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-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
BRC-20
[4WD/ABS]
TROUBLE DIAGNOSIS
11 5
Body
groundGround -Control unit ground
path 11 3
111
108
106
104
13 Stop lamp signalDepress the brake pedal.
Release brake pedal.Battery voltage (Approx.
12V)
Approx. 0VStop lamp switch
and path
5ABS MOTOR
RELAYABS motor actuated
(by active test mode of CONSULT-II)
ABS motor stopped (Ignition switch is in
ON)Approx. 2 V or less
Battery voltage (Approx.
12V)ABS motor, motor
relay and harness
17ABS ACTUATOR
RELAYWhen actuator relay is active.
(the engine running)
When actuator relay is inactive.
(In fail-safe mode, before starting
engine)Approx. 2 V or less
Battery voltage (Approx.
12V)ABS actuator relay
and harness
11 6Front RH wheel IN
solenoid
Actuator is activated (by active test
mode of CONSULT-II) or actuator relay
is not activated
(In fail-safe mode, before starting
engine)
Actuator is not activated and actuator
relay is activated (Vehicle stopped with
engine running)Approx. 0V
Battery voltage (Approx.
12V)ABS solenoid valve
path 11 4Front RH wheel
OUT solenoid
11 2Front LH wheel IN
solenoid
11 0Front LH wheel
OUT solenoid
107Rear RH wheel IN
solenoid
105Rear RH wheel
OUT solenoid
103Rear LH wheel IN
solenoid
101Rear LH wheel
OUT solenoid
74WD warning lamp
(Note 2)4WD warning lamp ON
4WD warning lamp OFFApprox. 0V
Battery voltage (Approx.
12V)4WD warning lamp
and harness
4ABS warning lamp
(Note 3)ABS warning lamp ON
ABS warning lamp OFFApprox. 0V
Battery voltage (Approx.
12V)ABS warning lamp
and path
16
AUTO indicator
lampAUTO indicator lamp ON
AUTO indicator lamp OFFApprox. 0V
Battery voltage (Approx.
12V)AUTO indicator
lamp and harness
6LOCK indicator
lampLOCK indicator lamp ON
LOCK indicator lamp OFFApprox. 0V
Battery voltage (Approx.
12V)LOCK indicator
lamp and harness
46 37 FR RH SENSOR
At vehicle rotating (Approx. 30km/
h(19MPH))Pulse generation
Approx. 200HzSpeed sensor and
harness 34 43 FR LH SENSOR
36 45 RR RH SENSOR
44 35 RR LH SENSOR Terminal No.
Location Standard (note 1)(Note) Check
points when result
was malfunctioning +–
TROUBLE DIAGNOSIS
BRC-21
[4WD/ABS]
C
D
E
G
H
I
J
K
L
MA
B
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
BRC-22
[4WD/ABS]
TROUBLE DIAGNOSIS
Throttle position sensor
[V]Throttle valve open/
close conditionClosed throttle to wide
open throttleWhen closed throttle:
Approx. 0.5V
Throttle position sensor
and harness
When wide open throt-
tle: Approx. 4.0 V
Stop lamp switch Brake pedal statusDepress the brake
pedal.ON
Stop lamp switch and
path
Release brake pedal. OFF
ENGINE RPM SIG-
NAL [STOP/RUN]With engine runningEngine RPM below 400
rpmSTOP
Engine RPM signal path
Engine RPM 400 rpm
or higherRUN
ABS inlet S/V
FR, FL, RR, RL (ON/
OFF)
Solenoid valve opera-
tionActuator (solenoid
valve) is activated (by
active test mode of
CONSULT-II) or actua-
tor relay is not acti-
vated (in fail-safe
mode, before starting
engine)ON
ABS solenoid valve path
ABS outlet S/V
FR, FL, RR, RL (ON/
OFF)Actuator (solenoid
valve) is not activated
and actuator relay is
activated (vehicle
stopped with (Engine
running)OFF
E-TS solenoid valve (A)
(4WD solenoid valve)4WD solenoid valve
current supply monitor-
ing conditionIn LOCK mode, at start-
ing vehicle (when
accelerator pedal was
depressed)Approx. 2.8 AE-TS solenoid valve
(4WD solenoid valve)
and harness
ABS actuator relay
(ON/OFF)Actuator relay activatedVehicle stopped
Ignition switch ONOFF
ABS actuator relay and
harness
Vehicle stopped
Engine runningON
ABS motor relay (ON/
OFF)Motor relay and motor
activated condition(Ignition switch ON or
engine is running): ABS
inactiveOFF
ABS motor and motor
relay harness
(Ignition switch ON or
engine is running): ABS
activeON
E-TS actuator relay
(4WD actuator relay)
(ON/OFF)E-TS actuator relay
(4WD actuator relay)
activation conditionVehicle stopped (Igni-
tion switch ON)OFFE-TS actuator relay
(4WD actuator relay) and
harness
Engine running ON
Warning lamp (ON/
OFF)ABS warning lamp ON
condition (Note 2)ABS warning lamp ON
conditionON
ABS warning lamp and
path
ABS warning lamp OFF
conditionOFF
G-SENSOR POWER
(4WD) [V]G -sensor power sup-
ply conditionWith vehicle stopped
on flat road.Approx. 8V (reference
value)G -sensor and harness
POWER VOLTAGE (V)Battery voltage sup-
plied to control moduleIgnition switch ON Approx. 10 - 16 VControl unit power supply
circuit
4WD WARNING LAMP
[ON/OFF]4WD warning lamp ON
condition4WD warning lamp ON ON 4WD warning lamp and
harness
Refer to “4WD Warning
Lamp”. 4WD warning lamp
OFFOFF Items to be monitored ContentsData monitor
(Reference)
Check points when result
was malfunctioning ConditionReference values in
normal operation
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××–