BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
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SECTION
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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-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-12
[4WD/ABS]
TROUBLE DIAGNOSIS
Wiring Diagram — ABS —
EFS001CL
TFWA0002E
TROUBLE DIAGNOSIS
BRC-21
[4WD/ABS]
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BRC
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
GENERAL INFORMATION
BRC-61
[ESP/TCS/ABS]
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BRC
System DiagramEFS0019X
SFIA0911E
BRC-62
[ESP/TCS/ABS]
CAN COMMUNICATION
CAN COMMUNICATION
PFP:23710
System DescriptionEFS002AW
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
FOR A/T MODELS
System diagram
Input/output signal chart
T: Transmit R: Receive
FOR M/T MODELS
System diagram
Input/output signal chart
T: Transmit R: Receive
SKIA0884E
Signals ECM TCM
Engine coolant temperature signal T R
Accelerator pedal position signal T R
A/T self-diagnosis signal R T
SKIA0885E
Signals ECMSteering wheel
angle sensor4WD control unitESP/ TCS / ABS
control unit
Engine speed signal T R R
Accelerator pedal position signal T R
ESP operation signal R R T
TCS operation signal R R T
ABS operation signal R R T
Stop lamp switch signalRT
Steering wheel angle sensor signal T R
ESP-OFF switch signalRT
TROUBLE DIAGNOSIS
BRC-69
[ESP/TCS/ABS]
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BRC
Wiring Diagram —ESP/TCS/ABS—EFS001A5
TFWA0010E