Part 3

INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION

INITIALIZATION (Continued)

9. ELECTRONICALLY CONTROLLED BREAK SYSTEM (CALIBRATION)
(a) DESCRIPTION
- After replacing the VSC relevant components or performing "Front wheel alignment adjustment", clear and read the sensor calibration data.
- Follow the procedure to perform calibration.

(b) CLEAR ZERO POINT CALIBRATION (WHEN USING TECHSTREAM)
(1) Connect the Techstream to the DLC3.
(2) Turn the engine switch on (IG).
(3) Operate the Techstream to erase the codes (select "Reset Memory").
HINT: Refer to the Techstream operator's manual for further details.

(c) CLEAR ZERO POINT CALIBRATION (WHEN USING TECHSTREAM)
(1) Connect the Techstream to the DLC3.
(2) Turn the engine switch on (IG).
(3) Operate the Techstream to erase the codes (select "Reset Memory").
HINT: Refer to the Techstream operator's manual for further details.

(d) PERFORM ZERO POINT CALIBRATION OF YAW RATE AND ACCELERATION SENSOR (WHEN USING TECHSTREAM)
NOTICE:
- While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it. Keep it in a stationary condition and do not start the engine.
- Choose a level surface with an inclination of less than 1°.
(1) Procedures for Test Mode.
1 Ensure that the steering wheel is centered, move the shift lever to the P position, and apply the parking brake.
NOTE:
DTC C1210/36 and C1336/98 will be recorded if the shift lever is not in the P position.

2 Connect the Techstream to the DLC3.

(2) Turn the engine switch on (IG).
(3) Set the Techstream to Test Mode (select "Test Mode").
HINT: Refer to the Techstream operator's manual for further details.
(4) Obtain the zero point of the yaw rate and acceleration sensor.
1 Keep the vehicle stationary on a level surface for 4 seconds or longer.
2 Check that the ABS warning light and brake warning light / yellow (minor malfunction) blink and "VSC TEST" is indicated on the multi-information display (Test Mode).

(1) Turn the engine switch on (IG).
(2) Using SST, connect and disconnect terminals 12 (TS) and 4 (CG) of the DLC3 4 times or more within 8 seconds.
SST: 09843-18040
(3) Check that no codes other than ABS code 42, VSC code 45 and electronically controlled brake system code 48, 66, or 95 are stored in the diagnostic system.

HINT: The ABS warning light and multi-information display do not indicate the normal system code.

(f) PERFORM ZERO POINT CALIBRATION OF YAW RATE AND ACCELERATION SENSOR (WHEN USING SST CHECK WIRE)
NOTICE:
- While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking. Keep it in a stationary condition and do not start the engine.
- Choose a level surface with an inclination of less than 1°.
(1) Procedures for Test Mode.
SST: 09843-18040
1 Turn the engine switch off.
2 Using SST, connect terminals 12 (TS) and 4 (CG) of the DLC3.

3 Check that the steering wheel is in the centered position and move the shift lever to the P position.
NOTE:
DTC C1210/36 and C1336/98 will be recorded if the shift lever is not in the P position.
(2) Obtain the zero point of the yaw rate and acceleration sensor.
1 Turn the engine switch on (IG).
2 Keep the vehicle in a stationary condition on a level surface for 4 seconds or more.
3 Check that the ABS warning light and brake warning light / yellow (minor malfunction) blink and "VSC TEST" is indicated on the multi-information display (Test Mode).

HINT:
- If the ABS warning light and brake warning light / yellow (minor malfunction) do not blink and "VSC TEST" is not indicated on the multi-information display, perform zero point calibration again.
- The zero point calibration is performed only once after the system enters the Test Mode.
- Calibration cannot be performed again until the stored data is cleared.

10. BRAKE FLUID
CAUTION:
The Techstream must be used with air bleeding and fluid replacement. If not used, the air bleeding and fluid replacement will be incomplete, which is hazardous and may lead to an accident.
NOTICE:
- When replacing the brake fluid, replace the front and rear brake fluid as a set.
- Perform fluid replacement with the shift lever on P and the parking brake set.
- Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on the brake fluid reservoir.
- As brake fluid may overflow when bleeding air, do not place the fluid can on the reservoir filler opening.
- Air bleeding will be difficult if the following occurs: 1) the brake fluid reservoir's No. 2 brake actuator hose (the hose between the brake accumulator pump and brake fluid reservoir) is lowered into the fluid and air enters the hose; and 2) during the fluid replacement procedure, air enters the brake accumulator pump while operating the pump motor.
- While performing fluid replacement, the accumulator pressure drop may cause a buzzer to sound. As there is no problem, continue with the fluid replacement.
- During fluid replacement, DTCs for pressure sensor malfunctions, etc. may be stored. After fluid replacement and if instructed in the procedures, clear the DTCs.
- Do not allow brake fluid to contact the vehicle's paint surfaces. If contact occurs, clean it off immediately.
HINT:
- For air bleeding, refer to the PRECAUTION.
- Air bleeding with the Techstream cannot be performed when the engine switch is on (IG) or when the parking brake is not operating (electric parking brake operation signal is not input into skid control ECU).
- While performing air bleeding, a display and navigation assembly (with HDD navigation system) or multi-display (without HDD navigation system) malfunction warning is displayed. However, there is no malfunction. After performing air bleeding, erase the warning using the screen's menus.

(a) FILL RESERVOIR WITH BRAKE FLUID
NOTICE:
- As brake fluid may overflow when bleeding air, do not place the fluid can on the reservoir filler opening.
- If brake fluid leaks onto any painted surface, clean it off completely.

(b) FILL RESERVOIR WITH BRAKE FLUID

(1) Add brake fluid into the reservoir.
Fluid:
SAE J1703 or FMVSS No. 116 DOT 3

(c) REPLACE BRAKE FLUID
CAUTION:
The Techstream must be used during fluid replacement. If not used, the fluid replacement will be incomplete, which is hazardous and may lead to an accident.
NOTICE:
- Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on the brake fluid reservoir.
- As brake fluid may overflow, do not place the fluid can on the reservoir filler opening.
(1) Connect the Techstream to the DLC3 with the engine switch off.
(2) Check that the parking brake is set, and turn the engine switch on (IG).
(3) Enter the following menus: Chassis / ABS/VSC/TRC / Air Bleeding.
(4) Select the menu on the Techstream display based on the following list.

Bleeding work list

(d) After air bleeding or replacement, tighten the bleeder plug.
Torque: 11 Nm (110 kgf-cm, 8 ft-lbf)
NOTE:
If the brake accumulator pump operates while air remains inside the No. 2 brake actuator hose, air will enter the brake accumulator pump, resulting in difficulty in bleeding. Keep the 2 brake accumulator pump connectors disconnected before bleeding.

(e) Disconnect the 2 brake accumulator pump connectors.

(f) PERFORM ACCUMULATOR ZERO DOWN
HINT: Using the Techstream to perform accumulator zero down causes the pressurized fluid in the actuator's accumulator to be returned to the brake fluid reservoir.
(1) Drain the brake fluid in the reservoir tank near the MIN line.
(2) Connect the Techstream to the DLC3 with the engine switch off.
(3) Check that the parking brake is set, and turn the engine switch on (IG).
(4) Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Electronically Controlled Brake system Utility / Zero Down.
(5) When the buzzer sounds, turn the engine switch off.
(g) DISABLE BRAKE CONTROL
HINT: Using the 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.
(1) Check that the parking brake is set.
(2) Connect the Techstream to the DLC3 with the engine switch off.
(3) Turn the engine switch on (IG).
NOTE:
Do not start the engine.
(4) Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Electronically Controlled Brake system Utility / Electronically Controlled Brake system Invalid. Then brake control is disabled.

11. BRAKE PEDAL SUPPORT
(a) CHECK AND ADJUST BRAKE PEDAL HEIGHT
NOTE:
Fold back the carpet below the brake pedal for this inspection adjustment.

(1) Check the brake pedal height.
Standard pedal height from tibia pad:
144.2 to 154.2 mm (5.68 to 6.07 in.)
(2) 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 Nm (265 kgf cm, 19 ft.lbf)
6 Turn the stop light switch so that its protrusion is between 1.5 and 2.6 mm (0.059 and 0.102 in.). Then tighten the lock nut.

Torque:
17 Nm (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.
(b) ADJUST BRAKE PEDAL STROKE SENSOR
(1) Connect the Techstream to the DLC3 with the engine switch OFF.

(2) Loosen the 2 bolts.
(3) Turn the engine switch ON (IG). While reading the stroke sensor 1 value shown on the 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
(4) Tighten the 2 bolts.
Torque:
8.5 Nm (87 kgf cm, 75ft. lbf)
NOTE:
Do not depress the brake pedal while performing the linear valve offset learning, as this may cause a DTC to be stored.
(5) Perform the linear valve offset learning.
(c) CHECK BRAKE PEDAL FREE PLAY

(1) Press the pedal until a slight resistance is felt.
Measure the distance as shown in the illustration.
Standard pedal free play:
1.0 to 2.0 mm (0.0394 to 0.0787 in.)
If the pedal free play is 1.0 mm (0.0394 in) or less, check the protrusion of the stop light switch shaft.
Protrusion of the stop light switch shaft:
1.5 to 2.6 mm (0.0591 to 0.102 in.)
If the protrusion is not within the specified value range, adjust it.
If the protrusion is within the specified value range, troubleshoot the brake system and proceed to the "CHECK BRAKE PEDAL RESERVE DISTANCE" procedure.

(d) CHECK BRAKE PEDAL RESERVE DISTANCE
(1) Release the parking brake. Start the engine.

(2) Depress the brake pedal and check the pedal reserve distance as follows.
1 Depress the pedal with a force of 200 N (20 kgf, 45.0 lbf).
2 Measure the distance between the pedal and tibia pad shown in the illustration.
Standard pedal reserve distance:
More than 95 mm (3.74 in.)
If the distance is not as specified, troubleshoot the brake system.