Part 2
21. DISABLE BRAKE CONTROLHINT: Using the intelligent tester or Techstream to disable brake control causes the master pressure cut solenoid to turn OFF and the line from the master cylinder to the front disc brake caliper to open.
a. Check that the parking brake is set.
b. Connect the intelligent tester or Techstream to the DLC3 with the engine switch off.
c. Turn the engine switch on (IG).
NOTE: Do not start the engine.
d. Turn the intelligent tester or Techstream on and select "DIAGNOSTIC MENU" - - >"ABS/VSC"- - > "ELECTRONICALLY CONTROLLED BRAKE SYSTEM UTILITY" - - >"ELECTRONICALLY CONTROLLED BRAKE SYSTEM INVALID" on the intelligent tester or Techstream.
22. BLEED AIR FROM FRONT BRAKE SYSTEM
HINT: After replacing the brake master cylinder with simulator assembly, perform air bleeding on it (same as for common master cylinders) so that bleeding air from the front brake system is easier.
NOTE:
- Bleed air from the wheel furthest from the master cylinder.
- Repeat the bleeding procedures until all the air in the fluid is completely bled out.
a. Connect a vinyl tube to the bleeder plug on the front disc brake caliper LH and RH.
b. Depress the brake pedal several times, then loosen the bleeder plug with the pedal depressed.
c. When fluid stops coming out, temporarily tighten the bleeder plug, then release the brake pedal.
d. Repeat the above procedures until all the air in the fluid is completely bled out.
e. Tighten the bleeder plug.
Torque: 11 N.m (110 kgf.cm, 8 ft.lbf)
23. CANCEL DISABLE BRAKE CONTROL
a. Cancel "DISABLE BRAKE CONTROL" on the intelligent tester or Techstream.
24. CONNECT BRAKE ACCUMULATOR PUMP CONNECTORS
a. Turn the engine switch off.
b. Connect the 2 brake accumulator pump connectors.
c. Turn the engine switch on (IG).
25. BLEED AIR FROM PUMP SUCTION SYSTEM (RR)
HINT: Loosening the rear disc brake caliper's RH bleeder plug and using the intelligent tester or Techstream to select "BLEED PUMP SUCTION SYSTEM (RR)" causes the pump motor and solenoid to operate and pressurize the rear brake line.
a. Check that the parking brake is set.
b. Connect the intelligent tester or Techstream to the DLC3 with the engine switch off.
c. Turn the engine switch on (IG).
NOTE: Do not start the engine.
d. Connect a vinyl tube to the bleeder plug on the rear disc brake caliper RH.
e. Loosen the bleeder plug.
f. Turn the intelligent tester or Techstream on and select "DIAGNOSTIC MENU" "ABS/ VSC" "ELECTRONICALLY CONTROLLED BRAKE SYSTEM UTILITY" "BLEED PUMP SUCTION SYSTEM (RR)" on the intelligent tester or Techstream.
NOTE: Do not depress the brake pedal.
HINT: The solenoid operates for approximately 30 seconds.
g. Tighten the bleeder plug.
Torque: 11 N.m (110 kgf.cm, 8 ft.lbf)
26. DISABLE BRAKE CONTROL
a. Turn the intelligent tester or Techstream on and select "DIAGNOSTIC MENU" - - >"ABS/VSC" - - >"ELECTRONICALLY CONTROLLED BRAKE SYSTEM UTILITY" - - >"ELECTRONICALLY CONTROLLED BRAKE SYSTEM INVALID" on the intelligent tester or Techstream.
27. BLEED AIR FROM REAR BRAKE SYSTEM
a. Connect a vinyl tube to the bleeder plug on the rear disc brake caliper LH and RH.
b. With the brake pedal depressed, loosen the bleeder plug.
NOTE: Keep the fluid inside the reservoir above the MIN line by replenishing.
HINT:
- Depress and hold the brake pedal.
- After the solenoid operates for approximately 30 seconds, release the brake pedal to stop the solenoid.
- Repeat the above procedures until air is completely bled from the rear brake system.
- The brake control warning light comes on and the buzzer sounds while bleeding, but they do not indicate a malfunction.
c. Tighten the bleeder plug after bleeding.
Torque: 11 N.m (110 kgf.cm, 8 ft.lbf)
HINT: The fluid amount adjustment is easier to perform if fuel bleeding is completed with the brake fluid reservoir's fluid level at approximately 5 mm (0.20 in.) below the MAX level.
28. CANCEL DISABLE BRAKE CONTROL
a. Cancel "DISABLE BRAKE CONTROL" on the intelligent tester or Techstream.
29. PERFORM ACCUMULATOR ZERO DOWN
a. Connect the intelligent tester or Techstream to the DLC3 with the engine switch off.
b. Perform the accumulator pressure zero down as follows:
1. Check that the parking brake is set, and turn the engine switch on (IG).
2. Turn the intelligent tester or Techstream on and select "DIAGNOSTIC MENU" - - >"ABS/VSC" - - >"ELECTRONICALLY CONTROLLED BRAKE SYSTEM UTILITY"- - >"ZERO DOWN" on the intelligent tester or Techstream.
HINT: Using the intelligent tester or Techstream to perform accumulator zero down causes the pressurized fluid in the actuator's accumulator to be returned to the brake fluid reservoir.
3. When the buzzer sounds, turn the engine switch off.
c. Perform the accumulator fluid circulation as follows:
1. Perform the accumulator pressure zero down 5 times repeatedly.
HINT:
- Accumulator pressure is released and accumulated repeatedly, which circulates the fluid inside the accumulator every time accumulator zero down (accumulator depressurizing) is performed.
- The pump motor rotates and accumulator is pressurized every time the engine switch is turned from off to on (IG).
30. CHECK AND ADJUST BRAKE FLUID LEVEL IN RESERVOIR
a. After performing accumulator zero down (accumulator depressurizing), adjust the fluid level in the master cylinder reservoir to the MAX level.
NOTE: If using a dropper to adjust the fluid amount, make sure the dropper has not been used with mineral oils, water or deteriorated brake fluid. Sealed areas may deteriorate and lead to fluid leaks, or the fluid may deteriorate and lead to decreased efficiency.
HINT:
- After performing accumulator zero down (accumulator depressurizing), if the engine switch is turned on (IG), the fluid level in the accumulator increases, and the fluid level in the reservoir decreases.
- If the fluid level is adjusted without performing accumulator zero down (accumulator depressurizing), fluid is sent from the accumulator to the reservoir. The fluid level may exceed the MAX level, but it is normal.
b. After turning the engine switch on (IG), check that the fluid level in the brake fluid reservoir is slightly lower than the MAX level.
31. CLEAR DTC
a. Clear the DTCs.
32. PERFORM LINEAR VALVE OFFSET LEARNING
a. When the brake actuator is replaced, perform linear valve offset learning.
33. CHECK DTC
a. If any DTC is set, perform the troubleshooting for the DTC.
34. READ VALUE OF ACCUMULATOR PRESSURE SENSOR OUTPUT VOLTAGE
HINT: If removing and installing the No. 3 brake actuator tube, check for a brake fluid leak from the No. 3 tube connection area by monitoring the accumulator pressure sensor output value from the brake actuator. Directly checking for a brake fluid leak from the No. 3 tube connection area is difficult.
a. Turn the engine switch off.
b. Connect the intelligent tester or Techstream to the DLC3.
c. Turn the engine switch on (IG).
Skid Control ECU:
d. Operate the intelligent tester or Techstream according to the display and select "DATA LIST".
e. Depress the brake pedal 4 or 5 times to operate the pump motor, and check the output value on the intelligent tester or Techstream with the motor stopped (not braking).
OK: Accumulator pressure sensor's output voltage drops 0.2 V or less for 30 seconds.
If the voltage drops more than 0.2 V, there may be a brake fluid leak from the No. 3 brake actuator tube connection area. Remove the brake actuator and brake accumulator pump, and then repeat the procedures above from the retightening of the 2 union nuts of the No. 3 brake actuator tube.
SST 09023-00101
Torque:
15 N.m (155 kgf.cm, 11 ft.lbf) without SST
14 N.m (145 kgf.cm, 10 ft.lbf) with SST
HINT:
- Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
- This torque value is effective when SST is parallel to a torque wrench.
35. CHECK AND ADJUST BRAKE PEDAL HEIGHT
NOTE: Fold back the carpet below the brake pedal for this inspection adjustment.
a. Check the brake pedal height.
Standard pedal height from tibia pad: 144.2 to 154.2 mm (5.68 to 6.07 in.)
b. Adjust the pedal height.
1. Disconnect the connector from the stop light switch.
2. Loosen the stop light switch lock nut and turn the switch so that the pedal has free play.
3. Loosen the push rod clevis lock nut.
4. Adjust the pedal height by turning the push rod.
Standard pedal height from tibia pad: 144.2 to 154.2 mm (5.68 to 6.07 in.)
5. Tighten the push rod clevis lock nut.
Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
6. Turn the stop light switch so that its protrusion is between 1.5 and 2.6 (0.059 and 0.102 in.). Then tighten the lock nut.
Torque: 17 N.m (170 kgf.cm, 12 ft.lbf)
7. Connect the stop light switch connector.
8. Without depressing the brake pedal, check that the stop light does not illuminate. If it illuminates, adjust the brake pedal height again.
9. Push the brake pedal in 5 to 10 mm (0.20 to 0.39 in.), and check that the stop light comes on. If the stop light does not turn on, adjust the brake pedal height again.
36. ADJUST BRAKE PEDAL STROKE SENSOR
a. Connect the intelligent tester or Techstream to the DLC3 with the engine switch off.
b. Loosen the 2 bolts.
c. Turn the engine switch on (IG). While reading the stroke sensor 1 value shown on the intelligent tester or Techstream, turn the stroke sensor slowly to the right and left to adjust it to the standard voltage.
Standard voltage: 0.8 to 1.2 V
d. Tighten the 2 bolts.
Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)
NOTE: Do not depress the brake pedal while performing the linear valve offset learning, as this may cause a DTC to be stored.
e. Perform the linear valve offset learning.
37. RESET MEMORY (with Intelligent Tester or Techstream)
a. Turn the engine switch off.
b. Connect the intelligent tester or Techstream to the DLC3.
c. Turn the engine switch on (IG) and the tester ON.
d. Enter the following menus:
1. Intelligent tester - Select: DIAGNOSIS / OBD/ MOBD / CHASSIS / EPB* / UTILITY / RESET MEMORY /
HINT: *: Stands for electric parking brake
2. Techstream - Select: Chassis / Electric Parking Brake / Utility / Reset Memory /
e. Follow the tester display and perform reset memory.
HINT: When the reset memory is completed, the parking brake indicator light (RED) will blink at 0.5 second intervals.
38. RESET MEMORY (without Intelligent Tester or Techstream)
a. Turn the engine switch off.
b. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
SST 09843-18040
NOTE: Do not connect the wrong terminals, as this will cause parts to be damaged.
c. Turn the engine switch on (IG).
HINT: The parking brake indicator light (RED) will blink at 0.25 second intervals.
d. Perform both of the following procedures within 8 seconds:
1. Perform the following with the electric parking brake switch twice: lock condition - - >off - -> release condition - -> off.
2. Perform the following with the brake pedal: depress - -> release - -> depress - -> release.
e. With the engine switch on (IG), disconnect the connection of terminals 13 (TC) and 4 (CG) of the DLC3.
f. Check that the parking brake indicator light (RED) blinks at 0.5 second intervals.
NOTE: If terminal 13 (TC) and 4 (CG) of the DLC3 are not disconnected, the blinking pattern (0.5 second intervals) cannot be checked.
HINT: If the parking brake indicator light (RED) blinking pattern (0.5 second intervals) is confirmed, the clear procedure is completed. If not confirmed, repeat the procedures above.
39. ACQUIRE TENSION SENSOR ZERO POINT
a. After performing reset memory, perform the release control. Check that the parking brake indicator light (RED) turns off.
40. PARKING BRAKE BEDDING
CAUTION: Performing parking brake bedding forms the friction surfaces of the parking brake shoe and rear disc, which creates the basic braking force of the parking brake. If bedding is not performed, the parking brake performance may not be normal.
NOTE: If one of the following is performed, perform parking brake bedding.
- Rear disc is replaced or removed and installed
- Parking brake shoe is replaced or removed and installed
- electric parking brake actuator is replaced or removed and installed
a. Turn the engine switch off.
b. Using SST, connect terminals 12 (TS) and 4 (CG) of the DLC3.
SST 09843-18040
NOTE: Do not connect the wrong terminals, as this will cause parts to be damaged.
c. Turn the engine switch on (IG).
d. Perform the following procedures with the electric parking brake switch within 8 seconds:
1. Turning the lock switch ON and OFF 3 times.
2. Turn the release switch ON and OFF 3 times.
e. Check that the system is in test mode.
HINT: The multi-information display shows "EPB TEST". EPB stands for electric parking brake. If it is not displayed, repeat the procedures above.
f. Perform parking brake bedding.
g. Drive the vehicle at 30 km/h (19 mph).
h. Push the parking brake switch to the lock side for 5 seconds.
NOTE:
- The braking power is generated from the parking brake while driving the vehicle. This will cause the vehicle speed to decrease. Depress the acceleration pedal to maintain the speed at 30 km/h (19 mph).
- This procedure must be performed while driving the vehicle. If performed on a speed tester, etc., the front wheels do not rotate and the vehicle will determine that the vehicle is stopped.
HINT:
- The parking brake indicator light (RED) stops blinking at 0.125 second intervals, and illuminates.
- The buzzer turns ON (peeping sound).
- The tension is automatically adjusted.
i. After 5 seconds, check that the buzzer and the parking brake indicator light (RED) turn off.
HINT: The brake force decreases.
j. Release the parking brake lock switch.