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-54
[ESP/TCS/ABS]
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
PFP:00000
Adjustment of Neutral Position of Steering Angle SensorEFS0019R
lAfter removing/installing or replacing the ESP/TCS/ABS control unit, steering angle sensor, steering com-
ponents, suspension components, and tires, or after adjusting the wheel alignment, make sure to adjust
the neutral position of the steering angle sensor before running the vehicle.
CAUTION:
To adjust the neutral position of the steering angle sensor, make sure to use CONSULT-II.
(Adjustment cannot be done other than CONSULT-II.)
1. Stop the vehicle with the front wheels in the straight-ahead position.
2. Connect CONSULT-II to data link connector on the vehicle, and
turn the ignition switch to ON position (engine not running).
3. Touch “START”, “ABS”, “WORK SUPPORT” and “ST ANGLE
SENSOR ADJUSTMENT” on the CONSULT-II screen in this
order.
PBIB0196E
SFIA0364E
SFIA0365E
SFIA0370E
BRC-88
[ESP/TCS/ABS]
TROUBLE DIAGNOSIS
For Correct and Quick Diagnosis
EFS001A8
PRECAUTIONS FOR TROUBLE DIAGNOSIS
lBefore performing the trouble diagnosis, always read theGI-3, "PRECAUTIONS"to confirm the general
precautions.
lAfter replacement of ESP/TCS/ABS control unit, steering angle sensor, steering parts, suspension parts,
or tires, and adjustment of alignment, always adjust the neutral position of steering angle sensor before
driving.
lWhen the ESP/TCS/ABS control unit is replaced, check that the label on the computer unit is identical
color.
lAfter completing the trouble diagnosis, always erase the malfunctioning memory.BRC-77, "Functions of
CONSULT-II"
lWhen inspection of the continuity or voltage between units is performed, check the connector terminals for
disconnection, looseness, bend, or collapse. If any malfunction is detected, repair or replace the applica-
ble part.
lIntermittent problems may be caused by a malfunction on harness, connector, or terminal. Move the har-
nesses, harness connectors, or terminals by hand to make sure that there is no contact malfunction.
lIf a circuit tester is used for the check, be careful not to forcibly extend any connector terminal.
lFor self-diagnosis, active test, and work support of ESP/TCS/ABS control unit with CONSULT-II, stop and
connect CONSULT-II and select²ABS².
lCONSULT-II self-diagnosis results are displayed without regard to occurrence timing. In some case, the
later ones (timing value is small) appear on the next screen.
lWhile the self-diagnosis results of CONSULT-II shows a malfunction, if CONSULT-II active test is per-
formed, an engine system malfunction may be indicated. In this case, start the engine to resume the nor-
mal screen.
lESP/TCS/ABS system electronically controls the brake operation and engine output. The following symp-
toms may be caused by the normal operations.
Symptom Symptom description Result
Motor operation noiseDuring ESP, TCS, or ABS operation, sometimes a faint noise can be
heard. This is a motor operation noise in the ESP/TCS/ABS actuator.
Normal
Just after the engine starts, the motor operating noise may be heard.
This is a normal status of the system operation check.
System operation check
noiseWhen the engine starts, a²click²noise may be heard from the engine
compartment. This is a normal status of the system operation check.Normal
ESP/TCS operation
(SLIP lamp ON)When the vehicle is passing through a road where the surface friction
coefficient varies or the wheel speed changes suddenly by downshifting
or depressing of the accelerator pedal fully, TCS may be activated tem-
porarily.
Normal
Cancel the ESP/TCS
function for the
inspection on a chas-
sis dynamometer. Before the speedometer inspection, turn ESP OFF switch off to cancel
the ESP/TCS function.
When the accelerator pedal is depressed on a chassis dynamometer,
the vehicle speed will not increase. This is not malfunction, because
TCS is activated by the wheel speed difference between front and rear.
The warning lamp may also illuminate to show²sensor system failure²in
this case. This is not malfunction either, because the stationary front
wheels are detected. Restart the engine, and drive the vehicle at 30 km/
h or higher to check that the warning lamp no longer illuminates.
ABS operation (Longer stop-
ping distance)The stopping distance may be longer for the vehicles with ABS when the
vehicle is driver on snowy and rough road. When driving on the road like
that, slow down the speed.Normal
Sluggish feelDepending on road circumstances, the driver may have a sluggish feel.
This is not abnormal, because the optimum traction has the highest pri-
ority (safety first) by TCS operation. Sometimes the driver has a slight
sluggish feel against the substantial accelerator pedal operation.Normal
TROUBLE DIAGNOSIS
BRC-95
[ESP/TCS/ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
3.STEERING ANGLE SENSOR CURCUIT CHECK
1. Disconnect the ESP/TCS/ABS control unit connector and the
steering angle sensor connector.
2. Check for continuity between the ESP/TCS/ABS control unit
(vehicle-side connector) and the steering angle sensor (vehicle-
side connector).
Is inspection result OK?
OK >> GO TO 4.
NG >> Repair or replace the disconnected harness.
4.DATA MONITOR CHECK
Perform the²STR ANGLE SIG²value in²DATA MONITOR²and check that it is in normal condition.
Is inspection result OK?
OK >> Perform the ESP/TCS/ABS control unit self-diagnosis again.
NG >> Replace the spiral cable (with the steering angle sensor) and adjust the neutral position of steer-
ing angle sensor.BRC-54, "
Adjustment of Neutral Position of Steering Angle Sensor".
Inspection 6 Yaw Rate Sensor/ Side G sensor and the Circuit between Yaw Rate
Sensor/ Side G sensor and ESP/TCS/ABS Control Unit.
EFS001AG
Inspection procedure
1.SELF-DIAGNOSIS RESULT CHECK 1
Check the self-diagnosis results.
CAUTION:
When the vehicle on a turn-table at an entrance of parking lot or on a moving unit, the ESP OFF indica-
tor lamp turns ON, and the self-diagnosis with CONSULT-II may indicate that the yaw rate sensor sys-
tem is malfunction. In this case, the yaw rate sensor is not malfunction. Move the vehicle from the
turn-table or other moving unit, and restart the engine. This will return the status normal.
Are
²YAW R AT E S E N S O R²and²SIDE G-SEN CIRCUIT²indicated in the self-diagnosis results.
>> GO TO 2.
SFIA0374E
ESP/TCS/ABS control unit
(Vehicle-side connector)Steering angle sensor
(Vehicle-side connector)Continuity
61 4 Yes
63 5 Yes
Steering condition STR ANGLE SIG (Data monitor)
Straight-ahead – 5deg to + 5deg
Turn the wheel to the right by 90°. Approx. + 90deg
Turn the wheel to the left by 90°. Approx. - 90deg
Self-diagnosis results
CONSULT-II indication item
YAW RATE SENSOR
SIDE G-SEN CIRCUIT
STEERING WHEEL
PS-7
C
D
E
F
H
I
J
K
L
MA
B
PS
lStart engine. With engine at idle, turn steering wheel from stop
to stop and measure steering angles.
lIf angles are outside specification, measure rack stroke.
lIf rack stroke is outside of specification, disassemble steering
gear to check rack stroke.
lSteering angles are not adjustable. If any of steering angles is different from specified value, check steer-
ing gear, the column and the front suspension components for wear or damage. If any abnormality exists,
replace the malfunctioning parts.
Removal and InstallationEGS0004F
REMOVAL
1. Remove air bag module. Refer toSRS-27, "DRIVER AIR BAG MODULE".
2. Remove horn connector.
3. Remove steering wheel mounting nut and paint mating marks on steering wheel body and top of column
shaft.
4. Using a steering wheel puller, remove steering wheel.
INSTALLATION
Paying attention to following items, install in the reverse order of removal.
NOTE:
lWhen reconnecting spiral cable, fix cable with a tape so that fixing case and rotating part keep aligned.
This will omit neutral position alignment procedure during spiral cable installation.
lNeutral position (refer to figure)... Gently turn spiral cable clock-
wise until it comes to the stop. Then turn it counter clockwise
(approximately 3.0 turns) until centering mark is aligned with
adjustment mark. (Service part is fixed in neutral position with
stopper. It can be installed onto steering wheel without align-
ment once stopper is removed.)
CAUTION:
lPlace steering wheel as follows: Front wheels in straight-
ahead position. R mark on the cancel claw faces down. 3
bosses align with 3 holes behind steering wheel assembly.
Check that spiral cable is placed in neutral position and that
locating pin on the left of the spiral cable is aligned with the
locating pinhole behind the steering wheel assembly.
lDo not rotate spiral cable more than necessary. Do not tighten them excessively. (The cable may
be torn off.)
lAfter installation, check system for proper operation by observing air bag warning lamp.
lIf air bag indicator indicates any abnormal condition, use self-diagnosis function or CONSULT to
reset or cancel memory.Inner wheel: 39°+1°
-3°
Outer wheel: 31°
Rack stroke : 66.5 mm (2.618 in)
SGIA0055E
SGIA0080E
SGIA0096E
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