BRAKE CONTROL SYSTEM SECTION BRC CONTENTS BRAKES BRC-1 VDC/TCS/ABS SERVICE INFORMATION... 3

Transcription

1 BRAKES SECTION BRC A BRAKE CONTROL SYSTEM B C D CONTENTS E VDC/TCS/ABS SERVICE INFORMATION... 3 DTC INDEX... 3 C1101-C C1120-C C1140-C U PRECAUTIONS... 5 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN- SIONER"...5 Precaution for Brake System...5 Precaution for Brake Control...5 PREPARATION... 7 Special Service Tool...7 Commercial Service Tool...7 ON-VEHICLE SERVICE... 8 Adjustment of Steering Angle Sensor Neutral Position...8 Calibration of Decel G Sensor (AWD Models)...8 SYSTEM DESCRIPTION...10 Schematic...10 Functions...10 Fail-Safe Function...11 Hydraulic Circuit Diagram...12 CAN Communication...12 TROUBLE DIAGNOSIS...13 Fail-Safe Function...13 How to Proceed with Diagnosis...13 Component Part Location...16 Schematic...17 Wiring Diagram - VDC Control Unit Input/Output Signal Standard...23 CONSULT-III Functions (ABS)...26 Self-Diagnosis...26 Data Monitor...28 Active Test...30 For Fast and Accurate Diagnosis...31 Basic Inspection...32 TROUBLE DIAGNOSIS FOR SYSTEM...34 DTC C1101 RR RH SENSOR DTC C1102 RR LH SENSOR DTC C1103 FR RH SENSOR DTC C1104 FR LH SENSOR DTC C1105 RR RH SENSOR DTC C1106 RR LH SENSOR DTC C1107 FR RH SENSOR DTC C1108 FR LH SENSOR DTC C1109 BATTERY VOLTAGE [ABNORMAL]...36 DTC C1110 CONTROLLER FAILURE...37 DTC C1111 PUMP MOTOR...37 DTC C1113 G-SENSOR...38 DTC C1115 ABS SENSOR [ABNORMAL SIG- NAL]...39 DTC C1116 STOP LAMP SW...39 DTC C1120 FR LH IN ABS SOL...40 DTC C1121 FR LH OUT ABS SOL...41 DTC C1122 FR RH IN ABS SOL...41 DTC C1123 FR RH OUT ABS SOL...42 DTC C1124 RR LH IN ABS SOL...42 DTC C1125 RR LH OUT ABS SOL...42 DTC C1126 RR RH IN ABS SOL...42 DTC C1127 RR RH OUT ABS SOL...42 DTC C1130 ENGINE SIGNAL DTC C1131 ENGINE SIGNAL DTC C1132 ENGINE SIGNAL DTC C1133 ENGINE SIGNAL DTC C1136 ENGINE SIGNAL DTC C1140 ACTUATOR RLY...43 DTC C1142 PRESS SEN CIRCUIT...43 DTC C1143 ST ANG SEN CIRCUIT...44 DTC C1144 ST ANG SEN SIGNAL...45 DTC C1145 YAW RATE SENSOR...46 DTC C1146 SIDE G-SEN CIRCUIT...46 DTC C1155 BR FLUID LEVEL LOW...46 BRC G H I J K L M N O P BRC-1

2 DTC C1156 ST ANG SEN COM CIR DTC C1160 DECEL G SEN SET DTC C1164 CV DTC C1165 CV DTC C1166 SV DTC C1167 SV DTC C1170 VARIANT CODING DTC U1000 CAN COMM CIRCUIT Component Inspection TROUBLE DIAGNOSIS FOR SYMPTOMS Excessive ABS Function Operation Frequency Unexpected Pedal Reaction The Braking Distance Is Long The ABS Function Does Not Operate Pedal Vibration or ABS Operation Sound Occurs Vehicle Jerks During VDC/TCS/ABS Control WHEEL SENSORS Removal and Installation SENSOR ROTOR Removal and Installation ACTUATOR AND ELECTRIC UNIT (ASSEM- BLY) Removal and Installation G SENSOR Removal and Installation STEERING ANGLE SENSOR Removal and Installation BRC-2

3 DTC INDEX SERVICE INFORMATION DTC INDEX C1101-C1116 INFOID: A B DTC Items (CONSULT screen items) Reference C1101 RR RH SENSOR-1 BRC-34, "DTC C1101 RR RH SENSOR-1" C1102 RR LH SENSOR-1 BRC-35, "DTC C1102 RR LH SENSOR-1" C1103 FR RH SENSOR-1 BRC-35, "DTC C1103 FR RH SENSOR-1" C1104 FR LH SENSOR-1 BRC-35, "DTC C1104 FR LH SENSOR-1" C1105 RR RH SENSOR-2 BRC-36, "DTC C1105 RR RH SENSOR-2" C1106 RR LH SENSOR-2 BRC-36, "DTC C1106 RR LH SENSOR-2" C1107 FR RH SENSOR-2 BRC-36, "DTC C1107 FR RH SENSOR-2" C1108 FR LH SENSOR-2 BRC-36, "DTC C1108 FR LH SENSOR-2" C1109 BATTERY VOLTAGE [ABNORMAL] BRC-36, "DTC C1109 BATTERY VOLTAGE [ABNORMAL]" C1110 CONTROLLER FAILURE BRC-37, "DTC C1110 CONTROLLER FAILURE" C1111 PUMP MOTOR BRC-37, "DTC C1111 PUMP MOTOR" C1113 G-SENSOR BRC-38, "DTC C1113 G-SENSOR" C1115 ABS SENSOR [ABNORMAL SIGNAL] BRC-39, "DTC C1115 ABS SENSOR [ABNORMAL SIGNAL]" C1116 STOP LAMP SW BRC-39, "DTC C1116 STOP LAMP SW" C1120-C1136 INFOID: C D E BRC G H I DTC Items (CONSULT screen items) Reference C1120 FR LH IN ABS SOL BRC-40, "DTC C1120 FR LH IN ABS SOL" C1121 FR LH OUT ABS SOL BRC-41, "DTC C1121 FR LH OUT ABS SOL" C1122 FR RH IN ABS SOL BRC-41, "DTC C1122 FR RH IN ABS SOL" C1123 FR RH OUT ABS SOL BRC-42, "DTC C1123 FR RH OUT ABS SOL" C1124 RR LH IN ABS SOL BRC-42, "DTC C1124 RR LH IN ABS SOL" C1125 RR LH OUT ABS SOL BRC-42, "DTC C1125 RR LH OUT ABS SOL" C1126 RR RH IN ABS SOL BRC-42, "DTC C1126 RR RH IN ABS SOL" C1127 RR RH OUT ABS SOL BRC-42, "DTC C1127 RR RH OUT ABS SOL" C1130 ENGINE SIGNAL 1 BRC-42, "DTC C1130 ENGINE SIGNAL 1" C1131 ENGINE SIGNAL 2 BRC-42, "DTC C1131 ENGINE SIGNAL 2" C1132 ENGINE SIGNAL 3 BRC-42, "DTC C1132 ENGINE SIGNAL 3" C1133 ENGINE SIGNAL 4 BRC-42, "DTC C1133 ENGINE SIGNAL 4" C1136 ENGINE SIGNAL 6 BRC-42, "DTC C1136 ENGINE SIGNAL 6" C1140-C1170 DTC Items (CONSULT screen items) Reference C1140 ACTUATOR RLY BRC-43, "DTC C1140 ACTUATOR RLY" C1142 PRESS SEN CIRCUIT BRC-43, "DTC C1142 PRESS SEN CIRCUIT" C1143 ST ANG SEN CIRCUIT BRC-44, "DTC C1143 ST ANG SEN CIRCUIT" C1144 ST ANG SEN SIGNAL BRC-45, "DTC C1144 ST ANG SEN SIGNAL" INFOID: J K L M N O P BRC-3

4 DTC INDEX U1000 DTC Items (CONSULT screen items) Reference C1145 YAW RATE SENSOR BRC-46, "DTC C1145 YAW RATE SENSOR" C1146 SIDE G-SEN CIRCUIT BRC-46, "DTC C1146 SIDE G-SEN CIRCUIT" C1155 BR FLUID LEVEL LOW BRC-46, "DTC C1155 BR FLUID LEVEL LOW" C1156 ST ANG SEN COM CIR BRC-47, "DTC C1156 ST ANG SEN COM CIR" C1160 DECEL G SEN SET BRC-47, "DTC C1160 DECEL G SEN SET" C1164 CV1 BRC-47, "DTC C1164 CV 1" C1165 CV2 BRC-47, "DTC C1165 CV 2" C1166 SV1 BRC-47, "DTC C1166 SV 1" C1167 SV2 BRC-47, "DTC C1167 SV 2" C1170 VARIANT CODING BRC-48, "DTC C1170 VARIANT CODING" INFOID: DTC Items (CONSULT screen items) Reference U1000 CAN COMM CIRCUIT BRC-48, "DTC U1000 CAN COMM CIRCUIT" BRC-4

5 PRECAUTIONS PRECAUTIONS Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" INFOID: The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE-TENSIONER, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SUPPLEMENTAL RESTRAINT SYS- TEM and SEAT BELTS of this Service Manual. WARNING: To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SUPPLEMENTAL RESTRAINT SYSTEM. Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Precaution for Brake System BRC-5 INFOID: Recommended fluid is brake fluid DOT 3. Refer to MA-9. Do not reuse drained brake fluid. Be careful not to splash brake fluid on painted areas such as body. If brake fluid is splashed, wipe it off and flush area with water immediately. Do not use mineral oils such as gasoline or kerosene to clean. They will ruin rubber parts and cause improper operation. Using a flare nut crowfoot and torque wrench, securely tighten brake tube flare nuts. Brake system is an important safety part. If a brake fluid leak is detected, always disassemble the affected part. If a malfunction is detected, replace part with a new one. Before working, turn ignition switch OFF and disconnect electrical connectors of ABS actuator and electric unit (control unit) or battery negative terminal. When installing brake piping, be sure to check torque. WARNING: Clean brake pads and shoes with a waste cloth, then wipe with SBR686C a dust collector. Precaution for Brake Control INFOID: During VDC/TCS/ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal. Just after starting vehicle after turning ignition switch ON, brake pedal may vibrate or motor operating noise may be heard from engine room. This is a normal status of operation check. Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel, or snow-covered (fresh, deep snow) roads. When an error is indicated by ABS or another warning lamp, collect all necessary information from customer (what symptoms are present under what conditions) and check for simple causes before starting diagnostic servicing. Besides electrical system inspection, check booster operation, brake fluid level, and fluid leaks. If tire size and type are used in an improper combination, or brake pads are not Genuine NISSAN parts, stopping distance or steering stability may deteriorate. If there is a radio, antenna, or antenna lead-in wire (including wiring) near control module, VDC/TCS/ABS function may have a malfunction or error. If aftermarket parts (car stereo, CD player, etc.) have been installed, check for incidents such as harness pinches, open circuits, and improper wiring. A B C D E BRC G H I J K L M N O P

6 PRECAUTIONS If the following components are replaced with non-genuine components or converted, VDC OFF indicator lamp and SLIP indicator lamp may turn on or the VDC system may not operate properly. Components related to suspension (shock absorber, strut, spring, bushing, etc.), Tires, wheels (exclude specified size), components related to brake (pad, rotor, caliper, etc.), components related to engine (muffler, ECM, etc.), components related to body reinforcement (roll bar, tower bar, etc.). Driving in the condition of breakage or excessive wear of suspension, tires or components related to the brakes may cause VDC OFF indicator lamp and SLIP indicator lamp turn on, and the VDC system may not operate properly. When the TCS or VDC is activated by sudden acceleration or sudden turn, some noise may occur. The noise is a result of the normal operation of the TCS and VDC. When driving on roads which have extreme slopes (such as mountainous roads) or high banks (such as sharp carves on a freeway), the VDC may not operate normally, or VDC OFF indicator lamp and SLIP indicator lamp may turn on. However, this is not a malfunction, if normal operation can be resumed after restarting engine. Sudden turns (such as spin turns, acceleration turns), drifting, etc. When VDC function is OFF (VDC OFF SW ON) may cause the G sensor system indicate a malfunction. However, this is not a malfunction, if normal operation can be resumed after restarting engine. Change 4 tires at a time. Be sure to use specified-size tires that have the same brand name and pattern. Wheel sensor errors can be detected be self-diagnosis when tires have wide abrasion variations or the size is different from the genuine tires. BRC-6

7 PREPARATION PREPARATION Special Service Tool The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. INFOID: A B Tool number (Kent-Moore No.) Tool name Description C ST (J-25405) Drift a: 77 mm (3.03 in) dia. b: 55.5 mm (2.185 in) dia. D E ZZA0701D ST ( ) Drift a: 74.5 mm (2.933 in) dia. b: 62.5 mm (2.461 in) dia. Installing rear sensor rotor BRC G ZZA0832D H KV ( ) Drift a: 76.3 mm (3.004 in) dia. b: 67.9 mm (2.673 in) dia. ZZA0832D I J Commercial Service Tool INFOID: K Tool name Description L 1: Flare nut crowfoot a: 10 mm (0.39 in)/ 12 mm (0.47 in) 2: Torque wrench Installing brake tube M S-NT360 N O P BRC-7

8 ON-VEHICLE SERVICE ON-VEHICLE SERVICE Adjustment of Steering Angle Sensor Neutral Position INFOID: In case of doing work that applies to the list below, make sure to adjust neutral position of steering angle sensor before running vehicle. Situation CAUTION: To adjust neutral position of steering angle sensor, make sure to use CONSULT-III. (Adjustment can not be done without CONSULT-III.) 1. Stop vehicle with front wheels in straight-ahead position. 2. Touch WORK SUPPORT and ST ANGLE SENSOR ADJUSTMENT on CONSULT-III screen in this order. 3. Touch START. CAUTION: Do not touch steering wheel while adjusting steering angle sensor. 4. After approximately 10 seconds, touch END. (After approximately 60 seconds, it ends automatically.) 5. Turn ignition switch OFF, then turn it ON again. CAUTION: Be sure to perform above operation. 6. Run vehicle with front wheels in straight-ahead position, then stop. 7. Select DATA MONITOR, SELECTION FROM MENU, and STR ANGLE SIG on CONSULT-III screen. Then make sure STR ANGLE SIG is within 0 ± 3.5 deg. If value is more than specification, repeat steps 1 to Erase memory of ABS actuator and electric unit (control unit) and ECM. 9. Turn ignition switch OFF. Calibration of Decel G Sensor (AWD Models) BRC-8 Adjustment of Steering Angle Sensor Neutral Position Removing/Installing ABS actuator and electric unit (control unit) Replacing ABS actuator and electric unit (control unit) Removing/Installing steering angle sensor Removing/Installing steering components Removing/Installing suspension components Change 4 tires to new ones Tire rotation Adjusting wheel alignment INFOID: NOTE: After removing/installing or replacing yaw rate/side/decel G sensor, ABS actuator and electric unit (control unit), suspension components, or after adjusting wheel alignment, make sure to calibration of decel G sensor before running vehicle. CAUTION: To calibrate decel G sensor, make sure to use CONSULT-III. (Adjustment can not be done without CON- SULT-III.) 1. Stop vehicle with front wheels in straight-ahead position. CAUTION: The work should be done at a horizontal place when vehicle is in the unloaded vehicle condition. Keep all tires inflated to correct pressures. Adjust the tire pressure to the specified pressure value. 2. Touch WORK SUPPORT and DECEL G-SEN CALIBRATION on CONSULT-III screen in this order. 3. Touch START. CAUTION: Set vehicle as shown in the display. 4. After approximately 10 seconds, touch END. (After approximately 60 seconds, it ends automatically.)

9 ON-VEHICLE SERVICE 5. Turn ignition switch OFF, then turn it ON again. CAUTION: Be sure to perform above operation. 6. Run vehicle with front wheels in straight-ahead position, then stop. 7. Select DATA MONITOR, SELECTION FROM MENU, and DECEL G-SEN on CONSULT-III screen. Then make sure DECEL G-SEN is within 0 ± 0.08 G. If value is more than specification, repeat steps 1 to Erase memory of ABS actuator and electric unit (control unit) and ECM. 9. Turn ignition switch OFF. A B C D E BRC G H I J K L M N O P BRC-9

10 SYSTEM DESCRIPTION SYSTEM DESCRIPTION Schematic INFOID: SFIA1160E Functions INFOID: VDC In addition to the TCS/ABS function, the driver steering amount and brake operation amount are detected from steering angle sensor and pressure sensor, and the vehicle's driving status (amount of under steering / over steering) is determined from information from G sensor, wheel sensor, etc., and this information is used to improve vehicle stability by controlling the braking and engine power to all four wheels. SLIP indicator lamp flashes to inform the driver of VDC operation. During VDC operation, body and brake pedal lightly vibrate and mechanical noises may be heard. This is normal. ABS warning lamp, VDC OFF indicator lamp, and SLIP indicator lamp might turn on when vehicle is subject to strong shaking or large vibration, such as when vehicle is on a turn table, a ship or a steep slope such as bank while engine is running. In this case, restart engine on a normal road, and if ABS warning lamp, VDC OFF indicator lamp, and SLIP indicator lamp turn off, there is no malfunction. TCS The wheel spin of the drive wheels is detected by ABS actuator and electric unit (control unit) from the wheel speed signals from four wheels, so if wheel spin occurs, drive wheel right and left brake fluid pressure control and engine fuel cut are performed while throttle value is restricted to reduce the engine torque and decrease the amount of wheel spin. In addition, the degree throttle is opened is controlled to achieve the optimum engine torque. Depending on road circumstances, the driver may have a sluggish feel. This is normal, because the optimum traction has the highest priority under TCS operation. TCS may be activated any time vehicle suddenly accelerates, suddenly down/upshifts, or is driven on a road with a varying surface friction coefficient. During TCS operation, it informs a driver of system operation by flashing SLIP indicator lamp. ABS The Anti-Lock Braking 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. If the electrical system malfunctions, then the fail-safe function starts, the ABS becomes inoperative, and ABS warning lamp turns on. Electrical system diagnosis by CONSULT-III is available. During ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal. When starting engine, or just after starting vehicle, brake pedal may vibrate or motor operating noises may be heard from engine compartment. This is a normal status of operation check. BRC-10

11 SYSTEM DESCRIPTION Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel, or snow-covered (fresh, deep snow) roads. EBD The Electronic Brake Distribution is a function that detects subtle slippages between 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 electrical system malfunction, the fail-safe function is activated, EBD and ABS becomes inoperative, and ABS warning lamp and brake warning lamp are turned on. Electrical system diagnosis by CONSULT-III is available. During EBD operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal. When starting engine, or just after starting vehicle, brake pedal may vibrate or motor operating noises may be heard from engine compartment. This is a normal status of operation check. Stopping distance may be longer than that of vehicles without EBD when vehicle drives on rough, gravel, or snow-covered (fresh, deep snow) roads. Fail-Safe Function INFOID: VDC / TCS SYSTEM In case of malfunction in the VDC/TCS system, VDC OFF indicator lamp and SLIP indicator lamp are turned on, and the condition of vehicle is the same as the condition of vehicles without VDC/TCS system. In case of malfunction in the VDC/TCS system, the ABS control continues to operate normally without VDC/TCS control. CAUTION: If the fail-safe function is activated, then perform the self-diagnosis for VDC/TCS/ABS control system. ABS, EBD SYSTEM In case of electrical malfunctions with the ABS, ABS warning lamp, VDC OFF indicator lamp and SLIP indicator lamp will turn on. In case of electrical malfunctions with the EBD, brake warning lamp, ABS warning lamp, VDC OFF indicator lamp and SLIP indicator lamp will turn on. Simultaneously, the VDC/TCS/ABS become one of the following conditions of the fail-safe function. For malfunction of ABS, only the EBD is activated and the condition of vehicle is the same condition of vehicles without TCS/ABS system. NOTE: 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. For malfunction of EBD, EBD and ABS become inoperative, and the condition of vehicle is the same as the condition of vehicles without TCS/ABS, EBD system. A B C D E BRC G H I J K L M N O P BRC-11

12 SYSTEM DESCRIPTION Hydraulic Circuit Diagram INFOID: SFIA1163E CAN Communication INFOID: SYSTEM DESCRIPTION CAN (Controller Area Network) is a serial communication line for real time application.it is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and kinks 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. Refer to LAN-43, "CAN System Specification Chart". BRC-12

13 TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS Fail-Safe Function INFOID: VDC/TCS SYSTEM In case of malfunction in the VDC/TCS system, VDC OFF indicator lamp and SLIP indicator lamp are turned on, and the condition of vehicle is the same as the condition of vehicles without VDC/TCS system. In case of malfunction in the VDC/TCS system, the ABS control continues to operate normally without VDC/TCS control. CAUTION: If the fail-safe function is activated, then perform the self-diagnosis for VDC/TCS/ABS control system. ABS, EBD SYSTEM In case of electrical malfunctions with the ABS, ABS warning lamp, VDC OFF indicator lamp, SLIP indicator lamp will turn on. In case of electrical malfunctions with the EBD, brake warning lamp, ABS warning lamp, VDC OFF indicator lamp and SLIP indicator lamp will turn on. Simultaneously, the VDC/TCS/ABS become one of the following conditions of the fail-safe function. For malfunction of ABS, only the EBD is activated and the condition of vehicle is the same condition of vehicles without TCS/ABS system. NOTE: 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. For malfunction of EBD, EBD and ABS become inoperative, and the condition of vehicle is the same as the condition of vehicles without TCS/ABS, EBD system. How to Proceed with Diagnosis INFOID: BASIC CONCEPT Most important point to perform diagnosis is to understand systems (control and mechanism) in vehicle thoroughly. It is also important to clarify customer complaints before inspection. First of all, reproduce symptom, and understand it fully. Ask customer about his/her complaints carefully. In some cases, it will be necessary to check symptom by driving vehicle with customer. NOTE: Customers are not professionals. Do not assume maybe customer means... or maybe customer mentioned this symptom. A B C D E BRC G H I J K L It is essential to check symptoms right from beginning in order to repair a malfunction completely. For an intermittent malfunction, it is important to reproduce symptom based on interview with customer and past examples. Do not perform inspection on ad hoc basis. Most intermittent malfunctions are caused by poor contacts. In this case, it will be effective to shake suspected harness or connector by hand. When repairs are performed without any symptom check, no one can judge if malfunction has actually been eliminated. After diagnosis, make sure to perform erase memory. Refer to BRC-26, "Self-Diagnosis". SEF233G For an intermittent malfunction, move harness or harness connector by hand to check poor contact or false open circuit. Always read GI General Information to confirm general precautions. Refer to GI-3, "General Precaution". SEF234G M N O P BRC-13

14 TROUBLE DIAGNOSIS DIAGNOSIS FLOWCHART ASKING COMPLAINTS SFIA3407E BRC-14

15 TROUBLE DIAGNOSIS Complaints against malfunction vary depending on each person. It is important to clarify customer complaints. Ask customer about what symptoms are present and under what conditions. Use information to reproduce symptom while driving. It is also important to use diagnosis sheet so as not to miss information. A B C EXAMPLE OF DIAGNOSIS SHEET SBR339B D E BRC G H I J K L SFIA3265E M N O P BRC-15

16 TROUBLE DIAGNOSIS Component Part Location INFOID: SFIA2785E BRC-16

17 TROUBLE DIAGNOSIS Schematic INFOID: A B C D E BRC G H I J K L M N O TFWM0229E P BRC-17

18 TROUBLE DIAGNOSIS Wiring Diagram - VDC - INFOID: TFWM0230E BRC-18

19 TROUBLE DIAGNOSIS A B C D E BRC G H I J K L M N O TFWM0231E P BRC-19

20 TROUBLE DIAGNOSIS TFWM0232E BRC-20

21 TROUBLE DIAGNOSIS A B C D E BRC G H I J K L M N O TFWM0233E P BRC-21

22 TROUBLE DIAGNOSIS TFWM0234E BRC-22

23 TROUBLE DIAGNOSIS A B C D E BRC G H I J K L M N O Control Unit Input/Output Signal Standard TFWM0235E INFOID: P REFERENCE VALUE FROM CONSULT-III CAUTION: The display shows ABS actuator and electric unit (control unit) calculation data, so a normal value might be displayed even in the event the output circuit (harness) is open or short-circuited. BRC-23

24 TROUBLE DIAGNOSIS Monitor item SLCT LVR POSI GEAR FR RH SENSOR FR LH SENSOR RR RH SENSOR RR LH SENSOR ACCEL POS SIG ENGINE SPEED STR ANGLE SIG YAW RATE SEN SIDE G-SENSOR PRESS SENSOR BATTERY VOLT STOP LAMP SW OFF SW A/T shift position A/T gear position Wheel speed Display content Open/close condition of throttle valve (linked with accelerator pedal) With engine running Steering angle detected by steering angle sensor Yaw rate detected by yaw rate sensor Transverse G detected by side G sensor Brake fluid pressure detected by pressure sensor Battery voltage supplied to ABS actuator and electric unit (control unit) Brake pedal operation VDC OFF switch ON/OFF status ABS WARN LAMP ABS warning lamp ON condition (Note 2) MOTOR RELAY Operation status of motor and motor relay P: P position R: R position N: N position D: D position 1: 1st gear 2: 2nd gear 3: 3rd gear 4: 4th gear 5: 5th gear Vehicle stopped Condition Vehicle running (Note 1) Accelerator pedal not depressed (Engine stopped) Depress accelerator pedal (Engine stopped) With engine stopped Engine running Straight-ahead Steering wheel turned Vehicle stopped Vehicle running Data monitor Reference value in normal operation 0 [km/h (MPH)] Almost in accordance with speedometer display (within ± 10 %) 0 % 0 to 100 % 0 rpm Almost in accordance with tachometer display Approx. 0 deg 756 to 756 deg Approx. 0 d/s 100 to 100 d/s Vehicle stopped Approx. 0 m/s 2 Vehicle running 16.7 to 16.7 m/s 2 With ignition switch turned ON and brake pedal released With ignition switch turned ON and brake pedal depressed Ignition switch ON Brake pedal depressed Brake pedal not depressed VDC OFF switch ON (When VDC OFF indicator lamp is ON) VDC OFF switch OFF (When VDC OFF indicator lamp is OFF) ABS warning lamp ON ABS warning lamp OFF Ignition switch ON or engine running (ABS not operated) Ignition switch ON or engine running (ABS operated) Approx. 0 bar 0 to 170 bar 10 to 16 V ON OFF ON OFF ON OFF OFF ON BRC-24

25 TROUBLE DIAGNOSIS Monitor item Display content Condition Data monitor Reference value in normal operation A ACTUATOR RLY OFF LAMP Actuator relay operation status VDC OFF indicator lamp status (Note 3) Actuator (solenoid) is active ( ACTIVE TEST with CONSULT-III) When actuator relay is inactive (in fail-safe mode) When VDC OFF indicator lamp is ON When VDC OFF indicator lamp is OFF ON OFF ON OFF B C SLIP LAMP SLIP indicator lamp status (Note 4) When SLIP indicator lamp is ON When SLIP indicator lamp is OFF ON OFF D FR LH IN SOL FR LH OUT SOL FR RH IN SOL FR RH OUT SOL RR RH IN SOL RR RH OUT SOL RR LH IN SOL RR LH OUT SOL Solenoid valve operation Actuator (solenoid) is active ( ACTIVE TEST with CONSULT-III) and actuator relay is active (ignition switch ON) When actuator (solenoid) is not active or actuator relay is inactive (in fail-safe mode) ON OFF E BRC CV1 CV2 SV1 SV2 VDC/TCS switch-over valve status When actuator (switch-over valve) is active ( ACTIVE TEST with CONSULT-III) and actuator relay is active (ignition switch ON) When actuator (switch-over valve) is not active or actuator relay is inactive (in failsafe mode) ON OFF G H DECEL G-SEN Longitudinal acceleration detected by decel G sensor (Note 5) Vehicle stopped Vehicle running Approx. 0 G -1.7 to +1.7 G I FLUID LEV SW ON/OFF status of brake fluid level switch When brake fluid level switch ON When brake fluid level switch OFF ON OFF J VDC FAIL SIG TCS FAIL SIG ABS FAIL SIG EBD FAIL SIG Fail signal status VDC fail TCS fail ABS fail EBD fail VDC normal TCS normal ABS normal EBD normal ON OFF K L EBD WARN LAMP Brake warning lamp on condition (Note 6) Brake warning lamp ON Brake warning lamp OFF ON OFF M EBD SIGNAL EBD operation EBD active EBD not active ON OFF N ABS SIGNAL TCS SIGNAL VDC SIGNAL ABS operation TCS operation VDC operation ABS active ABS not active TCS active TCS not active VDC active VDC not active ON OFF ON OFF ON OFF O P CRANKING SIG CRANKING status Cranking Not cranking ON OFF 4WD FAIL REQ ETS fail status (Note 5) ETS fail ETS normal ON OFF BRC-25

26 TROUBLE DIAGNOSIS Monitor item 2WD/4WD Drive axle Display content Note 1: Confirm tire pressure is normal. Note 2: ON/OFF timing of ABS warning lamp ON: Approx. Within 2 seconds after ignition switch is turned ON, or when a malfunction is detected. OFF: Approx. 2 seconds after ignition switch is turned ON (when system is in normal operation) and VDC/TCS function is not activated. Note 3: ON/OFF timing of VDC OFF indicator lamp ON: Approx. Within 2 seconds after ignition switch is turned ON, or when a malfunction is detected and VDC OFF switch is ON. OFF: Approx. 2 seconds after ignition switch is turned ON (when system is in normal operation.) And when VDC OFF switch is OFF. Note 4: ON/OFF timing of SLIP indicator lamp ON: Approx. Within 2 seconds after ignition switch is turned ON, or when a malfunction is detected and VDC/TCS function is activated while driving. OFF: Approx. 2 seconds after ignition switch is turned ON (when system is in normal operation) and VDC/TCS function is not activated. Flashing: VDC/TCS function is active during driving Note 5: Only AWD models. Note 6: Serves as EBD warning lamp. CONSULT-III Functions (ABS) 2WD model AWD model Condition Data monitor 2WD AWD CONSULT-III MAIN FUNCTION CONSULT-III can display each diagnostic item using the diagnostic test modes shown following. Reference value in normal operation INFOID: Diagnostic test mode WORK SUPPORT SELF-DIAG RESULTS DATA MONITOR CAN DIAG SUPPORT MNTR ACTIVE TEST FUNCTION TEST ECU PART NUMBER Self-Diagnosis Function This mode enables a technician to adjust some devices faster and more accurately by following the indications on CONSULT-III. Self-diagnostic results can be read and erased quickly. Input/Output data in the ABS actuator and electric unit (control unit) can be read. The results of transmit/receive diagnosis of communication can be read. Diagnostic Test Mode in which CONSULT-III drives some actuators apart from the ABS actuator and electric unit (control unit) and also shifts some parameters in a specified range. Performed by CONSULT-III instead of a technician to determine whether each system is OK or NG. ABS actuator and electric unit (control unit) part number can be read. INFOID: OPERATION PROCEDURE Before performing the self-diagnosis, start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute. ERASE MEMORY After erasing DTC memory, start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute as the final inspection, and make sure that the ABS warning lamp, VDC OFF indicator lamp, SLIP indicator lamp and brake warning lamp turn OFF. CAUTION: If memory cannot be erased, perform applicably diagnosis. NOTE: When the wheel sensor malfunctions, after inspecting the wheel sensor system, the ABS warning lamp, VDC OFF indicator lamp, SLIP indicator lamp and brake waning lamp will not turn OFF even when the system is normal unless the vehicle is driving at approximately 30 km/h (19 MPH) or more for approximately 1 minute. Brake warning lamp will turn ON in case of parking brake operation (when switch is ON) or of brake fluid level switch should not stay ON position. VDC OFF switch should not stay ON position. BRC-26

27 TROUBLE DIAGNOSIS DISPLAY ITEM LIST Self-diagnostic item Malfunction detecting condition Check system RR RH SENSOR- 1 [C1101] (Note 1) RR LH SENSOR- 1 [C1102] (Note 1) FR RH SENSOR- 1 [C1103] (Note 1) FR LH SENSOR- 1 [C1104] (Note 1) RR RH SENSOR- 2 [C1105] (Note 1) RR LH SENSOR- 2 [C1106] (Note 1) FR RH SENSOR- 2 [C1107] (Note 1) FR LH SENSOR- 2 [C1108] (Note 1) BATTERY VOLTAGE [ABNORMAL] [C1109] CONTROLLER FAILURE [C1110] PUMP MOTOR [C1111] (Note 3) G - SENSOR [C1113] (Note 4) ABS SENSOR [ABNORMAL SIGNAL] [C1115] (Note 1) STOP LAMP SW [C1116] FR LH IN ABS SOL [C1120] FR LH OUT ABS SOL [C1121] FR RH IN ABS SOL [C1122] FR RH OUT ABS SOL [C1123] RR LH IN ABS SOL [C1124] RR LH OUT ABS SOL [C1125] RR RH IN ABS SOL [C1126] RR RH OUT ABS SOL [C1127] ENGINE SIGNAL 1 [C1130] Circuit of rear RH wheel sensor is open, shorted or sensor power voltage is unusual. Circuit of rear LH wheel sensor is open, shorted or sensor power voltage is unusual. Circuit of front RH wheel sensor is open, shorted or sensor power voltage is unusual. Circuit of front LH wheel sensor is open, shorted or sensor power voltage is unusual. ABS actuator and electric unit (control unit) can not identify sensor pulses, because of large gap between wheel sensor and sensor rotor. ABS actuator and electric unit (control unit) can not identify sensor pulses, because of large gap between wheel sensor and sensor rotor. ABS actuator and electric unit (control unit) can not identify sensor pulses, because of large gap between wheel sensor and sensor rotor. ABS actuator and electric unit (control unit) can not identify sensor pulses, because of large gap between wheel sensor and sensor rotor. ABS actuator and electric unit (control unit) power voltage is too low. Internal malfunction of ABS actuator and electric unit (control unit) During actuator motor operation with ON, when actuator motor turns OFF or when control line for actuator motor relay is open. During actuator motor operation with OFF, when actuator motor turns ON or when control line for relay is shorted to ground. Decel G sensor is malfunctioning, or signal line of decel G sensor is open or shorted. Wheel sensor input is malfunction. Stop lamp switch circuit is open or shorted. Circuit of front LH IN ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. Circuit of front LH OUT ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. Circuit of front RH IN ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. Circuit of front RH OUT ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. Circuit of rear LH IN ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. Circuit of rear LH OUT ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. Circuit of rear RH IN ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. Circuit of rear RH OUT ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. Based on the signal from ECM, ABS actuator and electric unit (control unit) judges that engine fuel cut system is malfunctioning. BRC-34, "DTC C1101 RR RH SENSOR-1" BRC-35, "DTC C1102 RR LH SENSOR-1" BRC-35, "DTC C1103 FR RH SENSOR-1" BRC-35, "DTC C1104 FR LH SENSOR-1" BRC-36, "DTC C1105 RR RH SENSOR-2" BRC-36, "DTC C1106 RR LH SENSOR-2" BRC-36, "DTC C1107 FR RH SENSOR-2" BRC-36, "DTC C1108 FR LH SENSOR-2" BRC-36, "DTC C1109 BAT- TERY VOLTAGE [ABNOR- MAL]" BRC-37, "DTC C1110 CON- TROLLER FAILURE" BRC-37, "DTC C1111 PUMP MOTOR" BRC-38, "DTC C1113 G-SEN- SOR" BRC-39, "DTC C1115 ABS SENSOR [ABNORMAL SIG- NAL]" BRC-39, "DTC C1116 STOP LAMP SW" BRC-40, "DTC C1120 FR LH IN ABS SOL" BRC-41, "DTC C1121 FR LH OUT ABS SOL" BRC-41, "DTC C1122 FR RH IN ABS SOL" BRC-42, "DTC C1123 FR RH OUT ABS SOL" BRC-42, "DTC C1124 RR LH IN ABS SOL" BRC-42, "DTC C1125 RR LH OUT ABS SOL" BRC-42, "DTC C1126 RR RH IN ABS SOL" BRC-42, "DTC C1127 RR RH OUT ABS SOL" BRC-42, "DTC C1130 ENGINE SIGNAL 1" A B C D E BRC G H I J K L M N O P BRC-27

28 TROUBLE DIAGNOSIS Self-diagnostic item Malfunction detecting condition Check system ENGINE SIGNAL 2 [C1131] ENGINE SIGNAL 3 [C1132] ENGINE SIGNAL 4 [C1133] ENGINE SIGNAL 6 [C1136] ACTUATOR RLY [C1140] (Note 3) PRESS SEN CIRCUIT [C1142] ST ANG SEN CIRCUIT [C1143] ST ANG SEN SIGNAL [C1144] YAW RATE SENSOR [C1145] SIDE G-SEN CIRCUIT [C1146] BR FLUID LEVEL LOW [C1155] ST ANG SEN COM CIR [C1156] DECEL G SEN SET [C1160] (Note 4) CV 1 [C1164] CV 2 [C1165] SV 1 [C1166] SV 2 [C1167] VARIANT CODING [C1170] CAN COMM CIRCUIT [U1000] (Note 2) Note 1: After completing repairs of shorted sensor circuit, when turning ignition switch ON, ABS warning lamp turned on. Make that ABS warning lamp turned off while driving vehicle at approximately 30 km/h (19 MPH) or more for approximately 1 minute according to selfdiagnosis procedure. In addition, if wheel sensor 2 is displayed for wheels, check wheel sensor circuit and also check ABS actuator and electric unit (control unit) power voltage. Note 2: If multiple malfunctions are detected including CAN communication line [U1000], perform diagnosis for CAN communication line first. Note 3: ACTUATOR RLY on the CONSULT-III self-diagnostic results indicates the malfunction of actuator relay or circuit. Actuator relay is imbedded in ABS actuator and electric unit (control unit). Note 4:Only AWD models. Data Monitor DISPLAY ITEM LIST Based on the signal from ECM, ABS actuator and electric unit (control unit) judges that engine ETC system is malfunctioning. Based on the signal from ECM, ABS actuator and electric unit (control unit) judges that engine CAN system is malfunctioning. Based on the signal from ECM, ABS actuator and electric unit (control unit) judges that engine torque down system is malfunctioning. Based on the signal from ECM, ABS actuator and electric unit (control unit) judges that engine control system is malfunctioning. Actuator solenoid valve relay is ON, even if control unit sends off signal. Actuator solenoid valve relay is OFF, even if control unit sends on signal. Pressure sensor signal line is open or shorted, or sensor power voltage is unusual, or pressure sensor is malfunctioning. Neutral position of steering angle sensor is dislocated, or steering angle sensor is malfunctioning. Neutral position correction of steering angle sensor is not finished. Yaw rate sensor has generated an error, or yaw rate sensor signal line is open or shorted. Side G sensor is malfunctioning, or signal line of side G sensor is open or shorted. Brake fluid level drops or circuit between ABS actuator and electric unit (control unit) and brake fluid level switch is open or shorted. CAN communication line or steering angle sensor has generated an error. Neutral position correction of decel G sensor is not finished. Primary side VDC switch-over solenoid valve 1 (cut valve 1) is open or shorted, or control line is open or shorted to power supply or ground. Secondary side VDC switch-over solenoid valve 2 (cut valve 2) is open or shorted, or control line is open or shorted to power supply or ground. Primary side VDC switch-over solenoid valve 1 (suction valve 1) is open or shorted, or control line is open or shorted to power supply or ground. Secondary side VDC switch-over solenoid valve 2 (suction valve 2) is open or shorted, or control line is open or shorted to power supply or ground. V coding is not functioning. When a ABS actuator and electric unit (control unit) is not transmitting or receiving CAN communication signal for 2 seconds or more. BRC-42, "DTC C1131 ENGINE SIGNAL 2" BRC-42, "DTC C1132 ENGINE SIGNAL 3" BRC-42, "DTC C1133 ENGINE SIGNAL 4" BRC-42, "DTC C1136 ENGINE SIGNAL 6" BRC-43, "DTC C1140 ACTUA- TOR RLY" BRC-43, "DTC C1142 PRESS SEN CIRCUIT" BRC-44, "DTC C1143 ST ANG SEN CIRCUIT" BRC-45, "DTC C1144 ST ANG SEN SIGNAL" BRC-46, "DTC C1145 YAW RATE SENSOR" BRC-46, "DTC C1146 SIDE G- SEN CIRCUIT" BRC-46, "DTC C1155 BR FLU- ID LEVEL LOW" BRC-47, "DTC C1156 ST ANG SEN COM CIR" BRC-47, "DTC C1160 DECEL G SEN SET" BRC-47, "DTC C1164 CV 1" BRC-47, "DTC C1165 CV 2" BRC-47, "DTC C1166 SV 1" BRC-47, "DTC C1167 SV 2" BRC-48, "DTC C1170 VARIANT CODING" BRC-48, "DTC U1000 CAN COMM CIRCUIT" INFOID: BRC-28

29 TROUBLE DIAGNOSIS Item (Unit) Data monitor item selection ECU INPUT SIGNALS MAIN SIGNALS Remarks GEAR Gear position judged by PNP switch signal is displayed. SLCT LVR POSI Shift position judged by PNP switch signal. FR RH SENSOR [km/h (MPH)] FR LH SENSOR [km/h (MPH)] RR RH SENSOR [km/h (MPH)] RR LH SENSOR [km/h (MPH)] BATTERY VOLT (V) ENGINE SPEED (rpm) DECEL G-SEN (G) (AWD models) OFF SW STOP LAMP SW YAW RATE SEN (d/s) ACCEL POS SIG (%) STR ANGLE SIG (deg) SIDE G-SENSOR (m/s 2 ) PRESS SENSOR (bar) FLUID LEV SW ABS WARN LAMP SLIP LAMP FR LH IN SOL FR LH OUT SOL RR RH IN SOL RR RH OUT SOL FR RH IN SOL FR RH OUT SOL : Applicable : Optional item Wheel speed calculated by front RH wheel sensor signal is displayed. Wheel speed calculated by front LH wheel sensor signal is displayed. Wheel speed calculated by rear RH wheel sensor signal is displayed. Wheel speed calculated by rear LH wheel sensor signal is displayed. Voltage supplied to ABS actuator and electric unit (control unit) is displayed. Engine speed judged by CAN communication signal is displayed. Longitudinal acceleration detected by decel G sensor is displayed. VDC OFF switch status is displayed. Stop lamp switch status is displayed. Yaw rate detected by yaw rate sensor is displayed. Throttle valve open/close status judged by CAN communication signal is displayed. Steering angle detected by steering angle sensor is displayed. Lateral acceleration detected by side G sensor is displayed. Brake fluid pressure detected by pressure sensor is displayed. Brake fluid level switch status is displayed. ABS warning lamp status is displayed. SLIP indicator lamp status is displayed. Front LH IN ABS solenoid status is displayed. Front LH OUT ABS solenoid status is displayed. Rear RH IN ABS solenoid status is displayed. Rear RH OUT ABS solenoid status is displayed. Front RH IN ABS solenoid status is displayed. Front RH OUT ABS solenoid status is displayed. A B C D E BRC G H I J K L M N O P BRC-29

30 TROUBLE DIAGNOSIS RR LH IN SOL RR LH OUT SOL OFF LAMP MOTOR RELAY ACTUATOR RLY CV1 CV2 SV1 SV2 Item (Unit) VDC FAIL SIG TCS FAIL SIG ABS FAIL SIG EBD FAIL SIG EBD SIGNAL ABS SIGNAL TCS SIGNAL VDC SIGNAL EBD WARN LAMP CRANKING SIG 4WD FAIL REQ 2WD/4WD (2WD/4WD) Note: Serves as EBD warning lamp. Active Test Data monitor item selection ECU INPUT SIGNALS MAIN SIGNALS Rear LH IN ABS solenoid status is displayed. Rear LH OUT ABS solenoid status is displayed. OFF Lamp status is displayed. ABS motor relay signal status is displayed. ABS actuator relay signal status is displayed. Primary side switch-over solenoid valve 1 (cut valve 1) status is displayed. Secondary side switch-over solenoid valve 2 (cut-valve 2) status is displayed. Primary side switch-over solenoid valve 1 (suction valve 1) status is displayed. Secondary side switch-over solenoid valve 2 (suction valve 2) (ON/ OFF) status is displayed. VDC fail signal status is displayed. TCS fail signal status is displayed. ABS fail signal status is displayed. EBD fail signal status is displayed. EBD operation status is displayed. ABS operation status is displayed. TCS operation status is displayed. VDC operation status is displayed. Brake warning lamp status is displayed. (Note) Cranking condition status is displayed. AWD fail-safe signal status is displayed. Distinguish 2WD and AWD Remarks CAUTION: Do not perform active test while driving vehicle. Make sure to completely bleed air from the brake system. Active test can not be performed when EBD, ABS, TCS or VDC operation is malfunction. ABS and brake warning lamps turn on during the active test. NOTE: INFOID: BRC-30

31 TROUBLE DIAGNOSIS When active test is performed while depressing, the pedal depression amount will change. This is normal. TEST IS STOPPED is displayed 10 seconds after operation start. After TEST IS STOPPED is displayed, touch BACK and perform test again. TEST ITEM Solenoid Valve NOTE: The example shown is for the front right wheel. The procedure for the other wheels is the same as given below. When performing an active test of the ABS function, select the main item for each test item. In addition, when performing an active test of the VDC/TCS function, select the item menu for each test item. For the ABS solenoid valve, touch UP KEEP DOWN, and for the ABS solenoid valve (ACT), touch UP ACTUATOR UP ACTUATOR KEEP, and check to make sure that all solenoid valve (in, out) are operating as given in the table below. Operation *: ON for 1 to 2 seconds after the touch, and then OFF ABS solenoid valve UP KEEP DOWN UP ABS solenoid valve (ACT) ACTUATOR UP ABS Motor Touch ON and OFF on the screen. Make sure ABS motor relay operates as shown in table below. ACTUATOR KEEP FR RH IN SOL OFF ON ON OFF OFF OFF FR RH OUT SOL OFF OFF ON* OFF OFF OFF CV 1 OFF OFF OFF OFF ON ON SV 1 OFF OFF OFF OFF ON* OFF A B C D E BRC G H I Operation ON OFF MOTOR RELAY ON OFF ACTUATOR RLY ON ON For Fast and Accurate Diagnosis INFOID: J K PRECAUTIONS FOR DIAGNOSIS Before performing diagnosis, always read precautions. Refer to BRC-13, "How to Proceed with Diagnosis". If ABS actuator and electric unit (control unit), steering angle sensor, steering system parts or suspension system parts have been replaced, or if alignment has been adjusted, be sure to adjust neutral position of steering angle sensor before driving. Refer to BRC-8, "Adjustment of Steering Angle Sensor Neutral Position". After diagnosis is finished, be sure to erase memory. Refer to BRC-26, "Self-Diagnosis". When checking continuity and voltage between units, be sure to check for disconnection, looseness, bend, or collapse of connector terminals. If any malfunction is found, repair or replace connector terminals. For intermittent symptoms, possible cause is malfunction in harness, harness connector, or terminals. Move harness, harness connector, and terminals to check for poor connections. If a circuit tester is used for the check, be careful not to forcibly extend any connector terminal. To use CONSULT-III to perform self-diagnosis of ABS actuator and electric unit (control unit), active tests, or work support, first stop work, then connect CONSULT-III and select ABS. While self-diagnostic results of CONSULT-III shows malfunction, if CONSULT-III active test is performed, an engine system error may be indicated. In this case, start engine to resume the normal screen. VDC/TCS/ABS system electronically controls brake operation and engine output. The following symptoms may be caused by normal operations: L M N O P BRC-31

32 TROUBLE DIAGNOSIS Symptom Symptom description Result Motor operation noise System operation check noise VDC/TCS operation (SLIP indicator lamp blinking) ABS operation (Longer stopping distance) Insufficient feeling of acceleration Basic Inspection This is noise of motor inside ABS actuator and electric unit (control unit). Slight noise may occur during VDC, TCS, and ABS operation. When the vehicle speed goes over 20 km/h (12.5 MPH), motor and valves operating noise may be heard. It happens only once after ignition switch is ON. This is a normal status of the system operation check. When engine starts, slight click noise may be heard from engine room. This is normal and is part of system operation check. TCS may activate momentarily if wheel speed changes when driving over location where friction coefficient varies, when up/downshifting, or when fully depressing accelerator pedal. For inspection of speedometer or other instruments, press VDC OFF switch to turn VDC/TCS function off. When accelerator pedal is depressed on a chassis dynamometer (fixed front-wheel type), vehicle speed will not increase. This is not normal. It is result of TCS being activated by stationary front wheels. Warning lamp may also illuminate to indicate sensor system error. This is also normal, and is the result of the stationary front wheels being detected. To be certain, restart engine, and drive vehicle at 30 km/h (19 MPH) or more. Make sure warning lamp does not illuminate. On roads with low friction coefficients, such as snowy roads or gravel roads, vehicles with ABS may require a longer stopping distance. Therefore, when driving on such roads, avoid overconfidence and keep speed sufficiently low. Depending on road conditions, driver may feel that feeling of acceleration is insufficient. This is because traction control, which controls engine and brakes to achieve optimal traction, has the highest priority (for safety). As a result, there may be times when acceleration is slightly less than usual for the same accelerator pedal operation. Normal Normal Normal Cancel the VDC/TCS function for the inspection on a chassis dynamometer. Normal Normal INFOID: BRAKE FLUID AMOUNT, LEAKS, AND BRAKE PADS INSPECTION 1. Check fluid level in the brake reservoir tank. If fluid level is low, refill brake fluid. 2. Check brake piping and around ABS actuator and electric unit (control unit) for leaks. If there is leaking or oozing fluid, check the following items. If ABS actuator and electric unit (control unit) connection is loose, tighten piping to the specified torque and re-perform the leak inspection to make sure there are no leaks. If there is damage to the connection flare nut or ABS actuator and electric unit (control unit) screw, replace the damaged part and re-perform the leak inspection to make sure there are no leaks. When there is fluid leaking or oozing from a part other than ABS actuator and electric unit (control unit) connection, if fluid is just oozing out, use a clean cloth to wipe off the oozing fluid and re-check for leaks. If fluid is still oozing out, replace the damaged part. When there is fluid leaking or oozing at ABS actuator and electric unit (control unit), if fluid is just oozing out, use a clean cloth to wipe off oozing fluid and re-check for leaks. If fluid is still oozing out, replace ABS actuator and electric unit (control unit) body. CAUTION: ABS actuator and electric unit (control unit) body can not be disassembled. 3. Check brake pad degree of wear. Refer to BR-18, "On-Vehicle Inspection" in Front Disc Brake and BR- 24, "On-Vehicle Inspection" in Rear Disc Brake POWER SYSTEM TERMINAL LOOSENESS AND BATTERY INSPECTION Make sure battery positive cable, negative cable and ground connection are not loose. If looseness is detected, tighten the cables. In addition, check the battery voltage to make sure it has not dropped and alternator is normal. ABS WARNING LAMP, VDC OFF INDICATOR LAMP, SLIP INDICATOR LAMP AND BRAKE WARN- ING LAMP INSPECTION BRC-32