Pinpoint Tests

Pinpoint Tests

PINPOINT TEST G545069p1 : BRAKES NOISY

G545069t1 : INSPECT BRAKE PADS
1 Inspect the condition of the front and rear brake pads. Check for damage to any anti-squeal shims.
- Are the brake pads OK?

->Yes
GO to Pinpoint Test G545069t2.

->No
CLEAN the front brake pads or INSTALL new front brake pads if necessary. For additional information, refer to Brake Pads - Vehicles With: Standard Brakes CLEAN the rear brake pads or INSTALL new rear brake pads if necessary. For additional information, refer to Brake Pads - Vehicles With: Standard Brakes Test vehicle for presence of brake squeal.

G545069t2 : INSPECT BRAKE DISCS
1 Inspect the brake discs for excessive corrosion, wear or disc thickness variation.
- Does excessive corrosion, wear or disc thickness variation exist?

->Yes
INSTALL new front brake discs and brake pads. For additional information, refer to Brake Disc - Vehicles With: Standard Brakes
For additional information, refer to Brake Pads - Vehicles With: Standard Brakes . INSTALL new rear brake discs and brake pads. For additional information, refer to Brake Disc - Vehicles With: Standard Brakes
For additional information, refer to Brake Pads - Vehicles With: Standard Brakes TEST the system for normal operation.

->No
Vehicle is OK.

PINPOINT TEST G545069p2 : VIBRATION WHEN BRAKES ARE APPLIED

G545069t3 : ROAD TEST VEHICLE
1 Road test the vehicle between 40-80 km/h (25-50 mph) without applying brakes.
- Is the vibration present?

->Yes
TEST for noise vibration and harshness. For additional information, refer to Noise, Vibration and Harshness (NVH) Testing and Inspection REPEAT road test if necessary.

->No
GO to Pinpoint Test G545069t4.

G545069t4 : CHECK FOR BRAKE VIBRATION
1 Road test the vehicle between 40-80 km/h (25-50 mph) with light and medium application on the brake pedal.
- Is a vibration present?

->Yes
CHECK the brake caliper mounting bolts and wheel hub nuts and TIGHTEN as necessary. CHECK the balance of all road wheels and tires and REPAIR as necessary. CHECK the brake discs for excessive wear, runout, thickness variation or cracks. INSTALL new brake discs and brake pads as necessary.
GO to Pinpoint Test G545069t5.

->No
Vehicle is OK.

G545069t5 : IS VIBRATION STILL PRESENT UNDER BRAKE APPLICATION?
1 Road test the vehicle between 40-80 km/h (25-50 mph) with light and medium application on the brake pedal.
- Is a vibration present?

->Yes
CHECK for wear or failure of steering gear bushings. CHECK for wear or failure of steering gear ball joints. CHECK for wear or failure of front wheel bearings, suspension bushings and ball joints. CHECK for wear or failure of rear wheel bearings, suspension bushings and ball joints. REFER to relevant section in this product and INSTALL new parts as necessary.

->No
Vehicle is OK.

PINPOINT TEST G545069p3 : THE BRAKES PULL OR DRIFT

G545069t6 : ROAD TEST VEHICLE
1 Road test the vehicle and apply the brake pedal.
- Does the vehicle pull or drift?

->Yes
GO to Pinpoint Test G545069t7.

->No
Vehicle is OK.

G545069t7 : INSPECT TIRE CONDITION/PRESSURE
1 Check for excessive tire wear or incorrect pressures.
- Are the tires at the correct pressure and in good condition?

->Yes
GO to Pinpoint Test G545069t8.

->No
ADJUST the tire pressures or INSTALL new tires if excessively worn. TEST the system for normal operation.

G545069t8 : CHECK CALIPERS
1 Check the disc brake caliper pistons and pins for binding, leaking or sticking.
- Do the disc brake caliper pistons and pins bind, leak or stick?

->Yes
RECTIFY sticking pins and INSTALL new brake calipers as necessary. For additional information, refer to Brake Caliper - Vehicles With: Standard Brakes
For additional information, refer to Brake Caliper - Vehicles With: Standard Brakes TEST the system for normal operation.

->No
GO to Pinpoint Test G545069t9.

G545069t9 : INSPECT BRAKE DISCS
1 Check the brake discs for excessive damage, thickness variation or runout. For additional information, refer to Brake Disc Runout Check Brake Disc Runout Check
- Does excessive damage or runout exist?

->Yes
INSTALL new brake discs and brake pads as necessary. TEST the system for normal operation.

->No
GO to Pinpoint Test G545069t10.

G545069t10 : INSPECT THE FRONT HUB AND WHEEL BEARING ASSEMBLY
1 Check the front hub and wheel bearing assembly.
- Are the wheel bearings OK?

->Yes
GO to Pinpoint Test G545069t11.

->No
INSTALL new wheel bearings. For additional information, refer to Wheel Bearing and Wheel Hub Front Suspension TEST the system for normal operation.

G545069t11 : CHECK SUSPENSION BUSHINGS AND BALL JOINTS.
1 Check all suspension bushings and ball joints.
- Are the suspension bushings and ball joints OK?

->Yes
GO to Pinpoint Test G545069t12.

->No
INSTALL new front suspension bushings and ball joints as necessary. INSTALL new rear suspension bushings and ball joints as necessary. REFER to the relevant section in this product.

G545069t12 : CHECK VEHICLE ALIGNMENT
1 Check the vehicle alignment. For additional information, refer to Front Subframe
- Is the alignment within specification?

->Yes
Vehicle is OK.

->No
Adjust the alignment as necessary. For additional information, refer to Front Subframe

PINPOINT TEST G545069p4 : THE PEDAL FEELS SPONGY

G545069t13 : CHECK FOR SPONGY PEDAL (ENGINE OFF)
1 Check for a firm brake pedal.
- Is the brake pedal effort and brake pedal travel normal?

->Yes
Vehicle is OK.

->No
GO to Pinpoint Test G545069t14.

G545069t14 : CHECK BRAKE PEDAL RESERVE (ENGINE OFF)
1 Pump the brake pedal 10 times and hold on the final application.
- Does the brake pedal feel firm on final application?

->Yes
GO to Pinpoint Test G545069t15.

->No
BLEED the brake system. For additional information, refer to Brake System Bleeding Service and Repair

G545069t15 : CHECK BRAKE PEDAL RESERVE (ENGINE ON)
1 Engine is idle.
2 Apply the brake pedal lightly three or four times.
3 Wait 15 seconds for the vacuum to recover.
4 Push down on the brake pedal until it stops moving downward or an increased resistance to the brake pedal travel occurs.
5 Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
6 Release the accelerator pedal.
- Does the brake pedal move downward as the engine speed returns to idle?

->Yes
GO to Pinpoint Test G545069t16.

->No
CHECK the vacuum to brake booster.

G545069t16 : CHECK BRAKE FLUID LEVEL
1 Check the brake master cylinder reservoir fluid level.
- Is the fluid level OK?

->Yes
BLEED the brake system. For additional information, refer to Brake System Bleeding Service and Repair TEST the system for normal operation.

->No
CHECK for leaking brake system and RECTIFY as necessary. ADD fluid and BLEED the brake system. For additional information, refer to Brake System Bleeding Service and Repair TEST the system for normal operation. REPEAT road test if necessary.

PINPOINT TEST G545069p5 : THE PEDAL GOES DOWN FAST

G545069t17 : ROAD TEST VEHICLE
1 Road test the vehicle and apply the brake pedal.
- Is the brake pedal effort and brake pedal travel normal?

->Yes
Vehicle is OK.

->No
GO to Pinpoint Test G545069t19.

G545069t19 : CHECK BRAKE PEDAL TRAVEL-PRESSURIZE SYSTEM
1 Pump the brake pedal rapidly (five times).
- Does the brake pedal travel build up and then hold?

->Yes
BLEED the brake system. For additional information, refer to Brake System Bleeding Service and Repair TEST the system for normal operation.

->No
GO to Pinpoint Test G545069t20.

G545069t20 : CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake system leaks. For additional information, refer to brake master cylinder component test. Component Tests
- Are leaks found?

->Yes
REPAIR as necessary, ADD fluid and BLEED brake system. For additional information, refer to Brake System Bleeding Service and Repair TEST the system for normal operation.

->No
System is OK.

PINPOINT TEST G545069p6 : THE PEDAL GOES DOWN SLOWLY

G545069t21 : ROAD TEST VEHICLE - CHECK BRAKE PEDAL OPERATION
1 Check if the condition occurs during actual stopping application by applying the brake pedal while the vehicle is moving.
- Does the condition occur when the vehicle is moving?

->Yes
GO to Pinpoint Test G545069t22.

->No
GO to Pinpoint Test G545069t23.

G545069t22 : CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake system leaks. For additional information, refer to brake master cylinder component test. Component Tests
- Are there any external brake system leaks?

->Yes
REPAIR as necessary. ADD fluid and BLEED the brake system. For additional information, refer to Brake System Bleeding Service and Repair TEST the system for normal operation.

->No
GO to Pinpoint Test G545069t23.

G545069t23 : CARRY OUT A BRAKE MASTER CYLINDER BYPASS TEST
1 Test for brake master cylinder bypass condition. Refer to Brake master cylinder component test. Component Tests
- Are any concerns found?

->Yes
INSTALL a new brake master cylinder, ADD fluid and BLEED the brake system. For additional information, refer to Brake System Bleeding Service and Repair TEST the system for normal operation.

->No
System is OK.

PINPOINT TEST G545069p7 : EXCESSIVE BRAKE PEDAL EFFORT

G545069t24 : CHECK BRAKE PADS
1 Check the brake pads for wear, contamination, correct installation, damage and type.
- Are any concerns found?

->Yes
INSTALL the front brake pads correctly or INSTALL new front brake pads if necessary. For additional information, refer to Brake Pads - Vehicles With: Standard Brakes INSTALL the rear brake pads correctly or INSTALL new rear brake pads if necessary. For additional information, refer to Brake Pads - Vehicles With: Standard Brakes TEST the system for normal operation. REPEAT road test.

->No
GO to Pinpoint Test G545069t25.

G545069t25 : CHECK VACUUM
1 Disconnect the vacuum hose from the brake booster.
2 Connect a vacuum/pressure tester to the vacuum hose.
3 Run the engine at normal operating temperature.
4 Record the vacuum reading.
- Is the reading 40.5 kPa (12 in-Hg) or greater?

->Yes
GO to Pinpoint Test G545069t26.

->No
LOCATE and REPAIR the source of low vacuum. TEST the system for normal operation.

G545069t26 : INSPECT SYSTEM
1 Switch the engine off.
2 Reconnect the vacuum hose.
3 Inspect the brake booster, rubber grommet, and all vacuum plumbing for cracks, holes, damaged connections, or missing clamps.
4 Pump the brake pedal several times to exhaust the vacuum. Push down on the brake pedal and hold.
- Does the brake pedal move down when the engine is started?

->Yes
Vacuum system is OK.

->No
GO to Pinpoint Test G545069t27.

G545069t27 : CHECK POWER BRAKE BOOSTER VALVE
1 Check the brake booster valve. For additional information, refer to Brake Booster component test. Component Tests
- Is the power brake booster valve OK?

->Yes
CHECK the brake booster. For additional information, refer to Brake Booster component test. Component Tests INSTALL a new brake booster if necessary. For additional information, refer to Brake Booster - RHD Brake Booster [RHD]
For additional information, refer to Brake Booster - LHD Brake Booster [LHD] TEST the system for normal operation.

->No
INSTALL a new brake booster valve. TEST the system for normal operation.

PINPOINT TEST G545069p8 : BRAKE LOCKUP DURING LIGHT BRAKE PEDAL FORCE

G545069t28 : TEST BRAKE LOCKUP
1 Road test the vehicle and apply the brake pedal lightly.
- Do the brakes lockup?

->Yes
GO to Pinpoint Test G545069t29.

->No
Vehicle is OK.

G545069t29 : INSPECT BRAKE PADS
1 Inspect brake pads for contamination, correct installation, damage and type.
- Are any concerns found?

->Yes
INSTALL the front brake pads correctly or INSTALL new front brake pads if necessary. For additional information, refer to Brake Pads - Vehicles With: Standard Brakes INSTALL the rear brake pads correctly or INSTALL new rear brake pads if necessary. For additional information, refer to Brake Pads - Vehicles With: Standard Brakes TEST the system for correct operation.

->No
GO to Pinpoint Test G545069t30.

G545069t30 : INSPECT BRAKE CALIPERS
1 Inspect brake calipers for binding, leaking or sticking.
- Are any concerns found?

->Yes
INSTALL the brake calipers correctly or INSTALL new brake calipers as necessary. For additional information, refer to Brake Caliper - Vehicles With: Standard Brakes
For additional information, refer to Brake Caliper - Vehicles With: Standard Brakes TEST the system for normal operation.

->No
Vehicle is OK.

PINPOINT TEST G545069p9 : BRAKES DRAG

G545069t31 : ROAD TEST VEHICLE
1 Road test the vehicle and apply the brakes.
- Are the brakes functioning correctly?

->Yes
Vehicle is OK.

->No
GO to Pinpoint Test G545069t32.

G545069t32 : CHECK BRAKE CALIPERS
1 Check the front caliper pistons and pins for binding, leaking or sticking. For additional information, refer to Brake Caliper - Vehicles With: Standard Brakes Check the rear caliper pistons and pins for binding, leaking or sticking. For additional information, refer to Brake Caliper - Vehicles With: Standard Brakes
- Do the disc brake caliper pistons and pins bind, leak or stick?

->Yes
INSPECT the brake calipers and parking brake cables. INSTALL new components as necessary. Test the system for normal operation. Road test vehicle if necessary.

->No
GO to Pinpoint Test G545069t33.

G545069t33 : CHECK BRAKE BOOSTER
1 Check the brake booster connecting rod alignment and travel.
- Is the connecting rod OK?

->Yes
Vehicle is OK.

->No
INSTALL a new brake booster. For additional information, refer to Brake Booster - RHD Brake Booster [RHD]
For additional information, refer to Brake Booster - LHD Brake Booster [LHD] TEST the system for normal operation.

PINPOINT TEST G545069p10 : EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL

G545069t34 : TEST ON ROUGH ROAD
1 Road test the vehicle on rough road conditions.
2 Apply the brakes slowly.
- Is the brake pedal effort and brake pedal travel normal?

->Yes
Vehicle is OK.

->No
GO to Pinpoint Test G545069t35.

G545069t35 : CHECK BRAKE FLUID LEVEL
1 Check the brake master cylinder reservoir fluid level.
- Is the fluid level OK?

->Yes
GO to Pinpoint Test G545069t36.

->No
CHECK brake master cylinder reservoir sealing points. For additional information, refer to Brake master cylinder component test. Component Tests ADD brake fluid and BLEED the brake system. For additional information, refer to Brake System Bleeding Service and Repair TEST the system for normal operation. REPEAT road test if necessary.

G545069t36 : CHECK BRAKE PEDAL RESERVE
1 Run engine at idle speed.
2 Apply the brake pedal lightly three or four times.
3 Wait 15 seconds for the vacuum to replenish.
4 Push down on the brake pedal until it stops moving downward or an increased resistance to the brake pedal travel occurs.
5 Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
6 Release the accelerator pedal.
- Does the brake pedal move downward as the engine speed returns to idle?

->Yes
GO to Pinpoint Test G545069t37.

->No
CHECK the vacuum to the brake booster.

G545069t37 : CHECK THE FRONT WHEEL BEARING ASSEMBLY
1 Check the front wheel bearing assembly.
- Are the front wheel bearings loose?

->Yes
INSTALL a new front wheel bearing if damaged. For additional information, refer to Wheel Bearing and Wheel Hub Front Suspension TEST the system for normal operation.

->No
CHECK the front brake discs for thickness variances.

PINPOINT TEST G545069p11 : SLOW OR INCOMPLETE BRAKE PEDAL RETURN

G545069t38 : CHECK FOR BRAKE PEDAL RETURN
1 Run the engine at idle while making several brake applications.
2 Pull the brake pedal rearward with approximately 44.5 N (10lb) force.
3 Release the brake pedal and measure the distance to the toe board.
4 Make a hard brake application.
5 Release the brake pedal and measure the brake pedal to toe board distance. The brake pedal should return to its original position.
- Does the brake pedal return to its original position?

->Yes
Vehicle is OK.

->No
GO to Pinpoint Test G545069t39.

G545069t39 : CHECK FOR BRAKE PEDAL BINDING
1 Disconnect the brake booster from the brake pedal. Check the brake pedal to ensure free operation.
- Is the brake pedal operating freely?

->Yes
INSTALL a new brake booster. For additional information, refer to Brake Booster - RHD Brake Booster [RHD]
For additional information, refer to Brake Booster - LHD Brake Booster [LHD] TEST the system for normal operation.

->No
REPAIR or INSTALL new brake pedal. TEST the system for normal operation.