AT-368
[ALL]
TORQUE CONVERTER CLUTCH SOLENOID VALVE
TORQUE CONVERTER CLUTCH SOLENOID VALVEPFP:31940
DescriptionECS004U4
The torque converter clutch solenoid valve is activated, with the gear
in “D
4 ”, by the TCM in response to signals sent from the vehicle
speed and throttle position sensors. Lock-up piston operation will
then be controlled.
Lock-up operation, however, is prohibited when A/T fluid tempera-
ture is too low.
When the accelerator pedal is depressed (less than 2/8) in lock-up
condition, the engine speed should not change abruptly. If there is a
big jump in engine speed, there is no lock-up.
CONSULT-II Reference ValueECS00CSV
Remarks: Specification data are reference values.
On Board Diagnosis LogicECS00CSW
Possible CauseECS00CW8
Check the following items.
Torque converter clutch solenoid valve.
Harness or connector.
(The solenoid circuit is open or shorted.)
DTC Confirmation ProcedureECS00CSX
CAUTION:
Always drive vehicle at a safe speed.
If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait
at least 10 seconds before continuing.
NOTE:
If “DTC Confirmation Procedure” has been previously performed, always turn ignition switch OFF and wait at
least 10 seconds before performing the next test.
After the repair, perform the following procedure to confirm the malfunction is eliminated.
WITH CONSULT-II
1. Turn ignition switch ON. (Do not start engine.)
2. Select “DATA MONITOR” mode for “A/T” with CONSULT-II and
wait at least 1 second.
3. Start engine and maintain the following condition for at least 5
consecutive seconds.
VHCL SPEED SE: 80 km/h (50 MPH) or more
THROTTLE POSI: 0.5/8 - 1.0/8
SLCT LVR POSI: D position
Driving location: Driving the vehicle uphill (increased
engine load) will help maintain the driving conditions
required for this test.
4. If the check result is NG, go to AT- 3 7 1 , "
Diagnostic Procedure" .
SCIA0718E
Monitor item Condition Specification
Torque converter clutch solenoid valve
dutyLock-up OFF
↓
Lock-up ONApproximately 4%
↓
Approximately 94%
Diagnostic trouble code Malfunction is detected when... Check items (Possible cause)
: T/C CLUTCH SOL/V
TCM detects an improper voltage drop
when it tries to operate the solenoid valve.
Harness or connectors
(The solenoid circuit is open or shorted.)
T/C clutch solenoid valve
: 7th judgement flicker
SAT014K
ALL MODE 4X4 SYSTEM
TF-11
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ALL MODE 4X4 SYSTEMPFP:47850
Power Transfer DiagramEDS001VA
System DescriptionEDS001VB
ELECTRIC CONTROLLED COUPLING
Operation Principle
1. The 4WD control unit supplies command current to electric con-
trolled coupling (4WD solenoid).
2. The control clutch is engaged by electromagnet and torque is
detected in control clutch.
3. The cam operates in response to control clutch torque and
applies pressure to main clutch.
4. The main clutch transmits torque to front wheels according to
pressing power.
Transmission torque to the rear wheels is determined accord-
ing to command current.
4WD CONTROL UNIT
4WD controls distribution of drive power between front-wheel
drive (100:0) and 4WD (50:50) conditions according to signals
from sensors.
Self-diagnosis can be done with CONSULT-II.
SDIA1607E
SFIA0284E
SDIA1844E
SDIA2285E
TF-14
ALL MODE 4X4 SYSTEM
COMPONENTS FUNCTION DESCRIPTION
CAN CommunicationEDS0027K
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.
CAN Communication UnitEDS002XA
Component parts Function
4WD control unit
Controls driving force distribution by signals from each sensor and switch from front wheel driving
mode (100:0) to 4WD mode (50:50).
2WD mode is available by fail-safe function if malfunction is detected in electrical system.
Wheel sensors Detects wheel speed.
4WD solenoid Controls electric controlled coupling by operation signal from 4WD control unit.
Electric controlled coupling Transmits driving force to rear final drive.
4WD mode switch Able to select from 2WD, AUTO or LOCK mode.
4WD warning lamp
Illuminates if malfunction is detected in electrical system of 4WD system.
There is 1 blink in 2 seconds if rotation difference of front wheels and rear wheels is large.
There are 2 blinks in 1 second if load is still applied to driving parts.
4WD indicator lamp Indicate operation with optimal distribution of torque to front/rear wheels.
LOCK indicator lamp Indicate that 4WD system is under direct 4-wheel driving mode.
ABS actuator and electric unit
(control unit) (without ESP) or
ESP/TCS/ABS control unit (with
ESP)Transmits the following signals via CAN communication to 4WD control unit.
Vehicle speed signal
Stop lamp switch signal (brake signal)
ECMTransmits the following signals via CAN communication to 4WD control unit.
Accelerator pedal position signal
Engine speed signal
Unified meter control unit Transmits conditions of parking brake switch via CAN communication to 4WD control unit.
Body typeWagon
Axle4WD
Engine YD22DDTi QR20DE/QR25DE YD22DDTi QR25DE
Transmission M/T A/T M/T A/T
Brake control ABS ESP
CAN system type 123456
FRONT WHEEL HUB AND KNUCKLE
FAX-7
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FA X
FRONT WHEEL HUB AND KNUCKLEPFP:40202
On-Vehicle InspectionEDS0005R
Inspect to check that there is no excessive play, cracking, wear, or
other damage to front axle.
Turn front wheels (left/right) and check the play.
Check that no nails or other foreign objects are embedded.
Retighten all axle nuts and bolts to the specified torque.
FRONT WHEEL BEARINGS
With the vehicle raised, inspect the following.
Move wheel hub in the axial direction by hand. Check that there is no looseness of front wheel bearings.
Rotate wheel hub and check that there is no unusual noise or other irregular conditions. If there are any
irregular conditions, replace the wheel bearing.
Removal and InstallationEDS0005S
REMOVAL
1. Remove tyre. Remove brake hose lock plate from strut.
2. Remove brake caliper from steering knuckle. Hang it in a place where it will not interfere with work. Refer
to BR-27, "
FRONT DISC BRAKE" .
CAUTION:
Avoid depressing the brake pedal with brake caliper removed.
3. Remove wheel sensor from steering knuckle. Refer to BRC-116, "
WHEEL SENSORS" .
CAUTION:
Do not pull on wheel sensor harness.
SMA525A
Axial end play : 0.05 mm (0.002 in)
1. Steering knuckle 2. Splash guard 3. Wheel bearing assembly
4. Snap ring 5. Wheel hub 6. Hub bolt
7. Cotter pin
SDIA0131E
FRONT DRIVE SHAFT
FAX-11
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FA X
FRONT DRIVE SHAFTPFP:39100
Removal and InstallationEDS0005U
REMOVAL
1. Remove tyre from vehicle.
2. Remove cotter pin. Use a hub lock nut wrench to remove lock
nut.
3. Remove wheel sensor from steering knuckle. Refer to BRC-116,
"WHEEL SENSORS" .
4. Use a pitman arm puller to remove tie rod from steering knuckle.
5. Remove lock plate from strut. Disconnect brake hose from strut.
Refer to BR-11, "
Removal and Installation of Front Brake Piping
and Brake Hose" .
6. Remove steering knuckle and strut installation bolts and nuts.
CAUTION:
Do not apply an excessive angle (22° or more) to drive shaft
joint. Firmly support steering knuckle so that slide joint is not excessively extended.
7. Use a puller to remove drive shaft from steering knuckle.
8. As shown in the figure, use a wheel wrench or other tool to
remove drive shaft from transaxle.
CAUTION:
When removing drive shaft from vehicle, be careful to
avoid interfering with brake hose, wheel sensor harness,
and other parts.
When removing drive shaft, do not apply an excessive
angle (22° or more) to drive shaft joint. Also be careful
not to excessively extend slide joint.
Do not lift drive shaft, with axle attached, by grasping
counter shaft only.
Do not allow drive shaft, with transaxle inserted, to hang down without support for counter
shaft, wheel joints, and other parts.
When the drive shaft listed below have been removed, check that a circular clip is attached to the end.
1. Support bearing bracket 2. Side flange 3. Drive shaft
4. Cotter pin
SDIA2333E
SFA649A
MAA0384D
RAX-6
WHEEL HUB (2WD)
WHEEL HUB (2WD)PFP:43200
On-vehicle Inspection and ServiceEDS0034G
Make sure that the mounting conditions (looseness, backlash) of each component and component status
(wear, damage) are normal.
WHEEL BEARING INSPECTION
Move wheel hub in the axial direction by hand. Make sure there is no looseness of wheel bearing.
Rotate wheel hub and make sure that is no unusual noise or other irregular conditions. If there are any
irregular conditions, replace wheel bearing.
Removal and InstallationEDS0034H
COMPONENT
REMOVAL
1. Remove tire from the vehicle with power tool.
2. Remove wheel sensor from axle housing. Refer to BRC-46, "
WHEEL SENSORS" .
CAUTION:
Do not pull on wheel sensor harness.
3. Remove torque member fixing bolts with power tool. Hang it in a place where it will not interfere with work.
Refer to BR-32, "
REAR DISC BRAKE" .
NOTE:
Avoid depressing brake pedal while brake caliper is removed.
4. Remove disc rotor.
5. Remove anchor block mounting nuts, and then remove anchor block and back plate from axle housing.
6. Remove fixing bolts and nuts, and then remove strut from axle housing. Refer to RSU-8, "
COIL SPRING
AND STRUT" .
7. Remove nut and bolt from axle housing side of radius rod. Refer to RSU-12, "
RADIUS ROD" .
8. Remove fixing bolt, washer and nut from axle housing side of front and rear parallel links. Remove axle
housing from vehicle.
INSPECTION AFTER REMOVAL
Check components for deformation, cracks and other damage. Replace if there.Axial end play : 0.05 mm (0.002 in) or less
1. Sensor rotor 2. Snap ring 3. Wheel bearing
4. Axle housing 5. Back plate 6. Wheel hub
SDIA2471E
WHEEL HUB (2WD)
RAX-7
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INSTALLATION
Install in the reverse order of removal. For tightening torque refer to RAX-6, "COMPONENT" .
Perform final tightening of nuts and bolts on each link mounting part (rubber bushing) under unladen con-
ditions with tires on level ground. Check wheel alignment. Refer to RSU-6, "
Wheel Alignment" .
Check wheel sensor harness for proper connection. Refer to BRC-46, "WHEEL SENSORS" .
Disassembly and AssemblyEDS0034I
DISASSEMBLY
CAUTION:
Do not disassemble if wheel bearing has no trouble.
1. Remove caulked of lock nut, and then remove lock nut from axle housing.
2. Remove sensor rotor from axle housing.
3. Set axle housing on vise at point where strut is attached. Using
a sliding hammer [SST] and attachment [SST] to remove wheel
hub from axle housing.
CAUTION:
When placing on vise, be careful not to damage strut
mounting surface of axle housing. Use an aluminum plate
or suitable tool.
4. Using a drift [SST] and a puller (suitable tool), press wheel bear-
ing outer side inner race from wheel hub.
5. Using a flat-bladed screwdriver or similar tool to remove snap
ring from axle housing.
6. Using a drift [SST] and a press wheel bearing from axle housing.
FAC0104D
SDIA2440E
SDIA0155E
BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
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SECTION BRC
A
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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/TYPE 2 .................................................... 8
TYPE 3 .................................................................. 9
TYPE 7/TYPE 8 .................................................. 10
TROUBLE DIAGNOSIS ............................................ 12
How to Proceed With Diagnosis ............................. 12
BASIC CONCEPT ............................................... 12
DIAGNOSIS FLOWCHART ................................ 13
ASKING COMPLAINTS ...................................... 14
EXAMPLE OF DIAGNOSIS SHEET ................... 14
Component Parts Location ..................................... 15
Schematic .............................................................. 16
Wiring Diagram — ABS — ..................................... 17
LHD MODEL ....................................................... 17
RHD MODEL ....................................................... 21
Control Unit Input/Output Signal Standard ............. 25
REFERENCE VALUE FROM CONSULT-II ......... 25
CONSULT- II Functions .......................................... 26
CONSULT-II MAIN FUNCTION ........................... 26
CONSULT-II BASIC OPERATION PROCEDURE
... 26SELF-DIAGNOSIS .............................................. 28
DATA MONITOR ................................................. 30
ACTIVE TEST ..................................................... 32
Correct and Quick Diagnosis .................................. 34
DIAGNOSIS PRECAUTIONS ............................. 34
Basic Inspection ..................................................... 35
BASIC INSPECTION 1 BRAKE FLUID AMOUNT,
LEAKS, AND BRAKE PADS INSPECTION ......... 35
BASIC INSPECTION 2 POWER SYSTEM TER-
MINAL LOOSENESS AND BATTERY INSPEC-
TION .................................................................... 35
BASIC INSPECTION 3 ABS WARNING LAMP ... 35
Inspection 1: Wheel Sensor System ....................... 36
INSPECTION PROCEDURE .............................. 36
Inspection 2: ABS Actuator and Electric Unit (Con-
trol Unit) 1 ............................................................... 38
Inspection 3: ABS Actuator and Electric Unit (Con-
trol Unit) Power Supply and Ground Circuit ............ 38
Inspection 4: ABS Actuator Relay or ABS Motor
Relay Power System .............................................. 39
Inspection 5: ABS Actuator and Electric Unit (Con-
trol Unit) 2 ............................................................... 40
Inspection 6: G Sensor System .............................. 41
Inspection 7: CAN Communication System ............ 43
Symptom 1: ABS Works Frequently ....................... 43
Symptom 2: Unexpected Pedal Reaction ............... 44
Symptom 3: Longer Stopping Distance .................. 44
Symptom 4: ABS Does Not Work ........................... 45
Symptom 5: Pedal Vibration and ABS Operation
Noise ...................................................................... 45
WHEEL SENSORS ................................................... 46
Removal and Installation ........................................ 46
REMOVAL ........................................................... 46
INSTALLATION ................................................... 46
G SENSOR ................................................................ 47
Removal and Installation ........................................ 47
REMOVAL ........................................................... 47
INSTALLATION ................................................... 47