Toyota Corolla Cross Owners & Service Manuals

Toyota Corolla Cross: Brake Pedal Position Sensor Supply Voltage Circuit Voltage Out of Range (C05621C,...,P157A62)

Toyota Corolla Cross (2022-2024) Service Manual / Brake / Brake Control / Dynamic Control Systems / Electronically Controlled Brake System (for Hev Model) / Brake Pedal Position Sensor Supply Voltage Circuit Voltage Out of Range (C05621C,...,P157A62)

DESCRIPTION

The brake pedal stroke sensor assembly sends the brake pedal stroke distance to the skid control ECU inside the brake actuator assembly.

DTC No.

Detection Item

DTC Detection Condition

Trouble Area

MIL

DTC Output from

Note

C05621C

Brake Pedal Position Sensor Supply Voltage Circuit Voltage Out of Range

Brake pedal stroke sensor assembly power source malfunction detected.

  • Brake pedal stroke sensor assembly
  • Skid control ECU (brake actuator assembly)

Does not come on

Brake/EPB

Output ECU: Skid control ECU (brake actuator assembly)

C139200

Zero Point Calibration of Stroke Sensor

While the brake pedal is not being depressed, brake pedal stroke sensor assembly zero point not calibrated signal is received. (A correct brake pedal stroke sensor assembly zero point learning value is not present).

  • Brake pedal stroke sensor assembly
  • Skid control ECU (brake actuator assembly)

Does not come on

Brake/EPB

Output ECU: Skid control ECU (brake actuator assembly)

P057A11

Brake Pedal Position Sensor "A" Circuit Short to Ground

Open or short detected due to abnormality in brake pedal stroke sensor assembly output circuit 1.

  • Brake pedal stroke sensor assembly
  • Skid control ECU (brake actuator assembly)

Does not come on

Brake/EPB

Output ECU: Skid control ECU (brake actuator assembly)

P057A15

Brake Pedal Position Sensor "A" Circuit Short to Battery or Open

Open or short detected due to abnormality in brake pedal stroke sensor assembly output circuit 1.

  • Brake pedal stroke sensor assembly
  • Skid control ECU (brake actuator assembly)

Does not come on

Brake/EPB

Output ECU: Skid control ECU (brake actuator assembly)

P057A28

Brake Pedal Position Sensor "A" Signal Bias Level Out of Range / Zero Adjustment Failure

Difference in change amount of brake pedal stroke sensor assembly output voltage 1 (SKS1) is abnormally large for 0.1 seconds or more. (SKS1 output comparison invalid).

  • Brake pedal stroke sensor assembly
  • Skid control ECU (brake actuator assembly)

Does not come on

Brake/EPB

Output ECU: Skid control ECU (brake actuator assembly)

P057A64

Brake Pedal Position Sensor "A" Signal Plausibility Failure

Difference in change amount of brake pedal stroke sensor assembly output voltage 1 (SKS1) is abnormally large for 0.2 seconds or more. (SKS1 output comparison invalid).

  • Brake pedal stroke sensor assembly
  • Skid control ECU (brake actuator assembly)

Does not come on

Brake/EPB

Output ECU: Skid control ECU (brake actuator assembly)

P05DB11

Brake Pedal Position Sensor "B" Circuit Short to Ground

Open or short detected due to abnormality in brake pedal stroke sensor assembly output circuit 2.

  • Brake pedal stroke sensor assembly
  • Skid control ECU (brake actuator assembly)

Does not come on

Brake/EPB

Output ECU: Skid control ECU (brake actuator assembly)

P05DB15

Brake Pedal Position Sensor "B" Circuit Short to Battery or Open

Open or short detected due to abnormality in brake pedal stroke sensor assembly output circuit 2.

  • Brake pedal stroke sensor assembly
  • Skid control ECU (brake actuator assembly)

Does not come on

Brake/EPB

Output ECU: Skid control ECU (brake actuator assembly)

P05DB28

Brake Pedal Position Sensor "B" Signal Bias Level Out of Range / Zero Adjustment Failure

Difference in change amount of brake pedal stroke sensor assembly output voltage 2 (SKS2) is abnormally large for 0.1 seconds or more. (SKS2 output comparison invalid).

  • Brake pedal stroke sensor assembly
  • Skid control ECU (brake actuator assembly)

Does not come on

Brake/EPB

Output ECU: Skid control ECU (brake actuator assembly)

P05DB64

Brake Pedal Position Sensor "B" Signal Plausibility Failure

Difference in change amount of brake pedal stroke sensor assembly output voltage 2 (SKS2) is abnormally large for 0.2 seconds or more. (SKS2 output comparison invalid).

  • Brake pedal stroke sensor assembly
  • Skid control ECU (brake actuator assembly)

Does not come on

Brake/EPB

Output ECU: Skid control ECU (brake actuator assembly)

P05E064

Brake Pedal Position Sensor "A"/"B" Signal Plausibility Failure

Difference between change amounts of brake pedal stroke sensor assembly output voltage 1 (SKS1) and brake pedal stroke sensor assembly output voltage 2 (SKS2) is abnormally large for 0.2 seconds or more. (SKS1 and SKS2 output comparison invalid).

  • Brake pedal stroke sensor assembly
  • Skid control ECU (brake actuator assembly)

Does not come on

Brake/EPB

Output ECU: Skid control ECU (brake actuator assembly)

P157A62

Brake Pedal Position Sensor "A" / "B" Brake Master Cylinder Pressure Sensor Multiple Sensor Signal Compare Failure

While driving at a vehicle speed of 3 km/h or more, the master cylinder pressure sensor value is too high relative to the brake pedal stroke sensor assembly value for 0.2 seconds or more.

  • Brake pedal stroke sensor assembly
  • Skid control ECU (brake actuator assembly)

Does not come on

Brake/EPB

Output ECU: Skid control ECU (brake actuator assembly)

WIRING DIAGRAM

PROCEDURE

1.

CHECK BRAKE PEDAL

(a) Check that the brake pedal and the brake pedal stroke sensor assembly are properly installed and that the pedal can be depressed normally.

(b) Check and adjust the brake pedal height.

Click here

(c) Adjust the brake pedal stroke sensor assembly.

Click here

NEXT

2.

CHECK DTC

(a) Read the DTCs using the GTS.

Chassis > Brake/EPB > Trouble Codes

Result

Proceed to

C05621C, C139200, P057A11, P057A15, P057A28, P057A64, P05DB11, P05DB15, P05DB28, P05DB64, P05E064 or P157A62 is output

A

Only C139200 is output

B

None of the above conditions are met

C

B

GO TO STEP 5

C

REPAIR CIRCUITS INDICATED BY OUTPUT DTCS

A

3.

CHECK HARNESS AND CONNECTOR (BRAKE ACTUATOR ASSEMBLY - BRAKE PEDAL STROKE SENSOR ASSEMBLY)

(a) Turn the ignition switch off.

(b) Make sure that there is no looseness at the locking part and the connecting part of the connectors.

OK:

The connector is securely connected.

(c) Disconnect the A151 skid control ECU (Brake Actuator Assembly) connector.

(d) Disconnect the A191 brake pedal stroke sensor assembly connector.

(e) Check both the connector case and the terminals for deformation and corrosion.

OK:

No deformation or corrosion.

(f) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

A151-17 (VSK) - A191-1 (VSK)

Always

Below 1 Ω

A151-17 (VSK) or A191-1 (VSK) - Body ground

Always

10 kΩ or higher

A151-6 (SKS1) - A191-2 (SKS1)

Always

Below 1 Ω

A151-6 (SKS1) or A191-2 (SKS1) - Body ground

Always

10 kΩ or higher

A151-42 (SKS2) - A191-4 (SKS2)

Always

Below 1 Ω

A151-42 (SKS2) or A191-4 (SKS2) - Body ground

Always

10 kΩ or higher

A151-29 (SKG) - A191-3 (SKG)

Always

Below 1 Ω

A151-29 (SKG) or A191-3 (SKG) - Body ground

Always

10 kΩ or higher

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

4.

INSPECT BRAKE ACTUATOR ASSEMBLY (SENSOR OUTPUT)

(a) Make sure that there is no looseness at the locking part and the connecting part of the connectors.

OK:

The connector is securely connected.

*a

Front view of wire harness connector

(to Brake Pedal Stroke Sensor Assembly)

(b) Disconnect the A191 brake pedal stroke sensor assembly connector.

(c) Check both the connector case and the terminals for deformation and corrosion.

OK:

No deformation or corrosion.

(d) Turn the ignition switch to ON.

(e) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Tester Connection

Condition

Specified Condition

A191-1 (VSK) - A191-3 (SKG)

Ignition switch ON

4.84 to 5.16 V

OK

REPLACE BRAKE PEDAL STROKE SENSOR ASSEMBLY

NG

REPLACE BRAKE ACTUATOR ASSEMBLY

5.

CLEAR BRAKE PEDAL STROKE SENSOR ASSEMBLY ZERO POINT

(a) Using the GTS, clear the brake pedal stroke sensor assembly zero point.

Chassis > Brake/EPB > Utility

Tester Display

Reset Memory

NEXT

6.

PERFORM BRAKE PEDAL STROKE SENSOR ASSEMBLY ZERO POINT CALIBRATION

(a) Using the GTS, perform the brake pedal stroke sensor assembly zero point calibration.

Chassis > Brake/EPB > Utility

Tester Display

Calibration

NEXT

7.

CLEAR DTC

(a) Clear the DTCs.

Chassis > Brake/EPB > Clear DTCs

(b) Turn the ignition switch off.

NEXT

8.

RECONFIRM DTC

(a) Based on the Freeze Frame Data and interview with the customer, attempt to reproduce the conditions when the malfunction occurred.

(b) Check if the same DTC is output.

Chassis > Brake/EPB > Trouble Codes

Result

Proceed to

C139200 is output

A

DTCs are not output

B

None of the above conditions are met

C

B

USE SIMULATION METHOD TO CHECK

C

REPAIR CIRCUITS INDICATED BY OUTPUT DTCS

A

9.

INSPECT BRAKE ACTUATOR ASSEMBLY (SENSOR OUTPUT)

(a) Turn the ignition switch off.

*a

Front view of wire harness connector

(to Brake Pedal Stroke Sensor Assembly)

(b) Make sure that there is no looseness at the locking part and the connecting part of the connectors.

OK:

The connector is securely connected.

(c) Reconnect the A191 brake pedal stroke sensor assembly connector.

(d) Check both the connector case and the terminals for deformation and corrosion.

OK:

No deformation or corrosion.

(e) Turn the ignition switch to ON.

(f) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Tester Connection

Condition

Specified Condition

A191-1 (VSK) - A191-3 (SKG)

Ignition switch ON

4.84 to 5.16 V

OK

REPLACE BRAKE PEDAL STROKE SENSOR ASSEMBLY

NG

REPLACE BRAKE ACTUATOR ASSEMBLY

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