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
TROUBLE DIAGNOSIS
TF-47
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8. Touch "MONITOR START".
9. Screen of data monitor is displayed.
Display item list
Item (Unit)Monitor item selection
Remarks
ECU INPUT SIG-
NALSMAIN
SIGNALSCAN DIAG SUP-
PORT MNTRSELECTION
FROM MENU
ENG SPEED SIG (STOP/
RUN)××-×Condition of engine
(STOP/RUN) is dis-
played.
BATTERY VOLT (V)×--×Indicates voltage sup-
plied by 4WD control
unit
G-SEN VOLT (V)×--×G-sensor power sup-
ply condition (ON/OFF)
THRTL POS SEN (V)××-×Indicates throttle posi-
tion sensor signal volt-
age
ETS ACTUATOR (ON-OFF) -×-×4WD actuator relay
ON/OFF condition
4WD WARNING LAMP
(ON-OFF)-×-×Indicates 4WD warn-
ing lamp operating con-
dition
ETS SOLENOID (A) -×-×Current supplied to
4WD solenoid valve
DECEL G-SEN (G)××-×G-sensor operating
condition
4WD MODE SW
(AUTO, LOCK, 2WD)-×-×4WD mode recognized
by control unit
4WD MODE MONI
(AUTO, LOCK, 2WD)-×-×Output condition of
4WD mode indicator
lamp signal
DIS-TIRE MONITOR (mm) -×-×Improper size tire
installed condition
P BRAKE SW (ON/OFF) -×-×Indicates parking brake
switch ON/OFF condi-
tion
SPEED MTR (O/P) (km/h) -×-×Indicates vehicle speed
recognized by meter
control unit
CAN EFFECT (OK-NG) -×-×CAN communication
signal (OK/NG) condi-
tion is displayed.
TCS FAIL SIG (ON-OFF) - - -×TCS fail signal condi-
tion is displayed (ON-
OFF)
EBD FAIL SIG (ON-OFF) - - -×EBD fail signal condi-
tion is displayed (ON-
OFF)
ABS FAIL SIG (ON-OFF) -×-×ABS operation (ON-
OFF) condition is dis-
played.
CAN COMM (OK-NG) - -×-CAN communication
signal (OK/NG) condi-
tion is displayed.
TF-48
TROUBLE DIAGNOSIS
*:In case that the output signal from ESP/TCS/ABS control unit malfunction in wheel speed system.
ACTIVE TEST
CAUTION:
●Do not perform active test while driving.
●Active test cannot be performed with 4WD warning lamp on.
Operation procedure
1. Connect CONSULT-II to data link connector and start engine.
2. Touch "START" on the display.
3. Touch "ALL MODE 4WD".
4. Touch "ACTIVE TEST".
5. Test item selection screen is displayed.
6. Touch test item.
7. Touch "START" with "MAIN SIGNALS" line inverted.
8. Active test screen is displayed.
CAN CIRC 1 (OK-UNKWN) - -×-
CAN communication
signal (OK/UNKWN)
condition is displayed. CAN CIRC 2 (OK-UNKWN) - -×-
CAN CIRC 3 (OK-UNKWN) - -×-
EBD SIGNAL (ON-OFF) - - -×EBD operation (ON-
OFF) condition is dis-
played
ABS SIGNAL - - -×ABS operation (ON-
OFF) status is dis-
played
AMR SIGNAL - - -×TCS engine control
operation (ON/OFF)
status is displayed
BMR SIGNAL - - -×TCS brake control
operation (ON/OFF)
status is displayed
VDC SIGNAL (ON-OFF) - - -×ESP operation (ON-
OFF) condition is dis-
played
VDC FAIL (ON-OFF) - - -×ESP fail signal condi-
tion is displayed (ON-
OFF)
ETS FAIL REQ (ON-OFF) -×-×ETS fail request signal
condition is displayed*
(ON-OFF) Item (Unit)Monitor item selection
Remarks
ECU INPUT SIG-
NALSMAIN
SIGNALSCAN DIAG SUP-
PORT MNTRSELECTION
FROM MENU
SDIA0625E
TROUBLE DIAGNOSIS
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4WD solenoid valve
Under the vehicle stopped with engine ON, touch UP, DOWN on
screen. Adjust 4WD solenoid command current.
Check the monitor current at that time. If monitor current is within
approx. ±10%, light switch is normal.
CAUTION:
Do not continuously energize solenoid for long period of time.
ECU PART NUMBER
Ignore the ECU part number displayed in the ECU PART NUMBER MODE.
Refer to parts catalog to order the ECU.
Component InspectionEDS000HC
4WD SOLENOID VALVE
●Disconnect connector B152 and measure resistance between
terminals 1(L/W) and 2(LG).
System InspectionEDS000IO
CONTROL UNIT POWER SUPPLY SYSTEM
Inspection procedure
Disconnect 4WD control unit connector. Check for continuity and voltage between each terminal of vehicle-
side connector and body ground.
SDIA0626E
Resistance : Approx. 2.45Ω
SDIA0136E
Terminal No. Signal name Measuring condition Measurement value
3, 4, 6, 16, 17, 18, 24, 109 Power supply Ignition switch ON Battery voltage
104, 106, 108, 111, 113, 115 Ground Ignition switch OFF Continuity should exist.
SDIA0129E
TF-56
TROUBLE DIAGNOSIS
2. COMBINATION METER POWER SUPPLY CIRCUIT INSPECTION
1. Disconnect combination meter connector.
2. Check voltage between the combination meter harness connector M46 terminal No. LHD models: 46 (W/
L) RHD models: 59 (W/L) and body ground.
OK or NG
OK >> Malfunctioning combination meter.
NG >> Check fuse 10A [#11] to combination meter harness and connector.
4WD WARNING LAMP DOES NOT GO OUT SEVERAL SECONDS AFTER ENGINE
STARTED.(4WD MODE INDICATOR LAMP GOES OUT)
1. PERFORM SELF-DIAGNOSIS
Using CONSULT-II perform self-diagnosis.
OK or NG
OK >> No malfunction detected. Perform inspection again.
NG >>
●Determine the location of the malfunction according to the result of Self-diagnosis using CON-
SULT-II. (Malfunction is present in the 4WD system.)
●CONSULT-II does not display 4WD system-related trouble codes. GO TO 2.
2. 4WD CONTROL UNIT CONNECTOR CONNECTION INSPECTION
●Check 4WD control unit connector for proper connection.
OK or NG
OK >> Reconnect the 4WD control unit connector properly and perform inspection again.
NG >> Repair or replace the connector.
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
1. PERFORM SELF-DIAGNOSIS.
Using CONSULT-II perform self-diagnosis.
OK or NG
OK >> GO TO 2. (No self-diagnosis malfunction indicated.)
NG >> Determine the location of the malfunction according to the result of self-diagnosis using CON-
SULT-II. (Malfunction is present in the 4WD system.)
2. CHECK USING THE DATA MONITOR FUNCTION OF THE CONSULT- II.
●Perform inspection by the data monitor function of the CONSULT-II.
●Check that the operation is in AUTO mode.
●Measure voltage when the accelerator pedal is not depressed. (Accelerator pedal not depressed: approx.
0.5V or lower)
●Measure the current supplied to the 4WD solenoid valve. (Accelerator pedal not depressed: approx. 0A)
OK or NG
OK >> GO TO 3. (No self-diagnosis malfunction indicated.)
NG >>
●Not in AUTO mode. GO TO 3.
●Voltage when accelerator pedal is not depressed is higher than approximately 0.5V.
●4WD solenoid valve current when the accelerator pedal is not depressed is other than 0A.
●Countermeasure: Keep the vehicle idling for approximately 15 minutes before checking again.
(Voltage when accelerator pedal is not depressed will be automatically reset to zero during this
period.)
TROUBLE DIAGNOSIS
TF-57
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3.INSPECTION USING 4WD MODE CHANGE-OVER SWITCH
●On data monitor screen of the CONSULT-II, check 4WD mode switch.
●Check if the display changes from ## to 2WD mode when the 2WD switch is pressed.
●Check if the display changes from ## to AUTO mode when the AUTO switch is pressed.
●Check if the display changes from ## to LOCK mode when the LOCK switch is pressed.
OK or NG
OK >> No malfunction detected.
NG >>
●Not in AUTO mode. (In 2WD or LOCK mode)
Countermeasure: Slightly depress the accelerator pedal and check that the operation mode
changes to LOCK mode.
●Check circuit between 4WD mode switch harness connector M39 terminal No.1 (BR) and
4WD control unit harness connector E122 terminal No. 27 (BR).
(AUTO mode is not available because a malfunction is present in the 2WD mode harness.)
NOTICE:
Mechanism of 4WD mode change-over.
●2WD mode: Operation changes to 2WD mode when 4WD control unit harness connector E122
terminal No. 27 (BR) is shorted to ground.
●AUTO mode: Operation changes to AUTO mode when 4WD control unit harness connector
E122 terminals No. 27 (BR) and No. 26 (L) is shorted to ground.
●LOCK mode: Operation changes to LOCK mode when 4WD control unit harness connector
E122 terminal No. 26 (L) is shorted to ground.
4WD MODES CANNOT BE SWITCHED AFTER ENGINE IS STARTED
1.INSPECTION USING 4WD MODE CHANGE-OVER SWITCH
●Drive modes cannot be switched after the engine is started.
●On data monitor screen of the CONSULT-II, check 4WD mode switch.
●Check if the display changes from ## to 2WD mode when the 2WD switch is pressed.
●Check if the display changes from ## to AUTO mode when the AUTO switch is pressed.
●Check if the display changes from ## to LOCK mode when the LOCK switch is pressed.
OK or NG
OK >> No malfunction detected.
NG >>
●CONSULT-II display does not change from ## when the 2WD switch is pressed. Check harness
of the 2WD switch.
●CONSULT-II display does not change from ## when the AUTO switch is pressed. Check har-
ness of the 2WD switch and LOCK switch.
●CONSULT-II display does not change from ## when the LOCK switch is pressed. Check har-
ness of the LOCK switch.
●Perform 4WD mode change-over switch inspection.
WHILE DRIVING, 4WD WARNING LAMP FLASHES RAPIDLY. (WHEN IT FLASHERS FOR
APPROX. ONE MINUTE, THEN DOES NOT ILLUMINATE.)
●While driving, 4WD warning lamp flashes rapidly. (when it flashes for approx. one minute, then does not
illuminate.)
Rapid flashing: 2 times/second
This phenomenon protects drivetrain parts when a heavy load is applied to the electronically controlled
coupling and multiple disc clutch temperature increases. It is not a malfunction.
When the difference of diameters by or with the front and rear wheel with AUTO mode the shift switch
occasionally changes to LOCK mode automatically. This is not a malfunction.
When the difference of revolution speed between the front and rear wheel with AUTO mode, the shift
switch occasionally changes to LOCK mode automatically. This is not a malfunction.
WHILE DRIVING, 4WD WARNING LAMP FLASHES SLOWLY. (WHEN IT CONTINUES TO ILLU-
MINATE UNTIL ENGINE TURNS OFF.)
1. Check using the data monitor function of the CONSULT-II.
TF-58
TROUBLE DIAGNOSIS
●Perform inspection with the data monitor function of the CONSULT- I I .
●Check if the value of IMPROPER SIZE TIRE MONITOR is 8 mm (0.31 in) or more.
●Stop the engine. Restart the engine and drive the vehicle at 20 km/h (12 MPH) or faster for approxi-
mately 200 seconds. Confirm the 4WD warning lamp flashes slowly.
(Check if the value of IMPROPER SIZE TIRE MONITOR is 8 mm (0.31 in) or more.)
When the tire size is normal, the value of IMPROPER SIZE TIRE MONITOR will change from 8 mm
(0.31 in) or more to 0 to 4 mm (0 to 0.16 in) (normal condition) after the vehicle is driven 20 km/h (12
MPH) or faster for approximately 5 seconds.
2. Tire inspection
●Inspection of tire pressure.
●Wear condition.
●Check size of the front and rear tires. (No excessive difference should be observed.)
VEHICLE DOES NOT ENTER 4WD MODE EVEN THOUGH 4WD WARNING LAMP IS OFF.
1. Check using the data monitor function of the CONSULT-II.
Perform inspection by the data monitor function of the CONSULT-II.
–Check if the vehicle operation changes to 2WD, AUTO, and LOCK modes.
–Check current supplied to the 4WD solenoid valve in AUTO mode.
2. Check using the active test function of the CONSULT-II.
Using active test mode of CONSULT-II, supply current to the 4WD solenoid valve and check that the mon-
itor current becomes close to this supply current.
●The 4WDcontrol unit is normal when the difference between 4WD solenoid valve current and the monitor
current is within ±10%.
It is necessary to inspect the electronically controlled coupling assembly.
TIGHT-CONER BRAKING SYMPTOM OCCURS WHEN THE VEHICLE IS STARTED IN AUTO
WARNING LAMP REMAIN OFF).
1. THROTTLE POSITION SENSOR AND HARNESS INSPECTION
Check accelerator pedal stroke.
OK or NG
OK >> Perform self-diagnosis again.
NG >> Malfunctioning throttle position sensor harness.
4WD ACTUATOR RELAY (4WD SOLENOID ACTUATOR RELAY) TURNS ON/OFF FREQUENTLY
1. SELF-DIAGNOSIS RESULT IS 4WD ACTUATOR RELAY (4WD SOLENOID ACTUATOR RELAY) ON
ERROR AND OFF ERROR.
Is self-diagnosis result [ON error and OFF error]?
OK or NG
OK >> GO TO 2.
NG >> Repair or replace as necessary.
2. 4WD ACTUATOR RELAY (4WD SOLENOID ACTUATOR RELAY) AND HARNESS INSPECTION
Is self-diagnosis result [ON error and OFF error]?
OK or NG
OK >> Perform self-diagnosis again.
NG >> Malfunctioning 4WD actuator relay (4WD solenoid actuator relay) harness. Accelerator pedal not
depressed:Approx. 0A
Accelerator pedal
depressed:Approx. 2.8A
Example) Monitor value becomes approx. 1A for 4WD solenoid current 1A setting.
BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
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SECTION
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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