Toyota Corolla Cross: Excessive Brake Pedal Travel (No Fluid Leaks and No Air in System)
PROCEDURE
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1. |
PRE-INSPECTION |
(a) Brake pedal inspection
(1) Perform a visual inspection and operate the brake pedal to check for any malfunctions.
(2) Check the brake pedal height, brake pedal free play and brake pedal reserve distance.
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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
(1) Check that the disc brake pads of each wheel are installed correctly.
(2) 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
(1) Check and take a note of the fluid level in the brake master cylinder reservoir assembly.
(2) Repeatedly depress the brake pedal and confirm that the brake pedal feels normal (no air in the system, etc.).
(3) Check if the brake fluid level in the brake master cylinder reservoir assembly has changed.
(4) 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
(1) Bleed air from the brake lines and brake actuator assembly.
Click here
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2. |
PERFORM ACTIVE TEST USING GTS (MOTOR RELAY) |
(a) Fully depress and hold the brake pedal.
HINT:
Make sure that the brake pedal has travelled excessively before holding it depressed.
(b) Operate the ABS motor relay using the Active Test and check if the brake pedal height changes when the pump motor is operating.
Chassis > Brake/EPB > Active Test|
Tester Display |
Measurement Item |
Control Range |
Restrict Condition |
Diagnostic Note |
|---|---|---|---|---|
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Motor Relay |
ABS motor relay |
Relay OFF / ON |
Vehicle condition: Vehicle stopped HINT: To protect this Actuator and Solenoid, this test will only last 5 seconds. |
Refer to on-vehicle inspection for the brake actuator (for Gasoline Model)* |
*: Click here
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Tester Display |
|---|
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Motor Relay |
OK:
The brake pedal height does not change (the brake pedal travel remains excessive).
| NG | .gif)
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REPLACE BRAKE ACTUATOR ASSEMBLY |
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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.
| NG |
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REPLACE BRAKE MASTER CYLINDER SUB-ASSEMBLY |
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4. |
INSPECT BRAKE BOOSTER ASSEMBLY |
Click here
OK:
The brake booster assembly is normal.
| OK |
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USE SIMULATION METHOD TO CHECK |
| NG |
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REPLACE BRAKE BOOSTER ASSEMBLY |
READ NEXT:
ABS Operates Before Necessary When Braking
DESCRIPTION
Troubleshooting for when ABS operates too soon due to a noisy
signal from the speed sensor, a difference in output, etc.
PROCEDURE
1.
PERFORM DEALER MODE (SIGNA
VSC does not Operate or VSC does not Operate Correctly
DESCRIPTION
When TRAC or VSC is operating, the skid control ECU (brake actuator
assembly) blinks the slip indicator light to inform the driver that slippage occurred.
When a communication malfunct
Brake Actuator Operation Sound is Loud during Initial Check
PROCEDURE
1.
PERFORM ROAD TEST
(a) After turning the ignition switch to ON, compare the operating
sound of the brake actuator the first time the vehicle speed reach
SEE MORE:
VEHICLE CONTROL HISTORY (RoB)
VEHICLE CONTROL HISTORY (RoB) DESCRIPTION
Vehicle Control History (RoB) is a function that captures and stores ECU data when triggered by specific vehicle behavior.
If the customer states that there was a problem such as the engine not restarting after having been stopped by the stop and s
Removal
REMOVAL
CAUTION / NOTICE / HINT
COMPONENTS (REMOVAL)
Procedure
Part Name Code
1
SECURE VEHICLE
-
-
-
2
AUXILIARY BATTERY
-
