DTC C1202/68: Master Reservoir Level Malfunction: Procedure

1. Check that the brake fluid level is sufficient.
   Fig 1: Identifying Brake Fluid Level

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

   Brake fluid level is sufficient.

   HINT: 

   • If the fluid level drops, check for fluid leaks and repair as necessary.
   • Check for brake fluid leakage (connection between the brake booster pump, brake master cylinder reservoir and brake actuator, and between the brake actuator and wheel cylinders).
   • If no leak exists, add and adjust fluid and then check that the trouble code is not output again.
2. Check that there are no leaks from the connections between the brake booster pump and brake actuator.
   Fig 2: Locating Brake Booster Pump And Brake Actuator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   As a visual check is very difficult, perform the check with the following procedure.

   1. Bleed air from the brake actuator, refer to BLEEDING .
   2. Connect the Techstream to the DLC3.
   3. Turn the ignition switch to ON.
   4. Select the Data List on the Techstream, refer to DATA LIST / ACTIVE TEST .
      ABS/VSC/TRAC
      
      

      Tester Display	Measurement Item/Range	Normal Condition	Diagnostic Note
      Accumulator Sensor	Accumulator pressure sensor / Min.: 0.00 V, Max.: 5.00 V	Specified value: 2.6 to 3.8 V	When brake fluid is stored in the accumulator: Accumulator pressure changes in accordance with volume of fluid stored in the accumulator

   5. Wait for 30 seconds without operating the brake pedal. Then check the accumulator pressure sensor output value's change is within the specified range.

      OK

      Accumulator pressure sensor output value's change is within 0.2 V.

NG → CHECK AND REPAIR BRAKE FLUID LEAKAGE OR ADD FLUID 

OK: Go to next step 

1. Turn the ignition switch off.
   Fig 3: Identifying Brake Fluid Level Warning Switch

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the reservoir filler cap and strainer.
3. Make sure that there is no looseness at the locking part and the connecting part of the connector.
4. Disconnect the brake fluid level warning switch connector.
5. Measure the resistance according to the value(s) in the table below.

   HINT: 

   A float is located inside the reservoir. Its position changes according to the level of brake fluid.

   Standard Resistance

   Tester Connection	Switch Condition	Specified Condition
   2 - 1	Brake fluid level warning switch OFF (Float up)	1.9 to 2.1 kΩ
   2 - 1	Brake fluid level warning switch ON (Float down)	Below 1 Ω

   HINT: 

   If there are no problems after completing the preceding inspection, adjust the brake fluid to the MAX level with the ignition switch ON.

NG → See step   7 

OK: Go to next step 

1. Make sure that there is no looseness at the locking part and the connecting part of the connector.
   Fig 4: Identifying A44 Skid Control ECU Connector & A21 Brake Fluid Level Warning Switch

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the A44 skid control ECU connector.
3. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   A44-6 (LBL) - A21-2	Always	Below 1 Ω
   A44-6 (LBL) - Body ground	Always	10 kΩ or higher
   A21-1 - Body ground	Always	Below 1 Ω

   TEXT IN ILLUSTRATION
   
   

   *1	Front view of wire harness connector (to Skid Control ECU)
   *2	Front view of wire harness connector (to Brake Fluid Level Warning Switch)

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Reconnect the skid control ECU connector and the brake fluid level warning switch connector.
   Fig 5: Identifying A44 Skid Control ECU With Harness Connected

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Turn the ignition switch to ON.
3. Measure the voltage according to the value(s) in the table below.

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   A44-6 (LBL) - Body ground	Ignition switch ON	4 to 7 V

   TEXT IN ILLUSTRATION
   
   

   *1	Component with harness connected (Skid Control ECU)

NG → See step   8 

OK: Go to next step 

1. Turn the ignition switch off.
2. Clear the DTCs, refer to DTC CHECK / CLEAR .
3. Turn the ignition switch to ON.
4. Check if the same DTC is recorded, refer to DTC CHECK / CLEAR .

   Result

   Result	Proceed to
   DTC (C1202/68) is not output	A
   DTC (C1202/68) is output	B

   HINT: 

   If troubleshooting has been carried out according to Problem Symptoms Table, refer back to the table and proceed to the next suspected area, refer to PROBLEM SYMPTOMS TABLE .

B → See step   8 

A → See step   6