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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 121 (Brake System (HEV) - Inspection) >> BRAKE SYSTEM (for HV Model) >> On-Vehicle Inspection [12/2019 - ] >> Procedure

On-Vehicle Inspection [12/2019 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSPECT PRESSURE SENSOR 
    1. Check the auxiliary battery voltage.

      Standard Voltage

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

    2. Set a pedal effort gauge and SST.

      HINT: 

      Simultaneously measure the brake fluid pressure of all 4 wheels, or 2 wheels at a time.

      1. Set a pedal effort gauge and SST.
        • SST: 09709-29018 
          1. 09709-00060
        GTY898171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Pedal Effort Gauge
        *b SST (LSPV Gauge)
        *c SST (No. 1 Nipple)
      2. Move the shift lever to P and apply the parking brake.
      3. Bleed air from SST (LSPV gauge).

        Refer to BLEEDING [12/2019 - ]

    3. Inspect the master cylinder sensor 1, reaction force pressure and servo pressure.
      1. Check the value output from "Master Cylinder Sensor 1", "Reaction Force Pressure" and "Servo Pressure" by depressing the brake pedal.

        Chassis > Brake/EPB > Data List 

        Tester Display
        Master Cylinder Sensor 1

        Chassis > Brake Booster > Data List 

        Tester Display
        Reaction Force Pressure
        Servo Pressure

        Standard Result

        Pedal Effort Reaction Force Pressure
        (MPa)        		 Servo Pressure
        (MPa)        		 Master Cylinder Sensor 1
        (MPa)        		 Front Left Wheel Hydraulic Pressure Front Right Wheel Hydraulic Pressure
        50 N (5 kgf, 11.2 lbf) 0.00 to 0.68 0.30 to 4.30 0.00 to 4.00 0.00 to 4.00 MPa (0.0 to 40.8 kgf/cm2 , 0 to 580 psi) 0.0 to 4.0 MPa (0.0 to 40.8 kgf/cm2 , 0 to 580 psi)
        100 N (10 kgf, 22.5 lbf) 0.61 to 1.41 3.23 to 7.23 2.93 to 6.93 2.93 to 6.93 MPa (29.9 to 70.7 kgf/cm2 , 425 to 1005 psi) 2.93 to 6.93 MPa (29.9 to 70.7 kgf/cm2 , 425 to 1005 psi)
        150 N (15 kgf, 33.7 lbf) 1.29 to 2.09 5.52 to 9.52 5.22 to 9.22 5.22 to 9.22 MPa (53.2 to 94.0 kgf/cm2 , 757 to 1337 psi) 5.22 to 9.22 MPa (53.2 to 94.0 kgf/cm2 , 757 to 1337 psi)
        200 N (20 kgf, 45.0 lbf) 1.96 to 2.76 7.30 to 11.30 7.00 to 11.00 7.0 to 11.0 MPa (71.4 to 112.2 kgf/cm2 , 1015 to 1595 psi) 7.0 to 11.0 MPa (71.4 to 112.2 kgf/cm2 , 1015 to 1595 psi)

        Standard Result

        Pedal Effort Reaction Force Pressure
        (MPa)        		 Servo Pressure
        (MPa)        		 Master Cylinder Sensor 1
        (MPa)        		 Rear Left Wheel Hydraulic Pressure Rear Right Wheel Hydraulic Pressure
        50 N (5 kgf, 11.2 lbf) 0.00 to 0.68 0.30 to 4.30 0.00 to 4.00 0.00 to 4.00 MPa (0.0 to 40.8 kgf/cm2 , 0 to 580 psi) 0.0 to 4.0 MPa (0.0 to 40.8 kgf/cm2 , 0 to 580 psi)
        100 N (10 kgf, 22.5 lbf) 0.61 to 1.41 3.23 to 7.23 2.93 to 6.93 2.93 to 6.93 MPa (29.9 to 70.7 kgf/cm2 , 425 to 1005 psi) 2.93 to 6.93 MPa (29.9 to 70.7 kgf/cm2 , 425 to 1005 psi)
        150 N (15 kgf, 33.7 lbf) 1.29 to 2.09 5.52 to 9.52 5.22 to 9.22 5.22 to 9.22 MPa (53.2 to 94.0 kgf/cm2 , 757 to 1337 psi) 5.22 to 9.22 MPa (53.2 to 94.0 kgf/cm2 , 757 to 1337 psi)
        200 N (20 kgf, 45.0 lbf) 1.96 to 2.76 7.30 to 11.30 7.00 to 11.00 7.0 to 11.0 MPa (71.4 to 112.2 kgf/cm2 , 1015 to 1595 psi) 7.0 to 11.0 MPa (71.4 to 112.2 kgf/cm2 , 1015 to 1595 psi)
    4. Remove the pedal effort gauge and SST.
      1. Remove the pedal effort gauge and SST, and bleed the brake line.

        Refer to BLEEDING [12/2019 - ]

    5. Inspect the accumulator pressure.
      1. While fully depressing the brake pedal 4 or 5 times, check that the "ECB Motor Relay" changes to ON once or more.

        Chassis > Brake Booster > Data List 

        Tester Display
        ECB Motor Relay
        Accumulator Pressure

        HINT: 

        Usually the "ECB Motor Relay" is OFF.

      2. After confirming that the brake booster pump motor stops, check the value output from "Accumulator Pressure".

        Standard Result

        15 to 21 MPa

  2. INSPECT BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY 
    1. Check the auxiliary battery voltage.

      Standard Voltage

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

    2. Set a pedal effort gauge and SST.

      HINT: 

      Simultaneously measure the brake fluid pressure of all 4 wheels, or 2 wheels at a time.

      1. Set a pedal effort gauge and SST.
        • SST: 09709-29018 
          1. 09709-00060
        GTY898171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Pedal Effort Gauge
        *b SST (LSPV Gauge)
        *c SST (No. 1 Nipple)
      2. Move the shift lever to P and apply the parking brake.
      3. Clear the DTCs.

        Refer to DTC CHECK / CLEAR [12/2019 - ]

      4. Bleed air from SST (LSPV gauge).

        Refer to BLEEDING [12/2019 - ]

    3. Check operation without brake boost.
      1. Inspect and adjust the brake pedal height.

        Refer to ADJUSTMENT [12/2019 - 10/2022] , or refer to ADJUSTMENT [10/2022 - ]

      2. Adjust the brake fluid level of the reservoir so that it is between the MIN line and fluid level support line.
        GTY938620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Fluid Level Support Line
        *b MIN Line
      3. Select "Motor Deactivate" on the "ECB (Electronically Controlled Brake system) Utility" screen.

        Chassis > Brake/EPB > Utility 

        Tester Display
        ECB Utility
      4. Perform "Motor Deactivate" according to the display on the GTS.
      5. Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.

        HINT: 

        A buzzer may sound due to low accumulator pressure. As this is not a malfunction, continue the procedure.

      6. Check that the brake pedal is firm.
      7. Check the values output from "Stroke Sensor" and "Stroke Sensor2" by depressing the brake pedal.

        Chassis > Brake Booster > Data List 

        Tester Display
        Stroke Sensor

        Chassis > Brake/EPB > Data List 

        Tester Display
        Stroke Sensor2

        Standard Result

        Pedal Effort Stroke Sensor
        (V)        		 Stroke Sensor2
        (V)        		 Front Left Wheel Hydraulic Pressure Front Right Wheel Hydraulic Pressure
        200 N (20 kgf, 45.0 lbf) 1.55 to 2.25 2.75 to 3.45 0.00 to 2.88 MPa (0.0 to 29.4 kgf/cm2 , 0 to 418 psi) 0.00 to 2.88 MPa (0.0 to 29.4 kgf/cm2 , 0 to 418 psi)
        500 N (51 kgf, 112.4 lbf) 1.97 to 2.67 2.33 to 3.03 1.13 to 5.13 MPa (11.5 to 52.3 kgf/cm2 , 164 to 744 psi) 1.13 to 5.13 MPa (11.5 to 52.3 kgf/cm2 , 164 to 744 psi)

        Standard Result

        Pedal Effort Stroke Sensor
        (V)        		 Stroke Sensor2
        (V)        		 Rear Left Wheel Hydraulic Pressure Rear Right Wheel Hydraulic Pressure
        200 N (20 kgf, 45.0 lbf) 1.55 to 2.25 2.75 to 3.45 0.00 to 2.88 MPa (0.0 to 29.4 kgf/cm2 , 0 to 418 psi) 0.00 to 2.88 MPa (0.0 to 29.4 kgf/cm2 , 0 to 418 psi)
        500 N (51 kgf, 112.4 lbf) 1.97 to 2.67 2.33 to 3.03 1.13 to 5.13 MPa (11.5 to 52.3 kgf/cm2 , 164 to 744 psi) 1.13 to 5.13 MPa (11.5 to 52.3 kgf/cm2 , 164 to 744 psi)

        HINT: 

        Check the performance of the brake booster with master cylinder assembly by comparing the pedal force with the value of the LSPV gauge and each stroke sensor. If there is a problem, determine the state of the brake booster with master cylinder assembly by using these results together with the results from inspecting the brake pedal stroke sensor.

      8. Remove the pedal effort gauge and SST, and bleed the brake system.

        Refer to BLEEDING [12/2019 - ]

      9. Check the value output from "Accumulator Pressure".

        Chassis > Brake Booster > Data List 

        Tester Display
        Accumulator Pressure

        Standard Result

        15 to 21 MPa

      10. Clear the DTCs.

        Refer to DTC CHECK / CLEAR [12/2019 - ]

  3. INSPECT STROKE SIMULATOR (BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY) 
    1. Check the auxiliary battery voltage.

      Standard Voltage

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

    2. Set a pedal effort gauge.
      1. Set a pedal effort gauge.
      2. Move the shift lever to P and apply the parking brake.
      3. Clear the DTCs.

        Refer to DTC CHECK / CLEAR [12/2019 - ]

    3. Check operation with brake boost.
      1. Depress the brake pedal 4 or 5 times.
      2. Check the values output from "Stroke Sensor" and "Stroke Sensor2" by depressing the brake pedal.

        Chassis > Brake Booster > Data List 

        Tester Display
        Stroke Sensor

        Chassis > Brake/EPB > Data List 

        Tester Display
        Stroke Sensor2

        Standard Voltage

        Pedal Effort Stroke Sensor
        (V)        		 Stroke Sensor2
        (V)
        50 N (5 kgf, 11.2 lbf) 1.20 to 1.90 3.10 to 3.80
        100 N (10 kgf, 22.5 lbf) 1.42 to 2.16 2.88 to 3.58
        150 N (15 kgf, 33.7 lbf) 1.61 to 2.31 2.69 to 3.39
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