On-Vehicle Inspection

BRAKE MASTER CYLINDER

ON-VEHICLE INSPECTION

NOTICE: A DTC may be stored during the inspection procedure. Be sure to clear the DTC and check that a normal system code is output after the inspection is finished.

1. CHECK BRAKE MASTER CYLINDER
(a) Check battery voltage.
Standard value:
11 to 14 V (while the engine switch is off)
(b) Connect intelligent tester or Techstream and pedal effort gauge.
(1) Connect the pedal effort gauge.
(2) Move the shift lever to the P position. Apply the parking brake and connect the intelligent tester or Techstream to the DLC3.
(3) Turn the engine switch on (IG).
(4) Clear the DTCs.
(c) Check operation without brake booster.
(1) Check and adjust the brake pedal height.
(2) Check and adjust the brake pedal stroke sensor.
(3) Check the brake pedal free play.
(4) Check the brake pedal reserve distance.
(5) Turn on the intelligent tester or Techstream and select "ELECTRONICALLY CONTROLLED BRAKE SYSTEM INVALID" to prohibit the brake control.
(6) Monitor "MAS CYL PRS 1", "MAS CYL PRS 2", "PEDAL STROKE" and "PEDAL STROKE 2" using the intelligent tester or Techstream.
(7) Check the value output from "MAS CYL PRS 1", "MAS CYL PRS 2", "PEDAL STROKE" and "PEDAL STROKE 2" by depressing the brake pedal.

Standard voltage:

(8) Finish the brake control prohibition on the intelligent tester or Techstream.

2. CHECK STROKE SIMULATOR
(a) Check battery voltage.
Standard value:
11 to 14 V (while the engine switch is off)
(b) Connect intelligent tester or Techstream and pedal effort gauge.
(1) Connect the pedal effort gauge.
(2) Move the shift lever to the P position. Apply the parking brake and connect the intelligent tester or Techstream to the DLC3.
(3) Turn the engine switch on (IG).
(4) Clear the DTCs.
(c) Check operation without brake booster.
(1) Check and adjust the brake pedal height.
(2) Check and adjust the brake pedal stroke sensor.
(3) Check the brake pedal free play.
(4) Check the brake pedal reserve distance.
(5) Turn on the intelligent tester or Techstream and select "ELECTRONICALLY CONTROLLED BRAKE SYSTEM INVALID" to prohibit the brake control.
(6) Monitor "MAS CYL PRS 1", "MAS CYL PRS 2", "PEDAL STROKE" and "PEDAL STROKE 2" using the intelligent tester or Techstream.
(7) Check the value output from "MAS CYL PRS 1", "MAS CYL PRS 2", "PEDAL STROKE" and "PEDAL STROKE 2" by depressing the brake pedal.

Standard voltage:

(8)Finish the brake control prohibition on the intelligent tester or Techstream.
(d) Check operation with brake booster
(1) Turn the engine switch on (IG).
(2) Turn on the intelligent tester or Techstream and monitor the value of "PEDAL STROKE" and "PEDAL STROKE 2".
(3) Depress the brake pedal 4 or 5 times.
(4) Check the value output from "PEDAL STROKE" and "PEDAL STROKE 2" by depressing the brake pedal.

Standard voltage:

3. CHECK BRAKE FLUID LEVEL WARNING SWITCH
(a) Remove the reservoir filler cap and strainer.
(b) Disconnect the brake fluid level warning switch connector.





(c) Measure the resistance of the switch.

HINT: There is a float inside the reservoir. Its position can be changed by increasing or decreasing the brake fluid level.

Standard resistance:

If the value is not as specified, replace the brake fluid reservoir.
(d) Add brake fluid to the MAX level.