LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2016 >> Highlander Hybrid Limited >> Repair and Diagnosis >> Brakes >> Anti-Lock Brakes >> Electronically Controlled Brake System - Diagnostic Codes & Symptom Tests - (Hybrid) >> Electronically Controlled Brake System >> DTC C1202-68: Master Reservoir Level Malfunction [11/2016 - ] >> Procedure

DTC C1202-68: Master Reservoir Level Malfunction [11/2016 - ]: Procedure

  1. CHECK BRAKE FLUID LEVEL 
    1. Check that the brake fluid level is sufficient.

      OK

      Brake fluid level is sufficient.

      HINT: 

      • If the fluid level is low, check for fluid leaks, and repair as necessary.
      • Check for brake fluid leaks (connection between the brake booster pump assembly, brake master cylinder reservoir assembly and the brake actuator assembly, and between the brake actuator assembly and wheel cylinders).
      • If no leaks exist, 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 assembly and brake actuator assembly.

      HINT: 

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

      1. Bleed air from the brake actuator assembly.

        Refer to BLEEDING [02/2014 - ]

      2. Connect the Techstream to the DLC3.
      3. Turn the power switch on (IG).
      4. Select the Data List on the Techstream.

        Refer to DATA LIST / ACTIVE TEST [11/2016 - ]

        Chassis > ABS/VSC/TRAC > Data List 

        Tester Display Measurement Item Range Normal Condition Diagnostic Note
        Accumulator Sensor Accumulator pressure sensor Min.: 0.00 V, Max.: 5.00 V Specified value: 2.60 to 3.80 V When brake fluid is stored in the accumulator: Accumulator pressure changes in accordance with volume of fluid stored in the accumulator

        Chassis > ABS/VSC/TRAC > Data List 

        Tester Display
        Accumulator Sensor
      5. Wait for 30 seconds without depressing the brake pedal.
      6. Check that the accumulator pressure sensor output value change is within the specified range.

        OK

        Accumulator pressure sensor output value change is less than 0.20 V.

      Result

      Proceed to
      OK
      NG

    Result:  2

    NG 

    CHECK AND REPAIR BRAKE FLUID LEAKS OR ADD FLUID 

    Result:  1

    OK 

    See step  2

  2. INSPECT BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Remove the brake master cylinder reservoir filler cap and strainer.
      GTY444659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component without harness connected
      (Brake Fluid Level Warning Switch (Brake Master Cylinder Reservoir Assembly))
    2. Make sure that there is no looseness at the locking part and the connecting part of the connector.
    3. Disconnect the A51 brake fluid level warning switch (brake master cylinder reservoir assembly) connector.
    4. 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 Condition Specified Condition
      2 (LBL) - 1 (GND) Brake fluid level warning switch (Brake master cylinder reservoir assembly) off (float up) 1.84 to 2.16 kΩ
      2 (LBL) - 1 (GND) Brake fluid level warning switch (Brake master cylinder reservoir assembly) 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 power switch on (IG).

      Result

      Proceed to
      OK
      NG

    Result:  2

    NG 

    REPLACE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY. Refer to  REMOVAL [02/2014 - ] 

    Result:  1

    OK 

    See step  3

  3. CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU ASSEMBLY - BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY) 
    1. Make sure that there is no looseness at the locking part and the connecting part of the connector.
    2. Disconnect the A63 skid control ECU assembly connector.
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      A63-6 (LBL) - A51-2 (LBL) Always Below 1 Ω
      A63-6 (LBL) or A51-2 (LBL) - Body ground Always 10 kΩ or higher
      A51-1 (GND) - Body ground Always Below 1 Ω

      Result

      Proceed to
      OK
      NG

    Result:  2

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result:  1

    OK 

    See step  4

  4. INSPECT SKID CONTROL ECU ASSEMBLY (SWITCH INPUT) 
    1. Reconnect the A63 skid control ECU assembly connector.
      GTY441009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Component with harness connected
      (Skid Control ECU Assembly)
    2. Reconnect the A51 brake fluid level warning switch (brake master cylinder reservoir assembly) connector.
    3. Turn the power switch on (IG).
    4. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Condition Specified Condition
      A63-6 (LBL) - Body ground Brake fluid level warning switch (Brake master cylinder reservoir assembly) off → on 4 to 8 V → Below 1.5 V

      Result

      Proceed to
      OK
      NG

    Result:  2

    NG 

    REPLACE SKID CONTROL ECU ASSEMBLY. Refer to  REMOVAL [02/2014 - ] 

    Result:  1

    OK 

    See step  5

  5. RECONFIRM DTC 
    1. Clear the DTCs.

      Refer to DTC CHECK / CLEAR [02/2014 - ]

      Chassis > ABS/VSC/TRAC > Clear DTCs 

    2. Turn the power switch off.
    3. Turn the power switch on (IG).
    4. Check if the same DTC is output.

      Refer to DTC CHECK / CLEAR [02/2014 - ]

      Chassis > ABS/VSC/TRAC > Trouble Codes 

      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 step.

      Refer to PROBLEM SYMPTOMS TABLE [02/2014 - ]

    Result:  1

    A 

    USE SIMULATION METHOD TO CHECK. Refer to  HOW TO PROCEED WITH TROUBLESHOOTING [11/2016 - ] 

    Result:  2

    B 

    REPLACE SKID CONTROL ECU ASSEMBLY. Refer to  REMOVAL [02/2014 - ] 

scientia non olet · About LEMON Manuals