RM35X0E _54 Brake _078667 BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS _0383093 ELECTRONICALLY CONTROLLED BRAKE SYSTEM(w/o VSC OFF Switch) J

BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS  ELECTRONICALLY CONTROLLED BRAKE SYSTEM(w/o VSC OFF Switch)  Excessive Brake Pedal Travel (No Fluid Leaks and No Air in System)  


CAUTION / NOTICE / HINT

NOTICE:

After replacing the skid control ECU (brake actuator assembly), perform store system information memorization.

Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>ELECTRONICALLY CONTROLLED BRAKE SYSTEM (w/o VSC OFF Switch)>UTILITY


PROCEDURE

1.PRE-INSPECTION
a.

Brake pedal inspection

i.

Perform a visual inspection and operate the brake pedal to check for any malfunctions.


ii.

Check the brake pedal height, brake pedal free play and brake pedal reserve distance.

for LHD: Click hereBrake>BRAKE SYSTEM (OTHER)>BRAKE PEDAL (for LHD)>ADJUSTMENT

for RHD: Click hereBrake>BRAKE SYSTEM (OTHER)>BRAKE PEDAL (for RHD)>ADJUSTMENT

HINT:

If the brake pedal height is not within specification, confirm that there are no other malfunctions before adjusting the brake pedal height.




b.

Brake inspection

i.

Check that the disc brake pads or brake shoe of each wheel are installed correctly.


ii.

Check that the bleeder plug and union bolt is not loose, and that there are no damaged gaskets or brake fluid leaks, for each wheel cylinder.



c.

Brake fluid leaks and air in brake line inspection

i.

Check and take a note of the fluid level in the brake master cylinder reservoir assembly.


ii.

Repeatedly depress the brake pedal and confirm that the brake pedal feels normal (no air in the system, etc.).


iii.

Check if the brake fluid level in the brake master cylinder reservoir assembly has changed.


iv.

If the brake fluid level has decreased, check for leaks due to damaged brake lines or hoses, loose union nuts, damaged brake master cylinder sub-assembly seals, etc.



d.

Bleeding air from brake system

i.

Bleed air from the brake lines and brake actuator assembly.

Click hereBrake>BRAKE SYSTEM (OTHER)>BRAKE FLUID>BLEEDING



Result:
Proceed to
NEXT



NEXT

2.PERFORM ACTIVE TEST USING GTS (MOTOR RELAY)
2.PERFORM ACTIVE TEST USING GTS (MOTOR RELAY)
a.

Connect the GTS to the DLC3.


b.

Turn the ignition switch to ON.


c.

Enter the following menus: Chassis / Brake / Active Test.

Chassis > Brake > Active Test
Tester Display Measurement Item Control Range Restrict Condition Diagnostic Note
Motor Relay ABS motor relay OFF / ON Vehicle condition: Vehicle stopped
HINT:

To protect this actuator and solenoid, this test will only last 5 seconds.


-
Chassis > Brake > Active Test
Tester Display
Motor Relay
50004 435 25

d.

Fully depress and hold the brake pedal.

HINT:

Make sure that the brake pedal has travelled excessively before holding it depressed.



e.

Operate the ABS motor relay using the Active Test and check if the brake pedal height changes when the pump motor is operating.

OK:

The brake pedal height does not change (the brake pedal travel remains excessive).



Result:
Proceed to
OK
NG



OK

3.CHECK BRAKE MASTER CYLINDER SUB-ASSEMBLY

NG

REPLACE BRAKE ACTUATOR ASSEMBLY

Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>BRAKE ACTUATOR>REMOVAL


3.CHECK BRAKE MASTER CYLINDER SUB-ASSEMBLY
a.

Check that there are no brake fluid leaks and no indications of a malfunction in the brake master cylinder sub-assembly.

OK:

There are no brake fluid leaks and no indications of a malfunction in the brake master cylinder sub-assembly.



Result:
Proceed to
OK
NG



OK

4.INSPECT BRAKE BOOSTER ASSEMBLY

NG

REPLACE BRAKE MASTER CYLINDER SUB-ASSEMBLY

for LHD: Click hereBrake>BRAKE SYSTEM (OTHER)>BRAKE MASTER CYLINDER (for LHD)>DISASSEMBLY

for RHD: Click hereBrake>BRAKE SYSTEM (OTHER)>BRAKE MASTER CYLINDER (for RHD)>DISASSEMBLY