ROAD WHEEL
WT-3
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WT
ROAD WHEELPFP:40300
InspectionEES000J2
ALUMINUM WHEEL
1. Check tires for wear and improper inflation.
2. Check wheels for deformation, cracks and other damage. If
deformed, remove wheel and check wheel runout.
a. Remove tire from aluminum wheel and mount on a tire balance
machine.
b. Set dial indicator as shown in the illustration.
STEEL WHEEL
1. Check tires for wear and improper inflation.
2. Check wheels for deformation, cracks and other damage. If
deformed, remove wheel and check wheel runout.
a. Remove tire from steel wheel and mount wheel on a tire balance
machine.
b. Set two dial indicators as shown in the illustration.
c. Set each dial indicator to 0.
d. Rotate wheel and check dial indicators at several points around
the circumference of the wheel.
e. Calculate runout at each point as shown below.
f. Select maximum positive runout value and the maximum nega-
tive value.
Add the two values to determine total runout.
In case a positive or negative value is not available, use the
maximum value (negative or positive) for total runout.
If the total runout value exceeds the limit, replace steel wheel. Wheel runout (Dial indicator value):
Refer to WT-6, "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)"SFA975B
Radial runout = (A+B)/2 : 0.5 mm (0.020 in)
Lateral runout = (C+D)/2 : 0.8 mm (0.031 in)
Wheel runout:
Refer to WT-6, "
SERVICE DATA AND SPECIFI-
CATIONS (SDS)"
SFA981B
BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
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SECTION
A
B
BRC
BRAKE CONTROL SYSTEM
4WD/ABS
PRECAUTIONS .......................................................... 4
Precautions for brake system ................................... 4
Precautions for brake control ................................... 4
PREPARATION ........................................................... 5
Special Service Tool ................................................. 5
Commercial Service Tool ......................................... 5
ALL MODE 4X4 SYSTEM .......................................... 6
System Description .................................................. 6
ABS FUNCTION ................................................... 6
4WD FUNCTION ................................................... 6
Control System Diagram .......................................... 6
TROUBLE DIAGNOSIS .............................................. 7
Fail-safe Function ..................................................... 7
How to Proceed with Trouble Diagnosis .................. 7
BASIC CONCEPT ................................................. 7
DIAGNOSIS FLOW ............................................... 8
ASKING COMPLAINTS ........................................ 9
TROUBLE DIAGNOSIS SHEET - EXAMPLE ....... 9
Component Parts Location ..................................... 10
Schematic ............................................................... 11
Wiring Diagram — ABS — ..................................... 12
Trouble Diagnosis Chart by Symptom .................... 18
4WD/ABS Control Unit Input/Output Signal Stan-
dard ........................................................................ 19
4WD/ABS CONTROL UNIT CONNECTOR TER-
MINAL ARRANGEMENT .................................... 19
REFERENCE STANDARD TABLE ..................... 19
CONSULT-II Functions ........................................... 23
CONSULT-II FUNCTION APPLICATION TABLE ... 23
SELF-DIAGNOSIS .............................................. 24
DATA MONITOR ................................................. 26
ACTIVE TEST ..................................................... 29
Component Inspection ........................................... 30
ABS ACTUATOR ................................................ 30
4WD SOLENOID VALVE .................................... 32
Basic Inspection ..................................................... 32
BASIC INSPECTION 1 BRAKE FLUID LEVEL
AND LEAKAGE INSPECTION ............................ 32
BASIC INSPECTION 2 INSPECTION FOR LOOSE POWER SUPPLY TERMINAL ............... 32
BASIC INSPECTION 3 ABS/4WD WARNING
LAMP INSPECTION ............................................ 32
Wheel Sensor System ............................................ 32
INSPECTION PROCEDURE .............................. 32
Control Unit Power Supply System ........................ 34
INSPECTION PROCEDURE .............................. 34
G -Sensor System (4WD models) .......................... 34
INSPECTION PROCEDURE .............................. 34
4WD Solenoid, Actuator Relay System .................. 35
4WD Mode Switch System ..................................... 37
Trouble Diagnoses for Symptoms .......................
... 38
4WD INDICATOR LAMP DOES NOT COME ON
FOR APPROXIMATELY 1 SECOND WHEN THE
IGNITION SWITCH IS TURNED TO ON ............. 38
4WD WARNING LAMP DOES NOT ILLUMINATE
WITH IGNITION ON ............................................ 39
4WD WARNING LAMP DOES NOT GO OUT
SEVERAL SECONDS AFTER ENGINE
STARTED.(4WD MODE INDICATOR LAMP
GOES OUT) ........................................................ 39
HEAVY TIGHT-CORNER BRAKING SYMPTOM
OCCURS WHEN THE VEHICLE IS DRIVEN IN
AUTO MODE AND THE STEERING WHEEL IS
TURNED FULLY TO EITHER SIDE AFTER THE
ENGINE IS STARTED ......................................... 39
4WD MODES CANNOT BE SWITCHED AFTER
ENGINE IS STARTED ......................................... 41
WHILE DRIVING, 4WD WARNING LAMP
FLASHES RAPIDLY. (WHEN IT FLASHERS FOR
APPROX. ONE MINUTE, THEN DOES NOT
ILLUMINATE.) ..................................................... 41
WHILE DRIVING, 4WD WARNING LAMP
FLASHES SLOWLY. (WHEN IT CONTINUES TO
ILLUMINATE UNTIL ENGINE TURNS OFF.) ...... 41
VEHICLE DOES NOT ENTER 4WD MODE
EVEN THOUGH 4WD WARNING LAMP IS OFF. ... 41
TIGHT-CORNER BRAKING SYMPTOM
OCCURS WHEN THE VEHICLE IS STARTED IN
AUTO WARNING LAMP REMAIN OFF). ............ 42
BRC-2
4WD ACTUATOR RELAY (4WD SOLENOID
A C T U AT O R R E L AY ) T U R N S O N / O F F F R E -
QUENTLY ............................................................ 42
ABS Warning Lamp Does Not Illuminate. (ABS
Warning Lamp Does Not Come On When The Igni-
tion Switch Is Turned ON.) ...................................... 42
ABS Warning Lamp Illuminates With Ignition ON,
But Does Not Illuminates After A Few Seconds.
(ABS Warning Lamp Has Illuminated.) ................... 42
4WD Warning Lamp Does Not Illuminate With Igni-
tion ON. .................................................................. 43
4WD Warning Lamp Does Not Go Out Several Sec-
onds After Engine Is Started. (Drive Mode Indicator
Lamp Goes Out.) .................................................... 43
Heavy Tight-corner Braking Symptom Occurs
When The Vehicle Is Driven In Auto Mode And The
Steering Wheel Is Turned Fully To Either Side After
The Engine Is Started. ............................................ 44
Drive Modes Cannot Be Switched After Engine Is
Started. ................................................................... 45
Wheel Driving, 4WD Warning Lamp Flashes Rap-
idly. (When It Flashes For Approx. One Minute, Then
Does Not Illuminate.) .............................................. 45
Wheel Driving, 4WD Warning Lamp Flashes Slowly.
(When It Continues To Illuminate Until Engine Turns
OFF.) ....................................................................... 45
Vehicle Does Not Enter 4WD Mode Even Though
4WD Warning Lamp Is OFF. ................................... 46
Tight-corner Braking Symptom Occurs When The
Vehicle Is Started In Auto Mode (4WD Warning
Lamp Remain OFF). ............................................... 46
E-TS Actuator Relay (4WD Solenoid Actuator
Relay) Turns ON/OFF Frequently. .......................... 46
Inspection Of Drive Mode Change-over Switch Path ... 47
4WD/ABS CONTROL UNIT ...................................... 48
Removal and Installation ........................................ 48
REMOVAL ........................................................... 48
INSTALLATION .................................................... 48
WHEEL SENSORS ................................................... 49
Removal and Installation ........................................ 49
G-SENSOR (4WD MODEL ONLY) ............................ 50
Removal and Installation ........................................ 50
SENSOR ROTOR ................................................... ... 51
Removal and Installation ........................................ 51
REMOVAL ........................................................... 51
INSTALLATION .................................................... 51
ACTUATOR ............................................................... 52
Removal and Installation ........................................ 52
REMOVAL ........................................................... 53
INSTALLATION .................................................... 53
ESP/TCS/ABS
PRECAUTIONS ......................................................... 54
Precautions for Brake System ................................ 54
Precautions for Brake Control ................................ 54
Precautions for CAN System .................................. 54
FOR INSPECTION .............................................. 54
FOR HARNESS REPAIR .................................... 55PREPARATION ......................................................... 56
Special Service Tool ................................................ 56
Commercial Service Tool ........................................ 56
ON-VEHICLE SERVICE ............................................ 57
Adjustment of Neutral Position of Steering Wheel
Angle Sensor .......................................................... 57
GENERAL INFORMATION ....................................... 59
Fail-Safe .................................................................. 59
ABS SYSTEM ...................................................... 59
ESP/TCS SYSTEM .............................................. 59
Hydraulic Circuit ...................................................... 59
ABS Functions ........................................................ 59
TCS Functions ........................................................ 60
ESP Functions ........................................................ 60
System Diagram ..................................................... 61
CAN COMMUNICATION ........................................... 62
System Description ................................................. 62
FOR A/T MODELS ............................................... 62
FOR M/T MODELS .............................................. 62
TROUBLE DIAGNOSIS ............................................ 64
How to Perform Trouble Diagnoses for Quick and
Accurate Repair ...................................................... 64
INTRODUCTION ................................................. 64
WORK FLOW ...................................................... 65
ASKING COMPLAINTS ....................................... 66
EXAMPLE OF DIAGNOSIS SHEET .................... 66
Component Parts and Harness Connector Location ... 67
Schematic ............................................................... 68
Wiring Diagram —ESP/TCS/ABS— ..................... 69
Control Unit Input/Output Signal Standard .............. 75
STANDARDS USING A CIRCUIT TESTER AND
OSCILLOSCOPE ................................................. 75
STANDARDS WITH CONSULT-II ........................ 78
Functions of CONSULT-II ....................................... 80
CONSULT-II MAINLY FUNCTION APPLICA-
TION TO ESP/TCS/ABS ...................................... 80
SELF-DIAGNOSIS ............................................... 81
DATA MONITOR .................................................. 83
ACTIVE TEST ...................................................... 87
For Correct and Quick Diagnosis ............................ 90
PRECAUTIONS FOR TROUBLE DIAGNOSIS ... 90
Basic Inspection ...................................................... 91
PRELIMINARY CHECK 1: (BRAKE FLUID
LEVEL AND LEAK INSPECTION) ....................... 91
PRELIMINARY CHECK 2: (INSPECTION FOR
LOOSE POWER SUPPLY TERMINAL) ............... 92
PRELIMINARY CHECK 3: (INSPECTION FOR
ABS WARNING LAMP, ESP OFF INDICATOR
LAMP, AND SLIP INDICATOR LAMP) ................. 92
Inspection 1 Wheel Sensor and Circuit ................... 92
Inspection 2 Engine System ................................... 94
Inspection 3 ESP/TCS/ABS Control Unit System ... 94
Inspection 4 Pressure Sensor and the Circuit
between Pressure Sensor and ESP/TCS/ABS Con-
trol Unit. ................................................................... 95
Inspection 5 Steering wheel Angle Sensor and the
Circuit between Steering Wheel Angle Sensor and
ESP/TCS/ABS Control Unit. ................................... 96
Inspection 6 Yaw Rate Sensor and Side G sensor
STEERING WHEEL
PS-7
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●Start engine. With engine at idle, turn steering wheel from stop
to stop and measure steering angles.
●If angles are outside specification, measure rack stroke.
●If rack stroke is outside of specification, disassemble steering
gear to check rack stroke.
●Steering angles are not adjustable. If any of steering angles is different from specified value, check steer-
ing gear, the column and the front suspension components for wear or damage. If any abnormality exists,
replace the malfunctioning parts.
Removal and InstallationEGS0004F
REMOVAL
1. Remove air bag module. Refer to SRS-29, "DRIVER AIR BAG MODULE" .
2. Remove horn connector.
3. Remove steering wheel mounting nut and paint mating marks on steering wheel body and top of column
shaft.
4. Using a steering wheel puller, remove steering wheel.
INSTALLATION
Paying attention to following items, install in the reverse order of removal.
NOTE:
●When reconnecting spiral cable, fix cable with a tape so that fixing case and rotating part keep aligned.
This will omit neutral position alignment procedure during spiral cable installation.
●Neutral position (refer to figure)... Gently turn spiral cable clock-
wise until it comes to the stop. Then turn it counter clockwise
(approximately 3.0 turns) until centering mark is aligned with
adjustment mark. (Service part is fixed in neutral position with
stopper. It can be installed onto steering wheel without align-
ment once stopper is removed.)
CAUTION:
●Place steering wheel as follows: Front wheels in straight-
ahead position. R mark on the cancel claw faces down. 3
bosses align with 3 holes behind steering wheel assembly.
Check that spiral cable is placed in neutral position and that
locating pin on the left of the spiral cable is aligned with the
locating pinhole behind the steering wheel assembly.
●Do not rotate spiral cable more than necessary. Do not tighten them excessively. (The cable may
be torn off.)
●After installation, check system for proper operation by observing air bag warning lamp.
●If air bag indicator indicates any abnormal condition, use self-diagnosis function or CONSULT to
reset or cancel memory.Inner wheel Minimum : 36°
Nominal : 39°
Maximum : 40°
Outer wheel : 31°
Rack stroke : 66.5 mm (2.618 in)
SGIA0055E
SGIA0080E
SGIA0096E
SC-1
STARTING & CHARGING SYSTEM
K ELECTRICAL
CONTENTS
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SECTION
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B
SC
STARTING & CHARGING SYSTEM
PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 2
Wiring Diagrams and Trouble Diagnosis .................. 2
BATTERY .................................................................... 3
How to Handle Battery ............................................. 3
METHODS OF PREVENTING OVER-DIS-
CHARGE ............................................................... 3
CHECKING ELECTROLYTE LEVEL .................... 3
SPECIFIC GRAVITY CHECK ............................... 4
Battery Test and Charging Chart .............................. 5
CHART I ................................................................ 5
CHART II ............................................................... 6
A: SLOW CHARGE ............................................... 7
B: STANDARD CHARGE ...................................... 8
C: QUICK CHARGE ............................................ 10
Removal and Installation ......................................... 11
CHARGING SYSTEM ............................................... 12
System Description ................................................ 12
Wiring Diagram — CHARGE — ............................. 13
Trouble Diagnoses ................................................. 14
WITH IC REGULATOR ....................................... 14
MALFUNCTION INDICATOR .............................. 14
Removal and Installation ........................................ 15
REMOVAL (QR ENGINE MODELS) ................... 15
REMOVAL (YD ENGINE MODELS) ................... 15
INSTALLATION ................................................... 15
Disassembly and Assembly ................................... 16
Disassembly ........................................................... 17
REAR COVER .................................................... 17
REAR BEARING ................................................. 18Inspection ............................................................... 18
ROTOR CHECK .................................................. 18
BRUSH CHECK .................................................. 18
PULLEY CHECK(WITH CLUTCH TYPE) ............ 18
STATOR CHECK ................................................. 18
Assembly ................................................................ 19
RING FITTING IN REAR BEARING .................... 19
REAR COVER INSTALLATION ........................... 19
STARTING SYSTEM ................................................. 20
System Description ................................................. 20
M/T MODELS ...................................................... 20
A/T MODELS ....................................................... 20
Wiring Diagram — START —/M/T models ............. 21
Wiring Diagram — START —/A/T models .............. 22
Trouble Diagnoses ..............................................
... 23
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSTALLATION ................................................... 24
Disassembly and Assembly .................................... 25
Inspection ............................................................... 28
MAGNETIC SWITCH CHECK ............................. 28
PINION/CLUTCH CHECK ................................... 28
BRUSH CHECK .................................................. 28
YOKE CHECK ..................................................... 29
ARMATURE CHECK ........................................... 30
Assembly ................................................................ 31
PINION PROTRUSION LENGTH ADJUST-
MENT .................................................................. 31
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 33
Battery .................................................................... 33
Starter ..................................................................... 33
Alternator ................................................................ 33
IDX-2
ALPHABETICAL INDEX
Numerics
4WD mode switch ................................... TF-54
,TF-57
4WD shift indicator lamp .................................... TF-55
4WD solenoid valve ................................ TF-49,TF-52
4WD warning lamp TF-40,TF-55,TF-56,TF-57,TF-58
A
A/C air flow ......................................... ATC-31
,MTC-5
A/C component layout ..................................... ATC-23
A/C compressor clutch removal and installation ...........
ATC-135
A/C compressor precaution ............................... ATC-9
A/C compressor special service tool ................ ATC-14
A/C diagnostic work flow (auto A/C) ................ ATC-33
A/C HFC134a (R134a) system precaution ........ ATC-4
A/C HFC134a (R134a) system service procedure .......
ATC-129
A/C HFC134a (R134a) system service tools ... ATC-15
A/C HFC134a system service equipment precaution ...
ATC-10
A/C lubricant (R134a) ...................................... ATC-24
A/C operational check ......................... ATC-54,MTC-7
A/C performance test diagnoses ..................... ATC-88
A/C reray .......................................................... ATC-84
A/C self-diagnoses (auto A/C) ......................... ATC-46
A/C system description (auto A/C) ................... ATC-27
A/C trouble diagnoses (auto A/C) ....... ATC-33,MTC-3
A/C, A - Wiring diagram ................................... ATC-38
A/CCUT - Wiring diagram .............................. EC-1572
A/T - Wiring diagram - AT - FTS ...................... AT-118
A/T - Wiring diagram - AT - MAIN .................... AT-350
A/T - Wiring diagram - AT - PNP/SW ............... AT-112
A/T - Wiring diagram - AT - VSS A/T . AT-124,AT-355
A/T fluid checking .................................. AT-13,MA-36
A/T fluid replacement ............................. AT-13,MA-36
A/T fluid temperature sensor ........................... AT-121
A/T IND - Wiring diagram .................................... DI-57
A/T indicator ........................................................ DI-57
A/T shift lock system ........................................ AT-406
A/T shift lock system - Wiring diagram ............ AT-407
A/T trouble diagnoses .......................... AT-56,AT-258
A/T Wiring diagram - AT - ENG SS ... AT-128,AT-393
A/T Wiring diagram AT - 1ST ........................... AT-134
A/T Wiring diagram AT - 2ND .......................... AT-140
A/T Wiring diagram AT - 3RD .......................... AT-146
A/T Wiring diagram AT - 4TH .......................... AT-152
A/T Wiring diagram AT - BA/FTS ....... AT-195,AT-388
A/T Wiring diagram AT - CAN ............ AT-191,AT-404
A/T Wiring diagram AT - LPSV .......... AT-165,AT-398
A/T Wiring diagram AT - OVRCSV .... AT-187,AT-378
A/T Wiring diagram AT - SSV/A ......... AT-172,AT-369
A/T Wiring diagram AT - SSV/B ......... AT-177,AT-374
A/T Wiring diagram AT - TCV ............ AT-160,AT-383
A/T Wiring diagram AT - TPS ............ AT-182,AT-364
A/T Wiring diagrawm AT - VSSMTR .. AT-201,AT-360
ABS - Wiring diagram ..................................... BRC-12
Absolute pressure sensor .............................. EC-1494
Accelerator control system ............................... ACC-2
Accelerator pedal position (APP) sensor ........ EC-355,
EC-361
,EC-373,EC-631,EC-637,EC-651,EC-893,
EC-1222
,EC-1460
Accelerator pedal released position learning . EC-1404
Accelerator pedal released position switch .... EC-1531
Actuator relay ..................................................... TF-52
Aiming adjustment ............................................... LT-4
Air bag .............................................................. SRS-3
Air bag disposal .............................................. SRS-41
Air bleeding (hydraulic clutch) .............................. CL-8
Air bleeding for brake system ............................ BR-10
Air cleaner and air duct(QR20DE•QR25DE) .... EM-14
Air cleaner and air duct(YD22DDTi) ............... EM-120
Air cleaner filter replacement(QR20DE•QR25DE) ........
MA-22
Air cleaner filter replacement(YD22DDTi) ......... MA-32
Air cleaner filter(QR20DE•QR25DE) ................ EM-14
Air cleaner filter(YD22DDTi) ........................... EM-120
Air conditioner cut control .... EC-36,EC-446,EC-768,
EC-1132
,EC-1401
Air flow meter - See Mass air flow sensor ....... EC-138,
EC-516
,EC-870,EC-999,EC-1202
Air mix door control linkage adjustment ......... ATC-66,
ATC-125
,MTC-10,MTC-28
Air mix. door motor ......................... ATC-64,ATC-125
Air spoiler, rear ................................................... EI-21
Alternator ........................................................... SC-12
Ambient sensor ............. ATC-100,ATC-102,ATC-112
Angular tightening application(QR20DE•QR25DE) ......
EM-5
Angular tightening application(YD22DDTi) ..... EM-110
Antenna - See Power antenna ........................... AV-16
APPS - Wiring diagram ... EC-895,EC-1225,EC-1462
APPS1 - Wiring diagram ................... EC-357,EC-633
APPS2 - Wiring diagram ................... EC-363,EC-640
APPS3 - Wiring diagram ................... EC-375,EC-653
APRSW - Wiring diagram .............................. EC-1533
Audio .................................................................... AV-3
Auto air conditioner - Wiring diagram ............. ATC-38
Automatic amplifier ........................... ATC-44,ATC-57
Automatic transmission fluid replacement ....... MA-35,
MA-37
Axle ................................................................... MA-41
B
Back door ........................................................... BL-71
Back door trim ..................................................... EI-25
Back door window .............................................. GW-8
Back window ...................................................... GW-8
BACK/L - Wiring diagram ................................... LT-28
Back-up lamp .......................................... LT-28,LT-42
Back-up lamp switch (M/T) ............................... MT-12
Basic inspection ... EC-73,EC-465,EC-805,EC-1152,
EC-1412
Battery ................................................................. SC-3
Baulk ring (M/T) .................................... MT-18,MT-23
Blower motor ..... ATC-70,ATC-77,ATC-118,MTC-14,