Toyota Corolla Cross Owners & Service Manuals

Toyota Corolla Cross: Excessive Brake Pedal Travel (No Fluid Leaks and No Air in System)

PROCEDURE

1.

PRE-INSPECTION

(a) Brake pedal inspection

(1) Perform a visual inspection and operate the brake pedal to check for any malfunctions.

(2) Check the brake pedal height, brake pedal free play and brake pedal reserve distance.

Click here

HINT:

If the brake pedal height is not within specification, confirm that there are no other malfunctions before adjusting the brake pedal height.

(b) Brake inspection

(1) Check that the disc brake pads of each wheel are installed correctly.

(2) Check that the bleeder plug and union bolt is not loose, and that there are no damaged gaskets or brake fluid leaks, for each wheel cylinder.

(c) Brake fluid leaks and air in brake line inspection

(1) Check and take a note of the fluid level in the brake master cylinder reservoir assembly.

(2) Repeatedly depress the brake pedal and confirm that the brake pedal feels normal (no air in the system, etc.).

(3) Check if the brake fluid level in the brake master cylinder reservoir assembly has changed.

(4) If the brake fluid level has decreased, check for leaks due to damaged brake lines or hoses, loose union nuts, damaged brake master cylinder sub-assembly seals, etc.

(d) Bleeding air from brake system

(1) Bleed air from the brake lines and brake actuator assembly.

Click here

NEXT

2.

PERFORM ACTIVE TEST USING GTS (MOTOR RELAY)

(a) Fully depress and hold the brake pedal.

HINT:

Make sure that the brake pedal has travelled excessively before holding it depressed.

(b) Operate the ABS motor relay using the Active Test and check if the brake pedal height changes when the pump motor is operating.

Chassis > Brake/EPB > Active Test

Tester Display

Measurement Item

Control Range

Restrict Condition

Diagnostic Note

Motor Relay

ABS motor relay

Relay OFF / ON

Vehicle condition: Vehicle stopped

HINT:

To protect this Actuator and Solenoid, this test will only last 5 seconds.

Refer to on-vehicle inspection for the brake actuator (for Gasoline Model)*

*: Click here

Chassis > Brake/EPB > Active Test

Tester Display

Motor Relay

OK:

The brake pedal height does not change (the brake pedal travel remains excessive).

NG

REPLACE BRAKE ACTUATOR ASSEMBLY

OK

3.

CHECK BRAKE MASTER CYLINDER SUB-ASSEMBLY

(a) Check that there are no brake fluid leaks and no indications of a malfunction in the brake master cylinder sub-assembly.

OK:

There are no brake fluid leaks and no indications of a malfunction in the brake master cylinder sub-assembly.

NG

REPLACE BRAKE MASTER CYLINDER SUB-ASSEMBLY

OK

4.

INSPECT BRAKE BOOSTER ASSEMBLY

Click here

OK:

The brake booster assembly is normal.

OK

USE SIMULATION METHOD TO CHECK

NG

REPLACE BRAKE BOOSTER ASSEMBLY

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