.

NBR547

6. Touch “DATA MONITOR”.

7. Touch “SETTING” on “SELECT MONITOR ITEM” screen.
8. Touch “LONG TIME” on “SET RECORDING COND” screen.
9. Touch “START” on “SELECT MONITOR ITEM”.

0604BR

BR-61
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION / ABS BD-30 TI/BD-30 T

MONITOR PROCEDURE MODE

INSPECTION ITEM CONDITION SPECIFICATION
FR RH SENSOR
FR LH SENSOR Drive vehicle. Displays computed vehicle speed from wheel sensor signal.
RR RH SENSOR (Each wheel is rotating). Almost the same speed as speedometer.
RR LH SENSOR
Turn ignition switch ON and Depress the pedal: ON
STOP LAMP SW
depress brake pedal. Release the pedal: OFF
FR RH IN SOL
FR RH OUT SOL
FR LH IN SOL 1. Drive vehicle over 30 km/h Operating conditions for each solenoid valve are indicated.
FR LH OUT SOL (18.64 mph) for at least one ABS is not operating: OFF
RR IN SOL minute.
RR OUT SOL 2. Motor is running.
Displays ON/OFF condition of ABS actuator relay.
ACTUATOR RELAY
When turning ignition switch ON, ABS actuator relay is operated.
ABS is not operating: OFF
MOTOR RELAY
ABS is operating: ON
Ignition switch is turned ON o
Warning lamp is turned on: ON
WARNING LAMP engine is running.
Warning lamp is turned off: OFF
BATTERY VOLT Power supply voltage for control unit.

ACTIVE TEST PROCEDURE

● When conducting Active test, vehicle must be stationary.
● When ABS warning lamp stays on, never conduct Active test.
1. Turn ignition switch OFF.
2. Connect CONSULT-II to data link connector.
3. Start engine.
4. Touch “START” on CONSULT-II screen.

0602BR

5. Touch “ABS”.

NBR547

BR-62
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION / ABS BD-30 TI/BD-30 T

6. Touch “ACTIVE TEST”.

0604BR

7. Select active test item by touching screen.

0606BR

8. Touch “START”.
9. Carry out the active test by touching screen key.

0607BR

ACTIVE TEST MODE

TEST ITEM CONDITION JUDGEMENT
Brake fluid pressure control operation
IN SOL OUT SOL
FR RH SOLENOID
FR LH SOLENOID UP (Increase): OFF OFF
RR SOLENOID
KEEP (Hold): ON OFF
Engine is running
DOWN (Decrease): ON ON
ABS actuator motor
ABS MOTOR ON: Motor runs (ABS motor relay connect)
OFF: Motor stops (ABS motor relay disconnect)
NOTE:
Active test will automatically stop ten seconds after the test starts. (Monitor LIMIT SIGNAL shows ON).

BR-63
 TROUBLE DIAGNOSIS - INTRODUCTION / ABS BD-30 TI/BD-30 T

TROUBLE DIAGNOSIS - INTRODUCTION / ABS BD-30 TI/BD-30 T PFP:00086

How to Perform Trouble Diagnoses for Quick and Accurate Repair EBS00Q01

INTRODUCTION
The ABS system has an electronic control unit to control major
functions.
The control unit accepts input signals from sensors and instantly
drives actuator. It is essential that both kinds of signals are proper
and stable. It is also important to check for conventional problems:
such as air leaks in the booster or lines, lack of brake fluid, or other
problems with the brake system.
It is much more difficult to diagnose a problem that occurs intermit-
tently rather than continuously. Most intermittent problems are
caused by poor electric connections or faulty wiring. In this case,
careful checking of suspicious circuits may help prevent the replace- 0534BR
ment of good parts. A visual check only may not find the cause of the
problems, so a road test should be performed.
Before undertaking actual checks, take just a few minutes to talk with
a customer who approaches with a ABS complaint.
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. Also check related Service Bulletins for
information.

0533BR

BR-64
 TROUBLE DIAGNOSIS - BASIC INSPECTION / ABS BD-30 TI/BD-30 T

TROUBLE DIAGNOSIS - BASIC INSPECTION / ABS BD-30 TI/BD-30 T PFP:00087

Preliminary Check EBS00R01

1. CHECK BRAKE FLUID LEVEL

Check brake fluid level in reservoir tank.
Low fluid level may indicate brake pad wear or leakage from brake
line.
Is brake fluid filled out of correct range on reservoir tank and/or has
brake fluid been contaminated?
Yes >> 1. Repair
2. GO TO 2.
No >> GO TO 2.

0550BR

2. CHECK BRAKE LINE

Check brake line for leakage.
Is leakage present at or around brake lines, tubes or hoses or are
any of these parts cracked or damaged?
Yes >> 1. Repair
2. GO TO 3.
No >> GO TO 3.

0597BR

3. CHECK BRAKE BOOSTER OPERATION

Check brake booster for operation and air tightness.
Refer BR-25, "BRAKE SERVO".
Is brake booster airtight and functioning properly?
Yes >> GO TO 4.
No >> 1. Replace.
2. GO TO 4.

0598BR

4. CHECK BRAKE PAD AND ROTOR

Check brake pad, rotor and the drums.
Refer BR-32, "FRONT DISC BRAKES" and BR-38, "REAR DRUM
BRAKES".
Are brake pads, rotors and drums functioning properly?
Yes >> GO TO 5.
No >> Replace.

0599BR

BR-65
 TROUBLE DIAGNOSIS - BASIC INSPECTION / ABS BD-30 TI/BD-30 T

5. RECHECK BRAKE FLUID LEVEL

Check brake fluid level in reservoir tank again.
Is brake fluid filled out of correct range on reservoir tank and/or has
brake fluid been contaminated?
Yes >> 1. Replace.
2. GO TO 6.
No >> GO TO 6.

0550BR

6. CHECK WARNING LAMP ACTIVATION

Check warning lamp activation.
Does warning lamp turn on when ignition switch is turned “ON”?
Yes >> GO TO 7.
No >> Check fuse, warning lamp bulb and warning lamp circuit.

0593BR

7. CHECK WARNING LAMP DEACTIVATION

Check warning lamp for deactivation after engine is started.
Does warning lamp turn off when engine is started?
Yes >> GO TO 8.
No >> 1. Go to Self-diagnosis.
2. Refer BR-56, "Self-diagnosis" and BR-59, "CONSULT-II Inspection Procedure".

8. DRIVE VEHICLE
Drive vehicle at speeds over 30 km/h (18.64 mph) for at least one minute.
Does warning lamp remain off after vehicle has been driven at 30 km/h (18.64 mph) for at least one minute?
Yes >> END
No >> 1. Go to Self-diagnosis.
2. Refer BR-56, "Self-diagnosis" and BR-59, "CONSULT-II Inspection Procedure".

BR-66
 TROUBLE DIAGNOSIS - BASIC INSPECTION / ABS BD-30 TI/BD-30 T

Ground Circuit Check EBS00R02

ABS ACTUATOR AND ELECTRIC UNIT GROUND

● Check continuity between ABS actuator and electric unit, 16
and 19 connector terminals and ground.
Continuity should exist.

0551BR

BR-67
 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION / ABS BD-30 TI/BD-30 T

TROUBLE DIAGNOSIS - GENERAL DESCRIPTION / ABS BD-30 TI/BD-30 T PFP:00088

Malfunction Code/Symptom Chart EBS00S01

Code No.
Malfunctioning part Reference page
(No. of LED flashes)
18 *1 Sensor rotor BR-69
21 *1 Front right sensor (open-circuit) BR-69
22 *1 Front right sensor (short-circuit) BR-69
25 *1 Front left sensor (open-circuit) BR-69
26 *1 Front left sensor (short-circuit) BR-69
31 *1 Rear right sensor (open-circuit) BR-69
32 *1 Rear right sensor (short-circuit) BR-69
35 *1 Rear left sensor (open-circuit) BR-69
36 *1 Rear left sensor (short-circuit) BR-69
41 Actuator front right outlet solenoid valve BR-72
42 Actuator front right inlet solenoid valve BR-72
45 Actuator front left outlet solenoid valve BR-72
46 Actuator front left inlet solenoid valve BR-72
55 Actuator rear outlet solenoid valve BR-72
56 Actuator rear inlet solenoid valve BR-72
57 *2 Power supply (Low voltage) BR-77
61 *3 Actuator motor or motor relay BR-75
63 Solenoid valve relay BR-72
71 Control unit BR-79
Control unit power supply circuit
ABS warning lamp stays on Warning lamp bulb circuit
when ignition switch is Control unit or control unit connector BR-86
turned on. Solenoid valve relay stuck
Power supply for solenoid valve relay coil
ABS warning lamp does not
Fuse, warning lamp bulb or warning lamp circuit
come on when ignition BR-84
Control unit.
switch is turned on.
Pedal vibration and noise — BR-83
Long stopping distance — BR-82
Unexpected pedal action — BR-81
ABS does not work. — BR-82
ABS works frequently. — BR-81
*1 If one or more of the wheels skinds on roads with an uneven surface for more than 10 seconds, the ABS indicator may light up. In
such a case, the fault code refering to the wheel sensors may be memorized. Turn the engine OFF, turn it on again and drive the vehi-
cle at speeds above 30 km/h (18.64 mph) for approximately 1 minute, as indicated in BR-59, "SELF-DIAGNOSIS PROCEDURE".
Check that the ABS indicator goes off while the vehicle is being driven.
*2 Fault code 57 indicates a low electrical supply voltage. It does not indicate a fault in the ABS control unit. Do not replace the ABS con-
trol unit with a new one.
*3 Fault code 61 may appear on occasions when the ABS motor has not been correctly connected to the earth. If this fault code
appears, check the connection to earth of the ABS motor.

BR-68
 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS / ABS BD-30 TI/BD-30 T

TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS / ABS BD-30 TI/BD-30 T PFP:00089

Wheel Sensor or Rotor EBS00T01

DIAGNOSTIC PROCEDURE MALFUNCTION CODE NO. 21, 22, 25, 26, 31, 32, 35, 36 OR 18
NOTE:
Wheel position should be identified by code No. except code No. 18 (sensor rotor).

1. INSPECTION START
Wheel sensor inspection

NBR550

>> GO TO 2.

2. CHECK CONNECTOR
1. Disconnect connectors from control unit and wheel sensor of malfunction code No. Check terminals for
damage or loose connections. Then reconnect connectors.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
Yes >> GO TO 3.
No >> INSPECTION END

BR-69
 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS / ABS BD-30 TI/BD-30 T

3. CHECK WHEEL SENSOR CIRCUIT

1. Disconnect control unit connector.
2. Check resistance between T11 connector from the ABS actua-
tor and electric unit.
Code No. 21 or 22 (Front RH wheel)
Terminals 4 and 5 .
Code No. 25 or 26 (Front LH wheel)
Terminals 6 and 7 .
Resistance: 1,28 ÷ 1,92 kΩ
Code No. 31 or 32 (Rear RH wheel) 0553BR

Terminals 1 and 2 .
Code No. 35 or 36 (Rear LH wheel)
Terminals 8 and 9 .
Resistance: 1,28 - 1,92 kΩ
Is resistance 1,28 - 1,92 kΩ (FR and RR)?
Yes >> GO TO 5.
No >> GO TO 4.

4. CHECK WHEEL SENSOR

Check resistance of each sensor. (See NOTE.)
Resistance: 1,28 - 1,92 kΩ (FR and RR)
Is resistance 1,28 - 1,92 kΩ (FR and RR)?
Yes >> Check the following.
● Harness connector T11 .
● Harness for open or short between sensor connector,
wheel and ABS actuator and electric unit.
If NG, repair harness or connectors.
No >> Replace wheel sensor. NBR551

BR-70
 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS / ABS BD-30 TI/BD-30 T

5. CHECK TIRE
Check for inflation pressure, wear and size of each tire.
Are tire pressure and size correct and is tire wear within specifications?
Yes >> GO TO 6.
No >> Adjust tire pressure or replace tire(s).

6. CHECK WHEEL BEARING

Check wheel bearing axial end play.
Check the play between the sensor and the rotor on the front and rear axles.

NBR552

Is axial end play and clearance within specifications?

Yes >> GO TO 7.
No >> Clean sensor fixing portion, or replace sensor.

7. CHECK SENSOR ROTOR

Check sensor rotor for teeth damage.
Is sensor rotor free from damage?
Yes >> 1. Check control unit pin terminals for damage or the connection of control unit harness
connector.
2. Reconnect control unit harness connector.
3. Then retest.
No >> Replace sensor rotor.

BR-71
 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS / ABS BD-30 TI/BD-30 T

ABS Actuator Solenoid Valve or Solenoid Valve Relay EBS00T02

DIAGNOSTIC PROCEDURE MALFUNCTION CODE NO. 41, 45, 55, 42, 46, 56, 63
1. INSPECTION START
Solenoid valve relay inspection.

>> GO TO 2.

NBR553

2. CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT

Check 30A N.º B fusible link.
For fusible link layout, refer to EL-8, "POWER SUPPLY ROUTING" in EL Section
Is fusible link OK?
Yes >> GO TO 3.
No >> GO TO 7.

3. CHECK FUSE
Check 15A fuse Nº 17 . For fusible link layout, refer to EL-8, "POWER SUPPLY ROUTING" in EL section.
Is fuse OK?
Yes >> GO TO 4.
No >> GO TO 9.

BR-72
 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS / ABS BD-30 TI/BD-30 T

4. CHECK CONNECTOR
1. Disconnect ABS actuator and electric unit connector T11 . Check terminals for damage or loose connec-
tion. Then reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
Yes >> GO TO 5.
No >> INSPECTION END

5. CHECK GROUND CIRCUIT

Refer to BR-67, "ABS ACTUATOR AND ELECTRIC UNIT GROUND" in “Ground Circuit Check”.
Is ground circuit OK?
Yes >> GO TO 6.
No >> Repair harness and connectors.

6. CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector T11 .
2. Check the voltage between 18 terminal of ABS actuator and
electric unit connector T11 and ground.
Does battery voltage exist?
Yes >> Replace ABS actuator and electric unit.
No >> Check the following.
● Harness connector T11 .
● Harness for open or short between ABS actuator and
0556BR
electric unit and fusible link.
If NG, repair harness or connectors.

7. REPLACE FUSIBLE LINK

Replace fusible link.
Does the fusible link blow out when ignition switch is turned “ON”?
Yes >> GO TO 8.
No >> INSPECTION END

BR-73
 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS / ABS BD-30 TI/BD-30 T

8. CHECK RELAY UNIT POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector.
2. Check the continuity between 18 terminal of ABS actuator and
electric unit connector T11 and ground.
Does continuity exist?
Yes >> Replace ABS actuator and electric unit.
No >> Check the following.
● Harness connector T11 .
● Harness for open or short between ABS actuator and
electric unit and fusible link. 0557BR
If NG, repair harness or connectors.

9. REPLACE FUSE
Replace fuse.
Does the fuse blow out when ignition switch is turned “ON”?
Yes >> Check the following.
● Harness connector T11 .
● Harness for open or short between ABS actuator and electric unit and fuse.
If NG, repair harness or connectors.
No >> INSPECTION END

BR-74
 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS / ABS BD-30 TI/BD-30 T

Motor Relay or Motor EBS00T03

DIAGNOSTIC PROCEDURE MALFUNCTION CODE NO. 61

1. INSPECTION START
ABS motor relay inspection.

>> GO TO 2.

NBR554

2. CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT

Check 65A N.º E fusible link.
For fusible link layout, refer to EL-8, "POWER SUPPLY ROUTING" in EL Section
Is fusible link OK?
Yes >> GO TO 3.
No >> GO TO 6.

3. CHECK CONNECTOR
1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connection.
Then reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
Yes >> GO TO 4.
No >> INSPECTION END

BR-75
 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS / ABS BD-30 TI/BD-30 T

4. CHECK MOTOR RELAY POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector.
2. Check the voltage between 17 terminal of ABS actuator and
electric unit connector T11 and ground.
Does battery voltage exist?
Yes >> GO TO 5.
No >> Check the following.
● Harness connector T11 .
● Harness for open or short between ABS actuator and
electric unit and fusible link. 0559BR
If NG, repair harness or connectors.

5. CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT

Refer to BR-67, "ABS ACTUATOR AND ELECTRIC UNIT GROUND" in “Ground Circuit Check”.
Is ground circuit OK?
Yes >> Replace ABS actuator and electric unit.
No >> Check the following.
● Harness connector T11 .
● Harness for open or short between ABS actuator and electric unit and ground.
If NG, repair harness or connectors.

6. REPLACE FUSIBLE LINK

Replace fusible link.
Does the fusible link blow out when ignition switch is turned “ON”?
Yes >> GO TO 7.
No >> INSPECTION END

7. CHECK ABS ACTUATOR MOTOR POWER SUPPLY CIRCUIT

1. Disconnect battery cable and ABS actuator and electric unit
connector.
2. Check the continuity between 17 terminal of ABS actuator and
electric unit connector T11 and ground.
Does continuity exist?
Yes >> 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.
No >> Check the following. 0560BR

● Harness connector T11 .

● Harness for open or short between ABS actuator and electric unit and fusible link.
If NG, repair harness or connectors.

BR-76
 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS / ABS BD-30 TI/BD-30 T

Low Voltage EBS00T04

DIAGNOSTIC PROCEDURE MALFUNCTION CODE NO. 57

1. INSPECTION START
ABS actuator and electric unit power supply and ground circuit
inspection.

>> GO TO 2.

0586BR

2. CHECK CONNECTOR
1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connections.
Then reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
Yes >> GO TO 3.
No >> INSPECTION END

3. CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

1. Disconnect ABS actuator and electric unit connector.
2. Check the voltage between 15 terminal of ABS actuator and
electric unit connector T11 and ground.
Does battery voltage exist when ignition switch is turned ON?
Yes >> GO TO 4.
No >> GO TO 5.

0562BR

BR-77
 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS / ABS BD-30 TI/BD-30 T

4. CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND

Refer to BR-67, "ABS ACTUATOR AND ELECTRIC UNIT GROUND" in Ground Circuit Check.
Is ground circuit OK?
OK >> 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.
NG >> Check the following.
● Harness connector T11 .
● Harness for open or short between ABS actuator and electric unit and ground.
If NG, repair harness or connectors.

5. CHECK FUSE
Check 15A fuse No. 17 . For fuse layout, refer to EL-8, "POWER SUPPLY ROUTING" in EL section.
Is fuse OK?
Yes >> GO TO 6.
No >> Replace fuse.

6. CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

1. Check the continuity between battery and 15 terminal of ABS actuator and electric unit connector T11 .
Does continuity exist?
Yes >> Check battery. Refer to EL-14, "BATTERY" in EL section.
No >> Check the following.
● Harness connector T11 .
● Harness for open or short between ABS actuator and electric unit and fuse.
If NG, repair harness or connectors.

BR-78
 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS / ABS BD-30 TI/BD-30 T

Control Unit EBS00T05

DIAGNOSTIC PROCEDURE MALFUNCTION CODE NO. 71

1. INSPECTION START
ABS actuator and electric unit power supply and ground circuit
inspection.

>> GO TO 2.

0587BR

2. CHECK CONNECTOR
1. Disconnect ABS actuator and electric unit connector.
Check terminals for damage or loose connections and replace. Then reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
Yes >> GO TO 3.
No >> INSPECTION END

3. CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

1. Unplug the connector from the ABS actuator and electric unit.
2. Check the voltage between 15 terminal of ABS actuator and
electric unit connector T11 and ground.
Does battery voltage exist when ignition switch is turned ON?
Yes >> GO TO 6.
No >> GO TO 4.

0562BR

4. CHECK FUSE
Check 15A fuse No. 17 . For fuse layout, refer to EL-8, "POWER SUPPLY ROUTING" in EL section.
Is fuse OK?
Yes >> GO TO 5.
No >> Replace fuse.

BR-79
 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS / ABS BD-30 TI/BD-30 T

5. CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT

1. Check the continuity between battery and 15 terminal of ABS actuator and electric unit connector T11 .
Does continuity exist?
Yes >> Check battery. Refer to EL-14, "BATTERY" in EL section.
No >> Check the following.
● Harness connector T11 .
● Harness for open or short between ABS actuator and electric unit and fuse.
If NG, repair harness or connectors.

6. CHECK WARNING LAMP INDICATION

Does warning lamp indicate code No. 71 again?

Yes >> Replace ABS actuator and electric unit.

No >> Inspect the system according to the code No.

BR-80
 TROUBLE DIAGNOSES FOR SYMPTOMS / ABS BD-30 TI/BD-30 T

TROUBLE DIAGNOSES FOR SYMPTOMS / ABS BD-30 TI/BD-30 T PFP:00090

ABS Works Frequently EBS00U01

1. CHECK BRAKE FLUID PRESSURE

Check brake fluid pressure distribution.
Is brake fluid pressure distribution normal?
Yes >> GO TO 2.
No >> Perform Preliminary Check. Refer BR-65, "Preliminary Check".

2. CHECK WHEEL SENSOR

1. Check wheel sensor connector for terminal damage or loose connections.
2. Perform wheel sensor mechanical check.
Refer to BR-69, "Wheel Sensor or Rotor".
Are wheel sensors functioning properly?
Yes >> GO TO 3.
No >> Repair.

3. CHECK FRONT AXLE

Check front and rear axles for excessive looseness. Refer to FA section, FA-10, "Checking the front wheel
bearing play", “ON-VEHICLE SERVICE”
Is front axle installed properly?
Yes >> Go to BR-82, "CHECK WARNING LAMP INDICATION" in “Unexpected Pedal Action”.
No >> Repair.

Unexpected Pedal Action EBS00U02

1. CHECK BRAKE PEDAL STROKE

Check brake pedal stroke. Is stroke excessively large?

Yes >> Perform Preliminary Check. Refer to BR-65, "Prelimi-

nary Check".
No >> GO TO 2.

0600BR

2. CHECK CONNECTOR AND PERFORMANCE

1. Disconnect ABS actuator and electric unit connector.
2. Check whether brake is effective.
OK or NG
OK >> GO TO 3.
NG >> Perform Preliminary Check. Refer to BR-65, "Preliminary Check".

BR-81
 TROUBLE DIAGNOSES FOR SYMPTOMS / ABS BD-30 TI/BD-30 T

3. CHECK WARNING LAMP INDICATION

Ensure warning lamp remains off while driving.
Is warning lamp turned off?
Yes >> GO TO 4.
No >> Carry out self-diagnosis. Refer BR-56, "Self-diagnosis"
and BR-59, "CONSULT-II Inspection Procedure".

0593BR

4. CHECK WHEEL SENSOR

1. Check wheel sensor connector for terminal damage or loose connection.
2. Perform wheel sensor mechanical check.
Is wheel sensor mechanism OK?
Yes >> 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.
No >> Repair.

CAUTION:
Drive at low speed and brake gently to prevent the earth wheels from locking.

Long Stopping Distance EBS00U03

1. CHECK CONNECTOR AND PERFORMANCE

1. Cancel ABS by disconnecting ABS actuator and electric unit connector.
2. Check whether stopping distance is still long.
OK or NG
OK >> Perform Preliminary Check and air bleeding.
NG >> Go to BR-82, "CHECK WARNING LAMP INDICATION" in “Unexpected Pedal Action”.

NOTE:
Stopping distance may be longer than vehicles without ABS when road condition is slippery.

ABS Does Not Work EBS00U04

1. CHECK WARNING LAMP INDICATION

Does the ABS warning lamp activate?

Yes >> Carry out self-diagnosis. Refer to BR-56, "Self-diagnosis" and BR-59, "CONSULT-II Inspection
Procedure".
No >> Go to BR-82, "CHECK WARNING LAMP INDICATION" in “Unexpected Pedal Action”.

NOTE:
ABS does not work when vehicle speed is under 10 km/h (6.21 mph).

BR-82
 TROUBLE DIAGNOSES FOR SYMPTOMS / ABS BD-30 TI/BD-30 T

Pedal Vibration and Noise EBS00U05

1. INSPECTION START
Pedal vibration and noise inspection.

>> GO TO 2.

0601BR

2. CHECK SYMPTOM
1. Apply brake.
2. Start engine.
Does the symptom appear only when engine is started?
Yes >> Carry out self-diagnosis. Refer to BR-56, "Self-diagnosis" and BR-59, "CONSULT-II Inspection
Procedure"
No >> GO TO 3.

3. RECHECK SYMPTOM
Does the symptom appear when electrical equipment switches (such as headlamp) are operated?

Yes >> GO TO 4.
No >> Go to BR-82, "CHECK WARNING LAMP INDICATION" in “Unexpected Pedal Action”,

4. CHECK WHEEL SENSOR

Check wheel sensor shield ground. For location of shield ground, refer to wiring diagram and EL-158, "LOCA-
TION OF THE INSTALLATIONS" in EL section.
Is wheel sensor shield grounded properly?
Yes >> 1. Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actua-
tor and electric unit harness connector.
2. Reconnect ABS actuator and electric unit harness connector.
3. Then retest.
No >> Repair.

NOTE:
ABS may operate and cause vibration under any of the following conditions.
● Applying brake gradually when shifting or operating clutch.
● Low friction (slippery) road.
● High speed cornering.
● Driving over bumps and pot holes.
● Engine speed is over 5,000 rpm with vehicle stopped.

BR-83
 TROUBLE DIAGNOSES FOR SYMPTOMS / ABS BD-30 TI/BD-30 T

ABS Warning Lamp Does Not Come On when Ignition Switch Is Turned On EBS00U06

1. INSPECTION START
Warning lamp circuit inspection.

>> GO TO 2.

0686BR

2. CHECK FUSE
Check 15A fuse No. 17 for warning lamp. For fuse layout, refer to EL-8, "POWER SUPPLY ROUTING" in EL
section.
Is fuse OK?
OK >> GO TO 3.
NG >> Replace fuse.

3. CHECK WARNING LAMP INDICATION

Disconnect ABS actuator and electric unit connector.
Does the ABS warning lamp activate?
Yes >> GO TO 5.
No >> GO TO 4.

0593BR

BR-84
 TROUBLE DIAGNOSES FOR SYMPTOMS / ABS BD-30 TI/BD-30 T

4. CHECK HARNESS FOR SHORT

Check the voltage between 21 terminal of ABS actuator and electric
unit connector T11 and ground.
Does battery voltage exist?
Yes >> Check combination meter. Refer to EL-86, "WARNINGS
AND LIGHTS ON BUZZER" in EL section.
No >> Repair harness and connectors between fuse and 21
terminal ABS actuator and electric unit connector T11 .

0565BR

5. CHECK HARNESS CONNECTOR

Check ABS actuator and electric unit pin terminals for damage or connection of ABS actuator and electric unit
harness connector.
Reconnect ABS actuator and electric unit harness connector. Then reset.

OK >> INSPECTION END

NG >> Replace ABS actuator and electric unit.

BR-85
 TROUBLE DIAGNOSES FOR SYMPTOMS / ABS BD-30 TI/BD-30 T

ABS Warning Lamp Stays On When Ignition Switch Is Turned On EBS00U07

1. INSPECTION START
ABS control unit inspection.

0687BR

>> GO TO 2.

2. CHECK WARNING LAMP

1. Disconnect ABS actuator and electric unit connector.
2. Turn ignition switch “ON”.
Does warning lamp activate?
Yes >> GO TO 3.
No >> GO TO 4.

3. CHECK WARNING LAMP SIGNAL CIRCUIT FOR SHORT

1. Turn ignition switch “OFF”.
2. Disconnect IBC connector of instrument panel.
3. Check harness continuity between 21 and 16 terminals ABS
actuator and electric unit connector T11 .
Refer to wiring diagram.
OK or NG?
OK >> Replace instrument panel.
NG >> Repair short to ground in harness or connectors.
0569BR

4. CHECK ABS MOTOR GROUND

1. Turn ignition switch “OFF”.
2. Disconnect ABS actuator and electric unit connector.
3. Check continuity between 16 terminal of ABS actuator and
electric unit T11 and ground.
Does continuity exist?
Yes >> Replace ABS actuator and electric unit.
No >> Check the following.
● Harness connector T11 .
0568BR
● Harness for open or short between ABS actuator and
electric unit and fusible.
If NG, repair harness or connector.

BR-86
 REMOVAL AND INSTALLATION / ABS BD-30T / BD-30 TI

REMOVAL AND INSTALLATION / ABS BD-30T / BD-30 TI PFP:00091

Wheel Sensors EBS00V01

CAUTION:
Be careful not to damage sensor edge and sensor rotor teeth.
When removing the front or rear wheel hub assembly, first remove the ABS wheel sensor from the
assembly. Failure to do so may result in damage to the sensor wires making the sensor inoperative.
FRONT SENSOR - TL45

0680BR

BR-87
 REMOVAL AND INSTALLATION / ABS BD-30T / BD-30 TI

FRONT SENSOR - TL28 / 32 / 34 / 35

NBR555

COMPONENTS
1. Sensor 3. Phonic wheel (rotor)
2. Brake flexible fixing support A. View sensor assembly

BR-88
 REMOVAL AND INSTALLATION / ABS BD-30T / BD-30 TI

REAR SENSOR

0681BR

BR-89
 REMOVAL AND INSTALLATION / ABS BD-30T / BD-30 TI

ABS Actuator and Electric Unit EBS00V02

0655BR

COMPONENTS
1. Actuator 4. From the master cylinder (rear circuit)
2. Control unit 5. To the left front brake
3. From the master cylinder (front circuit) 6. To the rear brake circuit

REMOVAL
1. Disconnect battery cable.
2. Drain brake fluid.
3. Remove mounting bracket fixing bolts and nuts.
4. Disconnect connector, brake pipes and remove fixing nuts.
INSTALLATION
CAUTION:
After installation, refill brake fluid. Then bleed air.
1. Connect brake pipes temporarily.
2. Tighten fixing bolts and nuts.
3. Tighten brake pipes.
4. Connect connector and battery cable.
Nuts fixing the actuator to its support:
9 ÷ 12 N-m (0.9 ÷ 1.2 kgm; 6.6 ÷ 8.9 ft-lb)
Nuts fixing the support to the longitudinal beam:
22 ÷ 26 N-m (2.2 ÷ 2.7 kgm; 16.2 ÷ 19.2 ft-lb)

BR-90
 REMOVAL AND INSTALLATION / ABS BD-30T / BD-30 TI

Sensor Rotor EBS00V03

DISASSEMBLY - ASSEMBLY
Front axle
1. Remove the wheel hub. (Consult the chapter FA-20, "FRONT
AXLE - FRONT INDEPENDENT SUSPENSION (F.I.S) / DISAS-
SEMBLY" in the section FA).
2. Remove the phonic wheel (1) from the wheel hub (2).
3. To fit the new phonic wheel (1), place it on the hub, making sure
that it is totally parallel to its seating base and insert it fully with a
press.
NOTE:
Make sure that no cracks have appeared in the phonic wheel (1)
after inserting it in the hub (2).
0659BR
4. Fit the rest of the components. (Consult the chapter FA-19,
"FRONT AXLE - FRONT INDEPENDENT SUSPENSION (F.I.S) / ASSEMBLY").

Rear axle
1. Remove the wheel hub. (Consult RA-9, "Disassembly" in ET-
2000 engine, RA-20, "Disassembly" in ET-2200 and RA-32,
"Disassembly" in ET-3300 engine).
2. Remove the phonic wheel (1) from the wheel hub (2).
3. To fit the new phonic wheel (1), place it on the hub, making sure
that it is totally parallel to its seating base and insert it fully with a
press.
NOTE:
Make sure that no cracks have appeared in the phonic wheel (1)
after inserting it in the hub (2).
0537BR
4. Fit the rest of the components. (Consult RA-11, "Assembly" in
ET-2000 engine, RA-22, "Assembly" in ET-2200 and RA-34, "Assembly" in ET-3300 engine).

BR-91
 SERVICE DATA AND SPECIFICATIONS (SDS) / ABS BD-30 T / BD-30 TI

SERVICE DATA AND SPECIFICATIONS (SDS) / ABS BD-30 T / BD-30 TI PFP:00092

General Specifications EBS00W01

Unit: mm (inches)
Type Disk, ventilated
Front Brake
Cylinder diameter 2X48 (1,89) 2X52 (2,04)
Brake model LT28 (Drum)
Cylinder diameter 25,4 (1)
Lining
Rear Brake Length x width x thickness (primary) 111 x 55 x 8,95 (4,37x2,16x0,35)
Length x width x thickness (secondary) 114 x 55 x 3,95 (4,48x2,16x0,15)
Lining wear limit (minimum thickness) 1,52 (0,059)
Drum interior diameter 280 (11,023)
Brake pump Cylinder diameter 27 (1,06)
Servobrake Booster model MVT8 (203,2) + 9 (228,6)
Specified brake fluid DOT 4

Disc Brake
Unit: mm (inches)
CABSTAR 100 CABSTAR
Disk brake model 120 (35) 100 (45 GE / 45 GEHD)
VD PF 2X48 120 (45 / 45 HD) VD PF 2x52
Pad wear limit Minimum thickness 9 (0,35) : 6 (0,23) placa + 3 (0,12) lining
Maximum runout 0,07 (0,003)
Rotor repair limit
Minimum thickness 24 (0,944)

Brake Pedal
Unit: mm (inches)
Free height “H” 169 ÷ 174 (6,65 ÷ 6,85)
Pedal free play (A) 1 ÷ 5 (0,039 ÷ 0,196)
Pedal run (D) 140 (5,51)
Gap between the pedal and the brake switch 7 (0,28)

Parking Brake
Unit: mm (inches)
Type Mechanic
Number of teeth
9 ÷ 10
(under a force of 196 N [20 kg])
Number of teeth
1
when the switch of the optical warning is turned on

BR-92
 SERVICE DATA AND SPECIFICATIONS (SDS) / ABS BD-30 T / BD-30 TI

NOTE:

BR-93