BRAKE STROKE SIMULATOR CYLINDER ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

Note

A DTC may be stored during the inspection procedure. Be sure to clear the DTCs and check that no DTCs are output after the inspection is finished.

PROCEDURE


  1. INSPECT BRAKE MASTER CYLINDER SUB-ASSEMBLY


    1. Check auxiliary battery voltage.

      Standard Voltage
      11 to 14 V (while the power switch is off)

    2. Set a pedal effort gauge.

    3. Connect the GTS to the DLC3 with the power switch off, shift lever in P and parking brake applied.

    4. Turn the power switch on (IG) and turn the GTS on.

    5. Clear the DTCs.

      Click here

    6. Inspect operation without the brake booster.


      1. Inspect and adjust the brake pedal.

        for LHD: Click here

        for RHD: Click here

      2. Enter the following menus: Chassis / ABS/VSC/TRC / Active Test / ECB (Electronically Controlled Brake System) Control Invalid.


        Chassis > ABS/VSC/TRC > Active Test
        Active Test Display
        ECB Control Invalid
        Data List Display
        Master Cylinder Sensor
        Master Cylinder Sensor2
        Stroke Sensor
        Stroke Sensor2

      3. Select "Master Cylinder Sensor", "Master Cylinder Sensor 2", "Stroke Sensor" and "Stroke Sensor 2".

      4. Turn "ECB (Electronically Controlled Brake System) Control Invalid" on, and check the value output from "Master Cylinder Sensor", "Master Cylinder Sensor 2", "Stroke Sensor" and "Stroke Sensor 2" by depressing the brake pedal.

        Standard Voltage
        Pedal Effort Master Cylinder Sensor Master Cylinder Sensor 2 Stroke Sensor Stroke Sensor 2
        200 N (20 kgf, 45.0 lbf) 0.62 to 1.02 V 0.64 to 1.04 V 2.12 to 2.52 V 2.43 to 2.83 V
        500 N (51 kgf, 112.4 lbf) 1.30 to 1.70 V 1.30 to 1.70 V 2.49 to 2.89 V 2.07 to 2.47 V

        Tech Tips

        Check the performance of the brake master cylinder sub-assembly by comparing the output values from the master cylinder sensor and stroke sensor. If there is a problem, determine the state of the brake master cylinder sub-assembly by using these results together with the results from inspecting the brake actuator assembly and brake pedal stroke sensor.

      5. After inspection, turn "ECB (Electronically Controlled Brake System) Control Invalid" off.

  2. INSPECT BRAKE STROKE SIMULATOR CYLINDER SUB-ASSEMBLY


    1. Check auxiliary battery voltage.

      Standard Voltage
      11 to 14 V (while the power switch is off)

    2. Set a pedal effort gauge.

    3. Connect the GTS to the DLC3 with the power switch off, shift lever in P and parking brake applied.

    4. Turn the power switch on (IG) and turn the GTS on.

    5. Clear the DTCs.

      Click here

    6. Inspect operation without the brake booster.


      1. Inspect and adjust the brake pedal.

        for LHD: Click here

        for RHD: Click here

      2. Enter the following menus: Chassis / ABS/VSC/TRC / Active Test / ECB (Electronically Controlled Brake System) Control Invalid.


        Chassis > ABS/VSC/TRC > Active Test
        Active Test Display
        ECB Control Invalid
        Data List Display
        Master Cylinder Sensor
        Master Cylinder Sensor2
        Stroke Sensor
        Stroke Sensor2

      3. Select "Master Cylinder Sensor", "Master Cylinder Sensor 2", "Stroke Sensor" and "Stroke Sensor 2".

      4. Turn "ECB (Electronically Controlled Brake System) Control Invalid" on, and check the value output from "Master Cylinder Sensor", "Master Cylinder Sensor 2", "Stroke Sensor" and "Stroke Sensor 2 "by depressing the brake pedal.

        Standard Voltage
        Pedal Effort Master Cylinder Sensor Master Cylinder Sensor 2 Stroke Sensor Stroke Sensor 2
        200 N (20 kgf, 45.0 lbf) 0.62 to 1.02 V 0.64 to 1.04 V 2.12 to 2.52 V 2.43 to 2.83 V
        500 N (51 kgf, 112.4 lbf) 1.30 to 1.70 V 1.30 to 1.70 V 2.49 to 2.89 V 2.07 to 2.47 V

        Tech Tips

        Check the performance of the brake master cylinder sub-assembly by comparing the output values from the master cylinder sensor and stroke sensor. If there is a problem, determine the state of the brake master cylinder sub-assembly by using these results together with the results from inspecting the brake actuator assembly and brake pedal stroke sensor.

      5. After inspection, turn "ECB (Electronically Controlled Brake System) Control Invalid" off.

    7. Inspect operation with the brake booster.


      1. Enter the following menus: Chassis / ABS/VSC/TRC / Data List "Stroke Sensor" and "Stroke Sensor 2".


        Chassis > ABS/VSC/TRC > Data List
        Tester Display
        Stroke Sensor
        Stroke Sensor2

      2. Depress the brake pedal 4 or 5 times.

      3. Check the value output from "Stroke Sensor" and "Stroke Sensor 2" by depressing the brake pedal.

        Standard Voltage
        Pedal Effort Stroke Sensor Stroke Sensor 2
        50 N (5 kgf, 11.2 lbf) 1.39 to 1.79 V 3.17 to 3.57 V
        100 N (10 kgf, 22.5 lbf) 1.56 to 1.96 V 3.01 to 3.41 V
        150 N (15 kgf, 33.7 lbf) 1.71 to 2.11 V 2.85 to 3.25 V
        200 N (20 kgf, 45.0 lbf) 1.78 to 2.18 V 2.78 to 3.18 V