On-Vehicle Inspection

BRAKE: BRAKE MASTER CYLINDER: ON-VEHICLE INSPECTION

ON-VEHICLE INSPECTION
NOTE: 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 voltage:
11 to 14 V (while the power switch is OFF)
(b) Connect the intelligent tester or Techstream and the 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 power switch ON (IG).
(4) Clear the DTCs Reading and Clearing Diagnostic Trouble Codes.
(c) Check operation without brake booster.
(1) Check and adjust the brake pedal height Adjustments.
(2) Check and adjust the brake pedal stroke sensor Adjustments.
(3) Check the brake pedal free play Adjustments.
(4) Check the brake pedal reserve distance Adjustments.
(5) Intelligent tester:
Select and enter "ELECTRONICALLY CONTROLLED BRAKE SYSTEM INVALID" to prohibit the brake control.
(6) Techstream:
Select and enter "Electronically Controlled Brake system Invalid" to prohibit the brake control.
(7) Intelligent tester:
Monitor "MAS CYL PRESS 1", "MAS CYL PRESS 2", "PEDAL STROKE" and "PEDAL STROKE 2" using the intelligent tester.
(8) Techstream:
Monitor "Voltage of Master Cylinder Sensor", "Voltage of Master Cylinder Sensor 2", "Stroke Sensor" and "Stroke Sensor 2" using the Techstream.
(9) Intelligent tester:
Check the value output from "MAS CYL PRESS 1", "MAS CYL PRESS 2", "PEDAL STROKE" and "PEDAL STROKE 2" by depressing the brake pedal.
(10) Techstream:
Check the value output from "Voltage of Master Cylinder Sensor", "Voltage of Master Cylinder Sensor 2", "Stroke Sensor" and "Stroke Sensor 2" by depressing the brake pedal.
Standard voltage:

Intelligent tester





Techstream





(11) Finish the brake control prohibition on the intelligent tester or Techstream.
2. CHECK STROKE SIMULATOR
(a) Check battery voltage.
Standard voltage:
11 to 14 V (while the power switch is OFF)
(b) Connect the intelligent tester or Techstream and the 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 power switch ON (IG).
(4) Clear the DTCs Reading and Clearing Diagnostic Trouble Codes.
(c) Check operation without brake booster.
(1) Check and adjust the brake pedal height Adjustments.
(2) Check and adjust the brake pedal stroke sensor Adjustments.
(3) Check the brake pedal free play Adjustments.
(4) Check the brake pedal reserve distance Adjustments.
(5) Intelligent tester:
Select and enter "ELECTRONICALLY CONTROLLED BRAKE SYSTEM INVALID" to prohibit the brake control.
(6) Techstream:
Select and enter "Electronically Controlled Brake system Invalid" to prohibit the brake control.
(7) Intelligent tester:
Monitor "MAS CYL PRESS 1", "MAS CYL PRESS 2", "PEDAL STROKE" and "PEDAL STROKE 2" using the intelligent tester.
(8) Techstream:
Monitor "Voltage of Master Cylinder Sensor", "Voltage of Master Cylinder Sensor 2", "Stroke Sensor" and "Stroke Sensor 2" using the Techstream.
(9) Intelligent tester:
Check the value output from "MAS CYL PRESS 1", "MAS CYL PRESS 2", "PEDAL STROKE" and "PEDAL STROKE 2" by depressing the brake pedal.
(10) Techstream:
Check the value output from "Voltage of Master Cylinder Sensor", "Voltage of Master Cylinder Sensor 2", "Stroke Sensor" and "Stroke Sensor 2" by depressing the brake pedal.
Standard voltage:

Intelligent tester





Techstream





(11) Finish the brake control prohibition on the intelligent tester or Techstream.
(d) Check operation with brake booster.
(1) Turn the power switch ON (IG).
(2) Turn on the intelligent tester and monitor the value of "PEDAL STROKE" and "PEDAL STROKE 2".
(3) Turn on the Techstream and monitor the value of "Stroke Sensor" and "Stroke Sensor 2".
(4) Depress the brake pedal 4 or 5 times.
(5) Intelligent tester:
Check the value output from "PEDAL STROKE" and "PEDAL STROKE 2" by depressing the brake pedal.
(6) Techstream:
Check the value output from "Stroke Sensor" and "Stroke Sensor 2" by depressing the brake pedal.
Standard voltage:

Intelligent tester





Techstream





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 according to the value(s) in the table below.
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 result is not as specified, replace the brake fluid reservoir.
(d) Add brake fluid to the MAX level.