BRC-3
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BRC and the Circuit between Yaw Rate Sensor and Side
G sensor and ESP/TCS/ABS Control Unit. ............ 98
Inspection 7 Solenoid Valve, ESP Switch-over Sole-
noid Valve and Circuit ......................................... ... 99
Inspection 8 Actuator Motor, Motor Relay and Circuit
. 102
Inspection 9 Actuator Relay and Circuit ............... 104
Inspection 10 Stop Lamp Switch and Circuit ........ 106
Inspection 11 ESP/TCS/ABS Control Unit Power
Supply Circuit ....................................................... 106
Inspection 12 When “EMERGENCY BRAKE” is
indicated in the Self-Diagnosis Results ................ 108
Inspection 13 When “ST ANG SEN SIGNAL” is Indi-
cated in the Self-Diagnosis Results .....................108
Inspection 14 Brake Fluid Level of Reservoir Tank,
Communication Circuit between ESP/TCS/ABS
Control Unit and Brake Fluid Level Warning Switch . 109
Inspection 15 CAN Communication Circuit, ESP/
TCS/ABS Control Unit and Steering Wheel Angle
Sensor ................................................................... 110
Component Check ............................................... . 111
ESP OFF SWITCH ............................................ . 111
ESP RELAY BOX .............................................. . 111
ESP ACTUATOR ............................................... 112
Symptom 1: ABS Works Frequently. ..................... 114
Symptom 2: Unexpected Pedal Action .................. 114
Symptom 3: Longer Stopping Distance ................. 115
Symptom 4: ABS Does Not Work. ........................ 116Symptom 5: Pedal Vibration and Noise ................116
Symptom 6: ESP OFF Indicator Lamp Does Not Illu-
minate ...................................................................117
Symptom 7: SLIP Indicator Lamp Does Not Illumi-
nate .......................................................................118
Symptom 8: During ESP/TCS/ABS Control, Vehicle
Behavior is Jerky. .................................................118
ESP/TCS/ABS CONTROL UNIT ............................120
Removal and Installation ......................................120
REMOVAL .........................................................120
INSTALLATION .................................................120
WHEEL SPEED SENSORS ....................................121
Removal and Installation ......................................121
SENSOR ROTOR ...................................................122
Removal and Installation ......................................122
REMOVAL .........................................................122
INSTALLATION .................................................122
ESP/TCS/ABS ACTUATOR AND RELAY BOX .....123
Removal and Installation ......................................123
YAW RATE/SIDE G SENSOR .................................124
Removal and Installation ......................................124
REMOVAL .........................................................124
INSTALLATION .................................................124
ESP OFF SWITCH ................................................. .125
Removal and Installation ......................................125
REMOVAL .........................................................125
INSTALLATION .................................................125
BRC-6
[4WD/ABS]
ALL MODE 4X4 SYSTEM
ALL MODE 4X4 SYSTEM
PFP:47850
System DescriptionEFS001CJ
ABS FUNCTION
●During ABS operation, brake pedal lightly vibrates and its mechanical noise may be heard. This is a nor-
mal condition.
●When starting engine, or just after starting vehicle, brake pedal may vibrate. Also motor operating noise
may be heard from engine compartment. This is a normal status of operation check.
● When vehicle drives on rough, gravel, or snowy (fresh deep snow) road, the following conditions occur.
Stopping distance may be longer than that of vehicles without ABS.
4WD FUNCTION
● Electronically controlled 4WD is controlled by the same control module as that for ABS (4WD/ABS control
unit). 4WD/ABS control unit controls both electronically-controlled 4WD and ABS, based on input signals
from several sensors.
●If electrical system-related malfunction occurred in 4WD/ABS system, control unit illuminates the following
lamps: 4WD warning lamp and/or ABS warning lamp on meter control unit assembly. This notifies driver of
malfunction. At the same time, control unit indicates malfunctioning part detected by self-diagnosis with
flashing pattern of LED. Indication on electronic system diagnosis tester (CONSULT) corresponds to this
flashing pattern as shown below.
Control System DiagramEFS001CK
Self-diagnostic test mode Remarks
Result of self-diagnosis Conformable to 4WD/ABS
Data monitor Conformable to 4WD/ABS
Active testChecks ABS solenoid valve ON/OFF, ABS motor ON/OFF, 4WD sole-
noid
Control unit part No. 4WD/ABS control unit
SFIA0350E
BRC-20
[4WD/ABS]
TROUBLE DIAGNOSIS
11 5
Body
groundGround -Control unit ground
path 11 3
111
108
106
104
13 Stop lamp signalDepress the brake pedal.
Release brake pedal.Battery voltage (Approx.
12V)
Approx. 0VStop lamp switch
and path
5ABS MOTOR
RELAYABS motor actuated
(by active test mode of CONSULT-II)
ABS motor stopped (Ignition switch is in
ON)Approx. 2 V or less
Battery voltage (Approx.
12V)ABS motor, motor
relay and harness
17ABS ACTUATOR
RELAYWhen actuator relay is active.
(the engine running)
When actuator relay is inactive.
(In fail-safe mode, before starting
engine)Approx. 2 V or less
Battery voltage (Approx.
12V)ABS actuator relay
and harness
11 6Front RH wheel IN
solenoid
Actuator is activated (by active test
mode of CONSULT-II) or actuator relay
is not activated
(In fail-safe mode, before starting
engine)
Actuator is not activated and actuator
relay is activated (Vehicle stopped with
engine running)Approx. 0V
Battery voltage (Approx.
12V)ABS solenoid valve
path 11 4Front RH wheel
OUT solenoid
11 2Front LH wheel IN
solenoid
11 0Front LH wheel
OUT solenoid
107Rear RH wheel IN
solenoid
105Rear RH wheel
OUT solenoid
103Rear LH wheel IN
solenoid
101Rear LH wheel
OUT solenoid
74WD warning lamp
(Note 2)4WD warning lamp ON
4WD warning lamp OFFApprox. 0V
Battery voltage (Approx.
12V)4WD warning lamp
and harness
4ABS warning lamp
(Note 3)ABS warning lamp ON
ABS warning lamp OFFApprox. 0V
Battery voltage (Approx.
12V)ABS warning lamp
and path
16
AUTO indicator
lampAUTO indicator lamp ON
AUTO indicator lamp OFFApprox. 0V
Battery voltage (Approx.
12V)AUTO indicator
lamp and harness
6LOCK indicator
lampLOCK indicator lamp ON
LOCK indicator lamp OFFApprox. 0V
Battery voltage (Approx.
12V)LOCK indicator
lamp and harness
46 37 FR RH SENSOR
At vehicle rotating (Approx. 30km/
h(19MPH))Pulse generation
Approx. 200HzSpeed sensor and
harness 34 43 FR LH SENSOR
36 45 RR RH SENSOR
44 35 RR LH SENSOR Terminal No.
Location Standard (note 1)(Note) Check
points when result
was malfunctioning +–
TROUBLE DIAGNOSIS
BRC-21
[4WD/ABS]
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NOTE:
1. If a circuit tester for measuring voltage is used for the check, do not forcibly extend any connector termi-
nals.
2. 4WD warning lamp ON/OFF timing
3. ABS warning lamp ON/OFF timing
4. Unit name is indicated by the name used in circuit diagram (4WD solenoid valve). However, it is “E-TS
solenoid” in CONSULT-II data.
Specifications defined by CONSULT-II
CAUTION:
The displayed item is the data calculated by the control unit, so it may indicate a normal value even if
an output circuit (harness is open) is open or shorted.
102
Body ground
4WD solenoid valve
(E-TS solenoid
valve) (Note 4)At vehicle stop engine idlingB a t t e ry v o lta g e ( A p p ro x .
12V)4WD actuator relay
solenoid valve and
harness
18 4WD actuator relay At vehicle stop engine idling 2 V or lower4WD actuator relay
and harness
2 G - sensor power
supply
At ignition switch ON (vehicle horizontal
stop condition)Approx. 8 V
G -sensor and har-
ness
32Longitudinal G -
sensor Approx. 2.5V
41 G -sensor ground Approx. 0V
22Throttle position
sensorWide open throttle
Closed throttleApprox. 4.0 V
Approx. 0.5 VThrottle position
sensor and har-
ness
24Parking brake
switchIn parking position
In other than parking position-Parking brake
switch and harness
26Drive mode
change-over switch
AUTODrive mode change-over switch: 2WD
Drive mode change-over switch: other
than 2WDSW ON: Approx. 0 V
SW OFF: Approx. 5 VDrive mode
change-over switch
and path
27Drive mode
change-over switch
LOCKDrive mode change-over switch: LOCK
Drive mode change-over switch: other
than LOCKSW ON: Approx. 0 V
SW OFF: Approx. 5 VDrive mode
change-over switch
and path
ON : When ignition switch is turned ON (before engine starts) or when malfunction is
detected
OFF : After engine is started (When the system is in normal condition)
ON : When ignition switch is turned ON (before engine starts) or when malfunction is
detected
OFF : After engine is started (When the system is in normal condition)
Te r m i n a l N o .
Location Standard (note 1)(Note) Check
points when result
was malfunctioning +–
Items to be monitored ContentsData monitor
(Reference)
Check points when result
was malfunctioning ConditionReference values in
normal operation
Wheel sensor FR, FL,
RR, RL [km/h (MPH)]Vehicle wheel speedWhen the vehicle is
stopped0 km/h (MPH)
Wheel speed sensor and
harness
While driving (note:1)Almost in accordance
with speedometer dis-
play (within ±10%)
LONGITUDINAL G-
SENSOR (4WD mod-
els)G -sensor operating
conditionWith vehicle stopped
on flat road. plus; 0.15 G G -sensor and harness
BRC-22
[4WD/ABS]
TROUBLE DIAGNOSIS
Throttle position sensor
[V]Throttle valve open/
close conditionClosed throttle to wide
open throttleWhen closed throttle:
Approx. 0.5V
Throttle position sensor
and harness
When wide open throt-
tle: Approx. 4.0 V
Stop lamp switch Brake pedal statusDepress the brake
pedal.ON
Stop lamp switch and
path
Release brake pedal. OFF
ENGINE RPM SIG-
NAL [STOP/RUN]With engine runningEngine RPM below 400
rpmSTOP
Engine RPM signal path
Engine RPM 400 rpm
or higherRUN
ABS inlet S/V
FR, FL, RR, RL (ON/
OFF)
Solenoid valve opera-
tionActuator (solenoid
valve) is activated (by
active test mode of
CONSULT-II) or actua-
tor relay is not acti-
vated (in fail-safe
mode, before starting
engine)ON
ABS solenoid valve path
ABS outlet S/V
FR, FL, RR, RL (ON/
OFF)Actuator (solenoid
valve) is not activated
and actuator relay is
activated (vehicle
stopped with (Engine
running)OFF
E-TS solenoid valve (A)
(4WD solenoid valve)4WD solenoid valve
current supply monitor-
ing conditionIn LOCK mode, at start-
ing vehicle (when
accelerator pedal was
depressed)Approx. 2.8 AE-TS solenoid valve
(4WD solenoid valve)
and harness
ABS actuator relay
(ON/OFF)Actuator relay activatedVehicle stopped
Ignition switch ONOFF
ABS actuator relay and
harness
Vehicle stopped
Engine runningON
ABS motor relay (ON/
OFF)Motor relay and motor
activated condition(Ignition switch ON or
engine is running): ABS
inactiveOFF
ABS motor and motor
relay harness
(Ignition switch ON or
engine is running): ABS
activeON
E-TS actuator relay
(4WD actuator relay)
(ON/OFF)E-TS actuator relay
(4WD actuator relay)
activation conditionVehicle stopped (Igni-
tion switch ON)OFFE-TS actuator relay
(4WD actuator relay) and
harness
Engine running ON
Warning lamp (ON/
OFF)ABS warning lamp ON
condition (Note 2)ABS warning lamp ON
conditionON
ABS warning lamp and
path
ABS warning lamp OFF
conditionOFF
G-SENSOR POWER
(4WD) [V]G -sensor power sup-
ply conditionWith vehicle stopped
on flat road.Approx. 8V (reference
value)G -sensor and harness
POWER VOLTAGE (V)Battery voltage sup-
plied to control moduleIgnition switch ON Approx. 10 - 16 VControl unit power supply
circuit
4WD WARNING LAMP
[ON/OFF]4WD warning lamp ON
condition4WD warning lamp ON ON 4WD warning lamp and
harness
Refer to “4WD Warning
Lamp”. 4WD warning lamp
OFFOFF Items to be monitored ContentsData monitor
(Reference)
Check points when result
was malfunctioning ConditionReference values in
normal operation
TROUBLE DIAGNOSIS
BRC-23
[4WD/ABS]
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NOTE:
1. Check air pressure of tire under normal condition.
2. ABS warning lamp ON/OFF timing
CONSULT-II FunctionsEFS001BH
CONSULT-II FUNCTION APPLICATION TABLE
4WD MODE SWITCH
(ON/OFF)Input condition of drive
mode change-over
switchEngine running, vehicle
stopped, switch
pressed-Drive mode change-over
switch and path
4WD MODE MONITOROutput condition of
drive mode indicator
lamp signalEngine running, vehicle
stoppedUsing drive mode
change-over switchDrive mode indicator
lamp and path
IMPROPER SIZE TIRE
MONITOR (mm)Improper size tire
installed condition- 0 - 4, 4 - 8Front/Rear tire size differ-
ence, wear condition
PARKING BRAKE
SWITCH (ON/OFF)Parking brake switch
operating conditionParking brake
depressedON
Parking brake switch and
harness
Parking brake not
depressedOFF
METER OUTPUT (km/
h)Output condition of
vehicle speed for
speedometerWheel stopped 0 km/h
Speed meter and har-
ness
Vehicle run nin gAlmost in accordance
with the wheel speed
sensor display
ON : When ignition switch is turned ON (before engine starts) or when malfunction is
detected
OFF : After engine is started (When the system is in normal condition)
Items to be monitored ContentsData monitor
(Reference)
Check points when result
was malfunctioning ConditionReference values in
normal operation
Item Self-diagnosis Data monitor Active test
FR RH SENSOR××–
FR LH SENSOR [OPEN]××–
RR RH SENSOR××–
RR LH SENSOR××–
Speed sensor×––
FR RH IN ABS SOL×××
FR RH OUT ABS SOL×××
FR LH IN ABS SOL×××
FR LH OUT ABS SOL×××
RR RH IN ABS SOL×××
RR RH OUT ABS SOL×××
RR LH IN ABS SOL×××
RR LH OUT ABS SOL×××
ABS ACTUATOR RELAY××–
ABS MOTOR RELAY×××
ABS warning lamp –×–
Battery voltage××–
Control module×––
ABS MOTOR×–×
Longitudinal G -sensor××–
BRC-24
[4WD/ABS]
TROUBLE DIAGNOSIS
×: Applicable
–: Not applicable
SELF-DIAGNOSIS
Operation Procedure
1. After obtaining customer's information, perform BRC-32, "Basic Inspection" .
2. After turning ignition switch OFF, connect CONSULT-II connec-
tor to data link connector on vehicle.
3. Start engine and drive at Approx. 30 km/m (19 MPH) for Approx.
1 minute.
4. Stop vehicle. With engine at idle, touch “START”, “ABS” and
“SELF-DIAG RESULTS” on CONSULT-II screen in this order.
CAUTION:
“ABS” may not be displayed on the system selection
screen in the following case: When “START” was touched
just after engine is started or ignition switch is turned to
ON. In this case, repeat procedure from step 2.
5. Self-diagnosis result is displayed. (If necessary, touch “PRINT” to print self-diagnosis result.)
●If “NO MALFUNCTION” is displayed, check ABS warning lamp. Refer to BRC-32, "BASIC INSPEC-
TION 3 ABS/4WD WARNING LAMP INSPECTION" .
6. Check the faulty part indicated by the chart to repair or replace.
7. Start engine and drive at Approx. 30 km/m (19 MPH) for Approx. 1 minute.
CAUTION:
●Check again to make sure that there is NO FAILURE on other parts.
●If wheel speed sensor [SHORT] is detected, ABS warning lamp does not turn off until following
conditions: Vehicle is driven at Approx. 30km/h (19 MPH) for Approx. 1 minute, even in normal
conditions.
8. Turn OFF ignition switch to prepare for erasing memory.
9. Start engine. Touch “START,” “ABS,” “SELF-DIAG RESULTS,” and “ERASE MEMORY” on CONSULT-II
screen in this order to erase fault memory.
CAUTION:
If memory cannot be erased, proceed to 6.
10. Drive at Approx. 30 km/m (19 MPH) for Approx. 1 minute. Be sure ABS warning lamp is OFF.
4WD solenoid valve×××
4WD actuator relay –×–
Engine speed signal –×–
Throttle position sensor××–
Improper size tire monitor –×–
4WD mode monitor –×–
4WD warning lamp –×–
Stop lamp switch –×–
Parking brake switch –×–
Meter output –×– Item Self-diagnosis Data monitor Active test
PBIA0153E
TROUBLE DIAGNOSIS
BRC-25
[4WD/ABS]
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Display Item List
Faulty lines Malfunction detecting condition Check harness
Front RH wheel sensor [OPEN]Either of following causes may be possible. Circuit of front RH
wheel sensor is open. Irregularly high input voltage is caused by
a short to power supply on signal lines.
Wheel sensor harness Front LH wheel sensor [OPEN]Either of following causes may be possible. Circuit of front LH
wheel sensor is open. Irregularly high input voltage is caused by
a short to power supply on signal lines.
REAR RH wheel sensor [OPEN]Either of following causes may be possible. Circuit of rear RH
wheel sensor is open. Irregularly high input voltage is caused by
a short to power supply on signal lines.
REAR LH wheel sensor [OPEN]Either of following causes may be possible. Circuit of rear LH
wheel sensor is open. Irregularly high input voltage is caused by
a short to power supply on signal lines.
Front RH wheel sensor [short 1]or
Front RH wheel sensor [short 2]
(Note 1), (Note 2)At RH front wheel sensor, following conditions occur: irregularly
high or low input voltage by short to power supply or ground on
signal lines, malfunction input signal
Front LH wheel sensor [short 1]
or front LH wheel speed sensor
[short 2]
(Note 1), (Note 2)At LH front wheel sensor, following conditions occur: irregularly
high or low input voltage by short to power supply or ground on
signal lines, malfunction input signal
Rear RH wheel sensor [SHORT]
(Note 1), (Note 2)At RH rear wheel sensor, following conditions occur: irregularly
high or low input voltage by short to power supply or ground on
signal lines, malfunction input signal
Rear LH wheel sensor [SHORT]
(Note 1), (Note 2)At LH rear wheel sensor, following conditions occur: irregularly
high or low input voltage by short to power supply or ground on
signal lines, malfunction input signal
FR RH IN ABS SOL
[OPEN] [SHORT]At RH front wheel ABS inlet solenoid valve, following conditions
occur: open circuit, output voltage is irregularly lower or higher
than control value by short to ground on control line.
ABS solenoid valve and
actuator relay harness FR LH IN ABS SOL
[OPEN] [SHORT]At LH front wheel ABS inlet solenoid valve, following conditions
occur: open circuit, output voltage is irregularly lower or higher
than control value by short to ground on control line.
RR RH IN ABS SOL
[OPEN] [SHORT]At RH rear wheel ABS inlet solenoid valve, following conditions
occur: open circuit, output voltage is irregularly lower or higher
than control value by short to ground on control line.
RR LH IN ABS SOL
[OPEN] [SHORT]At LH rear wheel ABS inlet solenoid valve, following conditions
occur: open circuit, output voltage is irregularly lower or higher
than control value by short to ground on control line.
FR RH OUT ABS SOL
[OPEN] [SHORT]At RH front wheel ABS outlet solenoid valve, following condi-
tions occur: open circuit, output voltage is irregularly lower or
higher than control value by short to ground on control line.
FR LH OUT ABS SOL
[OPEN] [SHORT]At LH front wheel ABS outlet solenoid valve, following conditions
occur: open circuit, output voltage is irregularly lower or higher
than control value by short to ground on control line.
RR RH OUT ABS SOL
[OPEN] [SHORT]At RH rear wheel ABS outlet solenoid valve, following condition
s
occur: open circuit, output voltage is irregularly lower or higher
than control value by short to ground on control line.
RR LH OUT ABS SOL
[OPEN] [SHORT]At LH rear wheel ABS outlet solenoid valve, following conditions
occur: open circuit, output voltage is irregularly lower or higher
than control value by short to ground on control line.
ABS motor [ON error]ABS actuator motor turned ON when the ABS motor is con-
trolled OFF.ABS motor relay and
harness
ABS motor [OFF error]ABS actuator motor turned OFF when the ABS motor is con-
trolled ON.