Last Modified: 05-13-2024 6.11:8.1.0 Doc ID: RM100000001D2LI
Model Year Start: 2019 Model: GR Corolla Prod Date Range: [06/2018 - 09/2022]
Title: BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for Gasoline Model with Electric Parking Brake System): Excessive Brake Pedal Travel (No Fluid Leaks and No Air in System); 2019 - 2022 MY Corolla Corolla Hatchback GR Corolla [06/2018 - 09/2022]

Excessive Brake Pedal Travel (No Fluid Leaks and No Air in System)

CAUTION / NOTICE / HINT

NOTICE:

After replacing the skid control ECU (brake actuator assembly), perform acceleration sensor zero point calibration and store system information memorization.

Click here 2019 - 2022 MY Corolla Corolla Hatchback GR Corolla [06/2018 - 09/2022]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for Gasoline Model with Electric Parking Brake System): UTILITY

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 2019 - 2022 MY Corolla Corolla Hatchback GR Corolla [06/2018 - 09/2022]; BRAKE SYSTEM (OTHER): BRAKE PEDAL (for Gasoline Model): ADJUSTMENT

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 2019 MY Corolla Corolla Hatchback GR Corolla [06/2018 - 01/2019]; BRAKE SYSTEM (OTHER): BRAKE FLUID (for Gasoline Model): BLEEDING 2020 - 2022 MY Corolla Corolla Hatchback GR Corolla [01/2019 - 09/2022]; BRAKE SYSTEM (OTHER): BRAKE FLUID (for Gasoline Model): BLEEDING

NEXT

2.

PERFORM ACTIVE TEST USING TECHSTREAM (MOTOR RELAY)

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(c) Enter the following menus: Chassis / Brake/EPB / Active Test.

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.

-

Chassis > Brake/EPB > Active Test

Tester Display

Motor Relay

(d) Fully depress and hold the brake pedal.

HINT:

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

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

OK:

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

NG

REPLACE BRAKE ACTUATOR ASSEMBLY 2019 MY Corolla Corolla Hatchback GR Corolla [06/2018 - 01/2019]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: BRAKE ACTUATOR (for Gasoline Model): REMOVAL 2020 MY Corolla Corolla Hatchback GR Corolla [01/2019 - 03/2019]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: BRAKE ACTUATOR (for Gasoline Model): REMOVAL 2020 - 2022 MY Corolla Corolla Hatchback GR Corolla [03/2019 - 09/2022]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: BRAKE ACTUATOR (for Gasoline Model): REMOVAL

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

(a) Inspect operation of the brake booster assembly.

Click here 2019 - 2025 MY Corolla Corolla Hatchback GR Corolla [06/2018 -        ]; BRAKE SYSTEM (OTHER): BRAKE BOOSTER (for Gasoline Model): ON-VEHICLE INSPECTION

OK:

The brake booster assembly is normal.

OK

USE SIMULATION METHOD TO CHECK

NG

REPLACE BRAKE BOOSTER ASSEMBLY 2019 MY Corolla Corolla Hatchback GR Corolla [06/2018 - 01/2019]; BRAKE SYSTEM (OTHER): BRAKE BOOSTER (for Gasoline Model): REMOVAL 2020 - 2022 MY Corolla Corolla Hatchback GR Corolla [01/2019 - 09/2022]; BRAKE SYSTEM (OTHER): BRAKE BOOSTER (for Gasoline Model): REMOVAL