Brake Pressure Sensor / Brake Pedal Position Sensor Signal Compare Failure (X21D2) [12/2019 - ]: Procedure

1. Perform the Health Check using the GTS.

   Result

   Result	Proceed to
   DTCs are not output.	A
   DTCs are output.	B

Result: 

B 

GO TO DIAGNOSTIC TROUBLE CODE CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART [12/2019 - 10/2021]  , or Refer To  DIAGNOSTIC TROUBLE CODE CHART [10/2021 - 11/2023]  , or Refer To  DIAGNOSTIC TROUBLE CODE CHART [11/2023 - ] 

Result: 

A 

See step  2

1. Interview the customer to check the vehicle conditions when the brake system warning light (red indicator) and brake system warning light (yellow indicator) illuminated.
2. Using the GTS, check for Freeze Frame Data that is recorded when a X21D2 is stored.

   Refer to VEHICLE CONTROL HISTORY [12/2019 - 11/2023] , or refer to VEHICLE CONTROL HISTORY [11/2023 - ]

   Chassis > Brake Booster > Utility 

   Tester Display
   Vehicle Control History (RoB)

   HINT: 

   • Freeze Frame Data is only stored once when a X21D2 is stored.
   • If other vehicle control history are output, repair any malfunctions related to those vehicle control history first, and then reproduce the conditions that caused X21D2 to be stored based on the interview with the customer.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  3

1. With the brake pedal released, confirm the brake pedal stroke sensor assembly output voltage.

   Chassis > Brake Booster > Data List 

   Tester Display	Measurement Item	Range	Normal Condition	Diagnostic Note
   Stroke Sensor	Brake pedal stroke sensor 1	Min.: 0.0 V Max.: 5.0 V	Brake pedal released: 0.6 to 1.4 V	Reading increases when brake pedal is depressed

   Chassis > Brake Booster > Data List 

   Tester Display
   Stroke Sensor

   OK

   0.6 to 1.4 V

   Result

   Proceed to
   OK
   NG

Result: 

NG 

INSPECT/ADJUST INSTALLATION CONDITION OF BRAKE PEDAL STROKE SENSOR ASSEMBLY. Refer to  INSTALLATION [12/2019 - 11/2023]  , or refer to  INSTALLATION [11/2023 - ] 

Result: 

OK 

See step  4

1. Turn the ignition switch off.
2. Mount a pedal effort gauge.
3. Turn the ignition switch to ON (READY) and depress the brake pedal once.

   HINT: 

   Depress the brake pedal after turning the ignition switch to ON (READY) to set the vehicle to linear mode (switching solenoid (SSA) on).

4. Depress the brake pedal slowly and check the brake pedal stroke sensor assembly output voltages with respect to brake pedal depression force.

   Chassis > Brake Booster > Data List 

   Tester Display	Measurement Item	Range	Normal Condition	Diagnostic Note
   Stroke Sensor	Brake pedal stroke sensor 1	Min.: 0.0 V Max.: 5.0 V	Brake pedal released: 0.6 to 1.4 V	Reading increases when brake pedal is depressed

   Chassis > Brake Booster > Data List 

   Tester Display
   Stroke Sensor

   HINT: 

   Perform this procedure in linear mode (switching solenoid (SSA) on).

   Standard Voltage

   Brake Effort [N (kgf, lbf)]	Stroke Sensor [V]
   50 (5, 11.2)	1.20 to 1.90
   100 (10, 22.5)	1.42 to 2.16
   150 (15, 33.7)	1.61 to 2.31

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPLACE BRAKE PEDAL STROKE SENSOR ASSEMBLY. Refer to  REMOVAL [12/2019 - 10/2022]  , or refer to  REMOVAL [10/2022 - 11/2023]  , or refer to  REMOVAL [11/2023 - ] 

Result: 

OK 

See step  5

1. Depress the brake pedal slowly and check the reaction force pressure sensor output values with respect to brake pedal depression force.

   Chassis > Brake Booster > Data List 

   Tester Display	Measurement Item	Range	Normal Condition	Diagnostic Note
   Reaction Force Pressure	Pressure value of stroke simulator	Min.: 0.00 MPa Max.: 24.48 MPa	Brake pedal released: 0.00 to 1.53 MPa	Brake pedal is being depressed: Changes in proportion to the depression force of the brake pedal

   Chassis > Brake Booster > Data List 

   Tester Display
   Reaction Force Pressure

   HINT: 

   Perform this procedure in linear mode (switching solenoid (SSA) on).

   Standard Pressure

   Brake Effort [N (kgf, lbf)]	Reaction Force Pressure [MPa]
   50 (5, 11.2)	0.00 to 0.68
   100 (10, 22.5)	0.61 to 1.41
   150 (15, 33.7)	1.29 to 2.09
   200 (20, 45.0)	1.96 to 2.76

   Result

   Proceed to
   OK
   NG

Result: 

NG 

CHECK AND REPAIR BRAKE FLUID LEAKS 

Result: 

OK 

See step  6

1. Using the GTS, clear the Vehicle Control History.

   Chassis > Brake Booster > Utility 

   Tester Display
   Vehicle Control History (RoB)

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  7

1. Based on the Freeze Frame Data and interview with the customer, attempt to reproduce the conditions when the malfunction occurred.
2. Using the GTS, check for Vehicle Control History.

   Chassis > Brake Booster > Utility 

   Tester Display
   Vehicle Control History (RoB)

   Result

   Result	Proceed to
   X21D2 is not output.	A
   X21D2 is output.	B

Result: 

A 

END 

Result: 

B 

REPLACE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY. Refer to  REMOVAL [12/2019 - 10/2022]  , or refer to  REMOVAL [10/2022 - 11/2023]  , or refer to  REMOVAL [11/2023 - ]