GENERAL INFORMATION
BRC-59
[ESP/TCS/ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
GENERAL INFORMATIONPFP:00000
Fail-SafeEFS0019S
ABS SYSTEM
If a malfunction occurs in the electrical system, the ABS warning lamp, ESP OFF indicator lamp, and SLIP
indicator lamp in the meter will turn ON. In this condition, the ESP/TCS/ABS and EBD become one of the fol-
lowing conditions by the fail-safe function.
1. Only EBD operates. The same condition as that of models without ESP/TCS/ABS
2. ESP/TCS/ABS and EBD do not operate. Only normal brake operates on 4 wheels.
NOTE:
In the step 1 shown above, the self-diagnosis is carried out at the ignition switch is turned ON and when the
vehicle initial starts. ABS self-diagnosis noise may be heard as usual.
ESP/TCS SYSTEM
If a malfunction occurs in the electrical system, the ESP OFF indicator lamp and SLIP indicator lamp in the
meter turn on. In this condition, ESP/TCS will be deactivated and it becomes equal to that of models without
ESP/TCS. However, ABS is controlled normally.
If a malfunction occurs in the throttle control system, ESP/TCS control does not operate. Only ABS control
operates normally.
CAUTION:
If the fail-safe function operates, carry out the self-diagnosis for ESP/TCS/ABS control system.
Hydraulic Circuit EFS0019T
CAUTION:
●When installing, check for twist and fracture.
●Make sure that there is no interference with other parts when turning the steering clockwise or
counter clockwise.
●The brake piping is an important safety part. If a brake fluid leak is detected, always disassemble
and replace with a new one, if necessary.
ABS FunctionsEFS0019U
1. In cases of braking suddenly or braking on slippery road (ice road), ABS functions prevent wheels from
lock, improve the stability in sudden braking, and make efficient avoidance of obstacles with steering
manipulation by detecting 4-wheel speed and controlling 4-wheel brake fluid pressure.
2. EBD is integrated in ESP/TCS/ABS system.
CAUTION:
●During ABS operation, the brake pedal lightly vibrates and its mechanical noise may be heard.
This is a normal condition.
SFIA0346E
BRC-60
[ESP/TCS/ABS]
GENERAL INFORMATION
●When starting the engine, or just after starting the vehicle, the brake pedal may vibrate or the
motor operating noise may be heard from the engine compartment. This is a normal status of the
operation check.
●The stopping distance may be longer than that of vehicles without ABS when the vehicle drives on
rough, gravel, or snowy (fresh deep snow) road.
TCS FunctionsEFS0019V
1. With the wheel sensor signals from 4 wheels, the ESP/TCS/ABS control unit detects a wheel spin. If a
wheel spins, the control unit controls brake fluid pressure to the spinning wheel, and cuts the fuel to the
engine. It also closes the throttle valve to reduce the engine torque. Furthermore, throttle position is con-
trolled to the appropriate engine torque.
2. If a wheel spins, the TCS system works and function by applying brake fluid pressure to the spinning
wheel.
3. During TCS operation, it informs a driver of system operation by flashing SLIP indicator lamp.
CAUTION:
●During TCS operation, the body and the brake pedal lightly vibrate and the mechanical noise may
be heard. This is a normal condition.
●Depending on road circumstances, the driver may have a sluggish feel. This is not abnormal,
because the optimum traction has the highest priority by TCS operation.
●When the vehicle is passing through a road where the surface friction coefficient varies, down-
shifting or depressing the accelerator pedal fully may activate TCS temporarily.
ESP FunctionsEFS0019W
1. The Electronic Stability Program is called the ESP for short.
The ESP is indicated as the VDC (the Vehicle Dynamics Control) on the CONSULT-II screen.
2. In addition to the ABS/TCS function, ESP detects the driver's steering operation amount and brake opera-
tion amount from the steering wheel angle sensor and pressure sensor. Using the information from the
yaw rate and side G sensor and wheel sensors, ESP judges the driving condition (conditions of under-
steer and oversteer) to improve the stability by controlling the brake on 4 wheels and engine output.
3. During ESP operation, the SLIP indicator lamp flashes to inform the driver of the operation.
CAUTION:
●During ESP operation, the body and the brake pedal lightly vibrate and their mechanical noise
may be heard. This is a normal condition.
●If the vehicle is rotated on a turn table, or rolled and rocked on a ship, the ABS warning lamp,
ESP OFF indicator lamp, and SLIP indicator lamp may turn ON. In this case, start the engine on a
normal road again. If the ABS warning lamp, ESP OFF indicator lamp, and SLIP indicator lamp
turn OFF after the restart, it is normal.
●When driving in a steep slope such as a bank, the ABS warning lamp, ESP OFF indicator lamp,
and SLIP indicator lamp may turn ON. In this case, start the engine on a normal road again. If the
ABS warning lamp, ESP OFF indicator lamp, and SLIP indicator lamp turn OFF after the restart, it
is normal.
TROUBLE DIAGNOSIS
BRC-91
[ESP/TCS/ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
ABS Warning Lamp, ESP OFF Indicator Lamp, SLIP Indicator Lamp ON/OFF Timing
×:ON –: Lamp OFF
×: Applicable
–: Not applicable
Basic InspectionEFS001A9
PRELIMINARY CHECK 1: (BRAKE FLUID LEVEL AND LEAK INSPECTION)
1. Check the fluid level in the brake reservoir tank. If the fluid level is low, refill the brake fluid.
2. Check the area around the brake piping, ESP actuator for leaks. If a leak or oozing is detected, check as
follows:
●If the connections at the ESP actuator are loose, tighten the piping to the specified torque. Then check
again for leaks, and make sure that there is no fluid leak.
●If the flare nuts at the connections and the threads of the ESP actuator are damaged, replace the dam-
aged parts. Then check again for leaks, and make sure that there is no fluid leak.
●If a leak or oozing is detected on other parts than the ESP actuator connections, wipe the applicable
part with a clean cloth. Then check again for leaks, and if there is still a leak or oozing, replace the dam-
aged part.
ESP/TCS operation
(SLIP lamp ON)When the vehicle is passing through a road where the surface friction
coefficient varies or the wheel speed changes suddenly by downshifting
or depressing of the accelerator pedal fully, TCS may be activated tem-
porarily.
Normal
Cancel the ESP/TCS
function for the
inspection on a chas-
sis dynamometer. Before the speedometer inspection, turn ESP OFF switch off to cancel
the ESP/TCS function.
When the accelerator pedal is depressed on a chassis dynamometer,
the vehicle speed will not increase. This is not malfunction, because
TCS is activated by the wheel speed difference between front and rear.
The warning lamp may also illuminate to show “sensor system failure” in
this case. This is not malfunction either, because the stationary front
wheels are detected. Restart the engine, and drive the vehicle at 30 km/
h or higher to check that the warning lamp no longer illuminates.
ABS operation (Longer stop-
ping distance)The stopping distance may be longer for the vehicles with ABS when the
vehicle is driver on snowy and rough road. When driving on the road like
that, slow down the speed.Normal
Sluggish feelDepending on road circumstances, the driver may have a sluggish feel.
This is not abnormal, because the optimum traction has the highest pri-
ority (safety first) by TCS operation. Sometimes the driver has a slight
sluggish feel against the substantial accelerator pedal operation.Normal Symptom Symptom description Result
Condition ABS warning lampESP OFF
indicator lampSLIP indicator lamp Remarks
When the ignition switch is
OFF––– —
After the ignition switch is
turned ON
For Approx. 0.5 seconds×××—
Ignition switch ON
Approx. 0.5 seconds later––– —
When the ESP OFF switch
turns ON (ESP/TCS function
OFF).–×–Lamp goes off after Approx. 2
seconds when the engine re-start.
ESP/TCS/ABS
malfunction×××—
××–When the ESP/TCS/ABS control
unit is abnormal (power supply or
ground malfunction).
When the ESP/TCS ism
abnormal.–××—
TROUBLE DIAGNOSIS
BRC-109
[ESP/TCS/ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
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-114
[ESP/TCS/ABS]
TROUBLE DIAGNOSIS
Actuator operation check
1. Connect 9 and 10 terminals of actuator to 40 and 41 terminals of
relay box.
2. Measure the motor voltage (No.4 terminal to body earth) with
oscilloscope. Then check the motor reverse voltage occasioned
time.
The motor reverse voltage occasioned time is more than 0.1
sec.
CAUTION:
●Perform checking of motor relay unit. Then confirm that
relay functions.
●Driving actuator motor is with in 4 sec. to prevent heating
up.
●Standard condition of the motor reverse voltage occa-
sioned time is: Battery voltage is 12V. Temperature 20°.
when the battery voltage or temperature is lower than the
standard, the motor reverse voltage occasioned time
becomes slightly shorter.
Symptom 1: ABS Works Frequently.EFS001AS
Inspection procedure
1. INSPECTION START
Check the wheel sensor system.
●Sensor mounting inspection
●Sensor pick-up inspection for iron chips
●Sensor rotor inspection (e.g. Number of teeth, damaged teeth)
●Sensor connector engagement inspection
Is inspection result OK?
YES >> GO TO 2.
NO >> Refer to wheel sensor and rotor lines.
2. LOOSENESS INSPECTION
Check the front axle for looseness.
Is inspection result OK?
YES >>BRC-114, "Symptom 2: Unexpected Pedal Action"
NO >> Axle inspection and repair
Symptom 2: Unexpected Pedal ActionEFS001AT
Inspection procedure
1. BRAKE PEDAL STROKE INSPECTION
Check the brake pedal stroke.
Is stroke excessively long?
YES >> Check the bleeding and brake system.
NO >> GO TO 2.
SFIA0910E
BRC-116
[ESP/TCS/ABS]
TROUBLE DIAGNOSIS
4. WHEEL SENSOR INSPECTION
Check the wheel sensor system.
●Sensor mounting inspection
●Sensor pick-up inspection for iron chips
●Sensor rotor inspection (e.g. Number of teeth, damaged teeth)
●Sensor connector engagement inspection
Is inspection result OK?
YES >> Normal
NO >> Wheel sensor and rotor lines repair
Symptom 4: ABS Does Not Work.EFS001AV
Inspection procedure
1. ABS WARNING LAMP INDICATOR INSPECTION
Check that the ABS warning lamp illuminates.
Does the ABS warning lamp illuminate?
YES >> Perform the self-diagnosis.
NO >> GO TO 2.
2. WHEEL SENSOR INSPECTION
Check the wheel sensor system.
●Sensor mounting inspection
●Sensor pick-up inspection for iron chips
●Sensor rotor inspection (e.g. Number of teeth, damaged teeth)
●Sensor connector engagement inspection
Is inspection result OK?
YES >> Normal
NO >> Wheel sensor and rotor lines repair
Symptom 5: Pedal Vibration and NoiseEFS001AW
Inspection procedure
1. SYMPTOM CHECK
Check the brake system for pedal vibration or noise at the engine start.
Is inspection result OK?
YES >> Perform the self-diagnosis.
NO >> GO TO 2.
2. SYMPTOM CHECK 2
Check the brake system for pedal vibration or noise when the pedal depressed lightly (just put a foot on).
CAUTION:
Under the following driving conditions, the wheel speed will fluctuates, resulting in ABS activation.
●When shifting gears
●High speed cornering
●When a gust of wind
Is inspection result OK?
YES >> GO TO 3.
NO >> Normal
PS-6
STEERING WHEEL
STEERING WHEEL
PFP:48430
On-Vehicle Inspection and ServiceEGS0004E
PLAY INSPECTION
1. Turn steering wheel to straight-ahead position. Start engine and lightly turn steering wheel clockwise and
counter clockwise until front wheels start moving. Measure travel to starting point on circumference of
steering wheel.
2. If play is outside specifications, check following parts for proper installation: steering gear assembly, front
suspension, axles, and steering column
●Check steering wheel for vertical, horizontal, or axial play.
●Lift vehicle and check steering gear mounting bolts and nuts for looseness.
NEUTRAL POSITION INSPECTION
●After the wheel alignment inspection, carry out the neutral position inspection. Refer to FSU-6, "Wheel
Alignment" .
●Before removing steering wheel, check steering gear neutral position.
1. Set vehicle to straight-ahead position, and check that steering wheel is in neutral position.
2. If it is not in neutral position, remove steering wheel, and install again in properly.
3. If it is not adjusted within two teeth from center of gear, loosen tie rod lock nut. Then turn it to opposite
direction to adjust until amount of left and right becomes equal.
STEERING TORQUE CHECK
1. Stop vehicle on a dry flat paved road and apply parking brake.
2. Start engine and wait until power steering fluid warms up. Using
a preload gauge, check rotational torque of steering wheel.
3. If torque is outside specifications, check rack sliding torque and
oil pump relief pressure.
STEERING ANGLE INSPECTION
●After toe-in inspection, check steering angle. Place front wheels
on turning radius gauges and rear wheels on stands. Level the
vehicle. Check maximum inner and outer wheel steering angles
for LH and RH road wheels.Steering wheel play inspection standard : 0 - 35 mm (0 - 1.38 in)
Steering wheel axial endplay : 0 mm (0 in)
Tightening torque : 140 - 160 N·m (14.2 - 16.4 kg-m, 103 - 118 ft-lb)
Steering torque:
706 N·cm (72 kg-cm, 62 in-lb) or less
Rack sliding torque:
153 - 240 N (15.5 - 24.5 kg, 34.3 - 54.2 lb)
Oil pump relief hydraulic pressure:
8,140 - 8,728 kPa (81.4 - 87.3 bar, 83 - 89 kg/cm
2 , 1,180 - 1,266 psi)
STA0005D
FAA0016D
STEERING COLUMN
PS-11
C
D
E
F
H
I
J
K
L
MA
B
PS
Disassembly and AssemblyEGS00095
DISASSEMBLY
●Disassembly and assembly procedures should be done with steering lock unlocked.
1. Remove combination switch from jacket tube.
2. Remove jacket tube-to-column shaft mounting nut and remove column shaft from jacket tube.
3. Remove spring from mount assembly.
4. Remove mounting nut and adjusting stopper.
5. Remove steering adjusting bolt and remove tilt lever stopper and tilt lever.
INSPECTION AFTER DISASSEMBLY.
●If steering wheel does not turn smoothly, check the following and replace malfunctioning part.
1. Check column shaft bearing for damage and other malfunctions. Lubricate with grease or replace column
shaft if necessary.
2. Check jacket tube for deformation and cracks, and replace if necessary.
●If vehicle has slightly crashed, measure dimension“L” as shown.
If outside standard, replace steering column assembly.
ASSEMBLY
●Refer to component parts drawing for tightening torque and reverse disassembly procedure for assembly.
●After assembling steering column, check tilt mechanism.
1. Column shaft 2. Clip 3. Lower seal cover
4. Hole cover 5. Combination switch 6. Jacket tube
7. Mount assembly 8. Adjust stopper 9. Steering adjust bolt
10. Spring 11. Tilt lever stopper 12. Tilt lever
SGIA0016E
Dimension “L” : 543 mm (21.38 in)
STC0720D