BRAKE SYSTEM 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 PRESSURE SENSOR


    1. Check auxiliary battery voltage.

      Standard voltage
      11 to 14 V (while the ignition switch is off)

    2. Set a pedal effort gauge and SST, and connect the GTS.


      1. A01UZB1E01
        Text in Illustration
        *1 Pedal Effort Gauge
        *2 SST (LSPV Gauge)
        *3 SST (No. 1 Nipple)
        *4 SST (No. 3 Nipple)

        Set a pedal effort gauge and SST (LSPV gauge, No. 1 nipple and No. 3 nipple).

        SST
        09709-29018   ( 09709-00060, 09709-00080 )

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

      3. Turn the ignition switch to ON (IG) and turn the GTS on.

      4. Bleed air from SST (LSPV gauge) Click here.

    3. Inspect wheel cylinder pressure sensor and regulator pressure sensor.


      1. Enter the following menus: Chassis / ABS/VSC/TRC / Active Test / Power Supply Air Bleeding Pattern 1.

      2. Select "Wheel Cylinder Pressure Sensor" and "Regulator Pressure Sensor Output".

      3. Check the value output from "Wheel Cylinder Pressure Sensor" and "Regulator Pressure Sensor Output" by depressing the brake pedal.

        Standard Result

        Pedal Effort

        N (kgf, lbf)

        Regulator Pressure Sensor Output

        (V)

        Rear Right Wheel Hydraulic Pressure

        (MPa (kgf/cm2, psi))

        Rear Left Wheel Hydraulic Pressure

        (MPa (kgf/cm2, psi))
        50 (5, 11.2) 0.59 to 1.39 0.38 to 4.38 (3.9 to 44.6, 56 to 635) 0.38 to 4.38 (3.9 to 44.6, 56 to 635)
        100 (10, 22.5) 1.53 to 2.33 5.03 to 9.03 (51.2 to 92.0, 729 to 1309) 5.03 to 9.03 (51.2 to 92.0, 729 to 1309)
        150 (15, 33.7) 2.51 to 3.31 9.79 to 13.79 (99.9 to 140.6, 1421 to 2000) 9.79 to 13.79 (99.9 to 140.6, 1421 to 2000)
        200 (20, 45.0) 3.44 to 4.24 14.37 to 18.37 (146.5 to 187.3, 2083 to 2663) 14.37 to 18.37 (146.5 to 187.3, 2083 to 2663)
        Standard Result

        Pedal Effort

        N (kgf, lbf)

        Wheel Cylinder Pressure Sensor

        (V)

        Front Right Wheel Hydraulic Pressure

        (MPa (kgf/cm2, psi))

        Front Left Wheel Hydraulic Pressure

        (MPa (kgf/cm2, psi))
        50 (5, 11.2) 0.52 to 1.32 0.04 to 4.04 (0.5 to 41.1, 6 to 586) 0.04 to 4.04 (0.5 to 41.1, 6 to 586)
        100 (10, 22.5) 1.34 to 2.14 4.06 to 8.06 (41.4 to 82.1, 589 to 1169) 4.06 to 8.06 (41.4 to 82.1, 589 to 1169)
        150 (15, 33.7) 2.16 to 2.96 8.09 to 12.09 (82.5 to 123.2, 1174 to 1753) 8.09 to 12.09 (82.5 to 123.2, 1174 to 1753)
        200 (20, 45.0) 2.98 to 3.78 12.09 to 16.09 (123.3 to 164.0, 1754 to 2333) 12.09 to 16.09 (123.3 to 164.0, 1754 to 2333)

      4. After inspection, turn "Power Supply Air Bleeding Pattern 1" off.

    4. Remove pedal effort gauge and SST.


      1. Remove the pedal effort gauge and SST, and bleed brake line Click here.

    5. Inspect accumulator sensor.


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

      2. Depress the brake pedal 4 or 5 times and operate the booster pump motor.

      3. After confirming that the booster pump motor stops, check the output voltage.

        Standard voltage
        2.9 to 4.2 V

  2. INSPECT BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY


    1. Check auxiliary battery voltage.

      Standard voltage
      11 to 14 V (while the ignition switch is off)

    2. Connect the GTS and set a pedal effort gauge.


      1. Set a pedal effort gauge.

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

      3. Turn the ignition switch to ON (IG) and turn the GTS on.

      4. Clear the DTCs Click here.

    3. Check operation without the brake booster.


      1. Inspect and adjust the brake pedal height.


      2. Adjust the brake fluid level in the reservoir between the MIN line and the fluid level support line.

        A01UZGDE04
        Text in Illustration
        *A for LHD *B for RHD
        *a Fluid Level Support Line *b MIN Line

      3. Turn the GTS on and enter the following menus: Chassis / ABS/VSC/TRC / Utility / ECB* Utility / Zero Down.

        *: Electronically Controlled Brake System

        Note

        Go to the next step without turning the ignition switch off.

      4. Enter the following menus: Chassis / ABS/VSC/TRC / Data List "Wheel Cylinder Pressure Sensor", "Stroke Sensor" and "Stroke Sensor 2".

      5. Check the value output from "Wheel Cylinder Pressure Sensor", "Stroke Sensor" and "Stroke Sensor 2" by depressing the brake pedal.

        Standard Voltage

        Pedal Effort

        N (kgf, lbf)

        Wheel Cylinder Pressure Sensor

        (V)

        Stroke Sensor

        (V)

        Stroke Sensor 2

        (V)
        200 (20, 45.0) 0.51 to 1.31 1.13 to 1.83 3.17 to 3.87
        500 (51, 112.4) 1.12 to 1.92 1.42 to 2.12 2.88 to 3.58

      6. Turn the ignition switch off to finish "Zero Down".

      7. Turn the ignition switch to ON (IG) and wait for 20 seconds, then enter the following menus: Chassis / ABS/VSC/TRC / Data List "Accumulator Sensor", and check the output voltage.

        Standard voltage
        2.9 to 4.2 V

  3. INSPECT STROKE SIMULATOR


    1. Check auxiliary battery voltage.

      Standard voltage
      11 to 14 V (while the ignition switch is off)

    2. Connect the GTS and set a pedal effort gauge.


      1. Set a pedal effort gauge.

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

      3. Turn the ignition switch to ON (IG) and turn the GTS on.

      4. Clear the DTCs Click here.

    3. Check operation with the brake booster.


      1. Turn the ignition switch to ON (IG).

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

      3. Depress the brake pedal 4 or 5 times.

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

        Standard Voltage

        Pedal Effort

        N (kgf, lbf)

        Stroke Sensor

        (V)

        Stroke Sensor 2

        (V)
        50 (5, 11.2) 1.29 to 1.99 3.01 to 3.71
        100 (10, 22.5) 1.55 to 2.25 2.75 to 3.45
        150 (15, 34.0) 1.71 to 2.41 2.59 to 3.29