Tài liệu hướng dẫn sửa chữa Hệ thống phanh trên xe 22 2005 2006 toyota hilux factory service manual brake system he thong phanh. Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành chẩn đoán, sửa chữa nhanh chóng, chính xac
BC–302 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM TS and CG Terminal Circuit DESCRIPTION In sensor check mode, malfunctions of the speed sensor that cannot be detected when the vehicle is stopped are detected while driving Transition to the sensor check mode can be performed by connecting terminals TS and CG of the DLC3 and turning the ignition switch from OFF to the ON position WIRING DIAGRAM D4 DLC3 Master Cylinder Solenoid (Skid Control ECU) Instrument Panel J/B No TS CG R-B 12 DC DA R-B 24 S1 TS W-B IC BC F051289E03 DLC3: INSPECT DLC3 (TS TERMINAL VOLTAGE) (a) Turn the ignition switch to the ON position (b) Measure the voltage Standard CG NG OK Specified Condition D4-12 (TS) - D4-4 (CG) 10 to 14 V (c) Turn the ignition switch to OFF 10 11 12 13 14 15 16 D4 TS Tester Connection F100115E37 Go to step BC–303 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - DLC3) Skid Control ECU (harness side connector): S1 (a) Disconnect the skid control ECU connector (b) Measure the resistance Standard Tester Connection Specified condition S1-24 (TS) - D4-12 (TS) Below Ω (c) Measure the resistance Standard TS Tester Connection Specified Condition S1-24 (TS) - Body ground 10 kΩ or higher (d) Reconnect the skid control ECU connector DLC3: NG REPAIR OR REPLACE HARNESS OR CONNECTOR D4 10 11 12 13 14 15 16 TS C124792E03 OK BC REPLACE MASTER CYLINDER SOLENOID CHECK HARNESS AND CONNECTOR (BODY GROUND - DLC3) DLC3: D4 (a) Measure the resistance Standard NG 10 11 12 13 14 15 16 CG F100115E35 OK Tester Connection Specified condition D4 (CG) - Body ground Below Ω REPAIR OR REPLACE HARNESS OR CONNECTOR BC–304 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - DLC3) Skid Control ECU (harness side connector): S1 (a) Disconnect the skid control ECU connector (b) Measure the resistance Standard Tester Connection Specified condition S1-24 (TS) - D4-12 (TS) Below Ω (c) Measure the resistance Standard TS Tester Connection Specified Condition S1-24 (TS) - Body ground 10 kΩ or higher (d) Reconnect the skid control ECU connector DLC3: NG D4 10 11 12 13 14 15 16 TS C124792E03 OK BC REPLACE MASTER CYLINDER SOLENOID REPAIR OR REPLACE HARNESS OR CONNECTOR BRAKE CONTROL – BRAKE ACTUATOR (w/o VSC) BC–301 REMOVAL DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL DRAIN BRAKE FLUID NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces REMOVE AIR INJECTION CONTROL DRIVER (for 2TR-FE) (a) Disconnect the connectors F050573 (b) Remove the bolts and air injection control driver BC F050574 REMOVE BRAKE ACTUATOR (a) Release the connector lock lever (b) Disconnect the brake actuator connector F050575 (c) Using SST, disconnect the brake tubes from the brake actuator SST 09023-00101 F050576 BC–302 BRAKE CONTROL – BRAKE ACTUATOR (w/o VSC) (d) Use tags or labels to identify the place to reconnect each line To Front Wheel LH To Rear Wheel RH To Front Wheel RH To Rear Wheel LH To Master Cylinder Rear To Master Cylinder Front F050577E01 (e) Remove the nuts and brake actuator with bracket F050578 BC F050579 REMOVE BRAKE ACTUATOR BRACKET ASSEMBLY (a) Remove the nuts and bracket BRAKE CONTROL – BRAKE ACTUATOR (w/o VSC) BC–303 INSTALLATION INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY (a) Install the bracket with the nuts Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) INSTALL BRAKE ACTUATOR (a) Install the actuator with bracket with the nuts Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) NOTICE: • Be careful not to damage the brake tubes and wire harness • Tighten the bolts in order, from to as shown F050578E01 (b) Using SST, connect each brake line to the correct position of the brake actuator, as shown in the illustration SST 09023-00101 Torque: 15.2 N*m (155 kgf*cm, 11 ft.*lbf) (c) Connect the brake actuator connector (d) Lock the connector lock lever NOTICE: Make sure that the lever is locked securely To Front Wheel LH To Rear Wheel RH To Front Wheel RH To Rear Wheel LH To Master Cylinder Rear To Master Cylinder Front BC F050577E01 F050574 INSTALL AIR INJECTION CONTROL DRIVER (for 2TR-FE) (a) Install the air injection control driver with the bolts Torque: 10 N*m (102 kgf*cm, ft.*lbf) (b) Connect the connectors FILL RESERVOIR WITH BRAKE FLUID (See page BR7) BLEED MASTER CYLINDER (See page BR-7) BLEED BRAKE LINE (See page BR-7) CHECK FLUID LEVEL IN RESERVOIR (See page BR8) CHECK FOR BRAKE FLUID LEAKAGE CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) (See page IN-5) 10 CHECK BRAKE ACTUATOR WITH INTELLIGENT TESTER (See page BC-299) BRAKE – FRONT BRAKE (for 4WD and Pre-Runner) BR–63 DISASSEMBLY REMOVE CYLINDER BOOT (a) Using a screwdriver, remove the cylinder boots from the caliper REMOVE FRONT DISC BRAKE PISTON (a) Prepare a wooden plate to hold the pistons F043024 170 mm (6.70 in.) 50 mm (1.97 in.) 30 mm (1.18 in.) F042676E01 (b) Place the plate between the pistons and insert a pad into one side (c) Use compressed air and remove the pistons one side at a time from the cylinder CAUTION: Do not place your fingers in front of the pistons when using compressed air BR F042677 F042678 REMOVE PISTON SEAL (a) Using a screwdriver, remove the piston seals from the cylinder REMOVE FRONT DISC BRAKE BLEEDER PLUG (a) Remove the bleeder plug cap and bleeder plug from the disc brake cylinder BR–64 BRAKE – FRONT BRAKE (for 4WD and Pre-Runner) INSPECTION F042679 BR INSPECT BRAKE CYLINDER AND PISTON (a) Check the cylinder bore and piston for rust and scoring INSPECT PAD LINING THICKNESS (a) Using a ruler, measure the pad lining thickness Standard thickness: 11.5 mm (0.453 in.) Minimum thickness: 1.0 mm (0.039 in.) BRAKE – FRONT BRAKE (for 4WD and Pre-Runner) BR–65 REASSEMBLY TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG (a) Provisionally tighten the bleeder plug to the disc brake cylinder (b) Install the bleeder plug cap onto the bleeder plug INSTALL PISTON SEAL (a) Apply lithium soap base glycol grease to new piston seals (b) Install the piston seals onto the disc brake cylinder INSTALL FRONT DISC BRAKE PISTON (a) Apply lithium soap base glycol grease to the disc brake pistons (b) Install the disc brake pistons onto the disc brake cylinder NOTICE: Do not install the disc brake piston into the disc brake cylinder forcibly INSTALL CYLINDER BOOT (a) Apply lithium soap grease glycol grease to new cylinder boots (b) Install the cylinder boots onto the disc brake cylinder HINT: Install the cylinder boot securely onto the grooves of the disc brake cylinder and piston BR BR–66 BRAKE – FRONT BRAKE (for 4WD and Pre-Runner) INSTALLATION INSTALL FRONT DISC (a) Aligning the matchmarks, install the front disc HINT: When replacing the disc with a new one, select the installation position where the disc has the minimum runout INSPECT DISC RUNOUT (a) Provisionally fasten the disc with the hub nuts Torque: 113 N*m (1,152 kgf*cm, 83 ft.*lbf) (b) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc Maximum disc runout: 0.05 mm (0.0020 in.) (c) If the disc runout is the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout (see page AH-1) If the bearing play and axle hub runout are normal, adjust the disc runout or grind it on an on-car brake lathe INSTALL DISC BRAKE CYLINDER ASSEMBLY (a) Install the disc brake cylinder assembly with the bolts Torque: 123 N*m (1,254 kgf*cm, 91 ft.*lbf) F043106 F043121 BR (b) Using SST, connect the brake tube to the disc brake cylinder SST 09023-00101 Torque: 15.2 N*m (155 kgf*cm, 11 ft.*lbf) INSTALL ANTI SQUEAL SHIM KIT FRONT NOTICE: If necessary, replace the anti-squeal shim kit when replacing the brake pad (a) Install the anti-squeal shims on to each brake pad INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY) (a) Install the disc brake pads with anti-squeal shim onto the disc brake cylinder NOTICE: There should be no oil or grease on the friction surfaces of the brake pads and the front disc F043120 BC–287 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT SKID CONTROL ECU (CSW TERMINAL) (a) Disconnect the skid control ECU connector (b) Ground terminal CSW of the skid control ECU Standard Skid Control ECU (harness side connector): S1 Tester Connection Condition Specified Condition S1-43 (CSW) - Body ground AUTO LSD switch not pushed in 10 kΩ or higher (c) Reconnect the skid control ECU connector OK REPLACE MASTER CYLINDER SOLENOID CSW C121700E26 NG INSPECT AUTO LSD SWITCH (a) Remove the AUTO LSD switch (b) Disconnect the AUTO LSD switch connector (c) Measure the resistance Standard AUTO LSD Switch: Push Tester Connection Switch Condition Specified Condition T9-3 - T9-4 Released 10 kΩ or higher T9-3 - T9-4 Released Below Ω T9 Release I044044E01 (d) Reconnect the AUTO LSD switch connector (e) Reinstall the AUTO LSD switch NG OK REPLACE AUTO LSD SWITCH BC BC–288 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (AUTO LSD SWITCH CIRCUIT) (a) Disconnect the skid control ECU connector (b) Disconnect the AUTO LSD connector (c) Measure the resistance Standard Skid Control ECU (harness side connector): S1 Specified Condition Below Ω S1-43 (CSW) - Body ground 10 kΩ or higher T9-3 - Body ground Below Ω (d) Reconnect the AUTO LSD connector (e) Reconnect the skid control ECU connector CSW NG AUTO LSD switch (harness side connector): T9 C124802E01 OK BC Tester Connection S1-43 (CSW) - T9-3 REPLACE MASTER CYLINDER SOLENOID REPAIR OR REPLACE HARNESS OR CONNECTOR BC–289 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM AUTO LSD Indicator Light does not Come ON DESCRIPTION See page BC-278 WIRING DIAGRAM See page BC-279 CHECK AUTO LSD INDICATOR LIGHT (a) (b) (c) (d) Skid Control ECU (harness side connector): INFR Disconnect the skid control ECU connector Turn the ignition switch to the ON position Ground terminal INFR of the skid control ECU Check the AUTO LSD indicator light OK S1 INFR - GND Condition Illumination Condition Connecting OFF Disconnecting ON (e) Turn the ignition switch to OFF (f) Reconnect the skid control ECU connector OK REPLACE MASTER CYLINDER SOLENOID C121700E27 NG BC BC–290 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) Combination Meter (harness side view) (a) Disconnect the skid control ECU connector (b) Disconnect the combination meter connector (c) Measure the resistance Standard C9 C9-35 Tester Connection Specified Condition S1-15 (INFR) - C9?35 Below Ω S1-15 (INFR) - Body ground 10 kΩ or higher (d) Reconnect the combination meter connector (e) Reconnect the skid control ECU connector Skid Control ECU (harness side connector) INFR NG REPAIR OR REPLACE HARNESS OR CONNECTOR S1 F049577E01 OK BC INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (see page 051917) OK: Combination meter is normal NG OK REPLACE COMBINATION METER ASSEMBLY BC–291 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT SKID CONTROL ECU (CSW TERMINAL) (a) Disconnect the skid control ECU connector (b) Ground terminal CSW of the skid control ECU Standard Skid Control ECU (harness side connector): S1 Tester connection Condition Specified Condition S1-43 (CSW) - Body ground Auto LSd switch not pushed in 10 kΩ or higher (c) Reconnect the skid control ECU connector OK REPLACE MASTER CYLINDER SOLENOID CSW C121700E26 NG INSPECT AUTO LSD SWITCH (a) Remove the AUTO LSD switch (b) Disconnect the AUTO LSD switch connector (c) Measure resistance Standard AUTO LSD Switch: Push Tester Connection Switch Condition Specified Condition T9-3 - T9-4 Released 10 kΩ or higher T9-3 - T9-4 Pushed in Below Ω T9 Release I044044E01 (d) Reconnect the AUTO LSD switch connector (e) Reinstall the AUTO LSD switch NG OK REPLACE AUTO LSD SWITCH BC BC–292 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (AUTO LSD SWITCH CIRCUIT) (a) Disconnect the skid control ECU connector and the AUTO LSD switch connector (b) Measure the resistance Standard Skid Control ECU (harness side connector): S1 Specified Condition Below Ω S1-43 (CSW) - Body ground 10 kΩ or higher T9-4 - Body ground Below Ω (c) Reconnect the skid control ECU connector and the AUTO LSD switch connector CSW NG AUTO LSD switch (harness side connector): T9 C124802E01 OK BC Tester Connection S1-43 (CSW) - T9-3 REPLACE MASTER CYLINDER SOLENOID REPAIR OR REPLACE HARNESS OR CONNECTOR BC–293 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER) Combination Meter (harness side view) (a) Disconnect the skid control ECU connector (b) Disconnect the combination meter connector (c) Measure the resistance Standard C9 C9-35 Tester Connection Specified Condition S1-15 (INFR) - C9-35 Below Ω S1-15 (INFR) - Body ground 10 kΩ or higher (d) Reconnect the combination meter connector (e) Reconnect the skid control ECU connector Skid Control ECU (harness side connector) NG INFR REPAIR OR REPLACE HARNESS OR CONNECTOR S1 F049577E01 OK INSPECT COMBINATION METER ASSEMBLY (a) Check the combination meter system (See page ME-8) OK: Combination meter is normal NG OK CHECK FOR INTERMITTENT PROBLEMS REPLACE COMBINATION METER ASSEMBLY BC BC–294 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM Skid Control Buzzer Circuit DESCRIPTION The skid control buzzer sounds when the VSV or Hill-start Assist Control (HAC) operates WIRING DIAGRAM Master Cylinder Solenoid (Skid Control ECU) V7 VSC Warning Buzzer Instrument Panel J/B No 13 DC 13 DA LG GR LG IG1 NO GR 30 S1 BZ I7 Ignition SW Driver Side J/B 14 1C IA3 1A L-Y IG1 AM1 W-L Engine Room R/B and J/B BC B 2C AM1 ALT 21 2 Battery C124787E01 HINT: Start the inspection from step when using a intelligent tester and start from step2 when not using a intelligent tester PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SKID CONTROL BUZZER) (a) Connect the intelligent tester to the DLC3 BC–295 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM (b) Start the engine (c) Select the item "VSC/BR WARN BUZ" in the ACTIVE TEST and operate the skid control buzzer on the intelligent tester Item Vehicle Condition / Test Details VSV / BR WARN BUZ Turns VSV / BRAKE warning buzzer ON /OFF Diagnostic note Buzzer can be heard (d) Check that the buzzer sounds/stops when the skid control buzzer is turned on/off by using the intelligent tester Result Proceed to Buzzer sounds/stops A Buzzer does not sound or sounds constantly B A CHECK FOR INTERMITTENT PROBLEMS B INSPECT SKID CONTROL BUZZER (POWER SOURCE CIRCUIT) (a) Disconnect the skid control buzzer connector (b) Turn the ignition switch to the ON position (c) Measure the voltage Standard Skid Control Buzzer (harness side connector) V7 Tester Connection Specified Condition V7-2 - Body ground 10 to 14 V (d) Turn the ignition switch to OFF (e) Reconnect the skid control buzzer connector I044040E01 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (POWER SOURCE CIRCUIT) OK INSPECT SKID CONTROL BUZZER ASSEMBLY (+) (-) Skid Control Buzzer: NG F002192E08 OK (a) Disconnect the skid control buzzer connector (b) Apply battery voltage to terminals and of the skid control buzzer connector, and check that the buzzer sounds OK: The skid control buzzer sound should be heard (c) Reconnect the skid control buzzer connector REPLACE SKID CONTROL BUZZER ASSEMBLY BC BC–296 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (SKID CONTROL BUZZER - SKID CONTROL ECU) Skid Control ECU (harness side connector): BZ S1 (a) Disconnect the skid control ECU connector (b) Disconnect the skid control buzzer connector (c) Measure the resistance Standard Tester Connection Specified Condition S1-30 (BZ) - V7-1 Below Ω S1-30 (BZ) - Body ground 10 kΩ or higher (d) Reconnect the skid control buzzer connector (e) Reconnect the skid control ECU connector NG Skid Control Buzzer (harness side connector): V7 C124803E01 OK BC REPLACE MASTER CYLINDER SOLENOID REPAIR OR REPLACE HARNESS OR CONNECTOR BC–297 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM TC and CG Terminal Circuit DESCRIPTION Connecting terminals TC and CG of the DLC3 causes the ECU to display 2-digit DTCs by blinking the ABS and VSC TRAC warning lights WIRING DIAGRAM Master Cylinder Solenoid (Skid Control ECU) ECM 34 CANL E7 W J10 33 CANH E7 B J10 J/C J6 W-L IA3 W-L 25 S1 CANL J6 B-W IA3 B-W 11 S1 CANH D4 DLC3 Instrument Panel J/B No 23 17 TC E8 E7 (*1) (*2) P-B DB DA P-B 13 W-B BC TC CG *1 : 1GR-FE *2 : 2TR-FE IC C124788E01 BC–298 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM INSPECT DLC3 (TC TERMINAL VOLTAGE) DLC3: (a) Turn the ignition switch to the ON position (b) Measure the voltage Standard CG Tester Connection Specified Condition D4-13 (TC) - D4-4 (CG) 10 to 14 V (c) Turn the ignition switch to OFF 10 11 12 13 14 15 16 NG D4 TC Go to step F100115E36 OK CHECK CAN COMMUNICATION SYSTEM (a) Check whether CAN system DTCs are recorded (See page CA-14) Result Proceed to DTC not output A DTC output B B BC REPAIR CIRCUITS INDICATED BY OUTPUT DTCS A REPLACE MASTER CYLINDER SOLENOID CHECK HARNESS AND CONNECTOR (DLC3 - BODY GROUND) DLC3: D4 (a) Measure the resistance Standard NG 10 11 12 13 14 15 16 CG F100115E35 OK Tester Connection Specified Condition D4-4 (CG) - Body ground Below Ω REPAIR OR REPLACE HARNESS OR CONNECTOR BC–299 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (ECM - DLC3) (a) Disconnect the ECM connector (b) Measure the resistance Standard (1GR-FE) DLC3: D4 Tester Connection Specified Condition D4-13 (TC) - E8-23 (TC) Below Ω Standard (2TR-FE) 10 11 12 13 14 15 16 Tester Connection Specified Condition D4-13 (TC) - E7-17 (TC) Below Ω (c) Measure the resistance Standard TC ECM (1GR-FE): Tester Connection Specified Condition D4-13 (TC) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector E8 ECM (2TR-FE): REPAIR OR REPLACE HARNESS OR CONNECTOR TC BC E7 TC C124791E01 OK NG BC–300 BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (ECM - SKID CONTROL ECU) Skid Control ECU (harness side connector) S1 CANH (a) Disconnect the skid control ECU connector (b) Disconnect the ECM connector (c) Measure the resistance Standard Tester Connection Specified Condition S1-25 (CANL) - E7-33 (CANL) Below Ω S1-11 (CANH) - E7-34 (CANH) Below Ω (d) Reconnect the ECM connector (e) Reconnect the skid control ECU connector CANL NG 1GR-FE: REPAIR OR REPLACE HARNESS OR CONNECTOR ECM E7 CANH CANL 2TR-FE: ECM BC E7 CANL CANH F052067E01 OK DLC3: CHECK ECM (DLC3 (TC) INPUT) (a) Connect terminals TC and CG of DLC3 (b) Turn the ignition switch to the ON position (c) Check if the ECM warning light is blinking OK: ECM warning light is blinking (d) Turn the ignition switch to OFF (e) Disconnect the TC and CG terminals of DLC3 CG 10 11 12 13 14 15 16 D4 NG TC F100115E36 REPLACE ECM BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM BC–301 OK REPLACE MASTER CYLINDER SOLENOID BC