Part 2

INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION - Continued


16. FILL RESERVOIR WITH BRAKE FLUID
NOTICE:
- As brake fluid may overflow when bleeding air, do not place the fluid can on the reservoir filler opening.
- If brake fluid leaks onto any painted surface, clean it off completely.





(a) Add brake fluid into the reservoir.
Fluid:
SAE J1703 or FMVSS No. 116 DOT 3

17. DISABLE BRAKE CONTROL
HINT: Using the intelligent tester or 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 intelligent tester or Techstream to the DLC3 with the power switch OFF.
(c) Turn the power switch ON (IG).
NOTE: Do not start the engine.

(d) Enter the following menus:
(1) Intelligent tester - select: DIAGNOSIS / ABS/VSC / ELECTRONICALLY CONTROLLED BRAKE SYSTEM UTILITY / ELECTRONICALLY CONTROLLED BRAKE SYSTEM INVALID.
(2) Techstream - select: Chassis / ABS/VSC/TRC / Utility / Electronically Controlled Brake system Utility / Electronically Controlled Brake system Invalid.
18. 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)
19. CANCEL DISABLE BRAKE CONTROL
(a) Cancel "DISABLE BRAKE CONTROL" on the intelligent tester or Techstream.
20. CONNECT BRAKE ACCUMULATOR PUMP CONNECTORS
(a) Turn the power switch OFF.
(b) Connect the 2 brake accumulator pump connectors.






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

21. BLEED AIR FROM PUMP SUCTION SYSTEM (RR)
NOTICE:
- If work is not performed from "PERFORM ACCUMULATOR ZERO DOWN", air cannot be bled from the pump suction system (RR). Perform the procedure from "PERFORM ACCUMULATOR ZERO DOWN", then perform this step.
- The accumulator pressure is at zero down.
HINT: Loosening the rear disc brake caliper's RH bleeder plug and using the intelligent tester or Techstream 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 intelligent tester or Techstream to the DLC3 with the power switch OFF.
(c) Turn the power 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) Enter the following menus:
(1) Intelligent tester - select: DIAGNOSIS / ABS/VSC / ELECTRONICALLY CONTROLLED BRAKE SYSTEM UTILITY / ZERO DOWN RR.
(2) Techstream - select: Chassis / ABS/VSC/TRC / Utility / Electronically Controlled Brake system Utility / Zero Down Rear.
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)
22. DISABLE BRAKE CONTROL
(a) Enter the following menus:
(1) Intelligent tester - select: DIAGNOSIS / ABS/VSC / ELECTRONICALLY CONTROLLED BRAKE SYSTEM UTILITY / ELECTRONICALLY CONTROLLED BRAKE SYSTEM INVALID.
(2) Techstream - select: Chassis / ABS/VSC/TRC / Utility / Electronically Controlled Brake system Utility / Electronically Controlled Brake system Invalid.
23. 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 (0.197 in.) below the MAX level.

24. CANCEL DISABLE BRAKE CONTROL
(a) Cancel "DISABLE BRAKE CONTROL" on the intelligent tester or Techstream.
25. PERFORM ACCUMULATOR ZERO DOWN
(a) Connect the intelligent tester or Techstream to the DLC3 with the power switch OFF.
(b) Perform the accumulator pressure zero down.
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.
(1) Check that the parking brake is set, and turn the power switch ON (IG).
(2) Enter the following menus of intelligent tester - select: DIAGNOSIS / ABS/VSC / ELECTRONICALLY CONTROLLED BRAKE SYSTEM UTILITY / ZERO DOWN.
(3) Enter the following menus of Techstream - select: Chassis / ABS/VSC/TRC / Utility / Electronically Controlled Brake system Utility / Zero Down.
(4) When the buzzer sounds, turn the power switch OFF.
(c) Perform the accumulator fluid circulation.
(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 the accumulator is pressurized every time the power switch is turned from OFF to ON (IG).

26. 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 power 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 power switch ON (IG), check that the fluid level in the brake fluid reservoir is slightly lower than the MAX level.
27. CLEAR DTC
(a) Clear the DTCs.
28. PERFORM LINEAR VALVE OFFSET LEARNING
(a) When the brake actuator is replaced, perform linear valve offset learning.
29. CHECK DTC
(a) Check for DTC. If any DTC is output, perform the troubleshooting for that DTC.
30. READ VALUE OF ACCUMULATOR PRESSURE SENSOR OUTPUT VOLTAGE
31. 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 (0.0591 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 (0.197 to 0.394 in.), and check that the stop light illuminates.
If the stop light does not illuminate, adjust the brake pedal height again.
32. ADJUST BRAKE PEDAL STROKE SENSOR
(a) Connect the intelligent tester or Techstream to the DLC3 with the power switch OFF.






(b) Loosen the 2 bolts.

(c) Turn the power switch ON (IG). While reading the stroke sensor 1 value shown on the intelligent tester or 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)
(e) Perform the linear valve offset learning.
NOTE: Do not depress the brake pedal while performing the linear valve offset learning, as this may cause a DTC to be stored.

33. RESET MEMORY (with Intelligent Tester or Techstream)
(a) Turn the power switch OFF.
(b) Connect the intelligent tester or Techstream to the DLC3.
(c) Turn the power switch ON (IG) and the tester ON.
(d) Enter the following menus:
(1) Intelligent tester - Select: DIAGNOSIS / OBD/MOBD / CHASSIS / ELECTRIC PKB / UTILITY / RESET MEMORY.
(2) Techstream - Select: 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 seconds intervals.





34. RESET MEMORY (without Intelligent Tester or Techstream)
(a) Turn the power 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 power switch ON (IG).
HINT: The parking brake indicator light (RED) will blink at 0.25 seconds 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 power 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 seconds intervals.
NOTE: If terminals 13 (TC) and 4 (CG) of the DLC3 are not disconnected, the blinking pattern (0.5 seconds intervals) cannot be checked.
HINT: If the parking brake indicator light (RED) blinking pattern (0.5 seconds intervals) is confirmed, the clear procedure is completed. If not confirmed, repeat the procedures above.

35. ACQUIRE TENSION SENSOR ZERO POINT
(a) After performing reset memory, perform the release control. Check that the parking brake indicator light (RED) turns off.
36. 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 power 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 power 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:
- When the system enters test mode, the parking brake indicator light (RED) starts blinking.
- The multi-information display shows "EPB TEST" (*). If it is not displayed, repeat the procedures above.
- *: EPB stands for electric parking brake.





(f) Perform parking brake bedding.
(1) Drive the vehicle at 30 km/h (19 mph).
(2) Push the parking brake switch to the lock side for 5 seconds.
NOTE: 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).
HINT:
- The parking brake indicator light (RED) stops blinking at 0.125 seconds intervals, and illuminates.
- The buzzer turns ON (beeping sound).
- The tension is automatically adjusted.
(3) After 5 seconds, check that the buzzer and the parking brake indicator light (RED) turn off.
HINT: The brake force decreases.
(4) Release the parking brake lock switch.
37. STEERING ANGLE SENSOR INITIALIZATION (to obtain a tire angle (during straight-ahead driving) signal)






(a) Turn the power 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) Intelligent tester - Enter the VGRS menu using the tester. Select "STRAIGH ANG FLG" 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.
(2) 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 (power switch turned to ON (READY)).
(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.

38. 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
SST: 09843-18040
NOTE: If the procedures from *1 to *2 are not completed within 1 minute, or if errors are made during these procedures, perform the initialization again from the beginning.





(a) Turn the power switch ON (READY).
(b) Center the steering wheel.
(c) Using SST, connect terminals 12 (TS) and 4 (CG), and 13 (TC) and 4 (CG) of the DLC3. (*1)
(d) Disconnect SST from terminal 12 (TS) of the DLC3, and turn the steering wheel to the left 180° or more.
(e) Connect SST to terminal 12 (TS) of the DLC3.
(f) Disconnect SST from terminal 13 (TC) of the DLC3, and turn the steering wheel to the right 180° or more.
(g) Connect SST to terminal 13 (TC) of the DLC3. (*2)
HINT: When the master warning light comes on, DTC C1591/51 is memorized.
(h) Disconnect SST from the DLC3.
(i) Turn the power switch OFF.
NEXT -- Continue to next step.
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 turn the power switch ON (READY).
(a) Turn the power switch OFF.
(b) Disconnect the negative (-) terminal cable from the auxiliary battery.





(c) Disconnect the z16 connector from the steering actuator.
(d) Connect a jumper wire from terminal LV to the positive (+) 12 V battery terminal and another jumper wire from terminal LG to the negative (-) 12 V 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 (-) 12 V battery terminal cables from the steering actuator.
(b) Connect the z16 connector to the steering actuator.
(c) Connect the negative (-) terminal cable to the auxiliary 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 power switch OFF.

NEXT -- Continue to next step.
8. ADJUST ACTUATOR ANGLE
HINT: Activating and ending test mode will complete actuator angle adjustment.
(a) Make sure the power 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 power 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 power switch OFF.
(f) Disconnect SST from terminals 12 (TS) and 4 (CG) of the DLC3.
(g) Turn the power 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 power switch OFF, then ON (IG).
(c) Confirm that the master warning light is operating normally.
NEXT -- Continue to next step.
10. CHECK STEERING WHEEL OPERATION
(a) Turn the power switch ON (READY).
(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
39. VGRS SYSTEM CALIBRATION PROCEDURE (USING INTELLIGENT TESTER)
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 intelligent tester to the DLC3.
(b) Turn the power switch ON (IG).
(c) Turn the tester on.





(d) Enter the menu items in this order: DIAGNOSIS / OBD/MOBD / CHASSIS / VGRS. Then, select the "STEER ANGLE ADJ" item, and press "ENTER" to move to next screen.
(e) "NOTICE" screen is displayed. Then, press "ENTER".
NOTE: Press the "ENTER" key even if DTC C15B4/71 is output.
(f) "NOTICE" screen is displayed. Then, press "ENTER".
NOTE: Ensure that the power switch is OFF.
(g) "STEERING ANGLE ADJ" screen is displayed. Then, press "YES".
(h) "STEERING ANGLE ADJ" screen is displayed. Then, press "ENTER".
NOTE: If the centering of the spiral cable was not confirmed when the steering wheel was installed, confirm the centering of the spiral cable.
(i) "NOTICE" screen is displayed. Then, press "ENTER".
NOTE: Do not touch the steering wheel during these procedures.
(j) "NOTICE" screen is displayed. Then, press "ENTER".
(k) "NOTICE" screen is displayed. Then, press "ENTER".
NOTE: Do not touch the steering wheel during these procedures.





(l) The remaining time is displayed and the display switches automatically to the next screen.
NOTE: Do not touch the steering wheel during these procedures.
(m) Check that the VGRS system calibration is completed normally.
(n) Select "ENTER" to return the display to the "MENU" screen.
NEXT -- Continue to next step.
3. CHECK MASTER WARNING LIGHT
(a) Confirm that the master warning light is off.
(b) Turn the power switch OFF.
(c) Disconnect the intelligent tester from the DLC3.
(d) Turn the power switch ON (IG).
(e) Confirm that the master warning light is operating normally.
NEXT -- Continue to next step.
4. CHECK STEERING WHEEL OPERATION
(a) Turn the power switch ON (READY).
(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
40. VGRS SYSTEM CALIBRATION PROCEDURE (USING 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 Techstream to the DLC3.
(b) Turn the power 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 power switch OFF.
(c) Disconnect Techstream from the DLC3.
(d) Turn the power switch ON (IG).
(e) Confirm that master warning light is operating normally.
NEXT -- Continue to next step.
4. CHECK STEERING WHEEL OPERATION
(a) Turn the power switch ON (READY).
(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