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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Electronically Controlled Brake System (Except HV) - Diagnostic Codes (3 Of 3), Symptom Tests & Circuit Tests >> ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for Gasoline Model) >> Brake Warning Light Remains ON [10/2022 - ] >> Procedure

Brake Warning Light Remains ON [10/2022 - ]: Procedure

  1. PRE-CHECK 
    1. Check that all of the following conditions required for the brake system warning light (red indicator) to turn off are met:
      1. The brake fluid level in the brake master cylinder reservoir assembly is not low.
      2. The vacuum inside the brake booster decreases.

        HINT: 

        When the vacuum inside the brake booster decreases, the brake system warning light (red indicator) comes on.

      Result

      Proceed to
      NEXT

    Result: 

    NEXT 

    See step  2

  2. INSPECT BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. With a sufficient level of brake fluid, disconnect the A1 brake fluid level warning switch (brake master cylinder reservoir assembly) connector and confirm that the brake system warning light (red indicator) illuminates.

      OK

      The brake system warning light (red indicator) does not turn off.

      HINT: 

      If the brake system warning light (red indicator) turns off, there is a short in the brake fluid level warning switch (brake master cylinder reservoir assembly) circuit.

      Result

      Result Proceed to
      OK (except 12.3 Inch Display) A
      OK (for 12.3 Inch Display) B
      NG C

    Result: 

    See step  7

    Result: 

    REPLACE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Result: 

    See step  3

  3. CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY) 
    1. Turn the ignition switch off.
    2. Make sure that there is no looseness at the locking part and the connecting part of the connectors.

      OK

      The connector is securely connected.

    3. Disconnect the H21 combination meter assembly connector.
    4. Check both the connector case and the terminals for deformation and corrosion.

      OK

      No deformation or corrosion.

    5. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      H21-12 (SW) or A1-1 (+) - Body ground Always 10 kΩ or higher

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  4

  4. INSPECT COMBINATION METER ASSEMBLY 
    1. Reconnect the H21 combination meter assembly connector.
    2. Reconnect the A1 brake fluid level warning switch (brake master cylinder reservoir assembly) connector.
    3. Perform the Active Test of the combination meter assembly using the GTS.

      Body Electrical > Combination Meter > Active Test 

      Tester Display
      Brake Warning
    4. Check the combination meter assembly.

      OK

      The brake system warning light (red indicator) turns on or off in accordance with GTS operation.

      Result

      Result Proceed to
      OK (w/o Stop and Start System) A
      OK (w/ Stop and Start System) B
      NG C

    Result: 

    REPLACE BRAKE ACTUATOR ASSEMBLY. Refer to  REMOVAL [10/2022 - 11/2023]  , or refer to  REMOVAL [11/2023 - ] 

    Result: 

    INSPECT METER / GAUGE SYSTEM. Refer to  HOW TO PROCEED WITH TROUBLESHOOTING [12/2019 - ] 

    Result: 

    See step  5

  5. INSPECT VACUUM WARNING SWITCH ASSEMBLY 
    1. Turn the ignition switch off.
    2. Inspect the vacuum warning switch assembly.

      Refer to ON-VEHICLE INSPECTION [12/2019 - ]

      OK

      The vacuum warning switch assembly is normal.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPLACE VACUUM WARNING SWITCH ASSEMBLY. Refer to  REMOVAL [10/2022 - 11/2023]  , or refer to  REMOVAL [11/2023 - ] 

    Result: 

    OK 

    See step  6

  6. CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - VACUUM WARNING SWITCH ASSEMBLY) 
    1. Disconnect the A2 vacuum warning switch assembly connector.
    2. Disconnect the H21 combination meter assembly connector.
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      H21-7 (VCM) - A2-2 (+) Always Below 1 Ω
      H21-7 (VCM) or A2-2 (+) - Body ground Always 10 kΩ or higher
      A2-1 (E) - Body ground 1 minute or more after disconnecting the cable from the negative (-) auxiliary battery terminal Below 1 Ω

      Result

      Proceed to
      OK
      NG

    Result: 

    OK 

    REPLACE BRAKE ACTUATOR ASSEMBLY. Refer to  REMOVAL [10/2022 - 11/2023]  , or refer to  REMOVAL [11/2023 - ] 

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

  7. CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY) 
    1. Turn the ignition switch off.
    2. Make sure that there is no looseness at the locking part and the connecting part of the connectors.

      OK

      The connector is securely connected.

    3. Disconnect the H112 combination meter assembly connector.
    4. Check both the connector case and the terminals for deformation and corrosion.

      OK

      No deformation or corrosion.

    5. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      H112-11 (SW) or A1-1 (+) - Body ground Always 10 kΩ or higher

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  8

  8. INSPECT COMBINATION METER ASSEMBLY 
    1. Reconnect the H112 combination meter assembly connector.
    2. Reconnect the A1 brake fluid level warning switch (brake master cylinder reservoir assembly) connector.
    3. Perform the Active Test of the combination meter assembly using the GTS.

      Body Electrical > Combination Meter > Active Test 

      Tester Display
      Multi Display All (White)
    4. Check the combination meter assembly.

      OK

      The multi-information display turns on or off in accordance with GTS operation.

      Result

      Result Proceed to
      OK (w/o Stop and Start System) A
      OK (w/ Stop and Start System) B
      NG C

    Result: 

    REPLACE BRAKE ACTUATOR ASSEMBLY. Refer to  REMOVAL [10/2022 - 11/2023]  , or refer to  REMOVAL [11/2023 - ] 

    Result: 

    INSPECT METER / GAUGE SYSTEM. Refer to  HOW TO PROCEED WITH TROUBLESHOOTING [10/2022 - ] 

    Result: 

    See step  9

  9. INSPECT VACUUM WARNING SWITCH ASSEMBLY 
    1. Turn the ignition switch off.
    2. Inspect the vacuum warning switch assembly.

      Refer to ON-VEHICLE INSPECTION [12/2019 - ]

      OK

      The vacuum warning switch assembly is normal.

      Result

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPLACE VACUUM WARNING SWITCH ASSEMBLY. Refer to  REMOVAL [10/2022 - 11/2023]  , or refer to  REMOVAL [11/2023 - ] 

    Result: 

    OK 

    See step  10

  10. CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - VACUUM WARNING SWITCH ASSEMBLY) 
    1. Disconnect the A2 vacuum warning switch assembly connector.
    2. Disconnect the H112 combination meter assembly connector.
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      H112-27 (VCM) - A2-2 (+) Always Below 1 Ω
      H112-27 (VCM) or A2-2 (+) - Body ground Always 10 kΩ or higher
      A2-1 (E) - Body ground 1 minute or more after disconnecting the cable from the negative (-) auxiliary battery terminal Below 1 Ω

      Result

      Proceed to
      OK
      NG

    Result: 

    OK 

    REPLACE BRAKE ACTUATOR ASSEMBLY. Refer to  REMOVAL [10/2022 - 11/2023]  , or refer to  REMOVAL [11/2023 - ] 

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR