engine TOYOTA RAV4 2006 Service Repair Manual

BC–20BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM
BC
HINT:
*1: w/ Downhill assist control
*2: for 2WD w/ AUTO LSD
Steering Sensor • Detects the steering extent and direction and sends
signals to the skid control ECU via CAN communication
• Has a magnetic resistance element which detects the
rotation of the magnet housed in the detection gear in
order to detect the changes in magnetic resistance and
the steering amount and direction
Yaw Rate and Deceleration Sensor • Yaw rate sensor detects the vehicle's angular velocity
(yaw rate) in the vertical direction based on the extent
and direction of the deflection of the piezoelectric
ceramics
• Deceleration sensor measures the capacity of the
condenser that changes the distance between the
electrodes depending on G force, which occurs when
the vehicle is accelerated, and converts the measured
value into electrical signals
• Sends signals to the skid control ECU via CAN
communication
Master Cylinder Pressure Sensor • Detects the brake fluid pressure in the master cylinder
• Housed in the ABS and TRACTION actuator
ECM• Controls the engine output when TRC and VSC are
operating with the skid control ECU via CAN
communication
Downhill Assist Control switch*1 Allows the driver to turn downhill assist control ON and OFF
AUTO LSD switch*2 Allows the driver to turn AUTO LSD ON and OFF
Combination Meter ABS Warning Light • Illuminates to inform the driver that a malfunction in the
ABS has occurred
• Blinks to indicate DTCs that relate to the ABS
VSC Warning Light • Illuminates to inform the driver that a malfunction in the
VSC system has occurred
• Blinks to indicate DTCs that relate to the VSC
Brake Warning light • Illuminates to inform the driver that the parking brake is
ON when the system is normal, and when the brake
fluid has decreased
• Illuminates to inform the driver that a malfunction in the
EBD has occurred
Slip Indicator Light • Blinks to inform the driver that TRC, VSC, downhill
assist control and hill-start assist control are operating
• Illuminates to inform the driver that a malfunction has
occurred in the TRC or VSC system
AUTO LSD Indicator Light*2 Lights up to inform the driver when AUTO LSD operation is
possible
Downhill Assist Control Indicator
Light*1Lights up to inform the driver when downhill assist control
operation is possible
Skid Control Buzzer • Intermittently sounds to inform the driver that the VSC is
operating
• Housed in the combination meter Components Functions

BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEMBC–27
BC
3. PREFORM ZERO POINT CALIBRATION OF YAW
RATE AND DECELERATION SENSOR (When Using
Intelligent Tester)
NOTICE:
• While obtaining the zero point, do not vibrate the
vehicle by tilting, moving or shaking it and keep it
stationary. (Do not start the engine.)
• Perform this on a level surface (with an inclination
of less than 1
).
(a) Procedures for Test Mode.
(1) Check that the shift lever is in the P position and
apply the parking brake.
NOTICE:
DTCs C1210/36 and C1336/39 will be
recorded if the shift lever is not the P
position (see page BC-88).
(2) Connect the intelligent tester (with CAN VIM) to
the DLC3.
(3) Turn the ignition switch ON.
(4) Set the intelligent tester to test mode (select
"Test Mode").
HINT:
Refer to the intelligent tester operator's manual
for further details.
(b) Obtain the zero point of the yaw rate and
deceleration sensor.
(1) Keep the vehicle stationary on a level surface for
2 seconds or more.
(2) Check that the VSC warning light blinks as
shown in the illustration.
HINT:
• If the VSC warning light does not blink,
perform the zero point calibration again.
• The zero point calibration is performed only
once after the system enters test mode.
• Calibration cannot be performed again until
the stored data is cleared once.
(3) Turn the ignition switch OFF.
B127989E01
C106532
C108848E14

BC–28BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM
BC
4. CLEAR ZERO POINT CALIBRATION DATA (When not
Using Intelligent Tester)
(a) Clear the zero point calibration data.
(1) Turn the ignition switch ON.
(2) The warning light and indicator light come on for
3 seconds to indicate that the initial check is
completed.
(3) Using SST, connect and disconnect terminals 12
(TS) and 4 (CG) of the DLC3 4 times or more
within 8 seconds.
SST 09843-18040
(4) Check that the VSC warning light comes on.
(5) Remove SST from the terminals of the DLC3.
(6) Using a check wire, perform the zero point
calibration of the yaw rate and deceleration
sensor.
CAUTION:
If the ignition switch is turned ON for more
than 15 seconds with the shift lever in the P
position after zero point of the yaw rate and
acceleration sensor has been cleared, only
the zero point of the yaw rate sensor will be
stored. If the vehicle is driven under this
condition, the skid control ECU will
recognize that zero point calibration of the
acceleration sensor is not completed and will
indicate that there is a malfunction in the
VSC system using the indicator light.
5. PERFORM ZERO POINT CALIBRATION OF YAW
RATE AND DECELERATION SENSOR (When not
Using Intelligent Tester)
NOTICE:
• While obtaining the zero point, do not vibrate the
vehicle by tilting, moving or shaking it and keep it
stationary. (Do not start the engine.)
• Perform this on a level surface (with an inclination
of less than 1
).
(a) Procedures for Test Mode.
(1) Turn the ignition switch OFF.
(2) Using SST, connect terminals 12 (TS) and 4
(CG) of the DLC3.
SST 09843-18040
(3) Check that the shift lever is in the P position and
apply the parking brake.
NOTICE:
DTCs C1210/36 and C1336/39 will be
recorded if the shift lever is not the P
position (see page BC-88).
(b) Obtain the zero point of the yaw rate and
deceleration sensor.
(1) Turn the ignition switch ON.
(2) Keep the vehicle stationary on a level surface for
2 seconds or more.
H100769E03
H100769E03

BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEMBC–31
BC
(8) Check that the ABS warning light and VSC
warning light blink as shown in the illustration.
HINT:
If the ABS warning light and VSC warning
warning light do not blink, check the TS and CG
terminal circuit, and ABS and VSC warning light
circuits.
(9) Start the engine.
(b) w/ 16-inch disc only:
Check the lost booster pressure judgment and
perform the master cylinder pressure sensor zero
point calibration.
NOTICE:
Preform the check in the lost booster pressure
state (negative pressure in the booster is
depressurized).
(1) Turn the ignition switch ON.
(2) Check that the brake warning light comes on
when depressing the brake pedal with a force of
59 N (6 kgf, 13.2 lbf) or more for 1 second or
more. (The lost booster pressure state is judged
normal.)
(3) Start the engine depressing the brake pedal with
a force of 59 N (6 kgf, 13.2 lbf) or more for 1
second or more.
(4) Check that the brake warning light goes off when
quickly releasing the brake pedal. (The lost
booster pressure state is judged normal.)
(5) Leave the vehicle for 1 second or more. (Master
cylinder pressure sensor zero point calibration.)
NOTICE:
• If you slowly depress the brake pedal or
depress it again, master cylinder pressure
sensor zero point calibration is not
performed normally.
• If the lost booster pressure judgment
check is not completed normally, the
master cylinder pressure sensor check is
not judged.
• If a recheck is performed after the engine
has started, end the Test Mode, enter Test
Mode again, and release the vacuum in
the booster by pumping the brake pedal
prior to the recheck.
C108848E14
Section Title See procedure
ABS Warning Light does not Come ONBC-138
VSC Warning Light does not Come ONBC-142
TS and CG Terminal CircuitBC-177

BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEMBC–35
BC
HINT:
See the list of the DTCs (refer to "DTC OF TEST
MODE FUNCTION (SIGNAL CHECK)" below).
2. CHECK SENSOR SIGNAL BY TEST MODE (When not
Using Intelligent Tester)
(a) Procedures for test mode:
(1) Turn the ignition switch OFF.
(2) Check that the steering wheel is in the centered
position.
(3) Check that the shift lever is in the P position and
apply the parking brake.
(4) Using SST, connect terminals 12 (TS) and 4
(CG) of the DLC3.
SST 09843-18040
(5) Turn the ignition switch ON.
(6) Check that the ABS warning light and VSC
warning light blink as shown in the illustration.
HINT:
If the ABS warning light and VSC warning
warning light and multi information display and
master caution indicator light do not blink, check
the TS and CG terminal circuit, and ABS and
VSC warning light circuits.
(7) Start the engine.
(b) w/ 16-inch disc:
Check the lost booster pressure judgment and
perform the master cylinder pressure sensor zero
point calibration.
NOTICE:
Preform the check in the lost booster pressure
state (negative pressure in the booster is
depressurized).
(1) Turn the ignition switch ON.
(2) Check that the BRAKE warning light comes on
when depressing the brake pedal with a force of
59 N (6 kgf, 13.2 lbf) or more for 1 second or
more. (The lost booster pressure state is judged
normal.)
(3) Start the engine depressing the brake pedal with
a force of 59 N (6 kgf, 13.2 lbf) or more for 1
second or more.
H100769E03
C108848E14Section Title See procedure
ABS Warning Light does not Come ONBC-138
VSC Warning Light does not Come ONBC-142
TS and CG Terminal CircuitBC-177

BC–36BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM
BC
(4) Check that the brake warning light goes off when
quickly releasing the brake pedal. (The lost
booster pressure state is judged normal.)
(5) Leave the vehicle for 1 second or more. (Master
cylinder pressure sensor zero point calibration.)
NOTICE:
• If you slowly depress the brake pedal or
depress it again, master cylinder pressure
sensor zero point calibration is not
performed normally.
• If the lost booster pressure judgment
check is not completed normally, the
master cylinder pressure sensor check is
not judged.
• If a recheck is performed after the engine
has started, end the Test Mode, enter Test
Mode again, and release the vacuum in
the booster by pumping the brake pedal
prior to the recheck.
(c) Check the deceleration sensor.
(1) Keep the vehicle stationary on a level surface for
1 second or more.
HINT:
The deceleration sensor check can be
performed together with the following master
cylinder pressure sensor check.
(d) Check the master cylinder pressure sensor.
(1) Leave the vehicle in a stationary condition and
release the brake pedal for 1 second or more,
and quickly depress the brake pedal with a force
of 98 N (10 kgf, 22 lbf) or more for 1 second.
Check that the ABS warning light remains
illuminated for 3 seconds.
HINT:
• Ensure that the ABS warning light comes on.
• While the ABS warning light remains
illuminated, continue depressing the brake
pedal with a force of 98 N (10 kgf, 22 lbf) or
more.
• The ABS warning light comes on for 3
seconds every time the brake pedal operation
above is performed.
(e) Check the speed sensor.
(1) Check that the ABS warning light is blinking as
shown in the illustration.
(2) Check the speed sensor signal.
1. Drive the vehicle straight forward at a speed
of 45 km/h (28 mph) or more for several
seconds.
C108848E01

BC–54BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM
BC
GEAR POSITION Gear position information FAIL
1st
2nd
3rd
4th
5th
6th
P, N
R
NOT R
LEVER POSITION Shift lever position information FAIL
1st
2nd
3rd
4th
5th
6th/B
D/M
P, N
R
OPERATED SYSTEM Operated system status ABS: ABS activated
VSC: VSC activated
TRC: TRC activated
BA: BA activated
FAIL: Fail safe mode activated
HA-CTRL: Hill-start assist control activated
SYS: System prohibited
NON: No system activated
MAS CYL PRESS 1 Master cylinder pressure sensor reading Brake pedal released: 0.3 V to 0.9 V
Brake pedal depressed: 0.8 V to 4.5 V
M/C Sensor Grade Master cylinder pressure sensor change Min.: -30 MPa/s
Max.: 225 MPa/s
YAW RATE Yaw rate sensor reading Min.: -128 deg/s
Max.: 127 deg/s
STEERING SEN Steering sensor reading Left turn: Increase
Right turn: Decrease
LATERAL G Lateral G
Min.: -25.11 m/s
2
Max.: 24.91 m/s2
FORWARD&REA G Forward and backward G
Min.: -25.11 m/s2
Max.: 24.91 m/s2
FR WHEEL SPD FR wheel speed Min.: 0 km/h (0 mph)
Max.: 326.4 km/h (202.8 mph)
FL WHEEL SPD FL wheel speed Min.: 0 km/h (0 mph)
Max.: 326.4 km/h (202.8 mph)
RR WHEEL SPD RR wheel speed Min.: 0 km/h (0 mph)
Max.: 326.4 km/h (202.8 mph)
RL WHEEL SPD RL wheel speed Min.: 0 km/h (0 mph)
Max.: 326.4 km/h (202.8 mph)
VEHICLE SPD Vehicle speed Min.: 0 km/h (0 mph)
Max.: 326.4 km/h (202.8 mph)
SPD GARDE Vehicle speed grade
Min.: -25.11 m/s
2
Max.: 24.91 m/s2
ENGINE TORQUE Real engine torque Min.: -1024 Nm
Max.: 1023 Nm
ACCELERATOR % Accelerator pedal opening angle % Min.: 0%
Max.: 128%
INSPECTION MODE Inspection mode OTHER: Normal
INSPECT: Service Item (Display) Measurement Item Reference Values

BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEMBC–55
BC
FAIL-SAFE CHART
1. FAIL SAFE OPERATION
• If there is a problem with any sensor signals or
actuator systems, the skid control ECU prohibits the
power supply to the ABS and TRACTION actuator
and informs the ECM of VSC system failure.
The ABS and TRACTION actuator turns off the
solenoids and the ECM s huts off VSC control (traction
control signal) from the skid control ECU accordingly,
the result being that it is as if the ABS, TRC and VSC
systems were not installed.
• ABS control is prohibited, but EBD control continues
as far as possible. If EBD control is impossible, the
BRAKE warning light comes on to warn the driver
(see page BC-44).
• If system components have any malfunctions before
starting control, the operation stops immediately. If
system components have any malfunctions during
control, the control stops gradually so as not to trigger
a sudden change in vehicle conditions.
If it is impossible to control the systems, the warning
light comes on to inform the driver of malfunctions in
the systems (see page BC-44).
HINT:
• If the ABS system malfunctions, the brake system
operates normally without the ABS system.
• If the brake actuator malfunctions, a gradual loss of
brake performance is expected, and ABS system
control is prohibited.
ABS, EBD and BA system
TRC and VSC system:
Malfunction Area Fail-Safe Operation
ABS system ABS, BA, TRC and VSC control prohibited
BA system ABS, BA, TRC and VSC control prohibited
EBD system ABS, EBD, BA, TRC and VSC control prohibited
Malfunction Area Fail-Safe Operation
Engine control system
(TRC and VSC systems)Before control: Disables control
During control: Uses only the brakes to effect control
Brake control system
(VSC system)Before control: Disables control
During control: Uses only the engine to effect control
Brake control system
(TRC system)Before control: Disables control
During control: Disables control (by gradually ending control)

BC–58BRAKE CONTROL – VEHICLE STABILITY CONTROL SYSTEM
BC
FR ABS STATUS FR wheel ABS control status / ON
or OFFON: During control -
FL ABS STATUS FL wheel ABS control status / ON
or OFFON: During control -
RR ABS STATUS RR wheel ABS control status / ON
or OFFON: During control -
RL ABS STATUS RL wheel ABS control status / ON
or OFFON: During control -
RR EBD STATUS RR wheel EBD control status /
ON or OFFON: During control -
RL EBD STATUS RL wheel EBD control status / ON
or OFFON: During control -
BA STATUS BA control status / ON or OFF ON: During control -
TRAC STATUS TRC control status / ON or OFF ON: During control -
TRAC ENG STATUS TRC engine control status / ON or
OFFON: During control -
TRAC BRK STATUS TRC brake control status / ON or
OFFON: During control -
FR VSC STATUS FR wheel VSC control status / ON
or OFFON: During control -
FL VSC STATUS FL wheel VSC control status / ON
or OFFON: During control -
RR VSC STATUS RR wheel VSC control status /
ON or OFFON: During control -
RL VSC STATUS RL wheel VSC control status / ON
or OFFON: During control -
ENG REVOLUTIONS Engine revolutions / min.: 0 r/min,
max.: 65535 r/min--
ENGINE TORQUE Real engine torque / min.: -1024
Nm, max.: 1023 Nm--
ACCELERATOR % Percentage of accelerator pedal
opening angle / min.: 0%, max.:
128%--
SOL RELAY Solenoid relay / ON or OFF ON: Solenoid relay ON
OFF: Solenoid relay OFF-
ELECTRONICALLY
CONTROLLED BRAKE SYSTEM
MTR RELAYElectronically Controlled Brake
System Motor relay (VSC1 relay)
/ ON or OFFON: Motor relay ON
OFF: Motor relay OFF-
FAIL MTR RELAY Fail-safe motor relay / ON or OFF ON: Motor relay ON
OFF: Motor relay OFF-
SM2 TRC / VSC solenoid (SM2) / ON
or OFFON: Operates -
SM1 TRC / VSC solenoid (SM1) / ON
or OFFON: Operates -
SFRH*1 ABS solenoid (SFRH) / ON or
OFFON: Operates
OFF: Does not operate-
SFRR*2 ABS solenoid (SFRR) / ON or
OFFON: Operates
OFF: Does not operate-
SFLH*3 ABS solenoid (SFLH) / ON or
OFFON: Operates
OFF: Does not operate-
SFLR*4 ABS solenoid (SFLR) / ON or
OFFON: Operates
OFF: Does not operate-
SRRH*5 ABS solenoid (SRRH) / ON or
OFFON: Operates
OFF: Does not operate-
SRRR*6 ABS solenoid (SRRR) / ON or
OFFON: Operates
OFF: Does not operate-
SRLH*7 ABS solenoid (SRLH) / ON or
OFFON: Operates
OFF: Does not operate- Tester Display Measurement Item/Range Normal Condition Diagnostic Note

BR–14BRAKE – BRAKE PEDAL
BR
(6) Insert the switch into the adjuster until the
switch body touches the pedal.
NOTICE:
Do not depress the pedal.
(7) Turn the switch a quarter turn clockwise.
Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or
less
NOTICE:
Do not depress the pedal.
(8) Connect the connector to the switch.
(9) Check the switch clearance.
Standard stop light switch clearance:
1.5 to 2.5 mm (0.059 to 0.098 in.)
2. CHECK BRAKE PEDAL FREE PLAY
(a) Stop the engine. Depress the pedal several times
until there is no vacuum in the booster. Then
release the pedal.
(b) Depress the pedal until resistance is felt.
(c) Check the pedal's free play by measuring the
distance between the position in the previous step
and the pedal's released position.
Standard pedal free play:
1.0 to 6.0 mm (0.039 to 0.236 in.)
If the free play is not as specified, check the switch
clearance in the next step.
If the free play is as specified, proceed to the
"CHECK BRAKE PEDAL RESERVE DISTANCE"
procedure.
(d) Check the switch clearance.
Standard stop light switch clearance:
1.5 to 2.5 mm (0.059 to 0.098 in.)
If the clearance is not as specified, reinstall the
switch and recheck the pedal's free play.
If the clearance is as specified, troubleshoot the
brake system and proceed to the "CHECK BRAKE
PEDAL RESERVE DISTANCE" procedure.
C 111 3 0 1 E 0 3
C 111 3 0 2 E 0 1
C 111 3 0 6 E 0 1