TROUBLE DIAGNOSIS
BRC-85
[ESP/TCS/ABS]
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STR ANGLE SIG
(deg)×××–Steering wheel angle
detected by the steering
wheel angle sensor is dis-
played.
YAW RATE SEN
(d/s)×××–Yaw rate detected by the yaw
rate sensor is displayed.
SIDE G-SENSOR
(m/s
2 )×××–Transverse acceleration
detected by the side G sensor
is displayed.
PRESS SENSOR
(bar )×××–Brake fluid pressure detected
by the pressure sensor is dis-
played.
BATTERY VOLT
(V )×××–Voltage supplied to ESP/TCS/
ABS control unit is displayed.
MOTOR RELAY
(ON/OFF )–××–Motor relay signal (ON/OFF)
status is displayed.
ACTUATOR RLY
(ON/OFF )–××–Actuator relay signal (ON/
OFF) status is displayed.
STOP LAMP SW
(ON/OFF)×××–Stop lamp switch (ON/OFF)
status is displayed.
PARK BRAKE SW
(ON/OFF)×××–Parking brake switch (ON/
OFF) status is displayed.
OFF SW
(ON/OFF)×××–ESP OFF switch (ON/OFF)
status is displayed.
ABS WARN LAMP
(ON/OFF)–××–ABS warning lamp (ON/OFF)
status is displayed.
OFF LAMP
(ON/OFF)–××–ESP OFF indicator lamp (ON/
OFF) status is displayed.
SLIP LAMP
(ON/OFF)–××–SLIP indicator lamp (ON/
OFF) status is displayed.
FR LH IN SOL
(ON/OFF)–××–Front LH wheel inlet solenoid
valve (ON/OFF) status is dis-
played.
FR LH OUT SOL
(ON/OFF)–××–Front LH wheel outlet sole-
noid valve (ON/OFF) status is
displayed.
RR RH IN SOL
(ON/OFF)–××–Rear RH wheel inlet solenoid
valve (ON/OFF) status is dis-
played.
RR RH OUT SOL
(ON/OFF)–××–
Rear RH wheel outlet sole-
noid valve (ON/OFF) status is
displayed.
FR RH IN SOL
(ON/OFF)–××–Front RH wheel inlet solenoid
valve (ON/OFF) status is dis-
played.
FR RH OUT SOL
(ON/OFF)–××–Front RH wheel outlet sole-
noid valve (ON/OFF) status is
displayed.
RR LH IN SOL
(ON/OFF)–××–Rear LH wheel inlet solenoid
valve (ON/OFF) status is dis-
played. Data Monitor Item (Unit)Data Monitor item selection
Remarks
ECU INPUT
SIGNALSMAIN
SIGNALSSELECTION
FROM
MENUCAN DIAG
SUPPORT
MNTR
BRC-90
[ESP/TCS/ABS]
TROUBLE DIAGNOSIS
ABS Warning Lamp
Touch “ON” and “OFF”on the “ABS WARNING LAMP” screen to check that the ABS warning lamp operates as
follows.
NOTE:
During the active test when “OFF” on the “ABS WARNING LAMP” screen is touched, all of the ESP OFF indi-
cator lamp, SLIP indicator lamp, and ABS warning lamp flash once. This is not abnormal.
For Correct and Quick DiagnosisEFS001A8
PRECAUTIONS FOR TROUBLE DIAGNOSIS
●Before performing the trouble diagnosis, always read the GI-3, "PRECAUTIONS" to confirm the general
precautions.
●After replacement of ESP/TCS/ABS control unit, steering wheel angle sensor, steering parts, suspension
parts, or tires, and adjustment of alignment, always adjust the neutral position of steering wheel angle
sensor before driving.
●When the ESP/TCS/ABS control unit is replaced, check that the label on the computer unit is identical
color.
●After completing the trouble diagnosis, always erase the malfunctioning memory. Refer to BRC-81, "Pro-
cedure" .
●When inspection of the continuity or voltage between units is performed, check the connector terminals for
disconnection, looseness, bend, or collapse. If any malfunction is detected, repair or replace the applica-
ble part.
●Intermittent problems may be caused by a malfunction on harness, connector, or terminal. Move the har-
nesses, harness connectors, or terminals by hand to make sure that there is no contact malfunction.
●If a circuit tester is used for the check, be careful not to forcibly extend any connector terminal.
●For self-diagnosis, active test, and work support of ESP/TCS/ABS control unit with CONSULT-II, stop and
connect CONSULT-II and select “ABS”.
●CONSULT-II self-diagnosis results are displayed without regard to occurrence timing. In some case, the
later ones (timing value is small) appear on the next screen.
●While the self-diagnosis results of CONSULT-II shows a malfunction, if CONSULT-II active test is per-
formed, an engine system malfunction may be indicated. In this case, start the engine to resume the nor-
mal screen.
●ESP/TCS/ABS system electronically controls the brake operation and engine output. The following symp-
toms may be caused by the normal operations.
Operation ON OFF
ABS WARNING LAMP ON (Lamp ON) OFF (Lamp OFF)
Symptom Symptom description Result
Motor operation noiseDuring ESP, TCS, or ABS operation, sometimes a faint noise can be
heard. This is a motor operation noise in the ESP actuator.
Normal
Just after the engine starts, the motor operating noise may be heard.
This is a normal status of the system operation check.
System operation check
noiseWhen the engine starts, a“click” noise may be heard from the engine
compartment. This is a normal status of the system operation check.Normal
BRC-96
[ESP/TCS/ABS]
TROUBLE DIAGNOSIS
4. PRESSURE SENSOR INSPECTION
Check the “PRESS SENSOR” value in “DATA MONITOR”.
Is inspection result OK?
YES >> Perform the ESP/TCS/ABS control unit self-diagnosis again.
NO >> Pressure sensor malfunction. Replace the ESP actuator (with the pressure sensor).
Inspection 5 Steering wheel Angle Sensor and the Circuit between Steering
Wheel Angle Sensor and ESP/TCS/ABS Control Unit.
EFS001AF
Inspection procedure
1. SELF-DIAGNOSIS RESULT CHECK 1
Check the self-diagnosis results.
Perform inspection 15.
Refer to BRC-110, "
Inspection 15 CAN Communication Circuit, ESP/TCS/ABS Control Unit and Steering
Wheel Angle Sensor" .
Is
“ST ANG SEN CIRCUIT” indicated in the self-diagnosis results.
>> GO TO 2.
2. SELF-DIAGNOSIS RESULT CHECK 2
1. Repair or replace the poorly connected connector
–Check the connector housing for disconnect, loose, bent and collapse terminals
If any malfunction are detected, repair or replace the applicable part.
2. Perform the ESP/TCS/ABS control unit self-diagnosis again.
Is inspection result OK?
YES >> Inspection END
NO >> GO TO 3.Condition PRESS SENSOR (Data monitor)
Brake pedal depressed Positive value
Brake pedal released Approx. 0 bar
Self-diagnosis results
CONSULT-II indication item
ST ANG SEN CIRCUIT
TROUBLE DIAGNOSIS
BRC-97
[ESP/TCS/ABS]
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BRC
3.STEERING WHEEL ANGLE SENSOR CIRCUIT CHECK
1. Disconnect the ESP/TCS/ABS control unit connector and the steering wheel angle sensor connector.
2. Check for continuity between the ESP/TCS/ABS control unit
(vehicle-side connector B111) and the steering wheel angle sen-
sor (vehicle-side connector M81).
3. Check for continuity between the steering wheel angle sensor
and ground.
Is inspection result OK?
YES >> GO TO 4.
NO >> Repair or replace the disconnected harness.
4.DATA MONITOR CHECK
Perform the “STR ANGLE SIG” value in “DATA MONITOR” and check that it is in normal condition.
Is inspection result OK?
YES >> Perform the ESP/TCS/ABS control unit self-diagnosis again.
NO >> Replace the spiral cable (with the steering wheel angle sensor) and adjust the neutral position of
steering wheel angle sensor. BRC-57, "
Adjustment of Neutral Position of Steering Wheel Angle
Sensor" .
SFIA0899E
ESP/TCS/ABS control unit
(Vehicle-side connector B111)Steering wheel angle sensor
(Vehicle-side connector M81)Continuity
2 (Y/R) 3 (Y/R) Yes
SFIA0898E
Steering wheel angle sensor
(Vehicle-side connector M81)ground Continuity
2 (B) — Yes
Steering condition STR ANGLE SIG (Data monitor)
Straight-ahead – 5 deg to + 5 deg
Tun the wheel to the right by 90°Approx. + 90 deg
Tun the wheel to the left by 90°Approx. – 90 deg
BRC-108
[ESP/TCS/ABS]
TROUBLE DIAGNOSIS
5. ESP/TCS/ABS CONTROL UNIT POWER SUPPLY CIRCUIT INSPECTION 2
1. Check the fuse 10A.
2. Check for continuity between the battery positive terminal and
the ESP/TCS/ABS control unit (vehicle-side connector B111).
Is inspection result OK?
YES >> Check the battery for a loose terminal and low voltage or the alternator for abnormality.
NO >>
●Replace the fuse 10A.
●Harness disconnection
Inspection 12 When “EMERGENCY BRAKE” is indicated in the Self-Diagnosis
Results
EFS001AO
Inspection procedure
1. SELF-DIAGNOSIS RESULT CHECK
Check the self-diagnosis results.
When any items other than “EMERGENCY BRAKE” is displayed in the self-diagnosis results, follow the
instructions below.
CAUTION:
“EMERGENCY BRAKE” is indicated when the control unit itself is detected internal error. If this dis-
play item was indicated, replace the control unit.
Is
“EMERGENCY BRAKE” is indicated in the self-diagnosis results?
>> Replace the ESP/TCS/ABS control unit, and perform the self-diagnosis again.
Inspection 13 When “ST ANG SEN SIGNAL” is Indicated in the Self-Diagnosis
Results
EFS001AP
Inspection procedure
1. SELF-DIAGNOSIS RESULT CHECK 1
Check the self-diagnosis results.
When any items other than
“ST ANGLE SEN SIGNAL” is displayed in the self-diagnosis results:
YES >> Check and repair the applicable items. Perform the self-diagnosis again.
NO >> Perform the steering wheel angle sensor neutral position adjustment. GO TO 2.
SFIA0924E
ESP/TCS/ABS control unit
(Vehicle-side connector B111)Battery terminal Continuity
1 (G/R) positive Yes
Self-diagnosis results
CONSUL-II indication item
EMERGENCY BRAKE
Self-diagnosis results
CONSUL-II indication item
ST ANGLE SEN SIGNAL
TROUBLE DIAGNOSIS
BRC-109
[ESP/TCS/ABS]
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2.SELF-DIAGNOSIS RESULT CHECK 2
Turn the ignition switch OFF, and ON to erase the self-diagnosis results. And perform the ESP/TCS/ABS con-
trol unit self-diagnosis again.
Is the same self-diagnosis item indicated again?
YES >> After replacing the spiral cable (with the steering wheel angle sensor), perform the neutral position
adjustment. Then conduct the self-diagnosis again.
NO >> Inspection End
Inspection 14 Brake Fluid Level of Reservoir Tank, Communication Circuit
between ESP/TCS/ABS Control Unit and Brake Fluid Level Warning Switch
EFS001AQ
Inspection procedure
1.SELF-DIAGNOSIS RESULT CHECK 1
Check the self-diagnosis results.
Does the brake warning light turn on?
YES >> Check the pad for wear. Check the brake fluid for leakage.
NO >> GO TO 2.
2.SELF-DIAGNOSIS RESULT CHECK 2
1. Disconnect connectors for the brake fluid level warning switch and the ESP/TCS/ABS control unit.
2. Securely connect connectors. Perform the ESP/TCS/ABS control unit self-diagnosis again.
Is the same self-diagnosis item indicated again?
YES >> GO TO 3.
NO >> Poor connection of connector. Repair or replace the poorly connected connector.
3.CIRCUIT CHECK BETWEEN BRAKE FLUID LEVEL WARNING SWITCH AND ESP/TCS/ABS CON-
TROL UNIT
1. Disconnect connectors for the brake fluid level warning switch
and the ESP/TCS/ABS control unit.
2. Check for continuity between the brake fluid level warning switch (vehicle-side connector E19) and the
ESP/TCS/ABS control unit (vehicle-side connector B111).
Is inspection result OK?
YES >> Perform the ESP/TCS/ABS control unit self-diagnosis again.
NO >> Repair or replace the disconnected harness.
Self-diagnosis results
CONSUL-II indication item
BR FLUID LEVER LOW
SFIA0925E
ESP/TCS/ABS control unit
(Vehicle-side connector B111)Brake fluid level warning switch
(Vehicle-side connector E19)Continuity
40 (Y/B) 1 (Y/B) Yes
BRC-110
[ESP/TCS/ABS]
TROUBLE DIAGNOSIS
Inspection 15 CAN Communication Circuit, ESP/TCS/ABS Control Unit and
Steering Wheel Angle Sensor
EFS001C6
Inspection procedure
1. SELF-DIAGNOSIS RESULT CHECK 1
Check the self-diagnosis results.
Are any items other than above indicated in self-diagnosis results?
YES >> Repair or replace affected items.
NO >> GO TO 2.
2. CHECK HARNESS AND CONNECTORS BETWEEN ESP/TCS/ABS CONTROL UNIT AND STEERING
WHEEL ANGLE SENSOR.
1. Turn the ignition switch OFF, and disconnect the battery nega-
tive terminal.
2. Disconnect the ESP/TCS/ABS control unit connector and the
steering wheel angle sensor connector.
3. Check the harness between the ESP/TCS/ABS control unit
(vehicle-side connector B111) and the steering wheel angle sen-
sor (vehicle-side connector M81) for open and short circuit.
4. Check connectors for the control unit and the sensor.
–Check the connector housing for disconnected, loose, bent, and
collapsed terminals.
Is inspection result OK?
YES >> GO TO 3.
NO >> Repair disconnected harness or poorly connected connectors. GO TO 3.
3. SELF-DIAGNOSIS RESULT CHECK 2
1. Connect connectors to the control unit and the sensor.
2. Connect the battery negative terminal, and turn the ignition switch ON.
3. After erasing the self-diagnosis result, start the engine to perform the self-diagnosis again.
Is only
“ST ANGLE SEN COM CIR” indicated in the self-diagnosis results?
YES >> Replace the spiral cable (with the steering wheel angle sensor) and adjust the neutral position of
the steering wheel angle sensor. Refer to BRC-57, "
ON-VEHICLE SERVICE" .
NO >> GO TO 4.
Self-diagnosis results
CONSUL-II indication item
CAN COMM CIRCUIT
ST ANG SEN COM CIR
SFIA0904E
ESP/TCS/ABS control unit
(Vehicle-side connector B111)Steering wheel angle sensor
(Vehicle-side connector M81)Continuity
2 (Y/R) 3 (Y/R) Yes
PS-1
POWER STEERING SYSTEM
G STEERING
CONTENTS
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SECTION
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PS
POWER STEERING SYSTEM
PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 2
Caution ..................................................................... 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 4
NVH Trouble shooting Chart .................................... 4
POWER STEERING FLUID ........................................ 5
Checking Fluid Level ........................................... ..... 5
Checking Fluid Leak ............................................ ..... 5
Bleeding Hydraulic System ...................................... 5
STEERING WHEEL .................................................... 6
On-Vehicle Inspection and Service .......................... 6
PLAY INSPECTION .............................................. 6
NEUTRAL POSITION INSPECTION .................... 6
STEERING TORQUE CHECK .............................. 6
STEERING ANGLE INSPECTION ........................ 6
Removal and Installation .......................................... 7
REMOVAL ............................................................. 7
INSTALLATION ..................................................... 7
STEERING COLUMN ................................................. 9
Removal and Installation .......................................... 9
REMOVAL OF LOWER JOINT AND HOLE
COVER ................................................................. 9
INSTALLATION OF LOWER JOINT AND HOLE
COVER ................................................................. 9
REMOVAL OF STEERING COLUMN ASSEM-
BLY ...................................................................... 10
INSTALLING STEERING COLUMN ASSEMBLY ... 10
Disassembly and Assembly .................................... 11
DISASSEMBLY .................................................... 11
INSPECTION AFTER DISASSEMBLY. ............... 11
ASSEMBLY .......................................................... 11
POWER STEERING GEAR AND LINKAGE ............ 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12INSTALLATION ................................................... 12
Components ........................................................... 14
MODEL PR24AD ................................................. 14
Disassembly and Assembly .................................... 15
DISASSEMBLY ................................................... 15
INSPECTION AFTER DISASSEMBLY ................ 16
ASSEMBLY ......................................................... 17
POWER STEERING OIL PUMP ............................... 24
On-Vehicle Inspection and Service ......................... 24
OIL PUMP PULLEY HYDRAULIC PRESSURE
INSPECTION ...................................................... 24
Removal and Installation (QR20DE and QR25DE
engine models) ....................................................... 24
REMOVAL ........................................................... 24
INSTALLATION ................................................... 24
Disassembly and Assembly(QR20DE and
QR25DE engine models) ........................................ 25
INSPECTION BEFORE DISASSEMBLY ............. 25
DISASSEMBLY ................................................... 25
INSPECTION AFTER DISASSEMBLY ................ 26
ASSEMBLY ......................................................... 26
Removal and Installation (YD22DDTi engine
model) ..................................................................... 29
Disassembly and Assembly (YD22DDTi engine
model) ..................................................................... 30
INSPECTION BEFORE DISASSEMBLY ............. 30
DISASSEMBLY ................................................... 31
INSPECTION AFTER DISASSEMBLY ................ 32
ASSEMBLY ......................................................... 32
HYDRAULIC LINE .................................................
... 34
Removal and Installation ........................................ 34
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 36
Wheel ..................................................................... 36
Steering Angle ........................................................ 36
Steering Column ..................................................... 36
Steering Linkage ..................................................... 36
Steering Gear ......................................................... 37
Oil Pump ................................................................. 37
Steering Fluid .......................................................... 37