HYDRAULIC BRAKE BOOSTER(for RHD) ON-VEHICLE INSPECTION

PROCEDURE


  1. INSPECT BRAKE MASTER CYLINDER FLUID PRESSURE CHANGE


    1. B001B0HE02
      *1 Brake Pedal Effort Gauge

      Inspect the battery voltage.

      Standard Voltage
      11 to 14 V

    2. Turn the engine switch off and depress the brake pedal more than 20 times.

      Tech Tips

      When pressure in the power supply system is released the reaction force becomes light and the stroke becomes longer.

    3. Install the LSPV gauge (SST) and brake pedal effort gauge, and bleed air from the LSPV gauge (SST).

      SST
      09709-29018

    4. When the booster does not operate:

      Depress the brake pedal and check the fluid pressure.

      Standard Fluid Pressure with Pedal Depressing Force of 245 N (25 kgf, 55 lbf)
      Item Specified Condition
      Front brake pressure

      1900 kPa (19.4 kgf/cm2, 276 psi) or more
      Rear brake pressure

      0 kPa (0 kgf/cm2, 0 psi)
      Standard Fluid Pressure with Pedal Depressing Force of 343 N (35 kgf, 77 lbf)
      Item Specified Condition
      Front brake pressure

      2780 kPa (28.4 kgf/cm2, 403 psi) or more
      Rear brake pressure

      0 kPa (0 kgf/cm2, 0 psi)

    5. When the booster operates:


      1. Turn the engine switch on (IG) and wait until the pump motor has stopped.

      2. Depress the brake pedal and check the fluid pressure.

        Standard Fluid Pressure with Pedal Depressing Force of 49 N (5 kgf, 11 lbf)
        Item Specified Condition
        Front brake pressure

        1110 to 2310 kPa

        (11.4 to 23.5 kgf/cm2, 161 to 334 psi)
        Rear brake pressure

        1290 to 2490 kPa

        (13.2 to 25.3 kgf/cm2, 187 to 361 psi)
        Standard Fluid Pressure with Pedal Depressing Force of 98 N (10 kgf, 22 lbf)
        Item Specified Condition
        Front brake pressure

        6060 to 7260 kPa

        (61.8 to 74.0 kgf/cm2, 879 to 1052 psi)
        Rear brake pressure

        6800 to 8000 kPa

        (69.4 to 81.5 kgf/cm2, 986 to 1160 psi)
        Standard Fluid Pressure with Pedal Depressing Force of 147 N (15 kgf, 33 lbf)
        Item Specified Condition
        Front brake pressure

        11020 to 12220 kPa

        (112.4 to 124.6 kgf/cm2, 1598 to 1771 psi)
        Rear brake pressure

        12300 to 13500 kPa

        (125.5 to 137.6 kgf/cm2, 1784 to 1957 psi)
        Standard Fluid Pressure with Pedal Depressing Force of 196 N (20 kgf, 44 lbf)
        Item Specified Condition
        Front brake pressure

        15970 to 17170 kPa

        (162.9 to 175.0 kgf/cm2, 2316 to 2489 psi)
        Rear brake pressure

        17800 to 19000 kPa

        (181.6 to 193.7 kgf/cm2, 2581 to 2755 psi)

  2. INSPECT BRAKE MASTER CYLINDER OPERATION


    1. Inspect the battery voltage.

      Standard Voltage
      11 to 14 V

    2. Turn the engine switch off and depress the brake pedal more than 20 times.

      Tech Tips

      When pressure in the power supply system is released, the reaction force decreases and the stroke becomes longer.

    3. Check that the brake pedal reaction force decreases.

      If the pedal reaction force does not decrease, check and replace the brake line and brake master cylinder.

    4. Turn the engine switch on (IG) and check the pump motor operation noise. If the pump motor does not operate, check and replace the wire harness and brake booster pump assembly Click here.

    5. Connect the intelligent tester to the DLC3.

    6. Turn the engine switch on (IG).

    7. Turn the intelligent tester on.

    8. Enter the following menus: Chassis / ABS/VSC/TRC / Active Test.

    9. Jack up and support the vehicle.

    10. Release the parking brake lever.

    11. Move the shift lever to N and check that the rear wheels can be rotated by hand.

    12. Inspect the front VSC solenoid (SMCF) operation.


      1. Select "VSC/TRC Solenoid (SRCF)" on the intelligent tester.

      2. Turn "VSC/TRC Solenoid (SRCF)" on with the intelligent tester, depress the brake pedal with a stable force and check that the pedal cannot be depressed.

        If the pedal can be depressed, replace the brake master cylinder.

        Note

        When operating the solenoid continuously, set the interval to more than 20 seconds.

        Tech Tips

        To protect the solenoids, the intelligent tester turns off automatically 2 seconds after every solenoid has been turned on.

      3. Release the brake pedal.

      4. When the solenoid is off, depress the brake pedal again and check that the brake pedal can be depressed.

        If the pedal cannot be depressed, replace the brake master cylinder.

    13. Inspect the front VSC solenoid (SREA) operation.


      1. Select "VSC/TRC Solenoid (SRCR)" and "VSC/TRC Solenoid (SRCF)" on the intelligent tester.

      2. Turn "VSC/TRC Solenoid (SRCR)" and "VSC/TRC Solenoid (SRCF)" on simultaneously with the intelligent tester, then depress the brake pedal with a stable force.

      3. When the solenoids are on, check that the front wheels cannot be rotated by hand.

        If the front wheels can be rotated, replace the brake master cylinder.

        Note

        When operating the solenoid continuously, set the interval to more than 20 seconds.

        Tech Tips


        • To protect the solenoids, the intelligent tester turns off automatically 2 seconds after every solenoid has been turned on.

        • When rotating the wheels quickly, the fail-safe function is activated and judgment cannot be made properly. Rotate the wheels as slowly as possible.

      4. When the solenoids are off, turn "VSC/TRC Solenoid (SRCF)" on again, and then depress the brake pedal. Then check the front wheels by rotating them by hand.

        If the front wheels cannot be rotated, replace the brake master cylinder.

      5. When "VSC/TRC Solenoid (SRCF)" is off, depress the brake pedal again and check that the brake pedal can be depressed.

        If the pedal cannot be depressed, replace the brake master cylinder.

    14. Inspect the front ABS solenoid (SFRH) operation.


      1. Select "ABS Solenoid (SFRH)" on the intelligent tester.

      2. Turn "ABS Solenoid (SFRH)" on with the intelligent tester, then depress the brake pedal with a stable force.

      3. When the solenoid is on, check the right front wheel by rotating it by hand.

        If the right front wheel cannot be rotated, replace the brake master cylinder.

        Note

        When operating the solenoid continuously, set the interval to more than 20 seconds.

        Tech Tips


        • To protect the solenoids, the intelligent tester turns off automatically 2 seconds after every solenoid has been turned on.

        • When rotating the wheel quickly, the fail-safe function is activated and judgment cannot be made properly. Rotate the wheel as slowly as possible.

      4. When the solenoid is off, depress the brake pedal again and check that the right front wheel cannot be rotated by hand.

        If the right front wheel can be rotated, replace the brake master cylinder.

        Tech Tips

        When rotating the wheel quickly, the fail-safe function is activated and judgment cannot be made properly. Rotate the wheel as slowly as possible.

    15. Inspect the front ABS solenoid (SFLH) operation.


      1. Select "ABS Solenoid (SFLH)" on the intelligent tester.

      2. Turn "ABS Solenoid (SFLH)" on with the intelligent tester, then depress the brake pedal with a stable force.

      3. When the solenoid is on, check the left front wheel by rotating it by hand.

        If the left front wheel cannot be rotated, replace the brake master cylinder.

        Note

        When operating the solenoid continuously, set the interval to more than 20 seconds.

        Tech Tips


        • To protect the solenoids, the intelligent tester turns off automatically 2 seconds after every solenoid has been turned on.

        • When rotating the wheel quickly, the fail-safe function is activated and judgment cannot be made properly. Rotate the wheel as slowly as possible.

      4. When the solenoid is off, depress the brake pedal again and check that the left front wheel cannot be rotated by hand.

        If the left front wheel can be rotated, replace the brake master cylinder.

    16. Inspect the front ABS solenoid (SFRR) operation.


      1. Select "ABS Solenoid (SFRR)" and "ABS Solenoid (SFRH)" on the intelligent tester.

      2. Depress the brake pedal with a stable force, then turn "ABS Solenoid (SFRR)" and "ABS Solenoid (SFRH)" on simultaneously with the intelligent tester.

      3. When the solenoids are on, check the right front wheel by rotating it by hand.

        If the right front wheel cannot be rotated, replace the brake master cylinder.

        Note

        When operating the solenoid continuously, set the interval to more than 20 seconds.

        Tech Tips


        • To protect the solenoids, the intelligent tester turns off automatically 2 seconds after every solenoid has been turned on.

        • When rotating the wheel quickly, the fail-safe function is activated and judgment cannot be made properly. Rotate the wheel as slowly as possible.

      4. When the solenoids are off, depress the brake pedal again and check that the right front wheel cannot be rotated by hand.

        If the right front wheel can be rotated, replace the brake master cylinder.

    17. Inspect the front ABS solenoid (SFLR) operation.


      1. Select "ABS Solenoid (SFLR)" and "ABS Solenoid (SFLH)" on the intelligent tester.

      2. Depress the brake pedal with a stable force, then turn "ABS Solenoid (SFLR)" and "ABS Solenoid (SFLH)" on simultaneously with the intelligent tester.

      3. When the solenoids are on, check the left front wheel by rotating it by hand.

        If the left front wheel cannot be rotated, replace the brake master cylinder.

        Note

        When operating the solenoid continuously, set the interval to more than 20 seconds.

        Tech Tips


        • To protect the solenoids, the intelligent tester turns off automatically 2 seconds after every solenoid has been turned on.

        • When rotating the wheel quickly, the fail-safe function is activated and judgment cannot be made properly. Rotate the wheel as slowly as possible.

      4. When the solenoids are off, depress the brake pedal again and check that the left front wheel cannot be rotated by hand.

        If the left front wheel can be rotated, replace the brake master cylinder.

    18. Inspect the rear VSC solenoid (SREC) operation.


      1. Select "VSC/TRC Solenoid (SRMF)" on the intelligent tester.

      2. Depress the brake pedal with a stable force, then turn "VSC/TRC Solenoid (SRMF)" on with the intelligent tester.

      3. Release the brake pedal when the solenoid is on, and check that the rear wheels cannot be rotated by hand.

        If the rear wheels can be rotated, replace the brake master cylinder.

        Note

        When operating the solenoid continuously, set the interval to more than 20 seconds.

        Tech Tips


        • To protect the solenoids, the intelligent tester turns off automatically 2 seconds after every solenoid has been turned on.

        • When rotating the wheels quickly, the fail-safe function is activated and judgment cannot be made properly. Rotate the wheels as slowly as possible.

      4. When the solenoid is off, check the rear wheels by rotating them by hand.

        If the rear wheels cannot be rotated, replace the brake master cylinder.

    19. Inspect the rear VSC solenoid (STR) operation.


      1. Select "VSC/TRC Solenoid (SRMR)" and "VSC/TRC Solenoid (SRMF)" on the intelligent tester.

      2. Turn "VSC/TRC Solenoid (SRMR)" and "VSC/TRC Solenoid (SRMF)" on simultaneously with the intelligent tester.

      3. When the solenoids are on, check that the rear wheels cannot be rotated by hand.

        If the rear wheels can be rotated, replace the brake master cylinder.

        Note

        When operating the solenoid continuously, set the interval to more than 20 seconds.

        Tech Tips


        • To protect the solenoids, the intelligent tester turns off automatically 2 seconds after every solenoid has been turned on.

        • When rotating the wheels quickly, the fail-safe function is activated and judgment cannot be made properly. Rotate the wheels as slowly as possible.

      4. When the solenoids are off, turn "VSC/TRC Solenoid (SRMF)" on again, and check the rear wheels by rotating them by hand.

        If the rear wheels cannot be rotated, replace the brake master cylinder.

      5. When "VSC/TRC Solenoid (SRMF)" is off, depress the brake pedal again and check that the rear wheels cannot be rotated by hand.

        If the rear wheels can be rotated, replace the brake master cylinder.

    20. Inspect the rear ABS solenoid (SRRH) operation.


      1. Select "ABS Solenoid (SRRH)" on the intelligent tester.

      2. Turn "ABS Solenoid (SRRH)" on with the intelligent tester, then depress the brake pedal with a stable force.

      3. When the solenoid is on, check the right rear wheel by rotating it by hand.

        If the right rear wheel cannot be rotated, replace the brake master cylinder.

        Note

        When operating the solenoid continuously, set the interval to more than 20 seconds.

        Tech Tips


        • To protect the solenoids, the intelligent tester turns off automatically 2 seconds after every solenoid has been turned on.

        • When rotating the wheel quickly, the fail-safe function is activated and judgment cannot be made properly. Rotate the wheel as slowly as possible.

      4. When the solenoid is off, depress the brake pedal again and check that the right rear wheel cannot be rotated by hand.

        If the right rear wheel can be rotated, replace the brake master cylinder.

        Tech Tips

        When rotating the wheel quickly, the fail-safe function is activated and judgment cannot be made properly. Rotate the wheel as slowly as possible.

    21. Inspect the rear ABS solenoid (SRLH) operation.


      1. Select "ABS Solenoid (SRLH)" on the intelligent tester.

      2. Turn "ABS solenoid (SRLH)" on with the intelligent tester, then depress the brake pedal with a stable force.

      3. When the solenoid is on, check the left rear wheel by rotating it by hand.

        If the left rear wheel cannot be rotated, replace the brake master cylinder.

        Note

        When operating the solenoid continuously, set the interval to more than 20 seconds.

        Tech Tips


        • To protect the solenoids, the intelligent tester turns off automatically 2 seconds after every solenoid has been turned on.

        • When rotating the wheel quickly, the fail-safe function is activated and judgment cannot be made properly. Rotate the wheel as slowly as possible.

      4. When the solenoid is off, depress the brake pedal again and check that the left rear wheel cannot be rotated by hand.

        If the left rear wheel can be rotated, replace the brake master cylinder.

    22. Inspect the rear ABS solenoid (SRRR) operation.


      1. Select "ABS Solenoid (SRRR)" and "ABS Solenoid (SRRH)" on the intelligent tester.

      2. Depress the brake pedal with a stable force, then turn "ABS Solenoid (SRRR)" and "ABS Solenoid (SRRH)" on simultaneously with the intelligent tester.

      3. When the solenoids are on, check the right rear wheel by rotating it by hand.

        If the right rear wheel cannot be rotated, replace the brake master cylinder.

        Note

        When operating the solenoid continuously, set the interval to more than 20 seconds.

        Tech Tips


        • To protect the solenoids, the intelligent tester turns off automatically 2 seconds after every solenoid has been turned on.

        • When rotating the wheel quickly, the fail-safe function is activated and judgment cannot be made properly. Rotate the wheel as slowly as possible.

      4. When the solenoids are off, depress the brake pedal again and check that the right rear wheel cannot be rotated by hand.

        If the right rear wheel can be rotated, replace the brake master cylinder.

    23. Inspect the rear ABS solenoid (SRLR) operation.


      1. Select "ABS Solenoid (SRLR)" and "ABS Solenoid (SRLH)" on the intelligent tester.

      2. Depress the brake pedal with a stable force, then turn "ABS Solenoid (SRLR)" and "ABS Solenoid (SRLH)" on simultaneously with the intelligent tester.

      3. When the solenoids are on, check the left rear wheel by rotating it by hand.

        If the left rear wheel cannot be rotated, replace the brake master cylinder.

        Note

        When operating the solenoid continuously, set the interval to more than 20 seconds.

        Tech Tips


        • To protect the solenoids, the intelligent tester turns off automatically 2 seconds after every solenoid has been turned on.

        • When rotating the wheel quickly, the fail-safe function is activated and judgment cannot be made properly. Rotate the wheel as slowly as possible.

      4. When the solenoids are off, depress the brake pedal again and check that the left rear wheel cannot be rotated by hand.

        If the left rear wheel can be rotated, replace the brake master cylinder.

    24. Lower the vehicle.

    25. Disconnect the intelligent tester.

  3. CHECK FLUID LEVEL IN RESERVOIR

    Click here