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BR-67
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
HYDRAULIC BRAKE BOOSTER (w/
VSC) BR1Y8-01
ON-VEHICLE INSPECTION
1. CHECK HYDRAULIC BRAKE BOOSTER FLUID PRES-
SURE CHANGE
(a) Inspect the battery voltage.
Battery voltage: 10 to 14 V
(b) Turn the ignition switch off, and depress the brake pedal
more than 20 times.
HINT:
When pressure in the accumulator power supply system is re-
leased, reaction force becomes light and stroke becomes long-
er.
(c) Install the brake pedal effort gauge (SST), and bleed air.
SST 09709-29018
(d) When booster does not operate:
Depress the brake pedal and check fluid pressure.
At 245 N (25 kgf, 55 lbf):
Front brake pressure Rear brake pressure
2,050 to 3650 kPa
0 kPa (0 kgf/cm2, 0 psi)
(20.9 to 37.2 kgf/cm2, 297 to 529 psi)
At 343 N (35 kgf, 77 lbf):
Front brake pressure Rear brake pressure
3,270 to 4870 kPa
0 kPa (0 kgf/cm2, 0 psi)
(33.3 to 50 kgf/cm2, 474 to 711 psi)
(e) When booster operates:
(1) Turn the ignition switch on and wait until the pump
motor has stopped.
HINT:
Pump operating sound can be heard.
(2) Turn the ignition switch off, and depress the brake
pedal more than 20 times.
HINT:
When pressure in the accumulator is released, reaction force
becomes light and stroke becomes longer.
(3) Repeat (1) and (2) 5 times.
(4) Make sure that the interval between pump start and
pump stop is 8 to 14 seconds.
If it takes 14 seconds or more, repeat (3).
BR-68
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
(5) Depress the brake pedal and check fluid pressure.
At 49 N (5 kgf, 11 lbf):
Front brake pressure Rear brake pressure
933 to 2,533 kPa 993 to 1,888 kPa
(9.5 to 25.8 kgf/cm2, 135 to 367 psi) (10.1 to 19.3 kgf/cm2, 144 to 274 psi)
At 98 N (10 kgf, 22 lbf):
Front brake pressure Rear brake pressure
3,109 to 4,709 kPa 2,087 to 3,181 kPa
(31.7 to 48.0 kgf/cm2, 451 to 683 psi) (21.3 to 32.4 kgf/cm2, 303 to 461 psi)
At 147 N (15 kgf, 33 lbf):
Front brake pressure Rear brake pressure
5,284 to 6,884 kPa 3,713 to 5,311 kPa
(53.9 to 70.2 kgf/cm2, 766 to 998 psi) (37.9 to 54.2 kgf/cm2, 539 to 770 psi)
At 196 N (20 kgf, 44 lbf):
Front brake pressure Rear brake pressure
5,843 to 7,441 kPa
7,460 to 9,060 kPa
(59.6 to 75.9 kgf/cm2,
(76.1 to 92.4 kgf/cm2, 1,082 to 1,314 psi)
848 to 1,079 psi)
2. INSPECT HYDRAULIC BRAKE BOOSTER OPERA-
TION
(a) Inspect the battery voltage.
Battery voltage: 10 to 14 V
(b) Turn the ignition switch off, and depress the brake pedal
more than 20 times.
HINT:
When pressure in the accumulator power supply system is re-
leased, reaction force becomes light and stroke becomes long-
er.
(c) Check that the brake pedal becomes light to depress.
If the pedal does not become light to depress, check and re-
place the brake line and hydraulic brake booster.
(d) Turn the ignition switch on, and check the pump motor op-
eration noise.
If the pump motor does not operate, check and replace the wire
harness and pump motor (See page BR-90).
(e) Connect the hand-held tester.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch on.
(3) Select "ACTIVE TEST" mode on the hand-held tes-
ter.
HINT:
Hand-held S Please refer to the hand-held tester operator's manual
Tester
for further details.
D05981 S To protect solenoids, hand-held tester turns off automati-
cally 2 sec. after every solenoid has been turned on.
BR-69
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
3. INSPECTION PROCEDURE
Brake Fluid Reservoir
Accumulator
Brake
Pedal
Master
Cylinder
Solenoid
SREC STR SREA SMCF
SRLH SRRH SFLH SFRH
SRLR SRRR SFLR SFRR
RL w/c RR w/c FL w/c FR w/c
F19911
BR-70
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
Inspection order
SOL selected by active test SOL to be activated
(step)
(a) SRCF (SA1) SMCF
(c) SRCF (SA1) and SRCR (SA2) SREA and SMCF
(d) SFRH SFRH
(e) SFLH SFLH
(f) SFRR & SFRH SFRR and SFRH
(g) SFLR & SFLH SFLR and SFLH
(h) SRMF (SMCF, SA3) SREC
(i) SRMF (SMCF, SA3) and SRMR (SMCR, STR) STR and SREC
(j) SRRH SRRH
(k) SRLH SRLH
(l) SRH & SRR SRRR and SRRH
(m) SRLR & SRLH SRLR and SRLH
(a) Inspect front VSC solenoid (SMCF) operation.
HINT:
S ON: Activate SMCF and check that the brake pedal can-
not be depressed (the pedal feels tight).
S OFF: Deactivate SMCF and check that the brake pedal
can be depressed.
(1) Select "SRCF (SA1)" on the hand-held tester.
(2) Turn the "SRCF (SA1)" on by the hand-held tester,
then depress the brake pedal with stable force and
check that the pedal cannot be depressed.
If the pedal can be depressed, replace the hydraulic brake
booster.
HINT:
To protect the solenoids, the hand-held tester turns off auto-
matically 2 seconds after every solenoid has been turned on.
NOTICE:
When operating it continuously, set the interval of more
than 20 seconds.
(3) Release the brake pedal.
(4) When the solenoid is off, depress the brake pedal
again and check that the brake pedal can be de-
pressed.
If the pedal can be depressed, replace the hydraulic brake
booster.
(b) PREPARE THE VEHICLE
(1) Jack up and support the vehicle.
(2) Release the parking brake lever.
(3) Shift the transfer shift lever to the "N" position and
check the rear wheels by rotating them by hand.
BR-71
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
(c) Inspect front VSC solenoid (SREA) operation.
HINT:
S ON: Activate SREA and SMCF, depress the brake pedal,
and then check that the front wheels do not rotate.
S OFF: Deactivate SREA and SMCF. Reactivate SMCF, de-
press the brake pedal, and then check that the front
wheels rotate.
(1) Select "SRCR (SA2)" and "SRCF (SMCF)" on the
hand-held tester.
(2) Turn the "SRCR (SA2)" and "SRCF (SMCF)" on si-
multaneously by the hand-held tester, then de-
press the brake pedal with stable force.
(3) When the solenoids are on, check that the front
wheels do not rotate by hand.
If the front wheels rotate, replace the hydraulic brake booster.
NOTICE:
When operating it continuously, set the interval of more
than 20 seconds.
HINT:
S To protect the solenoids, the hand-held tester turns off
automatically 2 seconds after every solenoid has been
turned on.
S When rotating the wheels fast, the fail-safe function is ac-
tivated and judgement cannot be made properly.
So rotate the wheels as slowly as possible.
(4) When the solenoids are off, turn the "SRCF
(SMCF)" on again, then depress the brake pedal
and check the front wheels by rotating them by
hand.
If front wheels stop, replace the hydraulic brake booster.
(5) When the "SRCF (SMCF)" is off, depress the brake
pedal again and check that the brake pedal can be
depressed.
If the pedal can be depressed, replace the hydraulic brake
booster.
BR-72
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
(d) Inspect front ABS solenoid (SFRH) operation.
HINT:
S ON: Activate SFRH, depress the brake pedal, and then
check that the right front wheel rotates.
S OFF: Deactivate SFRH, depress the brake pedal, and
then check that the front right wheel does not rotate.
(1) Select "SFRH" on the hand-held tester.
(2) Turn the "SFRH" on by the hand-held tester, then
depress the brake pedal with stable force.
(3) When the solenoid is on, check the right front wheel
by rotating it by hand.
If the right front wheel stops, replace the hydraulic brake boost-
er.
NOTICE:
When operating it continuously, set the interval of more
than 20 seconds.
HINT:
S To protect the solenoids, the hand-held tester turns off
automatically 2 seconds after every solenoid has been
turned on.
S When rotating the wheel fast, the fail-safe function is acti-
vated and judgement cannot be made properly.
So rotate the wheel as slowly as possible.
(4) When the solenoid is off, depress the brake pedal
again and check that the right front wheel does not
rotate by hand.
If the right front wheel rotates, replace the hydraulic brake
booster.
BR-73
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
(e) Inspect front ABS solenoid (SFLH) operation.
HINT:
S ON: Activate SFLH, depress the brake pedal, and then
check that the left front wheel rotates.
S OFF: Deactivate SFLH, depress the brake pedal, and
then check that the front left wheel does not rotate.
(1) Select "SFLH" on the hand-held tester.
(2) Turn the "SFLH" on by the hand-held tester, then
depress the brake pedal with stable force.
(3) When the solenoid is on, check the left front wheel
by rotating it by hand.
If the left front wheel stops, replace the hydraulic brake booster.
NOTICE:
When operating it continuously, set the interval of more
than 20 seconds.
HINT:
S To protect the solenoids, the hand-held tester turns off
automatically 2 seconds after every solenoid has been
turned on.
S When rotating the wheel fast, the fail-safe function is acti-
vated and judgement cannot be made properly.
So rotate the wheel as slowly as possible.
(4) When the solenoid is off, depress the brake pedal
again and check that the left front wheel does not
rotate by hand.
If the left front wheel rotates, replace the hydraulic brake boost-
er.
BR-74
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
(f) Inspect front ABS solenoid (SFRR) operation.
HINT:
S ON: Depress the brake pedal, activate SFRR and SFRH,
and then check that the right front wheel rotates.
S OFF: Deactivate SFRR and SFRH, depress the brake
pedal, and then check that the right front wheel does not
rotate.
(1) Select "SFRR & SFRH" on the hand-held tester.
(2) Depress the brake pedal with stable force, then turn
the "SFRR & SFRH" on simultaneously by the
hand-held tester.
(3) When the solenoids are on, check the right front
wheel by rotating it by hand.
If the right front wheel stops, replace the hydraulic brake boost-
er.
NOTICE:
When operating it continuously, set the interval of more
than 20 seconds.
HINT:
S To protect the solenoids, the hand-held tester turns off
automatically 2 seconds after every solenoid has been
turned on.
S When rotating the wheel fast, the fail-safe function is acti-
vated and judgement cannot be made properly.
So rotate the wheel as slowly as possible.
(4) When the solenoids are off, depress the brake ped-
al again and check that the right front wheel does
not rotate by hand.
If the right front wheel rotates, replace the hydraulic brake
booster.
BR-75
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
(g) Inspect front ABS solenoid (SFLR) operation.
HINT:
S ON: Depress the brake pedal, activate SFLR and SFLH,
and then check that the left front wheel rotates.
S OFF: Deactivate SFLR and SFLH, depress the brake
pedal, and then check that the left front wheel does not
rotate.
(1) Select "SFLR & SFLH" on the hand-held tester.
(2) Depress the brake pedal with stable force, then turn
the "SFLR & SFLH" on simultaneously by the hand-
held tester.
(3) When the solenoids are on, check the left front
wheel by rotating it by hand.
If the left front wheel stops, replace the hydraulic brake booster.
NOTICE:
When operating it continuously, set the interval of more
than 20 seconds.
HINT:
S To protect the solenoids, the hand-held tester turns off
automatically 2 seconds after every solenoid has been
turned on.
S When rotating the wheel fast, the fail-safe function is acti-
vated and judgement cannot be made properly.
So rotate the wheel as slowly as possible.
(4) When the solenoids are off, depress the brake ped-
al again and check that the left front wheel does not
rotate by hand.
If the left front wheel rotates, replace the hydraulic brake boost-
er.
BR-76
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
(h) Inspect rear VSC solenoid (SREC) operation.
HINT:
S ON: Depress the brake pedal and activate SREC. Re-
lease the brake pedal and check that the rear wheels do
not rotate.
S OFF: Deactivate SREC and check that the rear wheels ro-
tate.
(1) Select "SRMF (SMCF, SA3)" on the hand-held tes-
ter.
(2) Depress the brake pedal with stable force, then turn
the "SRMF (SMCF, SA3)" on by the hand-held tes-
ter.
(3) Release the brake pedal when the solenoid is on,
and check that the rear wheels do not rotate by
hand.
If the rear wheels rotate, replace the hydraulic brake booster.
NOTICE:
When operating it continuously, set the interval of more
than 20 seconds.
HINT:
S To protect the solenoids, the hand-held tester turns off
automatically 2 seconds after every solenoid has been
turned on.
S When rotating the wheels fast, the fail-safe function is ac-
tivated and judgement cannot be made properly.
So rotate the wheels as slowly as possible.
(4) When the solenoid is off, check the rear wheels by
rotating them by hand.
If the rear wheels stop, replace the hydraulic brake booster.
BR-77
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
(i) Inspect rear VSC solenoid (STR) operation.
HINT:
S ON: Activate STR and SREC, then check that the rear
wheels do not rotate.
S OFF: Deactivate STR and SREC. Reactivate SREC and
check that the rear wheels rotate.
(1) Select "SRMR (SMCR, STR)" on the hand-held tes-
ter.
(2) Turn the "SRMR (SMCR, STR)" on simultaneously
by the hand-held tester.
(3) When the solenoids are on, check that the rear
wheels do not rotate by hand.
If the rear wheels rotate, replace the hydraulic brake booster.
NOTICE:
When operating it continuously, set the interval of more
than 20 seconds.
HINT:
S To protect the solenoids, the hand-held tester turns off
automatically 2 seconds after every solenoid has been
turned on.
S When rotating the wheels fast, the fail-safe function is ac-
tivated and judgement cannot be made properly.
So rotate the wheels as slowly as possible.
(4) When the solenoids are off, check the rear wheels
by rotating them by hand.
If the rear wheels stop, replace the hydraulic brake booster.
(5) When the "SRMF (SREC)" is off, depress the brake
pedal again and check that the rear wheels do not
rotate by hand.
If the rear wheels rotate, replace the hydraulic brake booster.
BR-78
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
(j) Inspect rear ABS solenoid (SRRH) operation.
HINT:
S ON: Activate SRRH, depress the brake pedal, and then
check that the right rear wheel rotates.
S OFF: Deactivate SRRH, depress the brake pedal, and
then check that the right rear wheel does not rotate.
(1) Select "SRRH" on the hand-held tester.
(2) Turn the "SRRH" on by the hand-held tester, then
depress the brake pedal with stable force.
(3) When the solenoid is on, check the right rear wheel
by rotating it by hand.
If the right rear wheel stops, replace the hydraulic brake boost-
er.
NOTICE:
When operating it continuously, set the interval of more
than 20 seconds.
HINT:
S To protect the solenoids, the hand-held tester turns off
automatically 2 seconds after every solenoid has been
turned on.
S When rotating the wheel fast, the fail-safe function is acti-
vated and judgement cannot be made properly.
So rotate the wheel as slowly as possible.
(4) When the solenoid is off, depress the brake pedal
again and check that the right rear wheel does not
rotate by hand.
If the right rear wheel rotates, replace the hydraulic brake boost-
er.
BR-79
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
(k) Inspect rear ABS solenoid (SRLH) operation.
HINT:
S ON: Activate SRLH, depress the brake pedal, and then
check that the left rear wheel rotates.
S OFF: Deactivate SRLH, depress the brake pedal, and
then check that the left rear wheel does not rotate.
(1) Select "SRLH" on the hand-held tester.
(2) Turn the "SRLH" on by the hand-held tester, then
depress the brake pedal with stable force.
(3) When the solenoids is on, check the left rear wheel
by rotating it by hand.
If the left rear wheel stops, replace the hydraulic brake booster.
NOTICE:
When operating it continuously, set the interval of more
than 20 seconds.
HINT:
S To protect the solenoids, the hand-held tester turns off
automatically 2 seconds after every solenoid has been
turned on.
S When rotating the wheel fast, the fail-safe function is acti-
vated and judgement cannot be made properly.
So rotate the wheel as slowly as possible.
(4) When the solenoid is off, depress the brake pedal
again and check that the left rear wheel does not ro-
tate by hand.
If the left rear wheel rotates, replace the hydraulic brake boost-
er.
BR-80
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
(l) Inspect rear ABS solenoid (SRRR) operation.
HINT:
S ON: Depress the brake pedal, activate SRRR and SRRH,
and then check that the right rear wheel rotates.
S OFF: Deactivate SRRR and SRRH, depress the brake
pedal, and then check that the right rear wheel does not
rotate.
(1) Select "SRH & SRR" on the hand-held tester.
(2) Depress the brake pedal with stable force, then turn
the "SRH & SRR" on simultaneously by the hand-
held tester.
(3) When the solenoids are on, check the right rear
wheel by rotating it by hand.
If the right rear wheel stops, replace the hydraulic brake boost-
er.
NOTICE:
When operating it continuously, set the interval of more
than 20 seconds.
HINT:
S To protect the solenoids, the hand-held tester turns off
automatically 2 seconds after every solenoid has been
turned on.
S When rotating the wheel fast, the fail-safe function is acti-
vated and judgement cannot be made properly.
So rotate the wheel as slowly as possible.
(4) When the solenoids are off, depress the brake ped-
al again and check that the right rear wheel does not
rotate by hand.
If the right rear wheel rotates, replace the hydraulic brake boost-
er.
BR-81
BRAKE - HYDRAULIC BRAKE BOOSTER (w/ VSC)
(m) Inspect rear ABS solenoid (SRLR) operation.
HINT:
S ON: Depress the brake pedal, activate SRLR and SRLH,
and then check that the left rear wheel rotates.
S OFF: Deactivate SRLR and SRLH, depress the brake
pedal, and then check that the left rear wheel does not ro-
tate.
(1) Select "SRLR & SRLH" on the hand-held tester.
(2) Depress the brake pedal with stable force, then turn
the "SRLR & SRLH" on simultaneously by the
hand-held tester.
(3) When the solenoids are on, check the left rear
wheel by rotating it by hand.
If the left rear wheel stops, replace the hydraulic brake booster.
NOTICE:
When operating it continuously, set the interval of more
than 20 seconds.
HINT:
S To protect the solenoids, the hand-held tester turns off
automatically 2 seconds after every solenoid has been
turned on.
S When rotating the wheel fast, the fail-safe function is acti-
vated and judgement cannot be made properly.
So rotate the wheel as slowly as possible.
(4) When the solenoids are off, depress the brake ped-
al again and check that the left rear wheel does not
rotate by hand.
If the left rear wheel rotates, replace the hydraulic brake boost-
er.
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