TF-2
SEVERAL SECONDS AFTER ENGINE
STARTED.(4WD MODE INDICATOR LAMP
GOES OUT) ........................................................ 55
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 ......................................... 56
4WD MODES CANNOT BE SWITCHED AFTER
ENGINE IS STARTED ......................................... 57
WHILE DRIVING, 4WD WARNING LAMP
FLASHES RAPIDLY.(WHEN IT FLASHERSFOR
APPROX. ONE MINUTE, THEN DOES NOT
ILLUMINATE.) ..................................................... 57
WHILE DRIVING, 4WD WARNING LAMP
FLASHES SLOWLY. (WHEN IT CONTINUES TO
ILLUMINATE UNTIL ENGINE TURNS OFF.) ...... 58
VEHICLE DOES NOT ENTER 4WD MODEEVEN THOUGH 4WD WARNING LAMP IS OFF.... 58
TIGHT-CONER BRAKING SYMPTOM OCCURS
WHEN THE VEHICLE IS STARTED IN AUTO
WARNING LAMP REMAIN OFF). .......................58
4WD ACTUATOR RELAY (4WD SOLENOID
ACTUATOR RELAY) TURNS ON/OFF FRE-
QUENTLY ............................................................58
SERVICE DATA AND SPECIFICATIONS (SDS) ......60
General Specifications ............................................60
Inspection and Adjustment ......................................60
PRELOAD TORQUE BEFORE DISASSEMBLY...60
PRELOAD TORQUE AFTER DISASSEMBLY
AND REASSEMBLY ............................................60
BACKLSH ............................................................60
SELECTIVE PARTS ............................................60
PINION SLEEVE SHIM ........................................61
ALL MODE 4X4 SYSTEM
TF-31
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ALL MODE 4X4 SYSTEMPFP:47850
PrecautionsEDS000IV
lThis section describes ESP/TCS/ABS model.
lRefer to the BRC section for model without ESP/TCS/ABS.Refer toBRC-6, "ALL MODE 4X4 SYSTEM"
System ComponentEDS000IJ
System DescriptionEDS000IK
ERECTRONIC COUPLING
lIn response to command current from 4WD control unit, control
clutch pull-in force is generated at the electromagnet and torque
is generated at the control clutch.
lThe cam operates in response to control clutch torque and
applies pressure to main clutch.
lMain clutch transmits torque from input shaft to output shaft,
according to the amount of pressure.
lThe actual amount of torque transfer is determined by control
current as shown in figure below (I-T characteristics figure).
4WD CONTROL UNIT
lControls distribution of drive power between front-wheel drive
(100:0) and 4WD (50:50) conditions circuit according to signals
from sensors.
lIf malfunction occurs in 4WD system, 4WD warning lamp turns
ON and vehicle changes to front-wheel drive.
lSelf-diagnosis can be done with CONSULT-II.
SFIA0283E
SFIA0284E
SFIA0285E
SFIA0286E
TF-32
ALL MODE 4X4 SYSTEM
4WD MODE SWITCT
AUTO mode (AUTO indicator lamp ON)
lElectronic control allows optimal distribution of torque to front/rear wheels to match road conditions.
lMakes possible stable driving, with no wheel spin, on snowy roads or other slippery surfaces.
lOn roads which do not require 4WD, it contributes to improved fuel economy by driving in conditions close
to front-wheel drive.
lSensors determine the vehicle's turning condition, and in response tight cornering/braking are controlled
by distributing optimum torque to rear wheels.
NOTE:
lWhen driving in AUTO mode or LOCK mode, if there is a large difference between front and rear wheel
speed which continues for a long time, oil temperature of drive system parts becomes too high and 4WD
warning lamp flashes rapidly. (When 4WD warning lamp flashes, vehicle changes to front-wheel drive
conditions.)
lWhen driving in AUTO mode, 4WD warning lamp may flash slowly if there is a significant difference in
pressure or wear between tires. At this time, vehicle performance is not fully available and cautious driving
is required. (Continues until engine is turned OFF.)
lIf 4WD warning lamp is flashing rapidly, stop vehicle and allow it to idle for some time. Flashing will stop
and AUTO mode will be restored.
lIf the warning lamp flashes slowly during driving but remains OFF after engine is restarted, the system is
normal. If it again flashes slowly after driving for some time, vehicle must be inspected.
lWhen 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 malfunction.
LOCK mode (LOCK indicator lamp and AUTO indicator lamp ON)
lFront/rear wheel torque distribution is fixed, ensuring stable driving when climbing slopes.
lWhen LOCK mode is selected, vehicle will switch automatically to AUTO mode if vehicle speed increases.
If vehicle speed then decreases, the vehicle automatically returns to direct 4-wheel driving conditions.
NOTE:
If there is a significant difference in pressure or wear between tires, full vehicle performance is not available.
Tire conditions are detected, and LOCK mode may be prohibited, or else speeds at which LOCK mode is
enabled may be restricted.
2WD mode (indicator lamps OFF)
Vehicle is in front-wheel drive.
NOTE:
lIf front wheels are slipping in 2WD mode, do not switch to AUTO or LOCK. This can cause difficulties for
the system.
lThe shift switch even if the shift switch is in 2WD mode, the sift switch occasionally automatically change
to 4WD mode depending on the driving condition (For example; Depressing the acceleration firmly). this is
not malfunction. How ever, 4WD mode indicator lamp dose not illuminate.
4WD WARNING LAMP
Turns ON when there is a malfunction in 4WD system. It indicates that fail-safe mode is engaged and vehicle
is in 2WD.
Also turns ON when ignition switch is turned ON, for purpose of bulb check. Turns OFF approximately for 3
seconds after the engine starts if system is normal.
4WD waning lamp indiction
Condition Display 4WD warning lamp
Self-diagnosisWhen self-diagnosis is performed, indicates location of
malfunction by number of flashes.-
Lamp checkTurns ON when engine is started to check for burned-out
lamps.Turns ON when ignition switch
is turned ON. Turns OFF
approximately 3 seconds after
engine start.
4WD system malfunction Turns ON if there is malfunction in 4WD system. ON
ALL MODE 4X4 SYSTEM
TF-33
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FAIL- SAFE FUNCTION
lIf a malfunction occurs in 4WD electrical system, and control unit detects the malfunction, 4WD warning
lamp on gauge turns ON to inform driver of system malfunction.
lWhen 4WD warning lamp is ON, vehicle is in 2WD.
System DiagramEDS000IL
CAN CommunicationEDS000IP
SYSTEM DESCRIPTION
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.
SYSTEM DIAGRAM
Largedifferenceindiameteroffront/
rear tires4WD warning lamp flashes slowly. Flashes once every 2 seconds.
Difference in front/rear wheel speed
continues and oil temperature of
drive system has increased.4WD warning lamp flashes rapidly. Flashes twice each second.
Other than above (system normal) OFF OFFCondition Display 4WD warning lamp
SFIA0287E
SKIA0885E
TF-40
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
PFP:00004
Fail-safe functionEDS000H4
lIf a malfunction occurs in 4WD electrical system, and control unit detects the malfunction, 4WD warning
lamp on gauge turns ON to inform driver of system malfunction.
lWhen 4WD warning lamp is ON, the vehicle is in 2WD.
How to proceed with trouble diagnosisEDS000H5
BASIC CONCEPT
lThe most important point to perform trouble diagnosis is to understand vehicle systems (control and
mechanism) thoroughly.
lIt is also important to clarify customer complaints before inspec-
tion.
First of all, reproduce symptom, and understand it fully.
Ask customer about his/her complaints carefully. In some cases,
it will be necessary to check symptoms by driving vehicle with
customer.
CAUTION:
Customers are not professional. It is dangerous to make an
easy guess like "maybe the customer means that...," or
"maybe the customer mentions this symptom".
lIt is essential to check symptoms right from the beginning in
order to repair a malfunction completely.
For intermittent malfunction, reproduce symptom based on inter-
view with customer and past examples. Do not perform inspec-
tion on ad hoc basis. Most intermittent malfunctions are caused
by poor contacts. In this case, it will be effective to shake sus-
pected harness or connector by hand. When repairing without
any symptom diagnosis, you cannot judge if malfunction has
actually been eliminated.
lAfter completing diagnosis, always erase diagnostic memory.
Refer toTF-45, "
Operation procedure".
lFor intermittent malfunction, move harness or harness connector by hand. Then check poor contact or
false open circuit.
SEF234G
SEF233G
TROUBLE DIAGNOSIS
TF-41
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Trouble diagnosis chart by symptomEDS0 00 IT
Symptom Condition Check items Reference page
When ignition switch is turned ON,
4WD mode indicator lamp does not
illuminate for approx. 1 second (4WD
mode lamp check)IGN-ON
lBlown 4WD mode indicator lamp bulb
lBlown fuse between ignition and 4WD mode
indicator lamp
lOpen circuit in wiring between ignition and
4WD mode indicator lampTF-54, "
4WD
INDICATOR
LAMP DOSE
NOT COME ON
FOR APPROXI-
MATELY 1
SECOND
WHEN THE
IGNITION
SWITCH IS
TURNED TO
ON"
4WD warning lamp does not illuminate
with ignition switch ON.IGN-ON
lMalfunction 4WD warning lamp circuit.
lBlown fuse between ignition and 4WD warn-
ing lamp
lOpen circuit in wiring between ignition and
4WD warning lamp
lOpen circuit in wiring between 4WD warning
lamp and 4WD actuator relay
lDisconnected 4WD actuator relay
lOpen circuit in wiring between 4WD actuator
relay and body groundTF-55, "
4WD
WAR NIN G
LAMP DOES
NOT ILLUMI-
NATE WITH
IGNITION ON"
4WD warning lamp does not go out
several seconds after engine is started.
(4WD mode indicator lamp goes out.)Engine runningl4WD control unit connector disconnected
lMalfunction presented in 4WD systemTF-55, "
4WD
WAR NIN G
LAMP DOES
NOT GO OUT
SEVERAL SEC-
ONDS AFTER
ENGINE
STARTED.(4W
DMODEINDI-
CATOR LAMP
GOES OUT)"
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).lEngine running
lAUTO mode
lSteering wheel
fully turned
lOperation is not in AUTO mode (in 2WD or
LOCK mode).
lThrottle position signal error
lMechanical malfunction of electronically con-
trolled coupling
lMalfunction present in 4WD systemTF-56, "
HEAVY
TIGHT-COR-
NER 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"
4WD mode cannot be switched after
engine is started (Note 3)Engine running
l4WD mode change-over switch is discon-
nected.
lOpen circuit between 4WD mode change-
over switch and 4WD control unit
lOpen circuit between 4WD mode change-
over switch and body groundTF-57, "
4WD
MODES CAN-
NOT BE
SWITCHED
AFTER
ENGINE IS
STARTED"
TF-42
TROUBLE DIAGNOSIS
NOTE:
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.
3. When the difference of revolution speed between the front and the rear wheels is large, the 4WD mode
does not change to other mode.this is not a malfunction.
4WD control unit input/output signal standardEDS000H9
4WD CONTROL UNIT CONNECTOR TERMINAL ARRANGEMENT
When ignition switch is turned to ON with connectors of 4WD control unit connected.
While driving, 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.)TF-57, "
WHILE
DRIVING, 4WD
WARN ING
LAMP
FLASHES RAP-
IDLY. (WHEN IT
FLASHERS
FOR APPROX.
ONE MINUTE,
THEN DOES
NOT ILLUMI-
NATE.)"
While driving, 4WD warning lamp
flashes slowly. (when it flashes for
approx. one minute, then does not illu-
minate.)Slow flashing: One flashing
per 2 secondslEngine running
lDriving at vehicle
speed 20km/
h(12MPH)Tire size is different for front and rear of vehicle.TF-58, "
WHILE
DRIVING, 4WD
WARN ING
LAMP
FLASHES
SLOWLY.
(WHEN IT
CONTINUES
TO ILLUMI-
NATE UNTIL
ENGINE
TURNS OFF.)"
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.)TF-58, "
VEHI-
CLE DOES
NOT ENTER
4WD MODE
EVEN
THOUGH 4WD
WARN ING
LAMP IS OFF."
Symptom Condition Check items Reference page
SDIA0120E
TROUBLE DIAGNOSIS
TF-43
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REFERENCE STANDARD TABLE
Specifications defined by circuit tester
NOTE:
*1:If a circuit tester for measuring voltage is used for the check, do not forcibly extend any connector terminals.
*2:4WD warning lamp ON/OFF timing
*3:Unit name is indicated by the one used in circuit diagram (4WD solenoid valve). However, it is "E-TS SOLE
NOID" in CONSULT-II data.
Te r m i n a l N o .
Location
Standard*1(Note) Check points when
result was malfunctioning
+-
3 Power supply Ignition switch ON Battery voltage (approx. 12V)Control unit power supply
circuit
11 5
Body
grou
ndGround - Control unit ground circuit 11 3
111
108
106
104
74WD warning lamp
*24WD warning lamp ON
4WD warning lamp OFFApprox. 0V
Battery voltage (approx. 12V)4WD warning lamp and
harness
16AUTO 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
1024WD solenoid valve
(E-TS solenoid
valve)
*3At vehicle stop engine idling Battery voltage (approx. 12V)4WD actuator relay sole-
noid valve and harness
18 4WD actuator relay At vehicle stop engine idling 2 V or lower4WD actuator relay and
harness
2 G-sensor power
supply1
At ignition switch ON (vehicle hori-
zontal stop condition)Approx. 8 V
G-sensor and harness
32 Longitudinal G-sen-
sor 1Approx. 2.5V
22Throttle position
sensorWide open throttle
Closed throttleApprox. 4.0 V
Approx. 0.5 VThrottle position sensor
and harness
24Parking brake
switchIn parking position
In other than parking position-Parking brake switch and
harness
264WD mode change-
over switch AUTO4WD mode change-over switch:
2WD
4WD mode change-over switch:
other than 2WDSW ON: Approx. 0 V
SW OFF: Approx. 5 V4WD mode change-over
switch and circuit
274WD mode change-
over switch LOCK4WD mode change-over switch:
LOCK
4WD mode change-over switch:
Other than LOCKSW ON: Approx. 0 V
SW OFF: Approx. 5 V4WD mode change-over
switch and circuit
39CAN communica-
tion L line---
48CAN communica-
tion H line---
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)