TROUBLE DIAGNOSISBRC-47
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TROUBLE DIAGNOSIS
How to Perform Trouble Diagnosis for Quick and Accurate RepairINFOID:0000000005612151
INTRODUCTION
The ABS/TCS/VDC system has an el ectronic control unit to control
major functions. The control unit accepts input signals from sensors
and controls actuator operation. It is also important to check for con-
ventional malfunctions such as air leaks in the booster or lines, lack
of brake fluid, or other malfunctions with the brake system.
It is much more difficult to diagnose a malfunction that occurs inter-
mittently rather than continuously. Most intermittent malfunctions are
caused by poor electrical connections or wiring. In this case, careful
checking of suspicious circuits may help prevent the replacement of
good parts.
A visual check only may not find t he cause of the malfunction, so a
road test should be performed.
Before undertaking actual checks, take just a few minutes to talk with
a customer who approaches with an ABS/TCS/VDC complaint. The
customer is a very good source of information, especially for inter-
mittent malfunctions. Through the talks with the customer, find out
what symptoms are present and under what conditions they occur.
Start your diagnosis by looking fo r “conventional” malfunctions first.
This is one of the best ways to troubleshoot brake malfunctions on
an ABS/TCS/VDC equipped vehicle. Also check related Service Bul-
letins for information.
SEF233G
SEF234G
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BRC-56
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TROUBLE DIAGNOSIS
Basic Inspection
INFOID:0000000005612155
BRAKE FLUID LEVEL, FLUID LEAK, AND BRAKE PAD INSPECTION
1. Check fluid level in the brake fluid reservoir. If fluid level is low, add fluid.
2. Check the brake piping and around the ABS actuator and electric unit (control unit) for leaks. If there is leaking or seeping fluid, check the following items.
• If ABS actuator and electric unit (control unit) connection is loose, tighten the piping to the specifiedtorque and recheck for leaks.
ABFWA0113GB
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• If there is damage to the connection flare nut or ABS actuator and electric unit (control unit) screw, replace the damaged part and recheck for leaks.
• When there is fluid leaking or seeping from a fluid connection, use a clean cloth to wipe off the fluid and
recheck for leaks. If fluid is still seeping out, replace the damaged part. If the fluid is leaking at the ABS
actuator and electric unit (control unit), replace the ABS actuator and electric unit (control unit) assem-
bly.
CAUTION:
The ABS actuator and electric unit (control unit) cannot be disassembl\
ed and must be replaced
as an assembly.
3. Check the brake pads for excessive wear.
POWER SYSTEM TERMINAL LOOSENESS AND BATTERY INSPECTION
Make sure the battery positive cable, negative cabl e and ground connection are not loose. In addition, make
sure the battery is sufficiently charged.
ABS WARNING LAMP, SLIP INDICATOR LAMP AND VDC OFF INDICATOR LAMP INSPECTION
1. Make sure ABS warning lamp, SLIP indicator lamp and VDC OFF indicator lamp (when VDC OFF switch
is off), turn on for approximately 2 seconds when the igni tion switch is turned ON. If they do not, check the
VDC OFF indicator lamp and then VDC OFF switch. Refer to BRC-79, "
Component Inspection". Check
CAN communications. If there are no errors with VDC OFF switch and CAN communication system,
check combination meter. Refer to DI-32, "
Component Inspection".
2. Make sure the lamps turn off approximately 2 seconds after the ignition switch is turned ON. If the lamp does not turn off, conduct self-diagnosis.
3. With the engine running, make sure VDC OFF indicator lamp turns on and off when VDC OFF switch is turned on and off. If the indicator lamp status does not correspond to switch operation, check the VDC
OFF switch system. Refer to BRC-79, "
Component Inspection".
4. Make sure ABS warning lamp, SLIP indicator lamp and VDC OFF indicator lamp turn off approximately 2 seconds after the engine is started. If ABS warning la mp, SLIP indicator lamp or VDC OFF indicator lamp
have not turned off 10 seconds after the engine has been started, conduct self-diagnosis of the ABS actu-
ator and electric unit (control unit).
5. After conducting the self-diagnosis, be sure to erase the error memory. Refer to BRC-60, "
CONSULT-III
Function (ABS)".
Warning Lamp and Indicator TimingINFOID:0000000005612156
×: ON –: OFF
Control Unit Input/Out put Signal StandardINFOID:0000000005612157
REFERENCE VALUE FROM CONSULT-III
CAUTION:
The display shows the control unit calculation data, so a normal value might be displayed even in the
event the output circuit (harness) is open or short circuited.
Condition ABS
warning lamp VDC OFF
indicator lamp SLIP
indicator lamp Remarks
When the ignition switch is OFF ––– –
After the ignition switch is turned
ON
For approx. 2 seconds ×××
–
Ignition switch ON
Approx. 2 seconds later ––– –
When the VDC OFF switch turns
ON (VDC function OFF). –
×––
ABS/TCS/VDC malfunction ×××
–
×× –When the ABS/TCS/VDC control
unit is malfunctioning (power sup-
ply or ground malfunction).
When the VDC is malfunctioning. –×× –
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ACCEL POS SIG Open/close condition
of throttle valve (linked
with accelerator pedal)Accelerator pedal not de-
pressed (ignition switch is ON)
0%
BRC-79, "
CAN Commu-
nication System Inspec-
tion"Depress accelerator pedal (ig-
nition switch is ON) 0 to 100%
SIDE G-SENSOR Transverse G detected
by side G-sensorVehicle stopped
Approx. 0 m/s
2
BRC-70, "Yaw Rate/Side/
Decel G Sensor System
Inspection"
Vehicle turning rightnegative value (m/
s2)
Vehicle turning left positive value (m/
s
2)
STR ANGLE SIG Steering angle detect-
ed by steering angle
sensorStraight-ahead
Approx. 0°BRC-69, "
Steering Angle
Sensor System Inspec-
tion"Steering wheel turned –720 to 720 °
PRESS SENSOR Brake fluid pressure
detected by pressure
sensorWith ignition switch ON and
brake pedal released
Approx. 0 bar
BRC-77, "
Pressure Sen-
sor System Inspection"With ignition switch ON and
brake pedal depressed –40 to 300 bar
EBD SIGNAL EBD operation EBD is active
On
—
EBD is inactive Off
ABS SIGNAL ABS operationABS is active
On
—
ABS is inactive Off
TCS SIGNAL TCS operationTCS is active
On
—
TCS is inactive Off
VDC SIGNAL VDC operationVDC is active
On
—
VDC is inactive Off
EBD FAIL SIG EBD fail-safe signal In EBD fail safe mode On
—
EBD is normal Off
ABS FAIL SIG ABS fail-safe signal In ABS fail safe mode
On
—
ABS is normal Off
TCS FAIL SIG TCS fail-safe signal In TCS fail safe mode
On
—
TCS is normal Off
VDC FAIL SIG VDC fail-safe signal In VDC fail safe mode On
—
VDC is normal Off
CRANKING SIG Crank operation Crank is active
On
—
Crank is inactive Off
FLUID LEV SW Status of brake fluid
level switchWhen brake fluid level switch
ON
On
BRC-76, "
Brake Fluid
Level Switch System In-
spection"When brake fluid level switch
OFF Off
PARK BRAKE SW Status of parking brake
switchParking brake switch is active On
BRC-79, "
Component In-
spection"Parking brake switch is inactive Off
Monitor item Display content
Data monitor
Note: Error inspection
checklist
Condition Reference value in
normal operation
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Note 1. If wheel sensor 2 for each wheel is indicated, check ABS actuator and electric unit (control unit) power
supply voltage in addition to wheel sensor circuit check.
Note 2. If multiple malfunctions are detected including CAN communication line [U1000], perform diagnosis for
CAN communication line first.
DATA MONITOR
Display Item List
USV LINE [FL-RR]
[C1147] Front side VDC switch-over solenoid valve (cut valve) is open or
shorted, or control line is open or shorted to power supply or
ground.
BRC-72, "
Solenoid and
VDC Change-Over Valve
System Inspection"
USV LINE [FR-RL]
[C1148]Rear side VDC switch-over solenoid valve (cut valve) is open or
shorted, or control line is open or shorted to power supply or
ground.
HSV LINE [FL-RR]
[C1149] Front side VDC switch-over solenoid valve (suction valve) is open
or shorted, or control line is open or shorted to power supply or
ground.
HSV LINE [FR-RL]
[C1150] Rear side VDC switch-over solenoid valve (suction valve) is open
or shorted, or control line is open or shorted to power supply or
ground.
EMERGENCY BRAKE
[C1153] When ABS actuator and el
ectric unit (control unit) is malfunction-
ing. (Pressure increase is too much or too little) BRC-68, "
ABS/TCS/VDC
Control Unit Inspection"
PNP POS SIG
[C1154]Transmission range switch signal or communication line between
the ABS actuator and electric unit (control unit) and TCM is open
or shorted. BRC-78, "Transmission
Range Switch System In-
spection"
BR FLUID LEVEL LOW
[C1155]
Brake fluid level drops or circuit between ABS actuator and elec-
tric unit (control unit) and brake fluid level switch is open or
shorted. BRC-76, "Brake Fluid
Level Switch System In-
spection"
ST ANG SEN COM CIR
[C1156]
CAN communication line or steering angle sensor has generated
an error. BRC-79, "
CAN Commu-
nication System Inspec-
tion"
(Note 2)
VARIANT CODING
[C1170] In case where VARIANT CODING is different. BRC-68, "
ABS/TCS/VDC
Control Unit Inspection"
CAN COMM CIRCUIT
[U1000]• CAN communication line is open or shorted.
• ABS actuator and electric unit (control unit) internal malfunction
• Battery voltage for ECM is suddenly interrupted for approxi-
mately 0.5 seconds or more. BRC-79, "
CAN Commu-
nication System Inspec-
tion"
(Note 2)
Self-diagnostic item
Malfunction detecting condition Check system
Item
(Unit) Data monitor item selection
Remarks
ECU INPUT
SIGNALS MAIN
SIGNALS SELECTION
FROM MENU
FR LH SENSOR
(km/h, mph) ××× Wheel speed (km/h, mph) calculated by front LH
wheel sensor signal is displayed.
FR RH SENSOR
(km/h, mph) ××× Wheel speed (km/h, mph) calculated by front RH
wheel sensor signal is displayed.
RR LH SENSOR
(km/h, mph) ×××
Wheel speed (km/h, mph) calculated by rear LH
wheel sensor signal is displayed.
RR RH SENSOR
(km/h, mph) ××× Wheel speed (km/h, mph) calculated by rear RH
wheel sensor signal is displayed.
FR RH IN SOL
(On/Off) —
×× Front RH IN ABS solenoid (On/Off) status is dis-
played.
FR RH OUT SOL
(On/Off) —
×× Front RH OUT ABS solenoid (On/Off) status is
displayed.
FR LH IN SOL
(On/Off) —
×× Front LH IN ABS solenoid (On/Off) status is dis-
played.
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TROUBLE DIAGNOSIS
FR LH OUT SOL
(On/Off)—
×× Front LH OUT ABS solenoid (On/Off) status is dis-
played.
RR RH IN SOL
(On/Off) —
×× Rear RH IN ABS solenoid (On/Off) status is dis-
played.
RR RH OUT SOL
(On/Off) —
×× Rear RH OUT ABS solenoid (On/Off) status is dis-
played.
RR LH IN SOL
(On/Off) —
×× Rear LH IN ABS solenoid (On/Off) status is dis-
played.
RR LH OUT SOL
(On/Off) —
×× Rear LH OUT ABS solenoid (On/Off) status is dis-
played.
STOP LAMP SW
(On/Off) ×××
Stop lamp switch (On/Off) status is displayed.
MOTOR RELAY
(On/Off) —
×× ABS motor relay signal (On/Off) status is dis-
played.
ACTUATOR RLY
(On/Off) —
×× ABS actuator relay signal (On/Off) status is dis-
played.
ABS WARN LAMP
(On/Off) —
×× ABS warning lamp (On/Off) status is displayed.
OFF LAMP
(On/Off) —
×× VDC OFF lamp (On/Off) status is displayed.
OFF SW
(On/Off) ×××
VDC OFF switch (On/Off) status is displayed.
SLIP LAMP
(On/Off) —
×× SLIP indicator lamp (On/Off) status is displayed.
BATTERY VOLT
(V) ××× Voltage (V) supplied to ABS actuator and electric
unit (control unit) is displayed.
GEAR
(1, 2, 3, 4) ××× A/T gear position (1, 2, 3, 4) determined by TCM
is displayed.
YAW RATE SEN
(d/s) ×××
Yaw rate (d/s) detected by yaw rate sensor is dis-
played.
ACCEL POS SIG
(%) ×
— ×Throttle valve open/close (%) status judged by
CAN communication signal is displayed.
SIDE G-SENSOR
(m/s
2) ×
— ×Lateral acceleration (m/s
2) detected by side G
sensor is displayed.
STR ANGLE SIG
(deg) ×
— ×Steering angle (deg) detected by steering angle
sensor is displayed.
PRESS SENSOR
(bar) ×
— ×Brake fluid pressure detected by pressure sensor
is displayed.
EBD SIGNAL
(On/Off) ——
×EBD operation (On/Off) status is displayed.
ABS SIGNAL
(On/Off) ——
×ABS operation (On/Off) status is displayed.
TCS SIGNAL
(On/Off) ——
×TCS operation (On/Off) status is displayed.
VDC SIGNAL
(On/Off) ——
×VDC operation (On/Off) status is displayed.
EBD FAIL SIG
(On/Off) ——
×EBD fail signal (On/Off) status is displayed.
ABS FAIL SIG
(On/Off) ——
×ABS fail signal (On/Off) status is displayed.
TCS FAIL SIG
(On/Off) ——
×TCS fail signal (On/Off) status is displayed.
VDC FAIL SIG
(On/Off) ——
×VDC fail signal (On/Off) status is displayed.
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× : Applicable
–: Not applicable
ACTIVE TEST
CAUTION:
• Do not perform active test while driving vehicle.
• Make sure to completely bleed air from brake system.
• The active test cannot be performed with the AB S warning lamp, VDC indicator lamp, SLIP indicator
lamp or brake warning lamp on.
• ABS warning lamp, VDC OFF indicator lamp, SLIP indicator lamp and brake warning lamp are on
during active test.
NOTE:
• When active test is performed while depressing the pedal, the pedal depression amount will change. This is normal. (Only solenoid valve and ABS motor)
• “TEST IS STOPPED” is displayed 10 seconds after operation start.
• After “TEST IS STOPPED” is displayed, to perform test again, touch BACK.
Test Item
SOLENOID VALVE
• When performing an active test of the ABS function, select “MAIN SIGNALS” for each test item.
• For ABS solenoid valve, touch “Up”, “Keep”, and “Dow n” on the display screen. For ABS solenoid valve
(ACT), touch “Up”, “ACT UP ”, “ACT KEEP” and confirm that solenoid valves operate as shown in the table
below.
CRANKING SIG
(On/Off) ——
×Cranking condition (On/Off) status is displayed.
FLUID LEV SW
(On/Off) ×
— ×Brake fluid level switch (On/Off) status is dis-
played.
PARK BRAKE SW
(On/Off) ×
— ×Parking brake switch (On/Off) status is displayed.
USV[FL-RR]
(On/Off) ——
×Primary side USV solenoid valve (On/Off) status is
displayed.
USV[FR-RL]
(On/Off) ——
×Secondary side USV solenoid valve (On/Off) sta-
tus is displayed.
HSV[FL-RR]
(On/Off) ——
×Primary side HSV solenoid valve (On/Off) status is
displayed.
HSV[FR-RL]
(On/Off) ——
×Secondary side HSV solenoid valve (On/Off) sta-
tus is displayed.
V/R OUTPUT
(On/Off) ——
×Valve relay operation signal (On/Off) status is dis-
played.
M/R OUTPUT
(On/Off) ——
×Motor relay operation signal (On/Off) status is dis-
played.
ENGINE RPM
(rpm) ×
— ×Engine speed judged by CAN communication sig-
nal is displayed.
Operation ABS solenoid va
lve ABS solenoid valve (ACT)
Up Keep Down Up ACT UP ACT KEEP
FR RH SOL FR RH IN SOL Off On On — —
—
FR RH OUT SOL Off Off On* — — —
USV [FR-RL] Off Off On* — — —
HSV [FR-RL] Off Off On* — — —
FR LH SOL FR LH IN SOL Off On On — —
—
FR LH OUT SOL Off Off On* — — —
USV [FL-RR] Off Off On* — — —
HSV [FL-RR] Off Off On* — — —
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BRC-76
< SERVICE INFORMATION >[VDC/TCS/ABS]
TROUBLE DIAGNOSIS FOR
SELF-DIAGNOSTIC ITEMS
OK or NG
OK >> Check the battery for loose terminals, low voltage, etc. Repair as necessary.
NG >> Repair the circuit.
Brake Fluid Level Switch System InspectionINFOID:0000000005612168
INSPECTION PROCEDURE
1.SELF-DIAGNOSIS RESULT CHECK
1. Check the brake reservoir tank fluid level. If the level is low, add brake fluid.
2. Erase the self-diagnosis results and check the self-diagnosis results.
Is the above displayed in the self-diagnosis display items?
YES >> GO TO 2.
NO >> Inspection End.
2.CONNECTOR INSPECTION
1. Disconnect the ABS actuator and electric unit (cont rol unit) and brake fluid level switch connectors.
2. Check the terminals for deformati on, disconnection, looseness or damage.
OK or NG
OK >> GO TO 3.
NG >> Repair or replace as necessary.
3.CHECK BRAKE FLUID LEVEL SWITCH
1. Turn ignition switch OFF.
2. Check continuity between brake fluid level switch terminals 1 and 2.
Is the inspection result normal?
YES >> GO TO 4
NO >> Replace brake fluid level switch.
4.CHECK BRAKE FLUID LEVEL SWITCH HARNESS
1. Disconnect combination meter connector.
2. Check continuity between combination meter connector M24 (A) terminal 25 and brake fluid level switch connector E40 (B) termi-
nal 1.
3. Check continuity between combination meter connector M24 (A) terminal 25 and ground.
Is the inspection result normal?
Power supply 2
—Battery voltage (Approx. 12V)
3
Ground 1
Continuity should exist.
4
Self-diagnosis results
BR FLUID LEVEL LOW
Brake fluid level switch terminals ConditionContinuity
1— 2 Brake fluid reservoir full No
Brake fluid reservoir empty Yes
AWFIA0621ZZ
25 - 1 : Continuity should exist.
25 - Ground : Continuity should not exist.
AWFIA0622ZZ
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