BRC-2
ACTUATOR RELAY) TURNS ON/OFF FRE-
QUENTLY ............................................................ 42
ABS warning lamp does not illuminate. (ABS warn-
ing lamp does not come on when the ignition 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 ignition
ON. ......................................................................... 43
4WD warning lamp does not go out several seconds
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 rapidly.
(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
WHEEL SENSORS ................................................... 48
Removal and Installation ........................................ 48
G-SENSOR (4WD MODEL ONLY) ............................ 49
Removal and Installation ........................................ 49
SENSOR ROTOR ...................................................... 50
Removal and Installation ........................................ 50
REMOVAL ........................................................... 50
INSTALLATION .................................................... 50
ACTUATOR ............................................................... 51
Removal and Installation ........................................ 51
REMOVAL ........................................................... 51
INSTALLATION .................................................... 51
ESP/TCS/ABS
PRECAUTIONS ......................................................... 52
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ................................................................. 52
Precautions for Brake System ................................ 52
Precautions for Brake Control ................................ 52
Precautions for CAN System .................................. 53
FOR INSPECTION .............................................. 53
FOR HARNESS REPAIR .................................... 53ON-VEHICLE SERVICE ............................................54
Adjustment of Neutral Position of Steering Angle
Sensor .....................................................................54
GENERAL INFORMATION .......................................56
Fail-Safe ..................................................................56
ABS SYSTEM ......................................................56
ESP/TCS SYSTEM ..............................................56
Hydraulic Circuit ......................................................56
ABS Functions ........................................................56
TCS Functions ........................................................57
ESP Functions ........................................................57
System Diagram .....................................................58
CAN COMMUNICATION ...........................................59
System Description .................................................59
FOR M/T MODELS ..............................................59
TROUBLE DIAGNOSIS ............................................60
How to Perform Trouble Diagnoses for Quick and
Accurate Repair ......................................................60
INTRODUCTION .................................................60
WORK FLOW ......................................................61
ASKING COMPLAINTS .......................................62
EXAMPLE OF DIAGNOSIS SHEET ....................62
Component Parts and Harness Connector Location... 63
Schematic ...............................................................64
Wiring Diagram —ESP/TCS/ABS— .....................65
Control Unit Input/Output Signal Standard ..............71
STANDARDS USING A CIRCUIT TESTER AND
OSCILLOSCOPE .................................................71
STANDARDS WITH CONSULT-II ........................75
Functions of CONSULT-II .......................................77
CONSULT-II MAINLY FUNCTION APPLICA-
TION TO ESP/TCS/ABS ......................................77
SELF-DIAGNOSIS ...............................................78
DATA MONITOR ..................................................81
ACTIVE TEST ......................................................84
For Correct and Quick Diagnosis ............................88
PRECAUTIONS FOR TROUBLE DIAGNOSIS ... 88
Basic Inspection ......................................................89
PRELIMINARY CHECK 1: (BRAKE FLUID
LEVEL AND LEAK INSPECTION) .......................89
PRELIMINARY CHECK 2: (INSPECTION FOR
LOOSE POWER SUPPLY TERMINAL) ...............89
PRELIMINARY CHECK 3: (INSPECTION FOR
ABS WARNING LAMP, ESP OFF INDICATOR
LAMP, AND SLIP INDICATOR LAMP) .................89
Inspection 1 Wheel Speed Sensor and Circuit .......90
Inspection 2 Engine System ...................................92
Inspection 3 ESP/TCS/ABS Control Unit System ...92
Inspection 4 Pressure Sensor and the Circuit
between Pressure Sensor and ESP/TCS/ABS Con-
trol Unit. ...................................................................93
Inspection 5 Steering Angle Sensor and the Circuit
between Steering Angle Sensor and ESP/TCS/ABS
Control Unit. ............................................................94
Inspection 6 Yaw Rate Sensor/ Side G sensor and
the Circuit between Yaw Rate Sensor/ Side G sen-
sor and ESP/TCS/ABS Control Unit. ......................95
Inspection 7 Solenoid Valve, ESP Switch-over Sole-
BRC-3
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BRC noid Valve and Circuit ............................................ 97
Inspection 8 Actuator Motor, Motor Relay and Circuit
. 100
Inspection 9 Actuator Relay and Circuit ............... 102
Inspection 10 Stop Lamp Switch and Circuit ........ 104
Inspection 11 ESP/TCS/ABS Control Unit Power
Supply Circuit ....................................................... 104
Inspection 12 When “EMERGENCY BRAKE” is
indicated in the Self-Diagnosis Results ................ 106
Inspection 13 When “ST ANG SEN SIGNAL” is Indi-
cated in the Self-Diagnosis Results ..................... 106
Inspection 14 Brake Fluid Level of Reservoir Tank,
Communication Circuit between ESP/TCS/ABS
Control Unit and Brake Fluid Level Warning Switch. 107
Inspection 15 CAN Communication Circuit, ESP/
TCS/ABS Control Unit and Steering Angle Sensor. 108
Component Check ............................................... 109
ESP OFF SWITCH ............................................ 109
ESP/TCS/ABS RELAY BOX ............................. 109
ESP/TCS/ABS ACTUATOR ............................... 110
Symptom 1: ABS Works Frequently. ..................... 112
Symptom 2: Unexpected Pedal Action .................. 112
Symptom 3: Longer Stopping Distance ................. 113
Symptom 4: ABS Does Not Work. ........................ 114
Symptom 5: Pedal Vibration and Noise ................ 114
Symptom 6: ESP OFF Indicator Lamp Does Not Illu-minate ...................................................................115
Symptom 7: SLIP Indicator Lamp Does Not Illumi-
nate .......................................................................116
Symptom 8: During ESP/TCS/ABS Control, Vehicle
Behavior is Jerky. .................................................116
ESP/TCS/ABS CONTROL UNIT ............................118
Removal and Installation ......................................118
REMOVAL .........................................................118
INSTALLATION .................................................118
WHEEL SPEED SENSORS ....................................119
Removal and Installation ......................................119
SENSOR ROTOR ...................................................120
Removal and Installation ......................................120
REMOVAL .........................................................120
INSTALLATION .................................................120
ESP/TCS/ABS ACTUATOR AND RELAY BOX .....121
Removal and Installation ......................................121
YAW RATE/SIDE G SENSOR .................................122
Removal and Installation ......................................122
REMOVAL .........................................................122
INSTALLATION .................................................122
ESP OFF SWITCH ..................................................123
Removal and Installation ......................................123
REMOVAL .........................................................123
INSTALLATION .................................................123
BRC-6
[4WD/ABS]
ALL MODE 4X4 SYSTEM
ALL MODE 4X4 SYSTEM
PFP:47850
System DescriptionEFS001CJ
ABS FUNCTION
lDuring ABS operation, brake pedal lightly vibrates and its mechanical noise may be heard. This is a nor-
mal condition.
lWhen 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.
lWhen 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
lElectronically 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.
lIf 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-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
(byactivetestmodeofCONSULT)
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) 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
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
46 37 FR RH SENSOR
At vehicle rotating (Approx. 30km/h)Pulse generation
Approx. 200HzSpeed sensor and
harness 34 43FR LH SENSOR
[OPEN]
36 45 RR RH SENSOR
44 35 RR LH SENSOR Te r m i n a l N o .
Location Standard (note 1)(Note) Check
points when result
was malfunctioning +-
TROUBLE DIAGNOSIS
BRC-21
[4WD/ABS]
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CAUTION:
1. If a circuit tester for measuring voltage is used for the check, do not forcibly extend any connector
terminals.
CAUTION:
2. 4WD warning lamp ON/OFF timing
CAUTION:
3. ABS warning lamp ON/OFF timing
CAUTION:
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
102
Body ground
4WD solenoid valve
(E-TS solenoid
valve)At vehicle stop engine idlingBattery voltage (Approx.
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
4G - sensor power
supply
At ignition switch ON (vehicle horizontal
stop condition)Approx. 8 V
G -sensor and har-
ness
32Longitudinal G -
sensorApprox. 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)
Terminal No.
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 speed sensor
FR,
FL, RR, RL (km/h)Vehicle wheel speedWhen the vehicle is
stopped0km/h
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 sen-
sor [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) 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 moni-
toring conditionIn LOCK mode, at
starting vehicle (when
accelerator pedal was
depressed)Approx. 2.8 AE-TS solenoid valve (4WD
solenoid valve) and har-
ness
ABS actuator relay
(ON/OFF)Actuator relay acti-
vatedVehicle stopped
Ignition switch ONOFF
ABS actuator relay and
harness
Vehicle stopped
Engine runningON
ABS motor relay (ON/
OFF)Motor relay and motor
activated(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 har-
ness
Engine running ON
Warninglamp(ON/
OFF)ABSwarninglampON
condition (Note 2)ABS warning lamp ON ON
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
ONON4WD warning lamp and
harness
Refer to “4WD Warning
Lamp ”. 4WD warning lamp
OFFOFF
4WD MODE SWITCH
(ON/OFF)Input condition of drive
mode change-over
switchEngine running, vehi-
cle stopped, switch
pressed-Drive mode change-over
switch and path
TROUBLE DIAGNOSIS
BRC-23
[4WD/ABS]
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CAUTION:
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 MONI-
TOROutput condition of
drive mode indicator
lamp signalEngine running, vehi-
cle 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 harness
Vehicle runningAlmost 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)
Item Self-diagnosis Data monitor Active test
FR RH SENSOR´´-
FR LH SENSOR [OPEN]´´-
RR RH SENSOR´´-
RR LH SENSOR´´-
Speed sensor´--
Stop lamp switch -´-
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´´-
4WD solenoid valve´´´
4WD actuator relay -´-
Engine speed signal -´-
Throttle position sensor´´-
BRC-24
[4WD/ABS]
TROUBLE DIAGNOSIS
´: Applicable
–: Not applicable
SELF-DIAGNOSIS
Operation procedure
1. After obtaining customer's information, performBRC-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.
1minute.
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
justafterengineisstartedorignitionswitchisturnedto
ON. In this case, repeat procedure from step 2.
5. Self-diagnosis result is displayed. (If necessary, touch “PRINT” to print self-diagnosis result.)
lIf“NO MALFUNCTION”is displayed, check ABS warning lamp. Refer toBRC-32, "BASIC INSPECTION
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:
lCheck again to make sure that there is NO FAILURE on other parts.
lIf wheel speed sensor [SHORT] is detected, ABS warning lamp does not turn off until following
conditions: Vehicle is driven at Approx. 30km/h 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.
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