TROUBLE DIAGNOSIS
BRC-111
[ESP/TCS/ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
2. PEDAL FORCE INSPECTION
Check that brake is effective with the pedal depressed.
Is the pedal force heavy, but effective?
YES >> Normal
NO >> GO TO 3.
3. CONNECTOR AND PERFORMANCE INSPECTION
Disconnect the actuator relay unit connector to deactivate the ABS function. Check that brake is effective.
Is brake effective?
YES >> GO TO 4.
NO >> Brake line inspection
4. ABS WARNING LAMP INDICATOR INSPECTION
Check that ABS warning lamp illuminates.
Does ABS warning lamp illuminate?
YES >> Perform the self-diagnosis.
NO >> GO TO 5.
5. WHEEL SENSOR INSPECTION
Check the wheel sensor system.
Sensor mounting inspection
Sensor pick-up inspection for iron chips
Sensor rotor inspection (e.g. Number of teeth, damaged teeth)
Sensor connector engagement inspection
Is inspection result OK?
YES >> Normal
NO >> Wheel sensor and rotor lines repair
Symptom 3: Longer Stopping DistanceEFS001AU
Inspection procedure
1. INSPECTION START
Check that the stopping distance when braking becomes longer only on a snowy or gravel road.
Does the stopping distance when braking become longer only on a snowy or gravel road?
YES >> It may be longer than that of vehicle without ABS.
NO >> GO TO 2.
2. PERFORMANCE CHECK
Disconnect the actuator relay box to deactivate the ABS function.
Is the stopping distance still longer?
YES >>Brake line air bleeding
Brake line inspection
NO >> GO TO 3.
3. ABS WARNING LAMP INDICATOR INSPECTION
Check that ABS warning lamp illuminates.
Does ABS warning lamp illuminate?
YES >> Perform the self-diagnosis.
NO >> GO TO 4.
BRC-112
[ESP/TCS/ABS]
TROUBLE DIAGNOSIS
4. WHEEL SENSOR INSPECTION
Check the wheel sensor system.
Sensor mounting inspection
Sensor pick-up inspection for iron chips
Sensor rotor inspection (e.g. Number of teeth, damaged teeth)
Sensor connector engagement inspection
Is inspection result OK?
YES >> Normal
NO >> Wheel sensor and rotor lines repair
Symptom 4: ABS Does Not Work.EFS001AV
Inspection procedure
1. ABS WARNING LAMP INDICATOR INSPECTION
Check that the ABS warning lamp illuminates.
Does the ABS warning lamp illuminate?
YES >> Perform the self-diagnosis.
NO >> GO TO 2.
2. WHEEL SENSOR INSPECTION
Check the wheel sensor system.
Sensor mounting inspection
Sensor pick-up inspection for iron chips
Sensor rotor inspection (e.g. Number of teeth, damaged teeth)
Sensor connector engagement inspection
Is inspection result OK?
YES >> Normal
NO >> Wheel sensor and rotor lines repair
Symptom 5: Pedal Vibration and NoiseEFS001AW
Inspection procedure
1. SYMPTOM CHECK
Check the brake system for pedal vibration or noise when engine starts.
Is inspection result OK?
YES >> Perform the self-diagnosis.
NO >> GO TO 2.
2. SYMPTOM CHECK 2
Check the brake system for pedal vibration or noise when pedal is depressed lightly (just put a foot on).
CAUTION:
Under the following driving conditions, the wheel speed will fluctuates, resulting in ABS activation.
When shifting gears
High speed cornering
When a gust of wind
Is inspection result OK?
YES >> GO TO 3.
NO >> Normal
TROUBLE DIAGNOSIS
BRC-113
[ESP/TCS/ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
3. SYMPTOM CHECK 3
Does the symptom appear during normal braking operation?
CAUTION:
ABS may work in following driving conditions even if there is no sudden brake.
When road friction is low.
High speed cornering
When a gust of wind
Is inspection result OK?
YES >> GO TO 4.
NO >> Normal
4. SYMPTOM CHECK 4
Check that the symptom is reproduce when the engine speed is increased with the vehicle stopped.
Is inspection result OK?
YES >> GO TO 5.
NO >>
Normal.
CAUTION:
This symptom may appear with vehicle stopped.
5. SYMPTOM CHECK 5
Check that the symptom is reproduced when any switch of electrical equipment is operated.
Is inspection result OK?
YES >> Check that there are no radio, antenna, and antenna lead-in wires (including wiring) near control
unit.
NO >> GO TO 6.
6. ABS WARNING LAMP INSPECTION
Check that the ABS warning lamp turns on.
Is inspection result OK?
YES >> Perform the self-diagnosis.
NO >> GO TO 7.
7. WHEEL SENSOR INSPECTION
Check the wheel sensor system.
Sensor mounting inspection
Sensor pick-up inspection for iron chips (e.g. Number of teeth, damaged teeth)
Sensor connector engagement inspection
Wheel sensor path harness and connector inspection
Is inspection result OK?
YES >> Normal
NO >> Wheel sensor and rotor lines repair
Symptom 6: ESP OFF Indicator Lamp Does Not IlluminateEFS001AX
Inspection procedure
1. ESP OFF INDICATOR LAMP INSPECTION
Disconnect ESP/TCS/ABS control unit connector.
Does ABS warning lamp and ESP OFF indicator lamp illuminate?
YES >> ESP/TCS/ABS control unit malfunction. Repair or replace the control unit.
NO >> Combination meter system malfunction. Check the combination meter.
MA-2 INSPECTION AFTER INSTALLATION ................ 32
Changing Air Cleaner Filter .................................... 32
VISCOUS PAPER TYPE ..................................... 32
Changing Engine Oil ............................................... 33
Changing Oil Filter (TYPE A) .................................. 33
REMOVAL ........................................................... 33
INSTALLATION .................................................... 34
INSPECTION AFTER INSTALLATION ................ 34
Changing Oil Filter (TYPE B) .................................. 35
REMOVAL ........................................................... 35
INSTALLATION .................................................... 36
INSPECTION AFTER INSTALLATION ................ 36
Draining Water ........................................................ 36
CHASSIS AND BODY MAINTENANCE ................... 37
Checking Exhaust System ...................................... 37
Checking Clutch Fluid Level and Leaks ................. 37
Checking Clutch System ........................................ 37
Checking M/T Oil .................................................... 37
Changing M/T Oil .................................................... 38
Checking A/T Fluid ................................................. 38
Changing A/T Fluid ................................................. 39
Checking Transfer Oil ............................................. 39
Changing Transfer Oil ............................................. 39
Checking Propeller Shaft ........................................ 40
Checking Differential Gear Oil ................................ 40
Changing Differential Gear Oil ................................ 40
Balancing Wheels ................................................... 41
Rotation .................................................................. 41
Checking Brake Fluid Level and Leaks .................. 41
Checking Brake Lines and Cables ......................... 41Changing Brake Fluid ............................................. 42
Checking Disc Brake ............................................... 43
ROTOR ................................................................ 43
CALIPER .............................................................. 43
PAD ...................................................................... 43
Checking Steering Gear and Linkage ..................... 43
STEERING GEAR ............................................... 43
STEERING LINKAGE .......................................... 43
Checking Power Steering Fluid and Lines .............. 44
Axle and Suspension Parts ..................................... 44
Drive Shaft .............................................................. 45
Lubricating Locks, Hinges and Hood Latches ......... 45
Checking Seat Belts, Buckles, Retractors, Anchors
and Adjusters .......................................................... 45
Checking Body Corrosion ....................................... 45
HEMMED PANELS .............................................. 45
PANEL JOINT ...................................................... 45
PANEL EDGE ...................................................... 45
PARTS CONTACT ............................................... 45
PROTECTORS .................................................... 46
ANTI-CORROSION MATERIALS ........................ 46
DRAIN HOLES ..................................................... 46
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 47
Standard and Limit .................................................. 47
BELT DEFLECTION AND TENSION ................... 47
RADIATOR ........................................................... 47
ENGINE COOLANT CAPACITY .......................... 47
ENGINE OIL CAPACITY (APPROXIMATE) ........ 47
SPARK PLUG ...................................................... 47
MA-8
PERIODIC MAINTENANCE
CHASSIS AND BODY MAINTENANCE (QR20DE AND QR25DE PETROL ENGINE)
(Annual Mileage <30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, L = Lubricate.
NOTE:
(1) Inspect once per year.
Maintenance items with “ ” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”. MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform either at number of kilometers
(miles) or months, whichever comes first.km x 1,000
(Miles x
1,000)
Months15
(9)
1230
(18)
2445
(27)
3660
(36)
4875
(45)
6090
(54)
72105
(63)
84120
(72)
96
Underhood and under vehicle
Headlamp aiming IIIIIIIILT- 1 4
Brake & clutch, systems and fluid (For
level & leaks)IIIIIIIIMA-37, MA-
41
Brake fluidRRRRMA-42
Brake booster vacuum hoses, connec-
tions & check valveIIIIBR-26
Power steering fluid & lines (For level &
leaks)IIIIIIIIMA-44
Manual transaxle gear oil (For leaks) I I I I I I I IMA-37
Automatic transaxle fluid (For level &
leaks)IIIIIIIIMA-38
Transfer gear oil (For level & leaks) I I I I I I I IMA-39
Differential gear oil (For level & leaks or
replace)IIIRIIIRMA-40, MA-
40
Steering gear & linkage, axle & suspen-
sion parts, propeller shaft, front drive
shafts & exhaust systemIIIIIIIIMA-43, MA-
44 , MA-40 ,
MA-45
, MA-
37
Wheel alignment (If necessary, rotate &
balance wheels)IIIIIIIIFSU-6, MA-
41
Brake pads, rotors & other brake compo-
nentsIIIIIIIIMA-43, MA-
43 , MA-43
Foot brake, parking brake & clutch (For
free play, stroke & operation)IIIIIIIIBR-6, PB-2 ,
CL-5
Ventilation air filterRRRRAT C - 1 3 0
Body corrosionSee
NOTE (1)MA-45
MA-10
PERIODIC MAINTENANCE
NOTE:
(1) Inspect once per year.
Maintenance items with “ ” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”.
MAINTENANCE UNDER SEVERE DRIVING CONDITIONS
(Annual Mileage <30,000 Km/year)
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is
mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.
Severe driving conditions
A — Driving in dusty conditions
B — Repeatedly driving short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity or mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
J — Frequent off road use or driving in water
K —Sustained high speed driving
L — For models without Euro-OBD system
Differential gear oil (For level & leaks or
replace)IIRIIRMA-40
Steering gear & linkage, axle & suspension
parts, propeller shaft, front drive shafts &
exhaust systemIIIIIIMA-43, MA-44
, MA-40
, MA-
45 , MA-37
Wheel alignment (If necessary, rotate & bal-
ance wheels)IIIIIIFSU-6, MA-41
Brake pads, rotors & other brake compo-
nentsIIIIIIMA-43, MA-43
, MA-43
Foot brake, parking brake & clutch (For free
play, stroke & operation)IIIIIIBR-6, CL-5
Ventilation air filterRRRRRRATC-130
Body corrosionSee
NOTE (1)MA-45
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform either at number of kilometers (miles)
or months, whichever comes first.km x 1,000
(Miles x 1,000)
Months20
(12)
1240
(24)
2460
(36)
3680
(48)
48100
(60)
60120
(72)
72
PERIODIC MAINTENANCE
MA-11
C
D
E
F
G
H
I
J
K
MA
B
MA
Maintenance operation: Check = Check and correct or replace as necessary.
Driving conditionMaintenance itemMainte-
nance
opera-
tionMaintenance intervalRefer-
ence
page
A...........Air cleaner filterPetrol models ReplaceEvery 30,000 km
(18,000 miles) or 24
monthsMA-23
Diesel models ReplaceEvery 30,000 km
(18,000 miles) or 18
monthsMA-32
ABCD
........Engine oil &
engine oil filter Petrol models ReplaceEvery 7,500 km (4,500
miles) or 6 monthsMA-23
,
MA-25
Diesel models ReplaceEvery 10,000 km (6,000
miles) or 6 monthsMA-33,
MA-33
A...E.......Fuel filter Diesel models Check &
drain
waterEvery 10,000 km (6,000
miles) or 6 monthsFL-17
ReplaceEvery 20,000 km
(12,000 miles) or 12
monthsMA-31
.....F......Brake fluidPetrol models ReplaceEvery 15,000 km (9,000
miles) or 12 monthsMA-42Diesel models ReplaceEvery 20,000 km
(12,000 miles) or 12
monthsMA-42
..C
....H
....Differential gear
oilPetrol models ReplaceEvery 30,000 km
(18,000 miles) or 24
monthsMA-40
Diesel models ReplaceEvery 30,000 km
(18,000 miles) or 18
monthsMA-40
..C....H....Automatic tran-
saxle fluidPetrol models ReplaceEvery 30,000 km
(18,000 miles) or 24
monthsMA-39
......GH....Steering gear &
linkage, axle &
suspension
parts, propeller
shaft, front drive
shafts & exhaust
systemPetrol models InspectEvery 7,500 km (4,500
miles) or 6 monthsMA-43
,
MA-44
,
MA-40
,
MA-45
,
MA-37
Diesel models InspectEvery 10,000 km (6,000
miles) or 6 monthsMA-43
,
MA-44
,
MA-40
,
MA-45
,
MA-37
A.C...GHI...Brake pads,
rotors & other
brake compo-
nentsPetrol models InspectEvery 7,500 km (4,500
miles) or 6 monthsMA-43
,
MA-43
,
MA-43
Diesel models InspectEvery 10,000 km (6,000
miles) or 6 monthsMA-43
,
MA-43
,
MA-43
A...........Ventilation air fil-
terPetrol models ReplaceEvery 15,000 km (9,000
miles) or 12 monthsAT C - 1 3 0
Diesel models ReplaceEvery 10,000 km (6,000
miles) or 6 monthsAT C - 1 3 0
PERIODIC MAINTENANCE
MA-13
C
D
E
F
G
H
I
J
K
MA
B
MA
CHASSIS AND BODY MAINTENANCE (QR20DE AND QR25DE PETROL ENGINE)
(Annual Mileage >30,000 Km/year)
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, L = Lubricate.
NOTE:
(1) Inspect once per year.
Maintenance items with “ ” should be performed more frequently according to “Maintenance Under Severe Driving
Conditions”. MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
page Perform either at number of kilometers
(miles) or months, whichever comes first.km x 1,000
(Miles x
1,000)
Months15
(9)30
(18)45
(27)60
(36)75
(45)90
(54)105
(63)120
(72)
Underhood and under vehicle
Headlamp aiming I I I ILT- 1 4
Brake & clutch, systems and fluid (For
level & leaks)IIIIMA-37, MA-
41
Brake fluidRRMA-42
Brake booster vacuum hoses, connec-
tions & check valveIIBR-26
Power steering fluid & lines (For level &
leaks)IIIIMA-44
Manual transaxle gear oil (For leaks) I I I IMA-37
Automatic transaxle fluid (For level &
leaks)IIIIMA-38
Transfer gear oil (For level & leaks) I I I IMA-39
Differential gear oil (For level & leaks or
replace)IRIRMA-40, MA-
40
Steering gear & linkage, axle & suspen-
sion parts, propeller shaft, front drive
shafts & exhaust systemIIIIMA-43, MA-
44 , MA-40 ,
MA-45
, MA-
37
Wheel alignment (If necessary, rotate &
balance wheels)IIIIFSU-6, MA-
41
Brake pads, rotors & other brake compo-
nentsIIIIMA-43, MA-
43 , MA-43
Foot brake, parking brake & clutch (For
free play, stroke & operation)IIIIBR-6, PB-2 ,
CL-5
Ventilation air filterRRRRAT C - 1 3 0
Body corrosionSee
NOTE (1)MA-45