On-Vehicle Inspection

CHECK HYDRAULIC BRAKE BOOSTER FLUID PRESSURE CHANGE

Inspect the battery positive voltage.
Battery positive voltage: 10 - 14 V
Turn the ignition switch OFF, depress the brake pedal more than 40 times.
HINT:

When a pressure in power supply system is released, reaction force becomes light and stroke becomes longer.
Install LSPV gauge (SST) and brake pedal effort gauge, bleed air.
SST 09709-29018

Fig 1: Installing LSPV Gauge And Brake Pedal Effort Gauge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

When booster does not operate:

Depress the brake pedal and check fluid pressure.

BRAKE PEDAL AND FLUID PRESSURE AT 245 N (25 kgf, 55 lbf) (BOOSTER DOES NOT OPERATE)

Front brake pressure	Rear brake pressure
2,700 kPa (27.5 kgf/cm² , 391 psi) or more	0 kPa (0 kgf/cm² , 0 psi)

BRAKE PEDAL AND FLUID PRESSURE AT 343 N (35 kgf, 77 lbf) (BOOSTER DOES NOT OPERATE)

Front brake pressure	Rear brake pressure
3,950 kPa (40 kgf/cm² , 568 psi) or more	0 kPa (0 kgf/cm² , 0 psi)

w/ ABS only, when booster operate:

Turn the ignition switch ON and wait until the pump motor has stopped.

Depress the brake pedal and check fluid pressure.

BRAKE PEDAL AND FLUID PRESSURE AT 49 N (5 kgf, 11 lbf) (W/ABS ONLY - BOOSTER OPERATES)

Front brake pressure	Rear brake pressure
1,618 - 2,795 kPa (16.5 - 28.5 kgf/cm² , 234 - 405 psi)	1,716 - 2,893 kPa (17.5 - 29.5 kgf/cm² , 249 - 419 psi)

BRAKE PEDAL AND FLUID PRESSURE AT 98 N (10 kgf, 22 lbf) (W/ABS ONLY - BOOSTER OPERATES)

Front brake pressure	Rear brake pressure
4,413 - 5,624 kPa (45 - 57 kgf/cm² , 639 - 809 psi)	3,187 - 4,364 kPa (32.5 - 44.5 kgf/cm² , 462 - 632 psi)

BRAKE PEDAL AND FLUID PRESSURE AT 147 N (15 kgf, 33 lbf) (W/ABS ONLY - BOOSTER OPERATES)

Front brake pressure	Rear brake pressure
7,208 - 8,436 kPa (73.5 - 85.5 kgf/cm² , 1,043 - 1,214 psi)	4,609 - 5,786 kPa (47 - 59 kgf/cm² , 667 - 838 psi)

BRAKE PEDAL AND FLUID PRESSURE AT 196 N (20 kgf, 44 lbf) (W/ABS ONLY - BOOSTER OPERATES)

Front brake pressure	Rear brake pressure
9,905 - 11,082 kPa (101 - 113 kgf/cm² , 1,434 - 1,604 psi)	6,031 - 7,208 kPa (61.5 - 73.5 kgf/cm² , 873 - 1,044 psi)

w/ ABS & TRAC & VSC ECU only, when booster operate:

Turn the ignition switch ON and wait until the pump motor has stopped.

Depress the brake pedal and check fluid pressure.

BRAKE PEDAL AND FLUID PRESSURE AT 49 N (5 kgf, 11 lbf) (W/ABS & TRAC & VSC ECU ONLY - WHEN BOOSTER OPERATE)

Front brake pressure	Rear brake pressure
1,618 - 2,795 kPa (16.5 - 28.5 kgf/cm² , 234 - 405 psi)	1,716 - 2,893 kPa (17.5 - 29.5 kgf/cm² , 249 - 419 psi)

BRAKE PEDAL AND FLUID PRESSURE AT 98 N (10 kgf, 22 lbf) (W/ABS & TRAC & VSC ECU ONLY - WHEN BOOSTER OPERATE)

Front brake pressure	Rear brake pressure
4,413 - 5,624 kPa (45 - 57 kgf/cm² , 639 - 809 psi)	4,609 - 5,786 kPa (47 - 59 kgf/cm² , 668 - 839 psi)

BRAKE PEDAL AND FLUID PRESSURE AT 147 N (15 kgf, 33 lbf) (W/ABS & TRAC & VSC ECU ONLY - WHEN BOOSTER OPERATE)

Front brake pressure	Rear brake pressure
7,208 - 8,436 kPa (73.5 - 85.5 kgf/cm² , 1,043 - 1,214 psi)	7,502 - 8,679 kPa (76.5 - 88.5 kgf/cm² , 1,088 - 1,259 psi)

BRAKE PEDAL AND FLUID PRESSURE AT 196 N (20 kgf, 44 lbf) (W/ABS & TRAC & VSC ECU ONLY - WHEN BOOSTER OPERATE)

Front brake pressure	Rear brake pressure
9,905 - 11,082 kPa (101 - 113 kgf/cm² , 1,434 - 1,604 psi)	10,346 - 11,523 kPa (105.5 - 117.5 kgf/cm² , 1,501 - 1,671 psi)

w/ ABS only, In case of using TOYOTA hand-held tester: INSPECT HYDRAULIC BRAKE BOOSTER OPERATION
1. Inspect the battery positive voltage.
  Battery positive voltage: 10 - 14 V
2. Turn the ignition switch OFF, depress the brake pedal more than 40 times.
  HINT:
  
  When a pressure in power supply system is released, reaction force becomes light and stroke becomes longer.
3. Turn the ignition switch ON, check the pump motor operation noise.
  If the pump motor does not operate, check and replace the wire harness and pump motor (See INSPECTION ).
4. Connect the TOYOTA hand-held tester.
  1. Connect the TOYOTA hand-held tester to the DLC3.
    
    Fig 2: Connecting Hand-Held Tester To DLC3
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Turn the ignition switch ON.
  3. Select the "ACTIVE TEST" mode on the TOYOTA hand-held tester.
    HINT:
    - Please refer to the TOYOTA hand-held tester operator's manual for further details.
    - To protect the solenoids, TOYOTA hand-held tester turns OFF automatically for 2 sec. after every solenoid has been turned ON.
5. Inspect the front ABS switching solenoid operation.
  1. Select "SA1" and "SA2" on the TOYOTA hand-held tester.
  2. With "SA1" and "SA2" turned ON simultaneously with the TOYOTA hand-held tester, depress the brake pedal with stable force and check that the pedal cannot be depressed.
    HINT:
    
    To protect the solenoids, TOYOTA hand-held tester turns OFF automatically for 2 sec. after every solenoid has been turned ON.
    
    If the pedal can be depressed, replace the hydraulic brake booster.
    
    NOTE: When operating it continuously, set the interval of more than 20 sec.
  3. Once, release the brake pedal.
  4. When the solenoids are OFF, after depressing the brake pedal again and check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
6. Inspect the front ABS solenoid operation.
  1. Select "SFRH" and "SFLH" on the TOYOTA hand-held tester.
  2. With "SFRH" and "SFLH" turned ON simultaneously with the TOYOTA hand-held tester, depress the brake pedal with stable force and check that the brake pedal cannot be depressed.
    HINT:
    
    To protect the solenoids, TOYOTA hand-held tester turns OFF automatically for 2 sec. after every solenoid has been turned ON.
    
    If the pedal can be depressed, replace the hydraulic brake booster.
  3. Once, release the brake pedal when the solenoids are OFF, check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
  4. Once, release the brake pedal. After depressing and holding the brake pedal with stable force, turn the SFRH and SFRR solenoids ON simultaneously.
    HINT:
    
    To protect the solenoids, TOYOTA hand-held tester turns OFF automatically for 2 sec. after every solenoid has been turned ON.
  5. When the solenoids are OFF, check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
  6. Once, release the brake pedal. After depressing and holding the brake pedal with stable force, turn the SFLH and SFLR solenoids ON simultaneously.
    HINT:
    
    To protect the solenoids, TOYOTA hand-held tester turns OFF automatically for 2 sec. after every solenoid has been turned ON.
  7. Once release the brake pedal when the solenoids are OFF, check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
7. Jack up and support the vehicle.
8. Release the parking brake lever.
9. Inspect the rear ABS solenoid.
  1. Select the "SRH" on the TOYOTA hand-held tester.
  2. Turn the "SRH" ON with the TOYOTA hand-held tester and depress the brake pedal with stable force, and rotate the right rear wheel by hand and check it.
    HINT:
    - To protect the solenoids, TOYOTA hand-held tester turns OFF automatically for 2 sec. after every solenoid has been turned ON.
    - When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible.
    - When solenoid is OFF, the wheel might stop temporarily. However if the wheel rotates again, the function works normally.
      If the rear wheels stop, replace the hydraulic brake booster.
  3. Once, release the brake pedal and turn the "SRH" OFF, after depressing the brake pedal with stable force and stop the rear right wheel by hand and check it.
    If the rear wheel rotate, replace the hydraulic brake booster.
  4. Depress the pedal with stable force, then turn the "SRH" and "SRR" ON simultaneously.
  5. When the solenoids are ON, rotate the rear wheel by hand and check it.
    HINT:
    - To protect the solenoids, TOYOTA hand-held tester turns OFF automatically for 2 sec. after every solenoid has been turned ON.
    - When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible.
10. Lower the vehicle.
11. Disconnect the TOYOTA hand-held tester.
w/ ABS & TRAC & VSC only, In case of using TOYOTA hand-held tester: INSPECT HYDRAULIC BRAKE BOOSTER OPERATION
1. Inspect the battery positive voltage.
  Battery positive voltage: 10 - 14 V
2. Turn the ignition switch OFF, depress the brake pedal more than 40 times.
  HINT:
  
  When a pressure in power supply system is released, reaction force becomes light and stroke becomes longer.
3. Check that the brake pedal becomes light to depress.
  If the pedal does not become to be light to depress, check and replace the brake line and hydraulic brake booster.
4. Turn the ignition switch ON, check the pump motor operation noise.
  If the pump motor does not operate, check and replace the wire harness and pump motor (See INSPECTION ).
5. Connect the TOYOTA hand-held tester.
  1. Connect the TOYOTA hand-held tester to the DLC3.
    
    Fig 3: Connecting Hand-Held Tester To DLC3
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Turn the ignition switch ON.
  3. Select the "ACTIVE TEST" mode on the TOYOTA hand-held tester.
    HINT:
    - Please refer to the TOYOTA hand-held tester operator's manual for further details.
    - To protect the solenoids, TOYOTA hand-held tester turns OFF automatically 2 sec. after every solenoid has been turned ON.
6. Inspect the front TRAC & VSC solenoid operation.
  1. Select "SA1" and "SA2" on the TOYOTA hand-held tester.
  2. With "SA1" and "SA2" turned ON simultaneously with the TOYOTA hand-held tester, depress the brake pedal with stable force and check that the pedal cannot be depressed.
    HINT:
    
    To protect the solenoids, TOYOTA hand-held tester turns OFF automatically 2 sec. after every solenoid has been turned ON.
    
    If the pedal can be depressed, replace the hydraulic brake booster.
    
    NOTE: When operating it continuously, set the interval of more than 20 sec.
  3. Once, release the brake pedal.
  4. When the solenoids are OFF, after depressing the brake pedal again and check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
7. Inspect the front ABS solenoid operation.
  1. Select "SFRH" and "SFLH" on the TOYOTA hand-held tester.
  2. With "SFRH" and "SFLH" turned ON simultaneously with the TOYOTA hand-held tester, depress the brake pedal with stable force and check that the brake pedal cannot be depressed.
    HINT:
    
    To protect the solenoids, TOYOTA hand-held tester turns OFF automatically 2 sec. after every solenoid has been turned ON.
    
    If the pedal can be depressed, replace the hydraulic brake booster.
  3. Once, release the brake pedal when the solenoids are OFF, check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
  4. Once, release the brake pedal. After depressing and holding the brake pedal with stable force, turn the SFRH and SFRR solenoids ON simultaneously.
    HINT:
    
    To protect the solenoids, TOYOTA hand-held tester turns OFF automatically 2 sec. after every solenoid has been turned ON.
  5. When the solenoids are OFF, check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
  6. Once, release the brake pedal. After depressing and holding the brake pedal with stable force, turn the SFLH and SFLR solenoids ON simultaneously.
    HINT:
    
    To protect the solenoids, TOYOTA hand-held tester turns OFF automatically 2 sec. after every solenoid has been turned ON.
  7. When the solenoids are OFF, check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
8. Jack up and support the vehicle.
9. Release the parking brake lever.
10. Shift the transfer shift lever to "N" position and check that the rear wheels by rotating them by hand.
11. Inspect the rear TRAC & VSC solenoid operation.
  1. Select the "SA3" and "STR" on the TOYOTA hand-held tester.
  2. Turn the "SA3" and "STR" ON simultaneously with the TOYOTA hand-held tester, and check that the rear wheel does not rotate by hand.
    HINT:
    
    When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible.
    
    If the rear wheels rotate, replace the hydraulic brake booster.
  3. Turn the "SA3" and "STR" OFF simultaneously, and check that the rear wheels by rotating them by hand.
    HINT:
    - To protect the solenoids, TOYOTA hand-held tester turns OFF automatically 2 sec. after every solenoid has been turned ON.
    - When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible.
    NOTE: When operating it continuously, set the interval of more than 20 sec.
    
    If the rear wheels stop, replace the hydraulic brake booster.
12. Inspect the right rear ABS solenoid.
  1. Select the "SA3", "STR" and "SRRH", on the TOYOTA hand-held tester.
  2. Turn the "SA3", "STR" and "SRRH" ON simultaneously with the TOYOTA hand-held tester, and check that the right rear wheel by rotating it by hand.
    HINT:
    - To protect the solenoids, TOYOTA hand-held tester turns OFF automatically 2 sec. after every solenoid has been turned ON.
    - When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible.
    - When solenoid is OFF, the wheel might stop temporarily. However if the wheel rotates again, the function works normally.
      If the rear wheels stop, replace the hydraulic brake booster.
  3. Turn the "SA3", "STR" and "SRRH" OFF, and check that the right rear wheel by rotating it by hand.
    HINT:
    - To protect the solenoids, TOYOTA hand-held tester turns OFF automatically 2 sec. after every solenoid has been turned ON.
    - When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible.
      If the right rear wheel stop, replace the hydraulic brake booster.
  4. Depress the pedal with stable force, then turn the "SRRH" and "SRRR" ON simultaneously.
  5. When the solenoids are ON, check that the right rear wheel by rotating it by hand.
13. Inspect the left rear ABS solenoid operation.
  1. Select the "SA3", "STR" and "SRLH" on the TOYOTA hand-held tester.
  2. Turn the "SA3", "STR" and "SRLH" ON with TOYOTA hand-held tester, and check that the left rear wheel by rotating it by hand.
    HINT:
    
    When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible.
    
    If the rear wheels stop, replace the hydraulic brake booster.
  3. Turn the "SA3", "STR" and "SRLH" OFF and check that the left rear wheel by rotating it by hand.
    HINT:
    - To protect the solenoids, TOYOTA hand-held tester turns OFF automatically 2 sec. after every solenoid has been turned ON.
    - When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible.
    - When solenoid is OFF, the wheel might stop temporarily. However if the wheel rotates again, the function works normally.
      If the left rear wheel stop, replace the hydraulic brake booster.
  4. Depress the pedal with stable force, then turn the "SRLH" and "SRLR" ON simultaneously.
    HINT:
    
    To protect the solenoids, TOYOTA hand-held tester turns OFF automatically 2 sec. after every solenoid has been turned ON.
  5. When the solenoids are ON, check that the left rear wheel by rotating it by hand.
    HINT:
    
    When rotating the wheel fast, the fail-safe function is activated and judgement cannot be made properly. So rotate the wheel as slowly as possible.
14. Lower the vehicle.
15. Disconnect the TOYOTA hand-held tester.
w/ ABS only, In case of using ABS actuator checker (SST): INSPECT HYDRAULIC BRAKE BOOSTER OPERATION
1. Inspect the battery positive voltage.
  Battery positive voltage: 10 - 14 V
2. Disconnect the 2 connectors from hydraulic brake booster.
  
  Fig 4: Disconnecting Connectors From Hydraulic Brake Booster
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the actuator checker (SST) to the hydraulic brake booster side wire harness via the sub-wire harness (SST), as shown in Fig 5.
  SST 09990-00150, 09990-00480
  
  HINT:
  
  Connect the connector with the label of "FRONT" attached to the connector of actuator checker.
  
  Fig 5: Connecting Actuator Checker (SST) To Hydraulic Brake Booster Side Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the red cable of the checker to the battery positive (+) terminal and the black cable to the negative (-) terminal.
5. Place "SHEET G" (SST) of "FRONT" on actuator checker.
  SST 09990-00240
6. Turn the ignition switch OFF, depress the brake pedal more than 40 times.
  HINT:
  
  When a pressure in power supply system is released, reaction force becomes light and stroke becomes longer.
7. Turn the ignition switch ON, check the pump motor operation noise.
  If the pump motor does not operate, check and replace the wire harness and pump motor (See INSPECTION ).
8. Inspect the front switching solenoid operation.
  1. Push in and hold the "SA1" and "SA2" switches simultaneously, depress strongly and hold the brake pedal with stable force.
    NOTE: Do not keep the "SA1" and "SA2" pushed down for more than 10 sec. When operating it continuously, set the interval of more than 20 sec.
    
    Fig 6: Pushing In & Holding "SA1" And "SA2" Switches Simultaneously
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Check that the brake pedal cannot be depressed.
    If the pedal can be depressed, replace the hydraulic brake booster.
  3. Release the "SA1" switch and check that the brake pedal can be depressed.
    If the pedal can not be depressed, replace the hydraulic brake booster.
  4. Release the "SA2" switch and check that the brake pedal can be depressed.
    If the pedal can not be depressed, replace the hydraulic brake booster.
9. Inspect the right front solenoid operation.
  1. Turn the selector switch to "RH" position.
    
    Fig 7: Turning Selector Switch To "RH" Position
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Push and hold in the MAIN push switch and "SA2" switch simultaneously depress and hold the brake pedal with stable force.
    NOTE: Do not keep the MAIN push switch and "SA2" switch pushed down for more than 10 sec. When operating it continuously, set the interval of more than 20 sec.
  3. Check that the brake pedal cannot be depressed.
    If the pedal can be depressed, replace the hydraulic brake booster.
  4. Release the MAIN push switch and "SA2" switch simultaneously and check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
  5. Release the brake pedal.
  6. Depress and hold the brake pedal with stable force, push and hold in MAIN push switch.
    NOTE: Do not keep the MAIN push switch pushed down for more than 10 sec. When operating it continuously, set the interval of more than 20 sec.
    
    Fig 8: Pushing And Holding In MAIN Push Switch
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Check that the brake pedal cannot be depressed.
    If the pedal can be depressed, replace the hydraulic brake booster.
  8. Release the MAIN push switch, and check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
  9. Release the brake pedal.
10. Inspect the left front solenoid operation.
  1. Turn the selector switch to "LH" position.
    
    Fig 9: Turning Selector Switch To "LH" Position
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Push and hold in the MAIN push switch and "SA1" switch simultaneously, depress and hold the brake pedal with stable force.
    NOTE: Do not keep the MAIN push switch and "SA1" switch pushed down for more than 10 sec. When operating it continuously, set the interval of more than 20 sec.
  3. Check that the brake pedal cannot be depressed.
    If the pedal can be depressed, replace the hydraulic brake booster.
  4. Release the MAIN push switch and "SA1" switch simultaneously, and check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
  5. Release the brake pedal.
  6. Depress and hold the brake pedal with stable force, push and hold in MAIN push switch.
    NOTE: Do not keep the MAIN push switch pushed down for more than 10 sec. When operating it continuously, set the interval of more than 20 sec.
    
    Fig 10: Pushing & Holding In MAIN Push Switch
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Check that the brake pedal cannot be depressed.
    If the pedal can be depressed, replace the hydraulic brake booster.
  8. Release the MAIN push switch, and check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
  9. Release the brake pedal.
11. Turn the ignition switch OFF, then reconnect the connector of sub-wire harness from the one with label of "FRONT" to "REAR".
12. Place "SHEET G" of "REAR" on the actuator checker.
13. Jack up and support the vehicle.
14. Start the engine and run it at idle.
15. Inspect the rear solenoid operation.
  1. Turn the selector switch to "RH" position.
    
    Fig 11: Turning Selector Switch To "RH" Position
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Depress the brake pedal several times and release the pedal when the pump begins rotating. Wait until the pump stops.
  3. Turn the ignition switch OFF.
  4. Depress the brake pedal with a force of 343 N (35 kgf, 77 lbf), record the fluid surface in the reservoir tank of the hydraulic brake booster.
  5. Press the MAIN push switch for 10 sec., and check that the fluid surface in the reservoir tank of the hydraulic brake booster dose not rise up at this time.
    If the fluid surface level rises up, replace the hydraulic brake booster.
    
    NOTE: Do not press MAIN push switch for more than 10 sec. When operating the switch continuously, do it an interval of more than 20 sec.
  6. Release the brake pedal and check that brake pedal is not hard to depress.
    If pedal is hard to depress, replace the hydraulic brake booster.
  7. Start the engine and run it at idle.
  8. Depress the brake pedal.
  9. Release the parking brake lever and shift the shift lever to "L" position.
  10. Once, release the brake pedal. After depressing the brake pedal with stable force, then push and hold MAIN push switch.
  11. Check that the right rear wheel rotates.
    If the right rear wheels stops, replace the hydraulic brake booster.
16. Stop the engine and lower the vehicle.
17. Remove the "SHEET G" (SST) and disconnect the actuator checker (SST) and sub-wire harness (SST) from the hydraulic brake booster.
18. Connect the 2 connectors to the actuator.
19. Clear the DTC (See PRE-CHECK ).
w/ ABS & TRAC & VSC only, In case of using ABS actuator checker (SST): INSPECT HYDRAULIC BRAKE BOOSTER OPERATION
1. Inspect the battery positive voltage.
  Battery positive voltage: 10 - 14 V
2. Disconnect the 2 connectors from hydraulic brake booster.
3. Connect the actuator checker (SST) to the hydraulic brake booster side wire harness via the sub-wire harness S (SST), as shown in Fig 12.
  SST 09990-00150, 09990-00480
  
  Fig 12: Connecting Actuator Checker (SST) To Hydraulic Brake Booster Side Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Connect the connector with the label of "FRONT" attached to the connector of actuator checker.
4. Connect the red cable of the checker to the battery positive (+) terminal and the black cable to the negative (-) terminal.
  
  Fig 13: Connecting Red Cable And Black Cable To Terminals
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Place "SHEET G" (SST) of "FRONT" on actuator checker.
  SST 09990-00240
6. Turn the ignition switch OFF, depress the brake pedal more than 40 times.
  HINT:
  
  When a pressure in power supply system is released, reaction force becomes light and stroke becomes longer.
7. Check that the brake pedal becomes light to depress.
  If the pedal does not become to be light to depress, check and replace the brake line and hydraulic brake booster.
8. Turn the ignition switch ON, check the pump motor operation noise.
  If the pump motor does not operate, check and replace the wire harness and pump motor (See INSPECTION ).
9. Inspect the front TRAC & VSC solenoid operation.
  1. Push in and hold the "SA1" and "SA2" switches simultaneously, depress strongly and hold the brake pedal with stable force.
    NOTE: Do not keep the "SA1" and "SA2" pushed down for more than 10 sec. When operating it continuously, set the interval of more than 20 sec.
  2. Check that the brake pedal cannot be depressed.
    If the pedal can be depressed, replace the hydraulic brake booster.
    
    Fig 14: Pushing In & Holding SA1 & SA2 Switches
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Release the "SA1" switch and check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
  4. Release the "SA2" switch and check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
10. Inspect the right front ABS solenoid operation.
  1. Turn the selector switch to "RH" position.
    
    Fig 15: Turning Selector Switch To "RH" Position
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Push and hold in the MAIN push switch and "SA2" switch simultaneously, depress and hold the brake pedal with stable force.
    NOTE: Do not keep the MAIN push switch and "SA2" switch pushed down for more than 10 sec. When operating it continuously, set the interval of more than 20 sec.
  3. Check that the brake pedal cannot be depressed.
    If the pedal can be depressed, replace the hydraulic brake booster.
  4. Release the MAIN push switch and "SA2" switch simultaneously and check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
  5. Release the brake pedal.
  6. Depress and hold the brake pedal with stable force, push and hold in MAIN push switch.
    NOTE: Do not keep the MAIN push switch pushed down for more than 10 sec. When operating it continuously, set the interval of more than 20 sec.
    
    Fig 16: Pushing And Holding In MAIN Push Switch
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Check that the brake pedal cannot be depressed.
    If the pedal can be depressed, replace the hydraulic brake booster.
  8. Release the MAIN push switch, and check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
  9. Release the brake pedal.
11. Inspect the left front ABS solenoid operation.
  1. Turn the selector switch to "LH" position.
    
    Fig 17: Turning Selector Switch To LH Position
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Push and hold in the MAIN push switch and "SA1" switch simultaneously, depress and hold the brake pedal with stable force.
    NOTE: Do not keep the MAIN push switch and "SA1" switch pushed down for more than 10 sec. When operating it continuously, set the interval of more than 20 sec.
  3. Check that the brake pedal cannot be depressed.
    If the pedal can be depressed, replace the hydraulic brake booster.
  4. Release the MAIN push switch and "SA1" switch simultaneously, and check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
  5. Release the brake pedal.
  6. Depress and hold the brake pedal with stable force, push and hold in MAIN push switch.
    NOTE: Do not keep the MAIN push switch pushed down for more than 10 sec. When operating it continuously, set the interval of more than 20 sec.
    
    Fig 18: Pushing & Holding In MAIN Push Switch
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Check that the brake pedal cannot be depressed.
    If the pedal can be depressed, replace the hydraulic brake booster.
  8. Release the MAIN push switch, and check that the brake pedal can be depressed.
    If the pedal cannot be depressed, replace the hydraulic brake booster.
  9. Release the brake pedal.
12. Turn the ignition switch OFF, then reconnect the connector of sub-wire harness from the one with label of "FRONT" to "REAR".
13. Place "SHEET G" of "REAR" on the actuator checker.
14. Jack up and support the vehicle.
15. Start the engine and run it at idle.
16. Inspect the rear TRAC & VSC solenoid.
  1. Release the parking brake lever and shift the shift lever to "L" position.
  2. Push and hold the "SA3" switch and "STR" switch simultaneously.
    NOTE:
    Do not keep the "STR" switch pushed down for more than 10 sec.
    
    Do not keep the "SA3" switch pushed down for more than 5 sec.
    
    When operating it continuously, set the interval of more than 20 sec.
  3. Check that the rear wheels stop.
    If the rear wheels rotate, replace the hydraulic brake booster.
  4. Release the "SA3" switch and "STR" switch simultaneously.
  5. Check that the rear wheels rotate.
    If the rear wheels stop, replace the hydraulic brake booster.
  Fig 19: Inspecting Rear TRAC & VSC Solenoid
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. Inspect the right rear ABS solenoid.
  1. Turn the selector switch to "RH" position.
  2. Depress the brake pedal several times and release the brake pedal when the pump begins rotating. Wait until the pump stops.
  3. Turn the ignition switch OFF.
  4. Depress the brake pedal with a force of 343 N (35 kgf, 77 lbf), record the fluid surface in the reservoir tank of the hydraulic brake booster.
  5. Press the MAIN push switch for 10 sec., and check that the fluid surface in the reservoir tank of the hydraulic brake booster does not rise up at this time.
    If the fluid surface level rises up, replace the hydraulic brake booster.
    
    NOTE: Do not press MAIN push switch for more than 10 sec. When operating the switch continuously, do it an interval of more than 20 sec.
  6. Start the engine and run it at idle.
  7. Depress the brake pedal.
  8. Release the parking brake lever and shift the shift lever to "L" position.
  9. Once, release the brake pedal. After depressing the brake pedal with stable force, then push and hold MAIN push switch.
  10. Check that the right rear wheel rotates.
    If the right rear wheel stops, replace the hydraulic brake booster.
  Fig 20: Inspecting Right Rear ABS Solenoid
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. Inspect the left rear ABS solenoid.
  1. Turn the selector switch to "LH" position.
  2. Depress the brake pedal several times and release the brake pedal when the pump begins rotating. Wait until the pump stops.
  3. Turn the ignition switch OFF.
  4. Depress the brake pedal with a force of 343 N (35 kgf, 77 lbf), record the fluid surface in the reservoir tank of the hydraulic brake booster.
  5. Press the MAIN push switch for 10 sec., and check that the fluid surface in the reservoir tank of the hydraulic brake booster does not rise up at this time.
    If the fluid surface level rises up, replace the hydraulic brake booster.
    
    NOTE: Do not press MAIN push switch for more than 10 sec. When operating the switch continuously, do it an interval of more than 20 sec.
  6. Start the engine and run it at idle.
  7. Depress the brake pedal.
  8. Release the parking brake lever and shift the shift lever to "L" position.
  9. Once, release the brake pedal. After depressing the brake pedal with stable force, then push and hold MAIN push switch.
  10. Check that the left rear wheel rotates.
    If the left rear wheel stops, replace the hydraulic brake booster.
  Fig 21: Inspecting Left Rear ABS Solenoid
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. Stop the engine and lower the vehicle.
20. Remove the "SHEET G" (SST) and disconnect the actuator checker (SST) and sub-wire harness S (SST) from the hydraulic brake booster.
21. Connect the 2 connectors to the actuator.
22. Clear the DTC (See PRE-CHECK ).