Brake Master Cylinder: Testing and Inspection

ON-VEHICLE INSPECTION

1. CHECK HYDRAULIC BRAKE MASTER CYLINDER FLUID PRESSURE CHANGE
a. Check the battery positive (+) voltage.
Standard: 10 to 14 V
b. Turn the ignition switch OFF, and then depress the brake pedal more than 40 times.
c. Install LSPV gauge (SST) and brake pedal effort gauge, and then bleed air.
SST 09709-29018
d. When operating the hydraulic brake master cylinder and depressing the brake pedal, check the fluid pressure.

Standard

e. When operating the hydraulic brake master cylinder:
1. Turn the ignition switch ON. Wait until the pump motor has stopped.
2. Depress the brake pedal (see table) and check the fluid pressure.

Standard

2. When using hand-held tester: INSPECT HYDRAULIC BRAKE MASTER CYLINDER OPERATION
a. Check the battery positive (+) voltage.
Standard: 10 to 14 V
b. Turn the ignition switch OFF, and then depress the pedal more than 40 times.
c. Check that the pedal becomes easy to depress.
If the pedal does not become easy to depress, check and replace the brake line and hydraulic brake master cylinder.
d. Turn the ignition switch ON, and then check the pump motor operation noise. If the pump motor operation noise cannot be heard, check the wire harness and pump motor. If necessary, replace them.
e. Connect the hand-held tester.
1. Connect the hand-held tester to the DLC3.
2. Turn the ignition switch ON.
3. Select the Active Test mode on the hand-held tester.

HINT: Please refer to the hand-held tester operator's manual for further details.

f. Check the front TRAC & VSC solenoid operation.
1. Select SA1 and SA2 on the hand-held tester.
2. With SA1 and SA2 turned ON simultaneously with the hand-held tester, depress the pedal with a constant force and check that the pedal cannot be depressed.

HINT: To protect the solenoids, the hand-held tester turns OFF automatically 2 seconds after a solenoid has been turned ON.

If the pedal can be depressed, replace the hydraulic brake master cylinder.

NOTICE: When operating the solenoid continuously, wait 20 seconds between each operation.

3. Release the pedal. When the solenoids are OFF, depress the pedal again and check that the pedal can be depressed. If the pedal cannot be depressed, replace the hydraulic brake master cylinder.
g. Check the front ABS solenoid operation.
1. Select SFRH and SFLH on the hand-held tester.
2. With SFRH and SFLH turned ON simultaneously with the hand-held tester, depress the pedal with a constant force and check that the pedal cannot be depressed.

HINT: To protect the solenoids, the hand-held tester turns OFF automatically 2 seconds after a solenoid has been turned ON.

NOTICE: When operating the solenoid continuously, wait 20 seconds between each operation.

If the pedal can be depressed, replace the hydraulic brake master cylinder.
3. Release the pedal. When the solenoids are OFF, check that the pedal can be depressed. If the pedal cannot be depressed, replace the hydraulic brake master cylinder.
4. Release the pedal. After depressing and holding the pedal with a constant force, turn the SFRH and SFRR solenoids ON simultaneously.

HINT: To protect the solenoids, the hand-held tester turns OFF automatically 2 seconds after a solenoid has been turned ON.

5. When the solenoids are OFF, check that the pedal can be depressed. If the pedal cannot be depressed, replace the hydraulic brake master cylinder.
6. Release the pedal. After depressing and holding the pedal with a constant force, turn the SFLH and SFLR solenoids ON simultaneously.

HINT: To protect the solenoids, the hand-held tester turns OFF automatically 2 seconds after a solenoid has been turned ON.

7. When the solenoids are OFF, check that the pedal can be depressed. If the pedal cannot be depressed, replace the hydraulic brake master cylinder.
h. Jack up and support the vehicle.
i. Release the parking brake pedal.
j. Move the shift lever to N and check that the rear wheels rotate by hand.
k. Check the rear TRAC & VSC solenoid operation.
1. Select SA3 and STR on the hand-held tester.
2. Turn SA3 and STR ON simultaneously with the hand-held tester, and check that the rear wheels do not rotate by hand.

HINT: To protect the solenoids, the hand-held tester turns OFF automatically 2 seconds after a solenoid has been turned ON.

If the rear wheels rotate, replace the hydraulic brake master cylinder.
3. Turn SA3 and STR OFF simultaneously, and check that the rear wheels rotate by hand.

HINT: Rotate the wheels as slowly as possible. When rotating the wheels too fast, the fail-safe function is activated and judgment cannot be made properly.

NOTICE: When operating the solenoid continuously, wait 20 seconds between each operation.

If the rear wheels do not rotate, replace the hydraulic brake master cylinder.
l. Check the right rear ABS solenoid operation.
1. Select SA3, STR and SRRH on the hand-held tester.
2. Turn SA3, STR and SRRH ON simultaneously with the hand-held tester, and check that the right rear wheel rotates by hand.

HINT:
^ To protect the solenoids, the hand-held tester turns OFF automatically 2 seconds after a solenoid has been turned ON.
^ Rotate the wheel as slowly as possible. When rotating the wheel too fast, the fail-safe function is activated and judgment cannot be made properly.

If the right rear wheel does not rotate, replace the hydraulic brake master cylinder.
3. Turn SA3, STR and SRRH OFF, and check that the right rear wheel rotates by hand.

HINT:
^ Rotate the wheel as slowly as possible. When rotating the wheel too fast, the fail-safe function is activated and judgment cannot be made properly.
^ When the solenoid is OFF, the wheel may stop temporarily. However, if the wheel rotates again, the function works normally.

If the right rear wheel does not rotate, replace the hydraulic brake master cylinder.
4. Depress the pedal with a constant force and then turn SRRH and SRRR ON simultaneously.
5. When the solenoids are ON, check that the right rear wheel rotates by hand.

HINT:
^ To protect the solenoids, the hand-held tester turns OFF automatically 2 seconds after a solenoid has been turned ON.
^ Rotate the wheel as slowly as possible. When rotating the wheel too fast, the fail-safe function activated and judgment cannot be made properly.

If the right rear wheel does not rotate, replace the hydraulic brake master cylinder.
m. Check the left rear ABS solenoid operation.
1. Select SA3, STR and SRLH on the hand-held tester.
2. Turn SA3, STR and SRLH ON simultaneously with the hand-held tester, and check that the left rear wheel rotates by hand.

HINT:
^ To protect the solenoids, the hand-held tester turns OFF automatically 2 seconds after a solenoid has been turned ON.
^ Rotate the wheel as slowly as possible. When rotating the wheel too fast, the fail-safe function is activated and judgement cannot be properly.

If the left rear wheel does not rotate, replace the hydraulic brake master cylinder.
3. Turn SA3, STR and SRLH OFF, and check that the left rear wheel rotates by hand.

HINT:
^ Rotate the wheel as slowly as possible. When rotating the wheel too fast, the fail-safe function is activated and judgment cannot be made properly.
^ When the solenoid is OFF, the wheel may stop temporarily. However, if the wheel rotates again, the function works normally.

If the left rear wheel does not rotate, replace the hydraulic brake master cylinder.
4. Depress the pedal with a constant force and then turn SRLH and SRLR ON simultaneously.
5. When the solenoids are ON, check that the left rear wheel rotates by hand.

HINT:
^ To protect the solenoids, the hand-held tester turns OFF automatically 2 seconds after a solenoid has been turned ON.
^ Rotate the wheel as slowly as possible. When rotating the wheel too fast, the fail-safe function is activated and judgment cannot be made properly.

If the left rear wheel does not rotate, replace the hydraulic brake master cylinder.
n. Lower the vehicle.
o. Disconnect the hand-held tester.

3. When using ABS actuator checker: INSPECT HYDRAULIC BRAKE MASTER CYLINDER OPERATION
a. Check the battery positive (+) voltage.
Standard: 10 to 14 V
b. Disconnect the 2 connectors from the hydraulic brake master cylinder.
c. Connect the actuator checker (SST) to the hydraulic brake master cylinder side wire harness via the sub-wire harness S (SST), as shown in the illustration on the next page.
SST 09990-00150, 09990-00480

HINT: Connect the sub-wire harness S (SST) connector labeled FRONT to the actuator checker's connector.

d. Connect the red cable of the checker to the positive (+) battery terminal and the black cable to the negative (-) battery terminal.

e. Place SHEET G FRONT on the actuator checker.
SST 09990-00240
f. Turn the ignition switch OFF, and then depress the pedal more than 40 times.
g. Check that the pedal becomes easy to depress. If the pedal does not become easy to depress, check the brake line and hydraulic brake master cylinder. If necessary, replace them.
h. Turn the ignition switch ON, and then check the pump motor operation noise.
If the pump motor operation noise cannot be heard, check the wire harness and pump motor. If necessary, replace them.

i. Check the front TRAC & VSC solenoid operation.
1. Push and hold the SA1 and SA2 switches simultaneously. Firmly depress and hold the pedal with a constant force.

NOTICE: Do not keep SA1 and SA2 pushed down for more than 10 seconds. When operating the solenoid continuously, wait 20 seconds between each operation.

2. Check that the pedal cannot be depressed.
If the pedal can be depressed, replace the hydraulic brake master cylinder.
3. Release the SA1 switch and check that the pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake master cylinder.
4. Release the SA2 switch and check that the pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake master cylinder.

j. Check the right front ABS solenoid operation.
1. Turn the selector switch to RH.
2. Push and hold the MAIN switch and SA2 switch simultaneously. Then depress and hold the pedal with a constant force.

NOTICE: Do not keep the MAIN switch and SA2 switch pushed down for more than 10 seconds. When operating the solenoid continuously, wait 20 seconds between each operation.

3. Check that the pedal cannot be depressed.
If the pedal can be depressed, replace the hydraulic brake master cylinder.
4. Release the MAIN switch and SA2 switch simultaneously. Check that the pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake master cylinder.
5. Release the pedal.

k. Check the left front ABS solenoid operation.
1. Turn the selector switch to LH.
2. Push and hold the MAIN switch and SA1 switch simultaneously. Then depress and hold the pedal with a constant force.

NOTICE: Do not keep the MAIN switch and SA1 switch pushed down for more than 10 seconds. When operating the solenoid continuously, wait 20 seconds between each operation.

3. Check that the pedal cannot be depressed.
If the pedal can be depressed, replace the hydraulic brake master cylinder.
4. Release the MAIN switch and SA1 switch simultaneously. Check that the pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake master cylinder.
5. Release the pedal.

6. Push and hold the MAIN switch. Then depress and hold the pedal with a constant force.

NOTICE: Do not keep the MAIN switch pushed down for more than 10 seconds. When operating the solenoid continuously, wait 20 seconds between each operation.

7. Check that the pedal cannot be depressed.
If the pedal can be depressed, replace the hydraulic brake master cylinder.
8. Release the MAIN switch, and then check that the pedal can be depressed.
If the pedal cannot be depressed, replace the hydraulic brake master cylinder.
9. Release the pedal.
l. Turn the ignition switch OFF. Disconnect the sub-wire harness S (SST) connector labeled FRONT. Then connect the connector labeled REAR to the actuator checker's connector.
SST 09990-00480
m. Place SHEET G REAR on the actuator checker.
SST 09990-00240
n. Jack up and support the vehicle.
o. Start the engine and run it at idle.

p. Check the rear TRAC & VSC solenoid operation.
1. Release the parking brake pedal and move the shift lever to L.
2. Push and hold the SA3 switch and STR switch simultaneously.

NOTICE:
^ Do not keep the STR switch pushed down for more than 10 seconds.
^ Do not keep the SA3 switch pushed down for more than 5 seconds.
^ When operating the solenoid continuously, wait 20 seconds between each operation.

3. Check that the rear wheels do not rotate.
If the rear wheels rotate, replace the hydraulic brake master cylinder.
4. Release the SA3 switch and STR switch simultaneously.
5. Check that the rear wheels rotate.
If the rear wheels do not rotate, replace the hydraulic brake master cylinder.

q. Check the right rear ABS solenoid operation.
1. Turn the selector switch to RH.
2. Depress the pedal several times and release the pedal when the pump begins rotating. Wait until the pump stops.
3. Turn the ignition switch OFF.
4. Depress the pedal with a force of 343 N (35 kgf, 77 lbs.) record the fluid level in the reservoir tank of the hydraulic brake master cylinder.
5. Press the MAIN switch for 10 seconds, and check that the fluid level in the reservoir tank of the hydraulic brake master cylinder does not increase at this time.

NOTICE: Do not keep the MAIN switch pushed down for more than 10 seconds. When operating the solenoid continuously, wait 20 seconds between each operation.

If the fluid level increases, replace the hydraulic brake master cylinder.
6. Start the engine and run it at idle.
7. Depress the pedal.
8. Release the parking brake pedal and move the shift lever to L.
9. Release the pedal. After depressing the pedal with a constant force, push and hold the MAIN switch.

NOTICE: Do not keep the MAIN switch pushed down for more than 10 seconds. When operating the solenoid continuously, wait 20 seconds between each operation.

10. Check that the right rear wheel rotates.
If the right rear wheel does not rotate, replace the hydraulic brake master cylinder.

r. Check the left rear ABS solenoid operation.
1. Turn the selector switch to LH.
2. Depress the pedal several times and release the pedal when the pump begins rotating. Wait until the pump stops.
3. Turn the ignition switch OFF.
4. Depress the pedal with a force of 343 N (35 kgf, 77 lbs.) record the fluid level in the reservoir tank of the hydraulic brake master cylinder.
5. Press the MAIN switch for 10 seconds, and check that the fluid level in the reservoir tank of the hydraulic brake master cylinder does not increase at this time.

NOTICE: Do not keep the MAIN switch pushed down for more than 10 seconds. When operating the solenoid continuously, wait 20 seconds between each operation.

If the fluid level increases, replace the hydraulic brake master cylinder.
6. Start the engine and run it at idle.
7. Depress the pedal.
8. Release the parking brake pedal and move the shift lever to L.
9. Release the pedal. After depressing the pedal with a constant force, push and hold the MAIN switch.

NOTICE: Do not keep the MAIN switch pushed down for more than 10 seconds. When operating the solenoid continuously, wait 20 seconds between each operation.

10. Check that the left rear wheel rotates.
If the left rear wheel does not rotate, replace the hydraulic brake master cylinder.
s. Stop the engine.
t. Remove SHEET G (SST), and disconnect the actuator checker (SST) and sub-wire harness S (SST) from the hydraulic brake master cylinder.
SST 09990-00150, 09990-00240, 09990-00480
u. Connect the 2 connectors to the actuator.
v. Clear the DTC.