TF-46
TROUBLE DIAGNOSIS
CAUTION:
If memory cannot be erased, proceed to 5.
9. Drive at approx. 30 km/h (19MPH) for approx. 1 minute. Be sure 4WD warning lamp is OFF.
Display item list
CAUTION:
●If "ALL MODE 4WD" is not displayed on system selection screen, check the following: 4WD actua-
tor and control unit, data link connector harness, and No. of CONSULT-II program card
●When several systems including CAN communication system indicates troubles, perform trouble
diagnosis of the CAN communication primarily.
DATA MONITOR
●For details of data monitor function, refer to CONSULT -II Operation Manual.
Operation procedure
1. Turn the ignition switch to OFF.
2. Connect CONSULT-II connector to data link connector on vehicle.
3. Turn ignition switch ON.
4. Touch "START" on the display.
5. Touch "ALL MODE 4WD" on the display.
CAUTION:
"ALL MODE 4WD" 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.
6. Touch "DATA MONITOR".
7. Return to monitor item selection screen. Touch any of "ECU INPUT SIGNALS," "MAIN SIGNALS," "CAN
DIG SUPPORT MNTR" or "SELECTION FROM MENU".
Refer to the following "Data monitor item chart".
Item Malfunction detecting condition Check harness
DECEL G-SENSOR Longitudinal G-sensor output voltage is outside specification.
G-sensor harness
G-SENSOR VOLTAGEPower voltage of longitudinal G-sensor remains abnormally high
or low for a certain period of time.
ETS SOLENOID
(4WD solenoid valve) (Open)4WD solenoid valve control terminal is not supplied with proper
voltage due to open circuit in 4WD solenoid valve.
4WD actuator relay,
solenoid and harness ETS SOLENOID
(4WD solenoid valve) (Short)4WD solenoid valve control terminal is not supplied with proper
voltage due to short circuit in 4WD solenoid valve.
ETS SOLENOID
(4WD solenoid valve)
(CURRENT FAILURE)Current supplied to 4WD solenoid valve is abnormally high or
low compared with the specification.
CONTROL UNIT Processing function of 4WD control unit is malfunctioning.4WD control unit, power
and ground circuits
DECEL G-SEN MONI Output voltage of longitudinal G-sensor is outside specification. G-sensor harness
DECEL G-SEN IN Input voltage of longitudinal G-sensor is outside specification. G-sensor harness
3 V POWER SUPLY CHECK 4WD control unit internal 3V power supply is malfunctioning.Control unit power sup-
ply circuit
4WD A/R CHECK 4WD actuator relay turned on while it is controlled OFF.
4WD actuator relay,
4WD solenoid and har-
ness. 4WD SOL/V CHECK4WD solenoid not supplied with proper voltage
due to open circuit in 4WD solenoid valve.
CAN COMM
●CAN communication function of 4WD control unit is malfunc-
tioning.
●CAN communication function of EPS control unit is malfunc-
tioning.Control unit power sup-
ply circuit
ABS 4WD COMMWheel speed sensor system of ESP/TCS/ABS control unit is
malfunctioning.ESP/TCS/ABS control
unit and harness
TF-54
TROUBLE DIAGNOSIS
4WD MODE SWITCH SYSTEM
1. INPUT SIGNAL CHECK
Check using the data monitor function of the CONSULT-II. While monitoring the 4WD mode switch items,
press 2WD mode switch. Check the display changes from ## to 2WD. Check the display for AUTO and LOCK
just the same. (## indicates when mode SW is not pressed.)
OK or NG
OK >>●4WD control unit input/output signal inspection.
●Recheck 4WD control unit connector terminals and connection.
NG >> GO TO 3.
2. INSPECTION OF 4WD MODE SWITCH POWER SUPPLY
●Disconnect 4WD mode switch connector.
●Turn ignition switch ON.
●Measure voltage between 4WD mode change and over switch harness connector M39 terminal No.2 (L),
No.1 (BR).
OK or NG
OK >> GO TO 4.
NG >> Harness malfunction or connector malfunction between ignition switch and 4WD mode switch
connector or connector malfunction.
3. HARNESS CONTINUITY INSPECTION
●Turn ignition switch OFF.
●Confirm the continuity between the following terminals.
–4WD control unit harness connector E122 terminal No. 26 (L) and 4WD mode switch harness connector
M39 terminal No. 2 (L).
–4WD control unit harness connector E122 terminal No. 27 (BR) and 4WD mode switch harness connec-
tor M39 terminal No. 1 (BR).
OK or NG
OK >> GO TO 5.
NG >> Malfunctioning harness or connector.
4. HARNESS CONTINUITY INSPECTION
Drive the vehicle for a while and the perform self-diagnosis.
OK or NG
OK >> End.
NG >>
●4WD control unit input/output signal inspection.
●Recheck 4WD control unit connector terminals and connection. 2 (L), 1 (BR) - Body ground : 4V or more.
26 (L) - 2 (L) : Continuity should exist.
27 (BR) - 1 (BR) : Continuity should exist.
BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
I
J
K
L
M
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
BRC-18
[4WD/ABS]
TROUBLE DIAGNOSIS
Trouble Diagnosis Chart by Symptom
EFS001BF
When ABS and 4WD warning lamps illuminate, perform self-diagnosis.
Symptom Condition Check items Reference page
4wd indicator lamp does not come on
for approximately 1 second when the
ignition switch is turned on.IGN-ON
●Blown drive mode indicator lamp bulb
●Blown fuse between ignition and drive mode
indicator lamp
●Open circuit of wiring between ignition and
drive mode indicator lampBRC-42
ABS warning lamp does not illuminate
with ignition ON. (ABS warning lamp
check)IGN-ON
●Blown ABS warning lamp bulb
●Blown fuse between ignition and ABS warning
lamp.
●Open circuit of wiring between ignition and
ABS warning lamp.
●Malfunction in ABS systemBRC-42
ABS warning lamp illuminates with
ignition ON, but does not illuminates
after a few seconds. (ABS warning
lamp has not illuminated.)IGN-ON●4WD/ABS control unit connector discon-
nected
●Malfunction in ABS systemBRC-42
4WD warning lamp does not illuminate
with ignition ON.IGN-ON
●Blown 4WD warning lamp bulb
●Blown fuse between ignition and 4WD warn-
ing lamp
●Open circuit in wire between ignition and 4WD
warning lamp
●Open circuit in wire between 4WD warning
lamp and 4WD actuator relay
●Disconnected 4WD actuator relay
●Open circuit in wire between 4WD actuator
relay and body groundBRC-43
4WD warning lamp does not go out
several seconds after engine is started.
(Drive mode indicator lamp goes out.)Engine running●4WD/ABS control unit connector discon-
nected
●Malfunction present in 4WD systemBRC-43
Heavy tight-corner braking symptom
occurs when vehicle is driven in the fol-
lowing conditions: AUTO mode and
steering wheel is turned fully to either
sides after engine is started (Note 1,
Note 2).●Engine run-
ning
●AUTO mode
●Steering
wheel fully
turned
●Operation is not in AUTO mode (in 2WD or
LOCK mode).
●Throttle position signal error
●Mechanical malfunction of electronically con-
trolled coupling
●Malfunction present in 4WD systemBRC-44
Drive modes cannot be switched after
engine is started.Engine running
●Drive mode change-over switch is discon-
nected.
●Open circuit between drive mode change-over
switch and 4WD /ABS control unit
●Open circuit between drive mode change-over
switch and body groundBRC-45
Vehicle running, 4WD warning lamp
flashes rapidly. (When it flashes for
Approx. One minute, then does not illu-
minate.) Rapid flashing: Two times
flashing per 1 secondEngine running
(to other than
2WD mode)Protection function was activated due to heavy
load to electronically controlled coupling. (4WD
system is not malfunctioning.)BRC-45
TROUBLE DIAGNOSIS
BRC-19
[4WD/ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
CAUTION:
1. Light tight-corner braking symptom may occur depending on driving conditions in AUTO mode.
This is not malfunction.
2. Heavy tight-corner braking symptom occurs when vehicle is driven in the following conditions:
LOCK mode, steering wheel is turned fully to either sides, and accelerator pedal was depressed.
4WD/ABS Control Unit Input/Output Signal StandardEFS001BG
4WD/ABS CONTROL UNIT CONNECTOR TERMINAL ARRANGEMENT
CAUTION:
When ignition switch is turned to ON with connectors of 4WD/ABS control unit and actuator con-
nected.
REFERENCE STANDARD TABLE
Specifications defined by circuit tester
Vehicle running, 4WD warning lamp
flashes slowly. (When it flashes for
Approx. One minute, then does not illu-
minate.) slow flashing: One flashing
per 2 seconds●Engine run-
ning
●Driving at
vehicle speed
30km/h (19
MPH)Tire size is different for front and rear of vehicle.BRC-45
Vehicle does not enter 4WD mode
even though 4WD warning lamp is off.Engine runningMechanical malfunction of electronically con-
trolled coupling (Mechanical engagement of
clutch is not possible.)BRC-46
Symptom Condition Check items Reference page
SFIA0351E
Te r m i n a l N o .
Location Standard (note 1)(Note) Check
points when result
was malfunctioning +–
3.
109Power supply Ignition switch ONB a t t e ry v o lta g e ( A p p ro x .
12V)Control unit power
supply circuit
TROUBLE DIAGNOSIS
BRC-23
[4WD/ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
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