Part 2

INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION - Continued


20. DISABLE BRAKE CONTROL
HINT: Using the Techstream to disable brake control causes the master pressure cut solenoid to turn OFF and the line from the master cylinder to the front disc brake caliper to open.

(a) Check that the parking brake is set.
(b) Connect the Techstream to the DLC3 with the engine switch OFF.
(c) Turn the engine switch ON (IG).
NOTE: Do not start the engine.

(d) ->->->Turn the Techstream on and select "DIAGNOSTIC MENU""ABS/VSC""ELECTRONICALLY CONTROLLED BRAKE SYSTEM UTILITY""ELECTRONICALLY CONTROLLED BRAKE SYSTEM INVALID" on the Techstream.
21. BLEED AIR FROM FRONT BRAKE SYSTEM
HINT: After replacing the brake master cylinder with simulator assembly, perform air bleeding on it (same as for common master cylinders) so that bleeding air from the front brake system is easier.
NOTICE:
- Bleed air from the wheel furthest from the master cylinder.
- Repeat the bleeding procedures until all the air in the fluid is completely bled out.





(a) Connect a vinyl tube to the bleeder plug on the front disc brake caliper LH and RH.

(b) Depress the brake pedal several times, then loosen the bleeder plug with the pedal depressed.






(c) When fluid stops coming out, temporarily tighten the bleeder plug, then release the brake pedal.

(d) Repeat the above procedures until all the air in the fluid is completely bled out.
(e) Tighten the bleeder plug.
Torque: 11 Nm (110 kgf-cm, 8 ft-lbf)
22. CANCEL DISABLE BRAKE CONTROL
(a) Cancel "DISABLE BRAKE CONTROL" on the Techstream.
23. CONNECT BRAKE ACCUMULATOR PUMP CONNECTORS
(a) Turn the engine switch OFF.
(b) Connect the 2 brake accumulator pump connectors.






(c) Turn the engine switch ON (IG).

24. BLEED AIR FROM PUMP SUCTION SYSTEM (RR)
HINT: Loosening the rear disc brake caliper's RH bleeder plug and using the Techstream to select "BLEED PUMP SUCTION SYSTEM (RR)" causes the pump motor and solenoid to operate and pressurize the rear brake line.

(a) Check that the parking brake is set.
(b) Connect the Techstream to the DLC3 with the engine switch OFF.
(c) Turn the engine switch ON (IG).
NOTE: Do not start the engine.

(d) Connect a vinyl tube to the bleeder plug on the rear disc brake caliper RH.
(e) Loosen the bleeder plug.
(f) ->->->Turn the Techstream on and select "DIAGNOSTIC MENU""ABS/VSC""ELECTRONICALLY CONTROLLED BRAKE SYSTEM UTILITY""BLEED PUMP SUCTION SYSTEM (RR)" on the Techstream.
NOTE: Do not depress the brake pedal.
HINT: The solenoid operates for approximately 30 seconds.

(g) Tighten the bleeder plug.
Torque: 11 Nm (110 kgf-cm, 8 ft-lbf)
25. DISABLE BRAKE CONTROL
(a) ->->->Turn the Techstream on and select "DIAGNOSTIC MENU""ABS/VSC""ELECTRONICALLY CONTROLLED BRAKE SYSTEM UTILITY""ELECTRONICALLY CONTROLLED BRAKE SYSTEM INVALID" on the Techstream.
26. BLEED AIR FROM REAR BRAKE SYSTEM






(a) Connect a vinyl tube to the bleeder plug on the rear disc brake caliper LH and RH.

(b) With the brake pedal depressed, loosen the bleeder plug.
NOTE: Keep the fluid inside the reservoir above the MIN line by replenishing.
HINT:
- Depress and hold the brake pedal.
- After the solenoid operates for approximately 30 seconds, release the brake pedal to stop the solenoid.
- Repeat the above procedures until air is completely bled from the rear brake system.
- The brake control warning light comes on and the buzzer sounds while bleeding, but they do not indicate a malfunction.





(c) Tighten the bleeder plug after bleeding.
Torque: 11 Nm (110 kgf-cm, 8 ft-lbf)
HINT: The fluid amount adjustment is easier to perform if fuel bleeding is completed with the brake fluid reservoir's fluid level at approximately 5 mm (0.20 in.) below the MAX level.

27. CANCEL DISABLE BRAKE CONTROL
(a) Cancel "DISABLE BRAKE CONTROL" on the Techstream.
28. PERFORM ACCUMULATOR ZERO DOWN
(a) Connect the Techstream to the DLC3 with the engine switch off.
(b) Perform the accumulator pressure zero down as follows:
(1) Check that the parking brake is set, and turn the engine switch ON (IG).
(2) ->->->Turn the Techstream on and select "DIAGNOSTIC MENU" "ABS/VSC" "ELECTRONICALLY CONTROLLED BRAKE SYSTEM UTILITY" "ZERO DOWN" on the Techstream.
HINT: Using the Techstream to perform accumulator zero down causes the pressurized fluid in the actuator's accumulator to be returned to the brake fluid reservoir.
(3) When the buzzer sounds, turn the engine switch OFF.
(c) Perform the accumulator fluid circulation as follows:
(1) Perform the accumulator pressure zero down 5 times repeatedly.
HINT:
- Accumulator pressure is released and accumulated repeatedly, which circulates the fluid inside the accumulator every time accumulator zero down (accumulator depressurizing) is performed.
- The pump motor rotates and accumulator is pressurized every time the engine switch is turned from OFF to ON (IG).

29. CHECK AND ADJUST BRAKE FLUID LEVEL IN RESERVOIR






(a) After performing accumulator zero down (accumulator depressurizing), adjust the fluid level in the master cylinder reservoir to the MAX level.
NOTE: If using a dropper to adjust the fluid amount, make sure the dropper has not been used with mineral oils, water or deteriorated brake fluid. Sealed areas may deteriorate and lead to fluid leaks, or the fluid may deteriorate and lead to decreased efficiency.
- After performing accumulator zero down (accumulator depressurizing), if the engine switch is turned ON (IG), the fluid level in the accumulator increases, and the fluid level in the reservoir decreases.
- If the fluid level is adjusted without performing accumulator zero down (accumulator depressurizing), fluid is sent from the accumulator to the reservoir. The fluid level may exceed the MAX level, but it is normal.

(b) After turning the engine switch ON (IG), check that the fluid level in the brake fluid reservoir is slightly lower than the MAX level.
30. CLEAR DTC
(a) Clear the DTCs.
31. PERFORM LINEAR VALVE OFFSET LEARNING
(a) When the brake actuator is replaced, perform linear valve offset learning.
32. CHECK DTC
(a) If any DTC is set, perform the troubleshooting for the DTC.
33. READ VALUE OF ACCUMULATOR PRESSURE SENSOR OUTPUT VOLTAGE
HINT: If removing and installing the No. 3 brake actuator tube, check for a brake fluid leak from the No. 3 tube connection area by monitoring the accumulator pressure sensor output value from the brake actuator. Directly checking for a brake fluid leak from the No. 3 tube connection area is difficult.

(a) Turn the engine switch OFF.
(b) Connect the Techstream to the DLC3.
(c) Turn the engine switch ON (IG).
(d) Operate the Techstream according to the display and select "DATA LIST".

Skid control ECU:









(e) Depress the brake pedal 4 or 5 times to operate the pump motor, and check the output value on the Techstream with the motor stopped (not braking).
OK:
Accumulator pressure sensor's output voltage drops 0.2 V or less for 30 seconds.
If the voltage drops more than 0.2 V, there may be a brake fluid leak from the No. 3 brake actuator tube connection area. Remove the brake actuator and brake accumulator pump, and then repeat the procedures above from the retightening of the 2 union nuts of the No. 3 brake actuator tube.
SST: 09023-00101
Torque: 15 Nm (155 kgf-cm, 11 ft-lbf)
Torque: 14 Nm (145 kgf-cm, 10 ft-lbf)
- Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
- This torque value is effective when SST is parallel to a torque wrench.

34. CHECK AND ADJUST BRAKE PEDAL HEIGHT
NOTE: Fold back the carpet below the brake pedal for this inspection adjustment.





(a) Check the brake pedal height.
Standard pedal height from tibia pad:
144.2 to 154.2 mm (5.68 to 6.07 in.)

(b) Adjust the pedal height.
(1) Disconnect the connector from the stop light switch.
(2) Loosen the stop light switch lock nut and turn the switch so that the pedal has free play.
(3) Loosen the push rod clevis lock nut.
(4) Adjust the pedal height by turning the push rod.
Standard pedal height from tibia pad:
144.2 to 154.2 mm (5.68 to 6.07 in.)
(5) Tighten the push rod clevis lock nut.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)





(6) Turn the stop light switch so that its protrusion is between 1.5 and 2.6 mm (0.059 and 0.102 in.). Then tighten the lock nut.
Torque: 17 Nm (170 kgf-cm, 12 ft-lbf)
(7) Connect the stop light switch connector.
(8) Without depressing the brake pedal, check that the stop light does not illuminate. If it illuminates, adjust the brake pedal height again.
(9) Push the brake pedal in 5 to 10 mm (0.20 to 0.39 in.), and check that the stop light comes on.
If the stop light does not turn on, adjust the brake pedal height again.
35. ADJUST BRAKE PEDAL STROKE SENSOR
(a) Connect the Techstream to the DLC3 with the engine switch OFF.






(b) Loosen the 2 bolts.

(c) Turn the engine switch ON (IG). While reading the stroke sensor 1 value shown on the Techstream, turn the stroke sensor slowly to the right and left to adjust it to the standard voltage.
Standard voltage:
0.8 to 1.2 V
(d) Tighten the 2 bolts.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)
NOTE: Do not depress the brake pedal while performing the linear valve offset learning, as this may cause a DTC to be stored.

(e) Perform the linear valve offset learning.
36. RESET MEMORY (with the Techstream)
(a) Turn the engine switch OFF.
(b) Connect the Techstream to the DLC3.
(c) Turn the engine switch ON (IG) and the tester ON.
(d) Enter the following menus: Chassis / Electric Parking Brake / Utility / Reset Memory.
(e) Follow the tester display and perform reset memory.
HINT: When the reset memory is completed, the parking brake indicator light (RED) will blink at 0.5 second intervals.





37. RESET MEMORY (without the Techstream)
(a) Turn the engine switch OFF.






(b) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
SST: 09843-18040
NOTE: Do not connect the wrong terminals, as this will cause parts to be damaged.

(c) Turn the engine switch ON (IG).
HINT: The parking brake indicator light (RED) will blink at 0.25 second intervals.

(d) Perform both of the following procedures within 8 seconds:
(1) ->->->Perform the following with the electric parking brake switch twice: lock condition off release condition off.
(2) ->->->Perform the following with the brake pedal: depress release depress release.





(e) With the engine switch ON (IG), disconnect the connection of terminals 13 (TC) and 4 (CG) of the DLC3.
(f) Check that the parking brake indicator light (RED) blinks at 0.5 second intervals.
NOTE: If terminal 13 (TC) and 4 (CG) of the DLC3 are not disconnected, the blinking pattern (0.5 second intervals) cannot be checked.
HINT: If the parking brake indicator light (RED) blinking pattern (0.5 second intervals) is confirmed, the clear procedure is completed. If not confirmed, repeat the procedures above.

38. ACQUIRE TENSION SENSOR ZERO POINT
(a) After performing reset memory, perform the release control. Check that the parking brake indicator light (RED) turns off.
39. PARKING BRAKE BEDDING
CAUTION: Performing parking brake bedding forms the friction surfaces of the parking brake shoe and rear disc, which creates the basic braking force of the parking brake. If bedding is not performed, the parking brake performance may not be normal.
NOTE: If one of the following is performed, perform parking brake bedding.
- Rear disc is replaced or removed and installed
- Parking brake shoe is replaced or removed and installed
- electric parking brake actuator is replaced or removed and installed

(a) Turn the engine switch OFF.






(b) Using SST, connect terminals 12 (TS) and 4 (CG) of the DLC3.
SST: 09843-18040
NOTE: Do not connect the wrong terminals, as this will cause parts to be damaged.

(c) Turn the engine switch ON (IG).
(d) Perform the following procedures with the electric parking brake switch within 8 seconds:
(1) Turning the lock switch ON and OFF 3 times.
(2) Turn the release switch ON and OFF 3 times.





(e) Check that the system is in test mode.
HINT: The multi-information display shows "EPB TEST". EPB stands for electric parking brake. If it is not displayed, repeat the procedures above.





(f) Perform parking brake bedding.
(g) Drive the vehicle at 30 km/h (19 mph).
(h) Push the parking brake switch to the lock side for 5 seconds.
NOTICE:
- The braking power is generated from the parking brake while driving the vehicle. This will cause the vehicle speed to decrease. Depress the acceleration pedal to maintain the speed at 30 km/h (19 mph).
- This procedure must be performed while driving the vehicle. If performed on a speed tester, etc., the front wheels do not rotate and the vehicle will determine that the vehicle is stopped.
HINT:
- The parking brake indicator light (RED) stops blinking at 0.125 second intervals, and illuminates.
- The buzzer turns ON (peeping sound).
- The tension is automatically adjusted.

(i) After 5 seconds, check that the buzzer and the parking brake indicator light (RED) turn off.
HINT: The brake force decreases.

(j) Release the parking brake lock switch.
40. STEERING ANGLE SENSOR INITIALIZATION (to obtain a tire angle (during straight-ahead driving) signal)






(a) Turn the engine switch ON (IG), and check that the master warning light illuminates for a few seconds.
NOTE: If the warning light remains on or blinks, repair the applicable system.

(b) Drive the vehicle on a straight road at 35 km/h (22 mph) or more for 5 seconds or longer.
HINT:
- At this point, the steering wheel will still remain off-center by 5 to 10°.
- In this step, the neutral position of the steering wheel is restored from the steering control ECU memory.

(c) Confirm that steering angle sensor initialization is completed (using the tester).
(1) the Techstream - Enter the VGRS menu using the tester. Select "Straight Angle Valid Flag" from "Data List". Check if the steering angle sensor has obtained a tire angle (during straight-ahead driving) signal.
Standard:
"Valid" is displayed on the tester screen.
(d) Confirm that steering angle sensor initialization is completed (not using the tester).
(1) Stop the vehicle (engine running).
(2) Slowly turn the steering wheel from lock to lock.
(3) If it turns approximately 2.7 turns, steering angle sensor initialization is completed. If it turns approximately 3.2 turns, steering angle sensor initialization is not completed.
NOTE: If the steering wheel turns approximately 3.2 turns, drive the vehicle on a straight road at 35 km/h (22 mph) or more for 5 seconds or longer. Then confirm the initialization again.

41. VGRS SYSTEM CALIBRATION PROCEDURE (USING SST CHECK WIRE)
1. FACE TIRES STRAIGHT AHEAD
NOTE: Drive the vehicle to confirm that the steering wheel is centered.

NEXT -- Continue to next step.
2. CHECK DTC
(a) Check for DTCs.
Result:






B -- Go to step 4
A -- Continue to next step.
3. PERFORM ACTUATOR ANGLE INITIALIZATION





(a) Start the engine.
(b) Center the steering wheel.
SST: 09843-18040
(c) Complete the following steps within 1 minute.
(1) Using SST, connect terminals 12 (TS) and 4 (CG), and 13 (TC) and 4 (CG) of the DLC3.
(2) Disconnect SST from terminal 12 (TS) of the DLC3, and turn the steering wheel to the left 180° or more.
(3) Connect SST to terminal 12 (TS) of the DLC3.
(4) Disconnect SST from terminal 13 (TC) of the DLC3, and turn the steering wheel to the right 180° or more.
(5) Connect SST to terminal 13 (TC) of the DLC3.
HINT: When the master warning light comes on, DTC C1591/51 is memorized.
(d) Disconnect SST from the DLC3.
(e) Turn the engine switch OFF.
NEXT -- Go to step 1
4. FACE TIRES STRAIGHT AHEAD
(a) Confirm that the steering wheel is centered when facing the tires straight ahead.
NOTE: Drive the vehicle to confirm that the steering wheel is centered.

Result:






B -- Go to step 8
A -- Continue to next step.
5. UNLOCK STEERING ACTUATOR
NOTE: Do not start the engine.
(a) Turn the engine switch OFF.
(b) Disconnect the negative (-) terminal cable from the battery.





(c) Disconnect the x2 connector from the steering actuator.
(d) Connect a jumper wire from terminal LV to the positive (+) battery terminal and another jumper wire from terminal LG to the negative (-) battery terminal.
NOTE: Do not apply voltage for more than 3 minutes.

NEXT -- Continue to next step.
6. STEERING CENTER ADJUSTMENT
(a) Center the steering wheel.
NOTE: If the centering of the spiral cable was not confirmed when the steering wheel was installed, confirm the centering of the spiral cable.

NEXT -- Continue to next step.
7. LOCK STEERING ACTUATOR
(a) Disconnect the positive (+) and negative (-) battery terminal cables from the steering actuator.
(b) Connect the x2 connector to the steering actuator.
(c) Connect the negative (-) terminal cable to the battery.
(d) Turn the steering wheel approximately 3° to the left and right. Confirm that the reaction force can be felt.
NOTICE:
- If the above procedures are not followed correctly, a DTC will be detected. If a DTC is detected, perform the above procedures again and then check for DTCs.
- Perform these procedures with the engine switch off.

NEXT -- Go to step 1
8. ADJUST ACTUATOR ANGLE
HINT: Activating and ending test mode will complete actuator angle adjustment.
(a) Make sure the engine switch is OFF.
NOTE: Do not touch the steering wheel during these procedures.





(b) Using SST, connect terminals 12 (TS) and 4 (CG) of the DLC3.
SST: 09843-18040
(c) Turn the engine switch ON (IG).
(d) Confirm that the "VGRS TEST MODE" is displayed on the multi-information display when test mode is activated.
HINT: Wait approximately 5 seconds.
(e) Turn the engine switch OFF.
(f) Disconnect SST from terminals 12 (TS) and 4 (CG) of the DLC3.
(g) Turn the engine switch ON (IG) again.
NEXT -- Continue to next step.
9. CHECK MASTER WARNING LIGHT
(a) Confirm that the master warning light is off.
(b) Turn the engine switch OFF.
(c) Confirm that the master warning light is operating normally.
NEXT -- Continue to next step.
10. CHECK STEERING WHEEL OPERATION
(a) Start the engine.
(b) Perform the steering angle sensor initialization.
(c) Turn the steering wheel from lock to lock and check that it rotates approximately 2.7 turns.
(d) Drive the vehicle and confirm that the steering wheel is centered.
NEXT -- END
42. VGRS SYSTEM CALIBRATION PROCEDURE (USING the Techstream)
1. FACE TIRES STRAIGHT AHEAD
NOTE: Drive the vehicle to confirm that the steering wheel is centered.

NEXT -- Continue to next step.
2. PERFORM VGRS SYSTEM CALIBRATION
(a) Connect the Techstream to the DLC3.
(b) Turn the engine switch ON (IG).
(c) Turn the tester on.
(d) Enter the menu items in this order: Chassis / VGRS / Utility / Steering Angle Adjust.
(e) Perform the following procedures displayed on the tester.
NEXT -- Continue to next step.
3. CHECK MASTER WARNING LIGHT
(a) Confirm that the master warning light is off.
(b) Turn the engine switch OFF.
(c) Disconnect the Techstream from the DLC3.
(d) Confirm that master warning light is operating normally.
NEXT -- Continue to next step.
4. CHECK STEERING WHEEL OPERATION
(a) Start the engine.
(b) Perform the steering angle sensor initialization.
(c) Turn the steering wheel from lock to lock and check that it rotates approximately 2.7 turns.
(d) Drive the vehicle and confirm that the steering wheel is centered.
NEXT -- END
43. ROTATION ANGLE SENSOR VALUE INITIALIZATION AND TORQUE SENSOR ZERO POINT CALIBRATION
NOTE: Clear the rotation angle sensor calibration value, initialize the rotation angle sensor value, and calibrate the torque sensor zero point if any of the following has occurred:
- The power steering ECU has been replaced.
- The power steering gear assembly has been replaced.
- Steering effort differs between left and right.

(a) Inspection before calibration.
(1) Connect the Techstream to the DLC3.
(2) Turn the engine switch ON (IG).
(3) Turn the Techstream on.
Techstream - Select "IG Supply" from the data list.
(4) Check the IG power supply voltage on the tester screen.

EMPS





Standard voltage:
11 to 14 V
NOTE: If the IG power supply voltage is 11 V or less, calibration cannot be performed. In this case, charge or replace the battery, and then perform calibration.

(b) Clearing rotation angle sensor calibration value, rotation angle sensor value initialization, and torque sensor zero point calibration.
NOTICE:
- If DTC C1516 (Torque Sensor Zero Point Adjustment Incomplete) is stored, the torque sensor zero point cannot be calibrated. Clear the DTC before starting calibration.
- If DTC C1526 (Motor Rotation Angle Sensor Initialization Incomplete) is stored, the rotation angle sensor value cannot be initialized. Clear the DTC before starting initialization.
(1) Connect the Techstream to the DLC3.
(2) Turn the engine switch ON (IG).
(3) Turn the Techstream on.
Techstream - Select "Torque Sensor Adjustment".
(4) Follow the procedures on the tester display to clear the rotation angle sensor calibration value, initialize the rotation angle sensor value, and calibrate the torque sensor zero point.
NOTICE:
- When initializing the rotation angle sensor value, observe the following to stabilize sensor voltage:
After turning the engine switch ON (IG), wait for at least 2.5 seconds before turning the steering wheel. Do not turn the steering wheel quickly.
- The steering wheel will vibrate during torque sensor zero point calibration. Do not touch the steering wheel while it is vibrating or for 2 seconds after it stops.

44. ZERO POINT CALIBRATION
(a) Zero point calibration procedures
(1) Check that all of the following conditions are met:

- The vehicle is parked on a level surface.
- No objects are placed on the front passenger seat.
- The front passenger seat belt buckle switch is OFF.
(2) Adjust the seat position according to the table below.





(3) Connect the Techstream to the DLC3.
(4) Turn the engine switch ON (IG).
(5) Perform zero point calibration by following the prompts on the tester screen.
HINT:
- Refer to the Techstream operator's manual for further details.
- If the zero point calibration is performed when the calibration conditions are not satisfied, DTC B1797 is output.
- If the zero point calibration has failed, DTC B1797 is output.
- If After Exchange is selected before the previous ECU data are stored in the Techstream, the display screen returns to CONDITION SELECT ECU: Occupant Detect.