RM38T0EC _54 Brake _112606 BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS _0608077 ELECTRONICALLY CONTROLLED BRAKE SYSTEM(for HEV Model) C

BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS  ELECTRONICALLY CONTROLLED BRAKE SYSTEM(for HEV Model)  C05621C  Brake Pedal Position Sensor Supply Voltage Circuit Voltage Out of Range  C139200  Zero Point Calibration of Stroke Sensor  P057A11  Brake Pedal Position Sensor "A" Circuit Short to Ground  P057A15  Brake Pedal Position Sensor "A" Circuit Short to Battery or Open  P057A28  Brake Pedal Position Sensor "A" Signal Bias Level Out of Range / Zero Adjustment Failure  P057A64  Brake Pedal Position Sensor "A" Signal Plausibility Failure  P05DB11  Brake Pedal Position Sensor "B" Circuit Short to Ground  P05DB15  Brake Pedal Position Sensor "B" Circuit Short to Battery or Open  P05DB28  Brake Pedal Position Sensor "B" Signal Bias Level Out of Range / Zero Adjustment Failure  P05DB64  Brake Pedal Position Sensor "B" Signal Plausibility Failure  P05E064  Brake Pedal Position Sensor "A"/"B" Signal Plausibility Failure  P157A62  Brake Pedal Position Sensor "A" / "B" Brake Master Cylinder Pressure Sensor Multiple Sensor Signal Compare Failure  


DESCRIPTION

The brake pedal stroke sensor assembly sends the brake pedal stroke distance to the skid control ECU inside the brake actuator assembly.

DTC No. Detection Item DTC Detection Condition Trouble Area MIL DTC Output from Note
C05621C Brake Pedal Position Sensor Supply Voltage Circuit Voltage Out of Range Brake pedal stroke sensor assembly power source malfunction detected.
·

Brake pedal stroke sensor assembly

·

Skid control ECU (brake actuator assembly)


Does not come on Brake/EPB Output ECU: Skid control ECU (brake actuator assembly)
C139200 Zero Point Calibration of Stroke Sensor While the brake pedal is not being depressed, brake pedal stroke sensor assembly zero point not calibrated signal is received. (A correct brake pedal stroke sensor assembly zero point learning value is not present).
·

Brake pedal stroke sensor assembly

·

Skid control ECU (brake actuator assembly)


Does not come on Brake/EPB Output ECU: Skid control ECU (brake actuator assembly)
P057A11 Brake Pedal Position Sensor "A" Circuit Short to Ground Open or short detected due to abnormality in brake pedal stroke sensor assembly output circuit 1.
·

Brake pedal stroke sensor assembly

·

Skid control ECU (brake actuator assembly)


Does not come on Brake/EPB Output ECU: Skid control ECU (brake actuator assembly)
P057A15 Brake Pedal Position Sensor "A" Circuit Short to Battery or Open Open or short detected due to abnormality in brake pedal stroke sensor assembly output circuit 1.
·

Brake pedal stroke sensor assembly

·

Skid control ECU (brake actuator assembly)


Does not come on Brake/EPB Output ECU: Skid control ECU (brake actuator assembly)
P057A28 Brake Pedal Position Sensor "A" Signal Bias Level Out of Range / Zero Adjustment Failure Difference in change amount of brake pedal stroke sensor assembly output voltage 1 (SKS1) is abnormally large for 0.1 seconds or more. (SKS1 output comparison invalid).
·

Brake pedal stroke sensor assembly

·

Skid control ECU (brake actuator assembly)


Does not come on Brake/EPB Output ECU: Skid control ECU (brake actuator assembly)
P057A64 Brake Pedal Position Sensor "A" Signal Plausibility Failure Difference in change amount of brake pedal stroke sensor assembly output voltage 1 (SKS1) is abnormally large for 0.2 seconds or more. (SKS1 output comparison invalid).
·

Brake pedal stroke sensor assembly

·

Skid control ECU (brake actuator assembly)


Does not come on Brake/EPB Output ECU: Skid control ECU (brake actuator assembly)
P05DB11 Brake Pedal Position Sensor "B" Circuit Short to Ground Open or short detected due to abnormality in brake pedal stroke sensor assembly output circuit 2.
·

Brake pedal stroke sensor assembly

·

Skid control ECU (brake actuator assembly)


Does not come on Brake/EPB Output ECU: Skid control ECU (brake actuator assembly)
P05DB15 Brake Pedal Position Sensor "B" Circuit Short to Battery or Open Open or short detected due to abnormality in brake pedal stroke sensor assembly output circuit 2.
·

Brake pedal stroke sensor assembly

·

Skid control ECU (brake actuator assembly)


Does not come on Brake/EPB Output ECU: Skid control ECU (brake actuator assembly)
P05DB28 Brake Pedal Position Sensor "B" Signal Bias Level Out of Range / Zero Adjustment Failure Difference in change amount of brake pedal stroke sensor assembly output voltage 2 (SKS2) is abnormally large for 0.1 seconds or more. (SKS2 output comparison invalid).
·

Brake pedal stroke sensor assembly

·

Skid control ECU (brake actuator assembly)


Does not come on Brake/EPB Output ECU: Skid control ECU (brake actuator assembly)
P05DB64 Brake Pedal Position Sensor "B" Signal Plausibility Failure Difference in change amount of brake pedal stroke sensor assembly output voltage 2 (SKS2) is abnormally large for 0.2 seconds or more. (SKS2 output comparison invalid).
·

Brake pedal stroke sensor assembly

·

Skid control ECU (brake actuator assembly)


Does not come on Brake/EPB Output ECU: Skid control ECU (brake actuator assembly)
P05E064 Brake Pedal Position Sensor "A"/"B" Signal Plausibility Failure Difference between change amounts of brake pedal stroke sensor assembly output voltage 1 (SKS1) and brake pedal stroke sensor assembly output voltage 2 (SKS2) is abnormally large for 0.2 seconds or more. (SKS1 and SKS2 output comparison invalid).
·

Brake pedal stroke sensor assembly

·

Skid control ECU (brake actuator assembly)


Does not come on Brake/EPB Output ECU: Skid control ECU (brake actuator assembly)
P157A62 Brake Pedal Position Sensor "A" / "B" Brake Master Cylinder Pressure Sensor Multiple Sensor Signal Compare Failure While driving at a vehicle speed of 3 km/h or more, the master cylinder pressure sensor value is too high relative to the brake pedal stroke sensor assembly value for 0.2 seconds or more.
·

Brake pedal stroke sensor assembly

·

Skid control ECU (brake actuator assembly)


Does not come on Brake/EPB Output ECU: Skid control ECU (brake actuator assembly)

WIRING DIAGRAM

C443937E20
2.365,1.219 2.823,1.417 0.458,0.198 10 false VSK 4.99,1.094 5.448,1.292 0.458,0.198 10 false 17 2.292,1.854 2.75,2.052 0.458,0.198 10 false SKS1 5.281,1.854 5.74,2.052 0.458,0.198 10 false SKS1 5.281,2.469 5.74,2.667 0.458,0.198 10 false SKS2 2.281,2.469 2.74,2.667 0.458,0.198 10 false SKS2 2.344,2.979 2.802,3.177 0.458,0.198 10 false SKG 5.281,2.969 5.74,3.167 0.458,0.198 10 false SKG 0.938,3.573 1.396,3.771 0.458,0.198 10 false A196 0.938,3.75 2.656,4.229 1.719,0.479 10 false Brake Pedal Stroke Sensor Assembly 5.229,3.573 5.688,3.771 0.458,0.198 10 false A151 5.219,3.75 6.76,4.146 1.542,0.396 10 false Skid Control ECU (Brake Actuator Assembly) 5.281,1.229 5.74,1.427 0.458,0.198 10 false VSK 5.042,1.698 5.5,1.896 0.458,0.198 10 false 6 5.01,2.333 5.469,2.531 0.458,0.198 10 false 42 5.01,2.844 5.469,3.042 0.458,0.198 10 false 29 2.781,1.083 3.24,1.281 0.458,0.198 10 false 1 2.792,1.698 3.25,1.896 0.458,0.198 10 false 2 2.792,2.323 3.25,2.521 0.458,0.198 10 false 4 2.792,2.844 3.25,3.042 0.458,0.198 10 false 3

PROCEDURE

1.CHECK BRAKE PEDAL
a.

Check that the brake pedal and the brake pedal stroke sensor assembly are properly installed and that the pedal can be depressed normally.


b.

Check and adjust the brake pedal height.

Click hereBrake>BRAKE SYSTEM (OTHER)>BRAKE PEDAL (for HEV Model)>ADJUSTMENT


c.

Adjust the brake pedal stroke sensor assembly.

Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>BRAKE PEDAL STROKE SENSOR (for HEV Model)>INSTALLATION


Result:
Proceed to
NEXT



NEXT

2.CHECK DTC
2.CHECK DTC
a.

Read the DTCs using the GTS.

Chassis > Brake/EPB > Trouble Codes
50001 435

Result:
Result Proceed to
C05621C, C139200, P057A11, P057A15, P057A28, P057A64, P05DB11, P05DB15, P05DB28, P05DB64, P05E064 or P157A62 is output A
Only C139200 is output B
None of the above conditions are met C



A

3.CHECK HARNESS AND CONNECTOR (BRAKE ACTUATOR ASSEMBLY - BRAKE PEDAL STROKE SENSOR ASSEMBLY)

B

5.CLEAR BRAKE PEDAL STROKE SENSOR ASSEMBLY ZERO POINT

C

REPAIR CIRCUITS INDICATED BY OUTPUT DTCS

3.CHECK HARNESS AND CONNECTOR (BRAKE ACTUATOR ASSEMBLY - BRAKE PEDAL STROKE SENSOR ASSEMBLY)
a.

Turn the ignition switch off.


b.

Make sure that there is no looseness at the locking part and the connecting part of the connectors.

OK:

The connector is securely connected.



c.

Disconnect the A151 skid control ECU (Brake Actuator Assembly) connector.


d.

Disconnect the A196 brake pedal stroke sensor assembly connector.


e.

Check both the connector case and the terminals for deformation and corrosion.

OK:

No deformation or corrosion.



f.

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

Standard Resistance:
Tester Connection Condition Specified Condition
A151-17 (VSK) - A196-1 (VSK) Always Below 1 Ω
A151-17 (VSK) or A196-1 (VSK) - Body ground Always 10 kΩ or higher
A151-6 (SKS1) - A196-2 (SKS1) Always Below 1 Ω
A151-6 (SKS1) or A196-2 (SKS1) - Body ground Always 10 kΩ or higher
A151-42 (SKS2) - A196-4 (SKS2) Always Below 1 Ω
A151-42 (SKS2) or A196-4 (SKS2) - Body ground Always 10 kΩ or higher
A151-29 (SKG) - A196-3 (SKG) Always Below 1 Ω
A151-29 (SKG) or A196-3 (SKG) - Body ground Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

4.INSPECT BRAKE ACTUATOR ASSEMBLY (SENSOR OUTPUT)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

4.INSPECT BRAKE ACTUATOR ASSEMBLY (SENSOR OUTPUT)
a.
C491383C09
0.25,1 0.667,1.25 0.417,0.25 1.135,1.823 1.385,1.323 true 2.073,1.813 1.823,1.313 true 0.292,1.031 0.75,1.229 0.458,0.198 10 false A196 0.167,0.135 0.479,0.333 0.313,0.198 10 false *a 1,1.844 1.458,2.042 0.458,0.198 10 false VSK 2.01,1.844 2.469,2.042 0.458,0.198 10 false SKG
*a Front view of wire harness connector
(to Brake Pedal Stroke Sensor Assembly)


Make sure that there is no looseness at the locking part and the connecting part of the connectors.

OK:

The connector is securely connected.



b.

Disconnect the A196 brake pedal stroke sensor assembly connector.


c.

Check both the connector case and the terminals for deformation and corrosion.

OK:

No deformation or corrosion.



d.

Turn the ignition switch to ON.


e.

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

Standard Voltage:
Tester Connection Condition Specified Condition
A196-1 (VSK) - A196-3 (SKG) Ignition switch ON 4.84 to 5.16 V



Result:
Proceed to
OK
NG



OK

REPLACE BRAKE PEDAL STROKE SENSOR ASSEMBLY

Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>BRAKE PEDAL STROKE SENSOR (for HEV Model)>REMOVAL


NG

REPLACE BRAKE ACTUATOR ASSEMBLY

Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>BRAKE ACTUATOR (for HEV Model)>REMOVAL


5.CLEAR BRAKE PEDAL STROKE SENSOR ASSEMBLY ZERO POINT
a.

Using the GTS, clear the brake pedal stroke sensor assembly zero point.

Chassis > Brake/EPB > Utility
Tester Display
Reset Memory
50005 435 4560

Result:
Proceed to
NEXT



NEXT

6.PERFORM BRAKE PEDAL STROKE SENSOR ASSEMBLY ZERO POINT CALIBRATION
6.PERFORM BRAKE PEDAL STROKE SENSOR ASSEMBLY ZERO POINT CALIBRATION
a.

Using the GTS, perform the brake pedal stroke sensor assembly zero point calibration.

Chassis > Brake/EPB > Utility
Tester Display
Calibration
50005 435 4554

Result:
Proceed to
NEXT



NEXT

7.CLEAR DTC
7.CLEAR DTC
a.

Clear the DTCs.

Chassis > Brake/EPB > Clear DTCs
50002 435

b.

Turn the ignition switch off.


Result:
Proceed to
NEXT



NEXT

8.RECONFIRM DTC
8.RECONFIRM DTC
a.

Based on the Freeze Frame Data and interview with the customer, attempt to reproduce the conditions when the malfunction occurred.


b.

Check if the same DTC is output.

Chassis > Brake/EPB > Trouble Codes
50001 435

Result:
Result Proceed to
C139200 is output A
DTCs are not output B
None of the above conditions are met C



A

9.INSPECT BRAKE ACTUATOR ASSEMBLY (SENSOR OUTPUT)

B

USE SIMULATION METHOD TO CHECK

Click hereGeneral>INTRODUCTION>HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS>HOW TO PROCEED WITH TROUBLESHOOTING


C

REPAIR CIRCUITS INDICATED BY OUTPUT DTCS

9.INSPECT BRAKE ACTUATOR ASSEMBLY (SENSOR OUTPUT)
a.
C491383C11
0.25,1 0.667,1.25 0.417,0.25 1.135,1.823 1.385,1.323 true 2.073,1.813 1.823,1.313 true 0.292,1.031 0.75,1.229 0.458,0.198 10 false A196 0.167,0.135 0.479,0.333 0.313,0.198 10 false *a 0.938,1.844 1.427,2.104 0.49,0.26 10 false VSK 2.01,1.844 2.469,2.042 0.458,0.198 10 false SKG
*a Front view of wire harness connector
(to Brake Pedal Stroke Sensor Assembly)


Turn the ignition switch off.


b.

Make sure that there is no looseness at the locking part and the connecting part of the connectors.

OK:

The connector is securely connected.



c.

Reconnect the A196 brake pedal stroke sensor assembly connector.


d.

Check both the connector case and the terminals for deformation and corrosion.

OK:

No deformation or corrosion.



e.

Turn the ignition switch to ON.


f.

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

Standard Voltage:
Tester Connection Condition Specified Condition
A196-1 (VSK) - A196-3 (SKG) Ignition switch ON 4.84 to 5.16 V



Result:
Proceed to
OK
NG



OK

REPLACE BRAKE PEDAL STROKE SENSOR ASSEMBLY

Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>BRAKE PEDAL STROKE SENSOR (for HEV Model)>REMOVAL


NG

REPLACE BRAKE ACTUATOR ASSEMBLY

Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>BRAKE ACTUATOR (for HEV Model)>REMOVAL