Brakes

Primary specifications of brake
1. Primary specifications of brake
Brake system
Master cylinder type Split
Cylinder inner diameter 22.2 mm { 0.87 in }
Master cylinder
Piston stroke
29 + 16 mm {1.14 + 0.63 in}
(primary + secondary)
Brake booster type Vacuum type
Diaphragm diameter 266 mm { 10.47 in }
Brake booster
Power cylinder stroke 50 mm { 1.97 in }
Pedal ratio 3.1
Except ABS specifications Blend proportioning valve
Brake force
distribution type ABS specifications or ESC EBD
specifications
Front disc brake

Cylinder type Pin slide
Disc outer diameter 300 mm { 11.81 in }
Disc thickness 27 mm { 1.06 in }
Piston diameter 44.45 mm { 1.75 in } x2
Adjustment method Automatic adjustment
Rear drum brake

Type Leading/trailing
Drum inner diameter 295 mm { 11.61 in }
Brake lining dimensions
283 x 50 x 5.0 mm
(Length x width x
{11.14 x 1.97 x 0.20 in}
thickness)
Wheel cylinder inner
23.8 mm { 0.94 in }
diameter
Rear disc brake

Cylinder type Pin slide
Disc outer diameter 318 mm { 12.52 in }
Disc thickness 18 mm { 0.71 in }
Piston diameter 42.86 mm { 1.69 in }
Parking brake (Rear drum brake)

Type Leading/trailing
Drum inner diameter 295 mm {11.61 in}
6 to 9 notches
Parking brake lever stroke
When pulled with a force of 294 N {30 kg/66 lb}
Parking brake (Rear disc brake)

Type Dual servo
Drum inner diameter 210 mm { 8.27 in }
6 to 9 notches
Parking brake lever stroke
When pulled with a force of 294 N {30 kg/66 lb}
Function, structure, operation of brake
1. Brake controls overview
1. ABS/EBD overview
The ABS is a system that prevents wheel lockup when braking and maintains the stability and maneuverability of the vehicle. The ABS is equipped with the
EBD function, which controls the braking force distribution of the front wheels and rear wheels according to the load status, and optimizes brake fluid
pressure of the rear wheels. If a system malfunction occurs, the fail-safe function activates and the ABS control and EBD control are inhibited, and then the
warning light illuminates.
2. TCS overview
The TCS is a system that controls engine output and braking and prevents wheel slippage during start-up. If a system malfunction occurs, the fail-safe
function activates, the TCS control is inhibited, and the warning light illuminates.
3. ESC overview
The ESC is a system that controls the braking of each wheel and the engine output when an unstable vehicle condition is detected because of a sudden
vehicle posture change while the vehicle is running, and ensures the stability and steerability of the vehicle. If a system malfunction occurs, the fail-safe
function activates, the ESC control is inhibited, and then the warning light illuminates.
Operation of the brake control function

Running mode
ABS EBD TCS ESC
2H (2WD) ○ ○ ○ ○
4H (4WD High) ○ ○ ○ ○
4L (4WD Low) ○ ○ ○ ×
Note
When 4L (4WD Low) is selected for the running mode, the ESC is deactivated, and the ESC OFF indication light turns on.
The driving mode is determined by the transfer operation state that the TCCM detected.
2. Brake controls
1. ABS control
The ABS controls the brake fluid pressure appropriately by having the EHCU retain, reduce, or increase the brake fluid pressure during braking based on
signals from the wheel speed sensors.
The EHCU calculates the wheel speed, wheel acceleration/deceleration, and vehicle speed using signals from the wheel speed sensors. When braking, if
the wheel speed decreases so rapidly that the difference between the wheel speed and the vehicle speed becomes more than or equal to the
predetermined level, the system determines that the wheels are tending toward lock-up and retains the brake pressure. The system determines that if the
wheel speed decreases further in this condition, the wheels will tend toward lock-up, and thus reduces the brake fluid pressure. If afterward the system
determines that locking of the wheels has been avoided, it returns to increasing, retaining or decreasing the brake fluid pressure.
2. EBD control
EBD is a system that appropriately controls braking force distribution between the front and rear according to the change of the vehicle loaded condition
and the load shift caused by deceleration, and the EHCU controls the braking force distribution between the front wheels and the rear wheels during
braking.
The EHCU detects the brake pedal stroke based on signals from the master cylinder pressure sensor and activates the EBD control. Once the EBD control
is activated, the EHCU calculates the optimum brake force for each wheel based on signals from each wheel speed sensor and controls the hydraulic unit.
3. TCS function (Models equipped with ESC)
Sudden acceleration on a slippery road surface may cause the drive wheels to skid, leading to impaired startup acceleration and maneuverability. The TCS
suppresses a skid by controlling the drive wheel brake and engine output and maintains the driving force appropriate for the road surface.
4. ESC control (Models equipped with ESC)
Due to road conditions, vehicle speed, sudden sharp turns in the case of an emergency, external factors, etc., oversteer (strong rear wheel skidding) or
understeer (strong front wheel skidding) may occur. When the ESC detects this kind of condition, it warns the driver as well as controls the brakes and the
engine output of each wheel to mitigate oversteer or understeer and ensure vehicle stability.
Note
When the 4L (4WD Low) driving mode is selected, the ESC does not operate.
1) Oversteer
If the EHCU detects oversteer, it applies the brake force to the front wheels and right/left rear wheels on the outside of the turn and controls oversteer by
generating moment towards the outside of the turning direction.
2) Understeer
If the EHCU detects understeer, it controls the engine output and applies the brake force to the front wheels and right/left rear wheels on the outside of the
turn, and generates moment in the turning direction to control understeer.
5. Rolling prevention function (Models equipped with ESC)
When large lateral G on the vehicle is generated, and the vehicle loses stability as its gradient angle increases, this function alerts the driver and controls
the engine output. Also, depending on the magnitude of the detected lateral G, the braking force is applied to the appropriate wheel.
6. Trailer sway control function (Models equipped with ESC for South Africa)
The EHCU detects the width of the sway transmitted from the towed vehicle at the towing vehicle side based on the signals from the yaw rate sensor, and
starts the trailer sway control. If the vehicle runs at a speed of 50 km/h {31.1 mph} or more while towing a vehicle, a swaying phenomenon of the towed
vehicle may occur depending on road conditions, etc. When the trailer sway control function detects this condition, it illuminates the brake lights and
controls the brakes and engine output of the towing vehicle to reduce the swaying phenomenon, and ensures the vehicle stability.
7. Hill Start Assist function (Models equipped with ESC)
The Hill Start Assist retains the brake pressure for approximately 2 seconds and prevents the vehicle from moving down, when switching from pressing
down on the brake pedal to pressing down on the accelerator pedal during vehicle start-up, on an ascending slope with an inclination of 10% or more. This
function is activated as well when ascending a slope in the reverse gear and deactivated by turning the ESC OFF.
8. Hill Descent Control function (Models equipped with ESC)
Hill Descent Control is a system that ensures hill decent stability by fixing the speed on steep slopes. It starts to operate when the accelerator pedal is
released while driving at a very low speed up to 30 km/h. The EHCU performs brake control of 4 wheels while monitoring the vehicle speed and gradient.
The desired hill descent speed can be adjusted by operating the accelerator pedal or brake pedal. During Hill Descent Control operation, the stoplight
illuminates together with the flashing of the Hill Descent Control indicator light.
1) Hill Descent Control start conditions
The Hill Descent Control switch is ON (indicator light illuminates).

A steep downhill.
The gear position is in forward (AT models: D, MT models: except R).
The gear position is in reverse (both AT models and MT models: R).
The vehicle speed is 30 km/h or less.
The accelerator pedal is OFF.
No interference from other controls and the system is normal.
2) Hill Descent Control stop conditions (system control status changes to standby status, indicator flashing to illumination)
The gradient becomes gentle.

The vehicle speed exceeds 30 km/h.
The vehicle is stopped.
Other controls interfere.
The vehicle speed is maintained only by the engine brake.
3) Hill Descent Control system stop conditions (complete termination, indicator OFF)
The Hill Descent Control switch is pressed while in control or standby.

The vehicle speed becomes 50 km/h or more while in standby.
The system becomes hot or malfunctions.
Note
If the system stop conditions are not met, it changes to standby mode.
3. EHCU operation
Hydraulic circuits diagram (Models equipped with ESC)
Legend
1. Front left hold solenoid valve

2. Master cylinder cut valve 1
3. Front right hold solenoid valve
4. Damper chamber
5. Master cylinder pressure sensor
6. Master cylinder
7. Motor
8. Rear left release solenoid valve
9. Rear left hold solenoid valve
10. Master cylinder cut valve 2
11. Rear right hold solenoid valve
12. Rear right release solenoid valve
13. Rear right brake
14. Rear left brake
15. Reservoir
16. Pump
17. Front right release solenoid valve
18. Front left release solenoid valve
19. Front right brake
20. Front left brake
Hydraulic circuits diagram (Except models equipped with ESC)

Legend
1. Front left hold solenoid valve

2. Front right hold solenoid valve
3. Motor
4. Rear release solenoid valve
5. Rear hold solenoid valve
6. Rear brake
7. Reservoir
8. Pump
9. Front right release solenoid valve
10. Front left release solenoid valve
11. Front right brake
12. Front left brake
1. Normal braking
During normal braking operations, the solenoid valves are not energized, and the hold solenoid valve is opened while the release solenoid valve is closed.
Brake fluid pressure passes through the hold solenoid valve and is then force-fed to the wheel cylinder.
Normal braking
2. When the ABS is in operation
The EHCU detects sudden deceleration based on the signal from the wheel speed sensors and drives the solenoid valve of each wheel to retain,
decrease, or increase the brake pressure, preventing wheel lock-up.
1) Brake pressure retention
When sudden deceleration signals are input from the wheel speed sensors, the hold solenoid valve closes, brake fluid from the master cylinder is cut off,
and the pressure in the wheel cylinders is retained.
When retaining
2) Brake pressure decrease
When the wheels are about to lock up due to braking, the release solenoid valve is opened, and the brake fluid that has been retained in the wheel
cylinders flows into the reservoir to reduce the pressure.
When pressure decreases
3) Brake pressure increase
When the wheel speed increases due to the pressure being reduced, the hold solenoid valve opens and the release solenoid valve closes. The brake fluid
that is force-fed by the pump motor and the brake fluid from the master cylinder are force-fed to the wheel cylinders. At this time, the driver may feel a
slight pulsation in the brake pedal, but this is not a malfunction. If the wheel approaches a locking state again with this pressure increase, the EHCU will
repeatedly retain, decrease, and increase the fluid pressure.
When pressure increases

Operation description
During ABS control
Valve operating When not
condition controlled Depressurization Pressurization
Hold mode
mode mode
Hold solenoid valve Open Close Close Open
Release solenoid
Close Close Open Close
valve
3. During TCS operation (Models equipped with ESC)
The TCS control applies the brake by leading hydraulic pressure generated in the pump in the hydraulic unit into the wheel cylinder of the driving wheel
and prevents slippage of the vehicle wheel due to driving force.
2WD
4WD
TCS control
When not
Valve operating condition
controlled Pressurization Hold mode Depressurization
mode mode
Master cylinder cut valve 1 Open Regulated Regulated Regulated
Master cylinder cut valve 2 Open Regulated Regulated Regulated
MAX oil
pressure wheel Hold
for 2-wheel solenoid Open Open Open Open
control in the valve
same system,
or control wheel Release
for 1-wheel solenoid Close Close Close Close
control in the valve
same system
Hold
MIN oil solenoid Open Open Close Close
pressure wheel valve
for 2-wheel
control in the Release
same system solenoid Close Close Close Open
valve
Hold
solenoid Open Close Close Close
Non-control valve
wheel Release
solenoid Close Close Close Close
valve
4. During ESC operation (Models equipped with ESC)
1) In case of the over steer
The brakes are operated by the hydraulic pressure generated by the pump inside the hydraulic unit being guided into the wheel cylinder of each wheel,
controlling the side skidding of the rear wheels.
In the case of oversteering, the front and rear wheel brakes on the outer side of the turn are operated.
2) In case of the under steer
The brakes are operated by the hydraulic pressure generated by the pump inside the hydraulic unit being guided into the wheel cylinder of each wheel,
controlling the side skidding of the front wheels.
In the case of understeer, the brakes of both rear wheels, or if necessary, the brakes of the front wheel outside of the turn are activated.
As an example, the illustration shows the front left/right brakes and the rear left brake as the controlled wheels, with the rear right brake as the uncontrolled
wheel.
During ESC control
Valve operating condition Pressurization Hold Depressurization
mode mode mode
Master cylinder cut valve Close Close Close
Hold solenoid
Open Close Close
Control valve
wheel Release
Control Close Close Open
solenoid valve
system
Hold solenoid
Open Close Close
Control valve
wheel Release
Close Close Open
solenoid valve
Master cylinder cut valve Close Close Close
Hold solenoid
Open Close Close
Control valve
Control wheel Release
system Close Close Open
solenoid valve
(Diagonal
wheels) Hold solenoid
Non- Close Close Close
valve
control
wheel Release
Open Open Open
solenoid valve
4. Brake controls components
1. Wheel speed sensor
The wheel speed sensor uses a Hall IC sensor. The wheel speed sensor for the front wheels is installed to the knuckles, and the wheel speed sensor for
the rear wheels is installed to the rear axle case. Voltage is generated in the sensor by the turning of the exciter rings that are firmly fitted into the front
wheel hubs and rear wheel axle shafts. The frequency of this voltage changes proportionately to the exciter ring rotational speed, thereby it is detected as
the wheel speed.
Legend
1. Wheel speed sensor

2. Exciter ring
2. Steering angle sensor (Models equipped with ESC)
The steering angle sensor is assembled on the steering column section to detect the steering angle and steering direction. Signals detected by the steering
angle sensor are sent to the EHCU via the CAN (private) communication circuit.
Legend
1. Detection gears
3. Yaw rate sensor (Models equipped with ESC)
The yaw rate sensor is comprised of the semiconductor-type yaw rate sensor and G sensor, and is built into the EHCU. It detects rotating angular speed
and lateral acceleration speed due to the changes in vehicle behavior, and sends them to the EHCU.
4. ABS warning light
The ABS warning light notifies the driver of an ABS malfunction. When the EHCU detects an ABS malfunction through the self-diagnosis function, it
illuminates the ABS warning light. Also, a short circuit between the terminals of the DLC makes the ABS warning light flash and a flash code displayed.
5. Brake system warning light
The brake system warning light illuminates if an EBD malfunction, brake fluid level lowering, or another brake-related abnormal condition is detected.
6. ESC warning light (Models equipped with ESC)
The ESC warning light informs the driver of an ESC malfunction. When the EHCU detects an ESC malfunction through the self-diagnosis function, it
illuminates the ESC warning light. The ESC warning light flashes during TCS or ESC operation.
7. Hill Descent Control indicator light (Models equipped with ESC)
The Hill Descent Control indicator light illuminates when the system is in a standby status, and flashes when the system is in operation.
8. Hill Descent Control switch (Models equipped with ESC)
The Hill Descent Control switch turns the Hill Descent Control function ON/OFF.
9. ESC OFF switch (Models equipped with ESC)
In an attempt to escape from mud, etc., depressing the accelerator with the TCS or ESC operating may limit the driving force and make the escape
difficult. The TCS and ESC can be deactivated by operating the ESC OFF switch.
1) When 2H (2WD) or 4H (4WD High) is selected for the driving mode
Briefly pushing the ESC OFF switch will switch the TCS to TCS OFF mode, deactivating the TCS. Also, the TCS OFF indication light in the instrument
panel cluster illuminates at this time.
Pressing and holding the ESC OFF switch for about 5 seconds or more with the vehicle stopped switches the ESC to ESC OFF mode, deactivating the
TCS and ESC. Also, the TCS OFF indicator light and ESC OFF indicator light in the instrument panel cluster illuminate at this time.
Each mode can be canceled by pressing the ESC OFF switch briefly or turning the ignition switch OFF.
2) When 4L (4WD Low) is selected for the driving mode
The ESC function stops operating.

Pressing and holding the ESC OFF switch for about 5 seconds or more with the vehicle stopped switches the TCS to TCS OFF mode, deactivating the
TCS. Also, the TCS OFF indicator light in the instrument panel cluster illuminates at this time.
The TCS OFF mode can be canceled by pressing the ESC OFF switch briefly or turning the ignition switch OFF.
Note
When the ESC OFF switch is pressed and held for 10 seconds or more, it returns to normal mode.
Control allowed/prohibited Indication light

Running
Operation Engine Brake Engine Brake
mode TCS OFF ESC OFF
TCS TCS ESC ESC
No ○ ○ ○ ○ OFF OFF
Short
× ○ ○ ○ Illuminated OFF
press
2H (2WD),
4H (4WD Long
High) press
(5 × × × × Illuminated Illuminated
seconds
or longer)
No × ○ × × OFF Illuminated
Short
× ○ × × Illuminated
press OFF
4L (4WD Long
Low) press
(5 × × × × Illuminated Illuminated
seconds
or longer)
10. EHCU
The EHCU consists of the control unit section and hydraulic unit section. The control unit is comprised of an ABS/TCS/EBD control part, malfunction
detection part, and fail-safe part. It drives the hydraulic unit, etc., based on signals from the various sensors. In the case of a system malfunction, it has the
ability to inhibit control using the fail-safe function. Using a self-diagnosis function, it also displays defective areas when performing trouble diagnosis. The
hydraulic unit is comprised of the motor, pump, solenoid valves, reservoir, master cylinder pressure sensor, etc.
1) Solenoid valve
When the brake fluid pressure is retained, reduces, or increases, the oil passage is switched.
2) Reservoir
The brake fluid is stored when pressure decreases.
3) Pump
The brake fluid stored in the reservoir is force-fed to the master cylinder.
4) Motor
The pump is driven.
5) Master cylinder pressure sensor
The master cylinder brake fluid pressure is detected.
Models equipped with ESC
Except models equipped with ESC

5. Brake controls component views
Legend
1. EHCU
2. Front wheel speed sensor
3. Rear wheel speed sensor
Note
The following illustration shows an RHD model.
Legend
1. ABS warning light

2. ESC warning light (Models equipped with ESC)
3. Brake system warning light
4. ESC OFF indicator light (Models equipped with ESC)
5. TCS OFF indicator light (Models equipped with ESC)
6. Hill Descent Control indicator light (Models equipped with ESC)
7. ESC OFF switch (Models equipped with ESC)
8. Hill Descent Control switch (Models equipped with ESC)
9. Steering angle sensor (Models equipped with ESC)
10. Stoplight switch
6. Brake system
1. Braking device system diagram
Models with blend proportioning valves
ABS specifications
ESC specifications
2. Master cylinder and brake booster
3. Vacuum hose
Caution
When attaching the vacuum hose, make sure the arrow painted on the hose is pointing to the engine side.
Legend
1. Engine side
2. Check valve
RZ4E engine, 4JJ1 engine, or 4JK1 engine models (RHD models)

RZ4E engine, 4JJ1 engine, or 4JK1 engine models (LHD models)
4. Blend proportioning valve
1) Blend proportioning valve installation position
The blend proportioning valve is set in the engine room.
Caution
Because the blend proportioning valve cannot be disassembled, replace it as an assembly if an abnormal condition is found.
RHD models
Legend
LHD models
Legend
2) Structure of the blend proportioning valve
For bypass valve, seal the routes 1 and 2 and use a seal to the piston end. The spring is pressed against the piston and spring seal is pressed against the
cylinder end surface in order to effectively seal the routes 1 and 2.
3) Blend proportioning valve operation
P-valve operation by the master cylinder pressure does not change up to the first and second break points. When the master cylinder fluid pressure
reaches the second break point, the fluid pressure compresses the seal (which branches into routes 1 and 2), and goes through route 1 on the master
cylinder side. Then it overcomes the spring operational force and fluid pressure, and affects the wheel cylinder seal. The piston is pressed to the right and
it consequently opens up routes 1 and 2 to cancel the P-valve operation. Next, the master cylinder fluid pressure and wheel cylinder fluid pressure affect
the same surface of the seal up to point C, and therefore they are decreased at the same rate. However, due to the action of the spring on the wheel
cylinder side, the wheel cylinder fluid pressure maintains balance with the lower master cylinder fluid pressure using the pressure difference caused by this
spring.
Proportioning valve structural diagram

Legend
1. Route 1
2. From master cylinder
3. Seal
4. Piston
5. To the wheel cylinder
6. Route 2
7. Bypass valve
8. Spring
9. P-valve
Proportioning valve characteristic curves
Legend
1. The first break point

2. The second break point
3. Point C
5. Front disc brake
6. Rear drum brake

7. Rear wheel cylinder
8. Rear disc brake
7. General circuit diagram
1. EHCU general circuit diagram (Models equipped with ESC)

Terminal No. Signal name
1 BAT (battery voltage)
2 GND (Ground)
4 GND (Ground)
5 CAN High (private)
6 CAN Low (private)
7 Stoplight 2
8 -
9 ESC OFF switch
10 -
11 FR Wheel speed sensor (+)
12 FR Wheel speed sensor (-)
13 RL Wheel speed sensor (+)
14 RL Wheel speed sensor (-)
15 -
16 Stoplight relay
17 DLC
18 -
19 CAN High (public)
20 -
21 -
22 -
23 FL Wheel speed sensor (+)
24 FL Wheel speed sensor (-)
25 RR Wheel speed sensor (+)
26 RR Wheel speed sensor (-)
27 Speed signal
28 IG (ignition voltage)
29 -
30 CAN Low (public)
31 -
32 -
33 -
34 -
35 Stoplight 1
36 -
37 Hill Descent Control switch
38 -
2. EHCU general circuit diagram (Except models equipped with ESC)

Terminal No. Signal name
1 GND (Ground)
3 GND (Ground)
5 -
6 -
7 RL Wheel speed sensor (-)
8 RL Wheel speed sensor (+)
9 FR Wheel speed sensor (-)
10 FR Wheel speed sensor (+)
11 -
12 -
13 -
14 -
15 CAN Low (public)
16 -
17 RR Wheel speed sensor (-)
18 RR Wheel speed sensor (+)
19 FL Wheel speed sensor (-)
20 FL Wheel speed sensor (+)
21 -
22 -
23 Speed signal
24 -
25 CAN High (public)
26 -
27 -
28 Stoplight switch
29 -
30 -
31 -
32 DLC
33 -
34 IG (ignition voltage)
Introduction to the trouble diagnosis of brake
1. Introduction to the trouble diagnosis of brake
Note
The scan tool DTC display shows an alphabetic character + 4 digits + 2 digits, such as DTC C00350F.
The final 2 digits of FTB show additional information on problems.
1. About self-diagnosis
The EHCU has a self-diagnosis function and performs the initial check when the system is started to determine the presence of system malfunctions and
failed sections. If a malfunction is detected, the ABS warning light or brake system warning light illuminates to inform the driver of the malfunction, and a
DTC is stored.
The illuminated warning light is turned OFF each time the ignition switch is turned OFF, but the DTC will continue to be stored until cleared.
2. Trouble diagnosis based on illumination pattern
If a malfunction is found in the ABS or ESC warning light illumination pattern inspection when the ignition switch is turned ON, or if a warning light
illuminates during a test drive, perform the trouble diagnosis indicated in the following chart for that particular illumination pattern.
Test drive after completion of repair

After the repair, temporarily turn the ignition switch OFF and then restart the engine to verify that each light turns OFF.
1) All lights illuminate normally.
Normal
2) One of the lights does not illuminate.
Light control circuit failure
Refer to "54.Brake Control 4A.Troubleshooting(ABS (ESC with Hill Descent Control function)) ABS warning light illuminating circuit system check".
3) The warning light remains illuminated.
Observe the DTC information.

If a DTC is stored, perform trouble diagnosis according to the flow chart for each DTC. If DTCs are not stored, inspect the warning light control circuit.
4) The warning light illuminates when the vehicle is running.
A DTC is stored. Check for a DTC, and perform trouble diagnosis according to the flow chart for each DTC.
5) The warning light flashes repeatedly after the ignition switch is turned ON, and illuminates while the vehicle is running.
Diagnostic switch circuit failure
6) The TCS OFF indicator light and ESC OFF indicator light remain illuminated.
ESC OFF switch circuit failure When the TCS and ESC are deactivated by the ESC OFF switch, the TCS OFF indicator light and ESC OFF indicator light
illuminate. The TCS and ESC always enter the operation standby state when the engine is started.
Note
If the ESC OFF switch circuit is stuck at ON, the TCS OFF indicator light and ESC OFF indicator light turn OFF after illuminating for
approximately 10 seconds.
7) The ESC warning light flashes while driving.
It is normal when displayed during ESC operation.

2. Diagnostic trouble codes (DTCs)
1. DTC display method
The vehicle must be stopped. The ABS warning light flashes and the DTC is displayed after pins No. 12 and No. 4 or No. 5 of the DLC are short-circuited
and the ignition switch is turned ON. Code 1 is repeatedly displayed when the status is normal. When there is a malfunction, each DTC is displayed once,
and then this is repeated. The DTCs are displayed in order, starting with the smallest number.
RHD models
LHD models
2. DTC clearing method
A DTC stored in the EHCU is not cleared even if the malfunction is repaired. Use one of the following methods to clear the DTC.
Short-circuit pins No. 12 and No. 4 or No. 5 of the DLC, and turn the stoplight switch (brake switch) ON/OFF 8 times or more within 5 seconds.
Clear with a scan tool.
Caution
Make sure to verify that the code is cleared after performing the clearing.
If the DTC cannot be cleared by short-circuiting the DLC, clear it using the scan tool.
3. Performing diagnosis
1. During general maintenance
Make sure to follow the following precautions when maintaining or diagnosing the ABS/ESC and other vehicle control systems.
When welding the vehicle using an electric arc welder, remove the EHCU connector before welding.
When installing or removing the EHCU connector, do so with the ignition switch OFF.
Do not disassemble the EHCU.
Take sufficient care to prevent foreign material from entering the hydraulic pressure circuit when inspecting or maintaining the brakes.
The DTC is set if only the rear wheels are rotated using a drum tester or with the vehicle jacked up. Therefore, clear the DTC after work.
2. Computer system maintenance
Be careful not to apply overcurrent to the EHCU circuit. When inspecting for open circuits or short circuits, do not ground the system or apply voltage to it
without careful consideration. Only inspect these circuits using a circuit tester with high internal resistance or using the special tools mentioned in this
section. When the ignition switch is in the ON position, do not connect or disconnect the EHCU power supply. Make sure to place the ignition switch in the
OFF position before disconnecting or connecting the battery cable, fuse, or connectors.
Caution
As the CAN communication line is disconnected if the ignition switch is turned ON with the harness removed from the EHCU, clear the
DTCs in the systems performing CAN communication after work.
Do not run the vehicle with the EHCU removed.
3. Inspection between EHCU terminals

EHCU terminal layout (Models equipped with ESC)
Measured value between EHCU connector terminals (Models equipped with

ESC)
Measurement
Circuit terminal Ignition Measurement Standard
Remarks
inspected switch range value
+ -
Disconnect the connectors to measure each terminal.
1 2 OFF DCV 10 to 16 V -
EHCU power 3 2 OFF DCV 10 to 16 V -
supply 28 2 OFF DCV 0V -
28 2 ON DCV 10 to 16 V -
2 Ground OFF Ω 0 to 1 Ω -
EHCU ground
Release the
35 2 OFF DCV 0V
Stoplight switch brake pedal.
1 Depress the
35 2 OFF DCV 10 to 16 V
brake pedal.
Release the
7 2 OFF DCV 0V
Stoplight switch brake pedal.
2 Depress the
7 2 OFF DCV 10 to 16 V
brake pedal.
Stoplight relay 16 2 OFF DCV 0V -
output 16 2 ON DCV 10 to 16 V -
Release the Hill
37 2 OFF Ω ∞Ω Descent Control
Hill Descent switch.
Control switch Depress the Hill
37 2 OFF Ω 0 to 1 Ω Descent Control
switch.
Release the ESC
9 2 OFF Ω ∞Ω
ESC OFF OFF switch.
switch Depress the ESC
9 2 OFF Ω 0 to 1 Ω
OFF switch.
EHCU terminal layout (Except models equipped with ESC)
Measured value between EHCU connector terminals (Except models

equipped with ESC)
Measurement
terminal Ignition Measurement Standard
Circuit inspected Remarks
switch range value
+ -
Measure each terminal with the connector disconnected.
2 1 OFF DCV 10 to 16 V -
EHCU power 4 1 OFF DCV 10 to 16 V -
supply 34 1 OFF DCV 0V -
34 1 ON DCV 10 to 16 V -
EHCU ground
Release
28 1 OFF DCV 0V the brake
pedal.
Stoplight switch
Depress
28 1 OFF DCV 10 to 16 V the brake
pedal.
4. When replacing the EHCU
The EHCU itself rarely malfunctions. Therefore, when replacing the EHCU, in addition to inspecting the connection status of the connectors, inspect for
short circuits between wire harnesses in advance.
5. Intermittent trouble
Because intermittent trouble often occurs due to temporary connection failures of wire harnesses and connectors, shake the wire harnesses without
damaging them, then inspect them.
Maintenance precautions of brake
1. Maintenance precautions of brake
1. Vacuum hose installation direction
When attaching the vacuum hose to vehicles with a check valve, make sure the arrow painted on the hose is pointing to the engine side.
Legend
1. Engine side
2. Check valve
2. Using circuit test tools
Unless instructed in the diagnostic procedure, do not use a test lamp. When a probe connector is required in the diagnostic procedure, use connector test
adapter kit 5-8840-2835-0.
3. Safety precautions
When performing an inspection using a scan tool with the engine ON in a closed location such as a garage, make sure to adequately ventilate the area.
Before performing a vehicle inspection test using a scan tool, firmly engage the parking brake, and stabilize the vehicle using chock blocks.
4. Commercial electronic equipment
Aftermarket electronic equipment refers to commercially available electronic equipment installed to the vehicle after it has been shipped from the factory.
Be careful because they are not taken into particular consideration at the vehicle design stage.
Aftermarket electronic equipment may cause malfunctions in the electronic control system, even if the equipment is usually installed. Therefore when
diagnosing the electronic system, first confirm whether such aftermarket electronic equipment is installed, and if installed, remove it from the vehicle to
check its effect to the malfunction.
Caution
Make sure that both the power supply and ground of aftermarket electronic equipment are connected to a circuit that is not affected by the
electronic control system.
5. Damage caused by electrostatic discharge
Because the electronic components used in the electronic control system are designed to operate at extremely low voltages, they can be easily damaged
by electrostatic discharge, and can be damaged by static electricity of 100 V or less, which cannot be felt by a person. The most common causes of
electrostatic charge build-up for a person are friction and induction. It is easy for a person to build an electrostatic charge by friction when they slide across
the seat of a vehicle. A person wearing insulated shoes can easily build an electrostatic charge by induction if they momentarily touch the ground while
standing near a highly charged object. A charge of the same polarity flows out, and with a highly opposing polarity, that person becomes charged. Be
careful because static electricity causes damage to electronic components.
Caution
To prevent damage caused by electrostatic discharge, do not touch the connector pins of the control unit or the electronic components
soldered onto the circuit board of the control unit.
To prevent damage caused by electrostatic discharge, do not open the package of a replacement part until the preparations for installation
of the part are completed.
To prevent damage caused by electrostatic discharge, connect the package to the vehicle ground to discharge the static electricity, before
removing the part from the package.
6. Control unit maintenance precautions
Make sure that the circuit does not overload so much as to affect the control unit. When testing for an open circuit and short circuit, do not ground or apply
voltage to the control unit circuit unless instructed to do so. Also, when performing these circuit tests, make sure to use a DMM with a large input
impedance.
ABS works frequently but the brake is not effective or TCS operates frequently
1. ABS works frequently but the brake is not effective or TCS operates frequently description of symptom
ABS works frequently but the brake is not effective or TCS operates frequently.
2. ABS works frequently but the brake is not effective or TCS operates frequently diagnostics
1. Preliminary inspection
Perform the brake system check.
Refer to "54.Brake Control 4A.Troubleshooting(ABS (ESC with Hill Descent Control function)) diagnostic System Check - Brake Controls".
Inspect for the following.
There should be no malfunctions in the warning light and indicator light operation.
There should be no DTC input.
2. Visual inspection
Visually inspect the vehicle condition with the following in mind before installing, removing, disassembling, and inspecting the components.
Terminal connection status inspection

Inspection for aftermarket accessory power diverged from the EHCU
EHCU ground installation status inspection
Installation status inspection of the pipes and hoses in the brake system
3. Diagnosis when the scan tool is not used
1) Tire inspection
Always inspect the size, air pressure, and uneven wear of the installed tires.
If the inspection results are normal, go to Brake distribution inspection on front and rear of vehicle.
If the inspection results are abnormal, replace the tire. After completing the procedure, go to Repair verification.
2) Inspection of brake distribution to the front and rear of the vehicle
Inspect the brake distribution to the front and rear of the vehicle.
If the inspection results are normal, go to Axle and related parts inspection.
If the inspection results are abnormal, repair the applicable brake system. After completing the procedure, go to Repair verification.
3) Axle and related parts inspection
Inspect the installation status of the axle and related parts.
If the inspection results are normal, go to Wheel speed sensor installation status inspection.
If the inspection results are abnormal, repair the applicable parts. After completing the procedure, go to Repair verification.
4) Wheel speed sensor installation status inspection
Inspect the installation status of the wheel speed sensors.
If the installation is normal, go to Wheel speed sensor and exciter ring inspection.
If the installation is abnormal, repair the installation condition of the wheel speed sensor. After completing the procedure, go to Repair verification.
5) Wheel speed sensor and exciter ring inspection
Inspect for foreign material attached to the wheel speed sensor or exciter ring.
If the inspection results are normal, go to Wheel speed sensor circuit inspection.
6) Wheel speed sensor circuit inspection
Refer to DTC C0035[00] - C0050[18], and inspect the wheel speed sensor circuit.
If the inspection results are normal, go to EHCU replacement.
If the inspection results are abnormal, repair the wheel speed sensor. After completing the procedure, go to Repair verification.
7) EHCU replacement
Note
Perform programming after replacing the EHCU.
Refer to "4.Brakes 4Z.Brake Electrical Control EHCU removal".
Refer to "4.Brakes 4Z.Brake Electrical Control EHCU installation".
Refer to "4.Brakes 4Z.Brake Electrical Control EHCU setting".
After completing the procedure, go to Repair verification.

8) Repair verification
Check whether all the components are properly installed.
Perform a test drive and check the symptoms.
4. Diagnosis when using a scan tool
1) Wheel speed sensor output inspection
Turn OFF the ignition switch.
Connect the scan tool.
Observe the wheel speed of each wheel with a scan tool.
Check whether the lowest speed of all the wheels is 4 km/h {2.5 mph} or less and stable.
Note
Because different wheel speed readings may be displayed in the case of vehicles equipped with tires of different diameters on the front and
rear wheels, check the speed after driving the vehicle at a fixed speed for a short period of time.
If the inspection results are abnormal, go to Wheel speed sensor circuit inspection.
3) EHCU replacement
Note

Brake abnormal noise
1. Brake abnormal noise diagnostics
Worn brake pad and lining
Replace.
Defective brake rotor
Correct or replace.
Brake does not work efficiently
1. Brake does not work efficiently diagnostics
Master cylinder malfunction
Inspect the operation.

Replace as necessary.
Brake booster malfunction

Insufficient brake fluid
Refill with the specified brake fluid.

Inspect for fluid leakage.
Air in the hydraulic system
Bleed the air from the hydraulic system.

Brake operation sounds are heard from the hydraulic unit even though the brake is not applied
1. Brake operation sounds are heard from the hydraulic unit even though the brake is not applied description of symptom
The operation sound of the hydraulic unit can be heard even though the brake pedal is not depressed.
2. Brake operation sounds are heard from the hydraulic unit even though the brake is not applied diagnostics

3. Diagnostics
1) Condition check upon generation of operating sound
It is normal if it operates under the following conditions.
At first driving after the engine is started.

The vehicle speed is 10 km/h {6.2 mph} or less.
At shift-down or clutch operation
When the vehicle is running on slippery (frozen or snow-covered) roads or under rough road conditions
When turning at high speed
When passing over a protrusion such as a curb
If the inspection results are abnormal, repair or replace the applicable parts. After completing the procedure, go to Repair verification.
5) EHCU replacement
Note

Brake pedal feeling is abnormal
1. Brake pedal feeling is abnormal description of symptom
Abnormal brake pedal feeling
2. Brake pedal feeling is abnormal diagnostics

3. Diagnostics
1) Stoplight switch signal check
Disconnect the EHCU harness connector.
Turn ON the ignition switch.
Depress the brake pedal.
Measure the voltage between the stoplight switch circuit of the EHCU harness connector and the frame ground using a DMM.
Value: 10 to 16 V
If the voltage reading is the specified value, go to Brake piping inspection.
If the voltage reading is less than or equal to the specified value, repair the stoplight switch circuit. After completing the procedure, go to Repair verification.
2) Brake piping inspection
Inspect for fluid leakage from the brake fluid piping or for air in the brake fluid pressure system.
If the inspection results are abnormal, repair the applicable areas. After completing the procedure, go to Repair verification.
3) EHCU replacement
Note

Brake pedal pulsates
1. Brake pedal pulsates diagnostics
Excessive horizontal rotor runout
Inspect for rotor runout.

Replace if it exceeds the specified value.
Excessive rotor thickness variation
Inspect for rotor thickness variation.

Excessive end play of the hub bearing
Replace.
Reversed pad installation direction
Replace the pad.

Repair the rotor as necessary.
Excessive wear on the brake drum
Measure the drum inner diameter, and grind as necessary.

Defective straight driving
1. Defective straight driving diagnostics
Improper tire air pressure
Equally adjust the left and right air pressures to the specified value.
Improper wheel alignment
Inspect and adjust the wheel alignment.
The tire sizes on the same axle are not identical.
Make the tire sizes on the same axle identical.
Clogging of the brake pipe and hose
Replace.
Malfunction of the caliper and the wheel cylinder assembly
Inspect for freezing, sticking or malfunction of the caliper and wheel cylinder assembly.
Pad and lining damage or defect
Inspect.
Loose sections of the suspension
Inspect the installation sections of the suspension and tighten to the specified torque.
Brake caliper looseness
Inspect the mounting bolts and tighten them to the specified torque.
Dragging brakes
1. Dragging brakes diagnostics
Return failure of the master cylinder piston
Readjust the brake booster rod length.

Replace the master cylinder as necessary.
Clogging of the brake pipe and hose
Replace.
Improper brake pedal play
Readjust the brake booster rod length.
Stuck caliper and wheel cylinder piston
Inspect and clean.

Defective vacuum hose
Replace.
Improper vacuum hose installation
Repair the installation.

ESC does not work efficiently
1. ESC does not work efficiently description of symptom
ESC malfunction and excessive operation
2. ESC does not work efficiently diagnostics

3. Diagnostics
1) Indicator light/running mode check
If the ESC do not operate, check the display status of the ESC OFF indicator light.
Check whether operating the ESC OFF switch resulted in a switch to ESC OFF mode.
2) ESC operating conditions check
Check whether the vehicle speed when the ESC did not operate was 15 km/h {9 mph} or less.
3) ESC warning light check
If the ESC warning light is illuminated, observe the DTC.
If a DTC is set, go to the applicable DTC diagnosis.
4) Tire inspection
Check whether the tires of the specified size are installed.
5) DTC verification
Observe the DTC information with a scan tool.
If a DTC is set, go to the applicable DTC diagnosis.
6) Scan tool data verification
Check the scan tool data using a scan tool.
If a problem is found, repair the applicable area.

Intermittent conditions of brake
1. Intermittent conditions of brake description of symptom
Perform the control system check.
Check the following items.
There should be no malfunctions in the ABS warning light operation.

The scan tool data is within the range of normal operation values.
The applicable diagnosis for addressing the customer's complaint has been performed.

Switch and sensor installation status inspection
3. Intermittent conditions
If an intermittent condition exists, inspect the installation status of the electronic equipment. Verify that any device that was additionally installed is not
connected to the CAN communication circuit.
1) Wire harness and connector
Intermittent open or short circuits may be caused by vibrations in the wire harnesses and connectors due to fluctuations in engine torque, bumps in the
road, etc. Therefore, perform the following inspections.
Shake the related connectors or wiring while monitoring the scan tool data.
Shake the related connectors or wiring and monitor component operation while turning the components ON and OFF using the scan tool.
If moving the wire harness or connector affects the data displayed or the component or system operation, inspect the wire harness and connector as
necessary.
2) Power supply and ground of the components
Inspect the power supply circuits of the components.

Inspect the installation status of the grounds of the components.
3) Effects caused by temperature
A malfunction may occur in the specific temperature range.
If the intermittent condition is caused by the temperature, inspect the following items.
Effects caused by outside air temperature

Effects caused by heat from the engine
Effects caused by heat from the exhaust piping and road surface
4) Sensitive to electrical noise
Some electronic components and circuits are sensitive to electrical noise. If electrical noise is suspected, inspect the following items.
Inspect whether wire harnesses are placed too close to the injector, motors, generators, etc.
Inspect the installation status of aftermarket products that use wireless devices and motors.
Inspect the generator rectifier circuit.
5) Malfunction symptom reproduction
If the malfunction can be reproduced frequently, the cause may be identified and the repair verification made easy.
6) Scan tool snapshot
Snapshots can be recorded using the scan tool. The snapshot function can be set to be triggered manually or automatically when a DTC sets. It can record
ECU data in chronological order and perform malfunction analysis by displaying the data individually or in combination.
One wheel locks
1. One wheel locks diagnostics

Defective brake caliper or wheel cylinder
Correct or replace.
Stepping power of the brake pedal is large
1. Stepping power of the brake pedal is large diagnostics
Inspect the booster operation.

Hydraulic system malfunction
Inspect the hydraulic system and repair as necessary.
Piston sticking or malfunction of caliper and wheel cylinder
Disassemble and assemble the caliper and wheel cylinder.
Brake booster vacuum leakage
Inspect the vacuum hose for breakage and looseness.
Brake pad and lining failure
Replace.
Stroke of the brake pedal is abnormal
1. Stroke of the brake pedal is abnormal diagnostics
Hydraulic system malfunction
Inspect the hydraulic system and repair as necessary.
Insufficient brake fluid
Refill with the specified brake fluid.

Inspect for fluid leakage.
Air in the hydraulic system
Bleed the air from the hydraulic system.

Uneven braking occurs while ABS works
1. Uneven braking occurs while ABS works description of symptom
Uneven braking occurs while the ABS works.
2. Uneven braking occurs while ABS works diagnostics

3. Diagnosis when the scan tool is not used
If the inspection results are normal, go to Brake pipe inspection.
4) Brake pipe inspection
Inspect the installation status of the brake pipe.
If the inspection results are abnormal, repair the brake pipe. After completing the procedure, go to Repair verification.
5) EHCU replacement
Note
4. Diagnosis when using a scan tool
1) Wheel speed sensor output inspection
Connect the scan tool.
Observe the wheel speed of each wheel with a scan tool.

Check whether the lowest speed of all the wheels is 4 km/h {2.5 mph} or less and stable.
Note
Because different wheel speed readings may be displayed in the case of vehicles equipped with tires of different diameters on the front and
rear wheels, check the speed after driving the vehicle at a fixed speed for a short period of time.
If the inspection results are abnormal, go to Wheel speed sensor circuit inspection.
3) Brake pipe inspection
Inspect the installation status of the brake pipe.
If the inspection results are abnormal, repair the brake pipe. After completing the procedure, go to Repair verification.
4) EHCU replacement
Note

Wheels lock when braking
1. Wheels lock when braking description of symptom
The wheels lock when braking.
2. Wheels lock when braking diagnostics

3. Diagnostics
1) ABS operation check
Perform a test drive and activate the ABS.
Go to Ground circuit inspection if the ABS does not activate.
If the vehicle speed during ABS operation is 10 km/h {6.2 mph} or less, go to Wheel speed sensor circuit inspection.
If the inspection results are normal, go to Ground circuit inspection.
3) Ground circuit inspection
Inspect for an open circuit, high resistance, or terminal connection status in the ground circuit of the EHCU and motor.
If the inspection results are abnormal, repair the applicable areas. After completing the procedure, go to Repair verification.
4) EHCU replacement
Note

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Primary specifications of brake

1. Primary specifications of brake

Front disc brake

Rear drum brake

Rear disc brake

Parking brake (Rear drum brake)

Parking brake (Rear disc brake)

1. Brake controls overview

Operation of the brake control function

3. TCS function (Models equipped with ESC)

4. ESC control (Models equipped with ESC)

5. Rolling prevention function (Models equipped with ESC)

8. Hill Descent Control function (Models equipped with ESC)

1) Hill Descent Control start conditions

The Hill Descent Control switch is ON (indicator light illuminates).

The gradient becomes gentle.

The Hill Descent Control switch is pressed while in control or standby.

Hydraulic circuits diagram (Models equipped with ESC)

1. Front left hold solenoid valve

Hydraulic circuits diagram (Except models equipped with ESC)

1. Front left hold solenoid valve

2. When the ABS is in operation

1) Brake pressure retention

When pressure decreases

3) Brake pressure increase

When pressure increases

3. During TCS operation (Models equipped with ESC)

4. During ESC operation (Models equipped with ESC)

1) In case of the over steer

2) In case of the under steer

4. Brake controls components

1. Wheel speed sensor

1. Wheel speed sensor

2. Steering angle sensor (Models equipped with ESC)

3. Yaw rate sensor (Models equipped with ESC)

4. ABS warning light

5. Brake system warning light

6. ESC warning light (Models equipped with ESC)

8. Hill Descent Control switch (Models equipped with ESC)

9. ESC OFF switch (Models equipped with ESC)

1) When 2H (2WD) or 4H (4WD High) is selected for the driving mode

2) When 4L (4WD Low) is selected for the driving mode

The ESC function stops operating.

Control allowed/prohibited Indication light

The brake fluid is stored when pressure decreases.

The pump is driven.

5) Master cylinder pressure sensor

The master cylinder brake fluid pressure is detected.

Models equipped with ESC

Except models equipped with ESC

1. ABS warning light

1. Braking device system diagram

Models with blend proportioning valves

RZ4E engine, 4JJ1 engine, or 4JK1 engine models (RHD models)

4. Blend proportioning valve

1) Blend proportioning valve installation position

The blend proportioning valve is set in the engine room.

1. Blend proportioning valve

1. Blend proportioning valve

2) Structure of the blend proportioning valve

3) Blend proportioning valve operation

Proportioning valve structural diagram

Proportioning valve characteristic curves

1. The first break point