TF-20
TROUBLE DIAGNOSIS
Circuit DiagramEDS001VH
TDWB0010E
TROUBLE DIAGNOSIS
TF-21
C
E
F
G
H
I
J
K
L
MA
B
TF
Wiring Diagram — 4WD —EDS001VI
LHD MODELS
TDWB0011E
TF-50
TROUBLE DIAGNOSIS FOR SYMPTOMS
DIAGNOSTIC PROCEDURE
1. CHECK PARKING BRAKE SWITCH SIGNAL
With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “DATA MONITOR” mode for “ALL MODE AWD/4WD” with CONSULT-II.
3. Operate parking brake and read out monitor “P BRAKE SW”.
OK or NG
OK >> GO TO 2.
NG >> Check the following. If any items are damaged, repair or
replace damaged parts.
Parking brake switch
Brake warning lamp circuit. Refer to DI-34, "Wiring
Diagram — WARN —/LHD Models" or DI-42, "Wiring Diagram — WARN —/RHD Models" .
2. CHECK 4WD SOLENOID
Check 4WD solenoid. Refer to TF-38, "
COMPONENT INSPECTION" .
OK or NG
OK >> GO TO 3.
NG >> Replace electric controlled coupling for malfunction of 4WD solenoid. Refer to RFD-22, "
Disas-
sembly and Assembly" .
3. CHECK 4WD CONTROL UNIT
Check 4WD control unit input/output signal. Refer to TF-28, "
4WD Control Unit Input/Output Signal Reference
Va l u e s" .
OK or NG
OK >> GO TO 4.
NG >> Check 4WD control unit pin terminals for damage or loose connection with harness connector. If
any items are damaged, repair or replace damaged parts.
4. SYMPTOM CHECK
Check again.
OK or NG
OK >>INSPECTION END
NG >> Replace electric controlled coupling for mechanical malfunction (mechanical engagement of
clutch is not possible.). Refer to RFD-22, "
Disassembly and Assembly" .
While Driving, 4WD Warning Lamp Flashes Rapidly (When Flashing in Approx.
1 Minute and Then Turning OFF)
EDS001VZ
NOTE:
Rapid flashing: 2 times/second
This symptom protects drivetrain parts when a heavy load is applied to the electric controlled coupling and
multiple disc clutch temperature increases. It is not a malfunction.
When this symptom occurs, stop vehicle and allow it to idle for some times. Flashing will stop and system will
be restored.
Monitor item Condition Display value
P BRAKE SWParking brake operated ON
Parking brake not operated OFF
SDIA1933E
BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
I
J
K
L
M
SECTION
A
B
BRC
BRAKE CONTROL SYSTEM
ABS
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 4
Precautions for Brake System .................................. 4
Precautions for Brake Control .................................. 4
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
SYSTEM DESCRIPTION ............................................ 6
System Diagram ....................................................... 6
ABS Function ........................................................... 6
EBD Function ........................................................... 6
Fail-Safe Function .................................................... 6
ABS, EBD SYSTEM .............................................. 6
Hydraulic Circuit Diagram ........................................ 7
CAN COMMUNICATION ............................................ 8
System Description .................................................. 8
CAN Communication Unit ........................................ 8
TYPE 1 .................................................................. 8
TYPE 2 .................................................................. 9
TROUBLE DIAGNOSIS .............................................11
How to Proceed With Diagnosis .............................. 11
BASIC CONCEPT ................................................ 11
DIAGNOSIS FLOWCHART ................................ 12
ASKING COMPLAINTS ...................................... 13
EXAMPLE OF DIAGNOSIS SHEET ................... 13
Component Parts Location ..................................... 14
Schematic .............................................................. 15
Wiring Diagram — ABS — ..................................... 16
Control Unit Input/Output Signal Standard ............. 24
REFERENCE VALUE FROM CONSULT-II ......... 24
CONSULT- II Functions .......................................... 25
CONSULT-II MAIN FUNCTION ........................... 25
CONSULT-II BASIC OPERATION PROCEDURE
... 25
SELF-DIAGNOSIS .............................................. 27
DATA MONITOR ................................................. 29
ACTIVE TEST ..................................................... 31
Correct and Quick Diagnosis ................................. 33DIAGNOSIS PRECAUTIONS ............................. 33
Basic Inspection ..................................................... 34
BASIC INSPECTION 1 BRAKE FLUID AMOUNT,
LEAKS, AND BRAKE PADS INSPECTION ......... 34
BASIC INSPECTION 2 POWER SYSTEM TER-
MINAL LOOSENESS AND BATTERY INSPEC-
TION .................................................................... 34
BASIC INSPECTION 3 ABS WARNING LAMP ... 34
Inspection 1: Wheel Sensor System ....................... 35
INSPECTION PROCEDURE .............................. 35
Inspection 2: ABS Actuator and Electric Unit (Con-
trol Unit) 1 ............................................................... 37
Inspection 3: ABS Actuator and Electric Unit (Con-
trol Unit) Power Supply and Ground Circuit ............ 37
Inspection 4: ABS Actuator Relay or ABS Motor
Relay Power System .............................................. 38
Inspection 5: ABS Actuator and Electric Unit (Con-
trol Unit) 2 ............................................................... 39
Inspection 6: G Sensor System .............................. 40
Inspection 7: CAN Communication System ............ 42
Symptom 1: ABS Works Frequently ....................... 42
Symptom 2: Unexpected Pedal Reaction ............... 43
Symptom 3: Longer Stopping Distance .................. 43
Symptom 4: ABS Does Not Work ........................... 44
Symptom 5: Pedal Vibration and ABS Operation
Noise ...................................................................... 44
WHEEL SENSORS ................................................... 45
Removal and Installation ........................................ 45
REMOVAL ........................................................... 45
INSTALLATION ................................................... 45
G SENSOR ................................................................ 46
Removal and Installation ........................................ 46
SENSOR ROTOR ..................................................... 47
Removal and Installation ........................................ 47
REMOVAL ........................................................... 47
INSTALLATION ................................................... 47
ABS ACTUATOR AND ELECTRIC UNIT (ASSEM-
BLY) ........................................................................... 48
Removal and Installation ........................................ 48
BRC-2
ESP/TCS/ABS
PRECAUTIONS ......................................................... 49
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ................................................................. 49
Precautions for Brake System ................................ 49
Precautions for Brake Control ................................ 49
PREPARATION ......................................................... 50
Special Service Tools ............................................. 50
ON-VEHICLE SERVICE ............................................ 51
Adjustment of Steering Angle Sensor Neutral Posi-
tion .......................................................................... 51
SYSTEM DESCRIPTION .......................................... 52
System Diagram ..................................................... 52
ESP Function .......................................................... 52
TCS Function .......................................................... 52
ABS Function .......................................................... 53
EBD Function ......................................................... 53
Fail-Safe Function .................................................. 53
ESP/ TCS SYSTEM ............................................ 53
ABS, EBD SYSTEM ............................................ 53
Hydraulic Circuit Diagram ....................................... 54
CAN COMMUNICATION ........................................... 55
System Description ................................................. 55
CAN Communication Unit ....................................... 55
TYPE 3/TYPE4 .................................................... 55
TYPE 5 ................................................................ 56
TROUBLE DIAGNOSIS ............................................ 58
How to Proceed With Diagnosis ............................. 58
BASIC CONCEPT ............................................... 58
DIAGNOSIS FLOWCHART ................................. 59
ASKING COMPLAINTS ....................................... 60
EXAMPLE OF DIAGNOSIS SHEET .................... 60
Component Parts and Harness Connector Location ... 61
Schematic ............................................................... 62
Wiring Diagram —ESP/TCS/ABS— ..................... 63
LHD MODEL ........................................................ 63
RHD MODEL ....................................................... 69
Control Unit Input/Output Signal Standard .............. 75
REFERENCE VALUE FROM CONSULT-II ......... 75
CONSULT-II Functions ........................................... 77
CONSULT-II MAIN FUNCTION ........................... 77
CONSULT-II BASIC OPERATION PROCEDURE
... 77
SELF-DIAGNOSIS .............................................. 79
DATA MONITOR .................................................. 81
ACTIVE TEST ..................................................... 84
For Fast and Accurate Diagnosis ........................... 86
PRECAUTIONS FOR DIAGNOSIS ..................... 86
Basic Inspection ..................................................... 87
BASIC INSPECTION 1 BRAKE FLUID AMOUNT,
LEAKS, AND BRAKE PADS INSPECTION ......... 87
BASIC INSPECTION 2 POWER SYSTEM TER-
MINAL LOOSENESS AND BATTERY INSPEC-
TION .................................................................... 87
BASIC INSPECTION 3 ABS WARNING LAMP,
ESP OFF INDICATOR LAMP, SLIP INDICATOR
LAMP AND BRAKE WARNING LAMP INSPEC-TION .................................................................... 88
Inspection 1 Wheel Sensor System ........................ 89
INSPECTION PROCEDURE ............................... 89
Inspection 2 Engine System ................................... 91
Inspection 3 ESP/TCS/ABS Control Unit System ... 91
Inspection 4 Pressure Sensor and the Circuit
between Pressure Sensor and ESP/TCS/ABS Con-
trol Unit. ................................................................... 91
Inspection 5 Steering Angle Sensor and Circuit
between Steering Angle Sensor and ESP/TCS/ABS
Control Unit. ............................................................ 93
Inspection 6 Yaw Rate/Side G sensor and the Circuit
between Yaw Rate/Side G sensor and ESP/TCS/
ABS Control Unit. .................................................... 95
Inspection 7 Solenoid Valve, ESP Switch-over Sole-
noid Valve and Circuit ............................................. 96
Inspection 8 Actuator Motor, Motor Relay and Circuit
... 99
Inspection 9 Actuator Relay and Circuit ................101
Inspection 10 Stop Lamp Switch and Circuit .........103
Inspection 11 ESP/TCS/ABS Control Unit Power
Supply Circuit ........................................................103
Inspection 12 When “EMERGENCY BRAKE” is
indicated in the Self-Diagnosis Results .................105
Inspection 13 When “ST ANG SEN SIGNAL” is Indi-
cated in the Self-Diagnosis Results ......................105
Inspection 14 Brake Fluid Level of Reservoir Tank,
Communication Circuit between ESP/TCS/ABS
Control Unit and Brake Fluid Level Warning Switch .106
Inspection 15 CAN Communication Circuit, ESP/
TCS/ABS Control Unit and Steering Angle Sensor .107
Component Check ................................................107
ESP OFF SWITCH ............................................107
ESP RELAY BOX ...............................................107
ESP ACTUATOR ...............................................108
Symptom 1: ABS Works Frequently. .....................110
Symptom 2: Unexpected Pedal Action .................110
Symptom 3: Longer Stopping Distance ................. 111
Symptom 4: ABS Does Not Work. ........................112
Symptom 5: Pedal Vibration and Noise ................112
Symptom 6: ESP OFF Indicator Lamp Does Not Illu-
minate ...................................................................113
Symptom 7: SLIP Indicator Lamp Does Not Illumi-
nate .......................................................................114
Symptom 8: Vehicle Jerks During ESP/TCS/ABS
Control ..................................................................114
WHEEL SENSORS .................................................116
Removal and Installation .......................................116
SENSOR ROTOR ....................................................117
Removal and Installation .......................................117
REMOVAL ..........................................................117
INSTALLATION ..................................................117
ESP/TCS/ABS CONTROL UNIT .............................118
Removal and Installation .......................................118
REMOVAL ..........................................................118
INSTALLATION ..................................................118
ESP/TCS/ABS ACTUATOR AND RELAY BOX ......119
Removal and Installation .......................................119
BRC-6
[ABS]
SYSTEM DESCRIPTION
SYSTEM DESCRIPTIONPFP:00000
System DiagramEFS004FZ
ABS FunctionEFS004G0
The Anti-Lock Brake System is a function that detects wheel revolution while braking, and it improves
handling stability during sudden braking by electrically preventing 4 wheel lock. Maneuverability is also
improved for avoiding obstacles.
In case of the electrical system breaks down, then the Fail-Safe function starts, the ABS becomes inoper-
ative, and the ABS warning lamp turns on.
Electrical System Diagnosis by CONSULT-II is available.
EBD FunctionEFS004G1
Electronic Brake Distributor is a function that detects subtle slippages between the front and rear wheels
during braking, and it improves handling stability by electronically controlling the Brake Fluid Pressure
which results in reduced rear wheel slippage.
In case of the electrical system break down, then the Fail-Safe function is starts, the EBD and ABS
becomes inoperative, and the ABS warning lamp is turned on.
Electrical System Diagnosis by CONSULT-II is available.
Fail-Safe FunctionEFS004G2
ABS, EBD SYSTEM
In case of the electrical problems with the ABS, the ABS warning lamp will turn on. In case of electrical prob-
lem with the EBD, ABS warning lamp will turn on. Simultaneously, the ABS become one of the following condi-
tions of the Fail-Safe function.
1. For ABS trouble, only the EBD is activated and the condition of the vehicle is the same condition of vehi-
cles without ABS equipment.
2. For EBD trouble, the EBD and ABS become inoperative, and the condition of the vehicle is the same as
the condition of vehicles without ABS, EBD equipment.
NOTE:
In condition 1 described above, an ABS self diagnosis sound may be heard. That is a normal condition
because a self diagnosis for “Ignition switch ON” and “the First Starting” are being performed.
SFIA2004E
SYSTEM DESCRIPTION
BRC-7
[ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
Hydraulic Circuit DiagramEFS004G3
SFIA2173E
BRC-8
[ABS]
CAN COMMUNICATION
CAN COMMUNICATIONPFP:23710
System DescriptionEFS0055R
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.
CAN Communication UnitEFS0055W
×: Applicable
TYPE 1
System diagram
Body typeWagon
Axle4WD
Engine QR20DE/QR25DE QR25DE YD22DDTi QR25DE
Transmission M/T A/T M/T A/T
Brake control ABS ESP
CAN communication unit
ECM×××××
TCM××
ABS actuator and electric unit (control unit)××
ESP/TCS/ABS control unit×××
Steering angle sensor×××
4WD control unit×××××
Combination meter×××××
CAN communication typeBRC-8, "
TYPE
1"
BRC-9, "TYPE
2"BRC-55, "TYPE 3/TYPE4"BRC-56,
"TYPE 5"
PKIA6458E