BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for HV Model): C05401C,...,C054096; Brake Pressure Sensor "A" Circuit Voltage Out of Range; 2023 - 2025 MY Corolla Corolla HV [09/2022

Last Modified: 01-27-2025	6.11:8.1.0	Doc ID: RM1000000025DTZ
Model Year Start: 2023	Model: Corolla	Prod Date Range: [09/2022 - ]
Title: BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for HV Model): C05401C,...,C054096; Brake Pressure Sensor "A" Circuit Voltage Out of Range; 2023 - 2025 MY Corolla Corolla HV [09/2022 - ]

DTC

C05401C

Brake Pressure Sensor "A" Circuit Voltage Out of Range

DTC

C054028

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

DTC

C054029

Brake Pressure Sensor "A" Signal Invalid

DTC

C054031

Brake Pressure Sensor "A" No Signal

DTC

C054049

Brake Pressure Sensor "A" Internal Electronic Failure

DTC

C054096

Brake Pressure Sensor "A" Component Internal Failure

DESCRIPTION

Refer to DTC C054016

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DTC No.	Detection Item	DTC Detection Condition	Trouble Area	MIL	DTC Output from	Note
C05401C	Brake Pressure Sensor "A" Circuit Voltage Out of Range	The voltage of the master cylinder pressure sensor signal is less than 0.129 V or more than 3.29 V for 0.1 seconds or more.	Skid control ECU (brake actuator assembly)	Does not come on	Brake/EPB	Output ECU: Skid control ECU (brake actuator assembly)
C054028	Brake Pressure Sensor "A" Signal Bias Level Out of Range / Zero Adjustment Failure	When the stop light switch assembly is off, the zero point of the master cylinder pressure sensor is less than -1.5 MPa (-15.3 kgf/cm ² , -218 psi) or more than 1.5 MPa (15.3 kgf/cm ² , 218 psi).	Skid control ECU (brake actuator assembly)	Comes on	Brake/EPB	SAE Code: C0541 (Case 1) Output ECU: Skid control ECU (brake actuator assembly)
C054029	Brake Pressure Sensor "A" Signal Invalid	A master cylinder pressure sensor internal malfunction is detected by the self-diagnosis function of the master cylinder pressure sensor circuit.	Skid control ECU (brake actuator assembly)	Comes on	Brake/EPB	SAE Code: C0540 (Case 4) Output ECU: Skid control ECU (brake actuator assembly)
C054031	Brake Pressure Sensor "A" No Signal	Signals from the master cylinder pressure sensor cannot be received and the input value from the signal line is outside of a certain range.	Skid control ECU (brake actuator assembly)	Comes on	Brake/EPB	SAE Code: C0540 (Case 5 and 6) Output ECU: Skid control ECU (brake actuator assembly)
C054049	Brake Pressure Sensor "A" Internal Electronic Failure	An internal malfunction of the master cylinder pressure sensor is detected during the self-test.	Skid control ECU (brake actuator assembly)	Does not come on	Brake/EPB	Output ECU: Skid control ECU (brake actuator assembly)
C054096	Brake Pressure Sensor "A" Component Internal Failure	The master cylinder pressure sensor value is outside of a certain range or an internal malfunction is detected.	Skid control ECU (brake actuator assembly)	Comes on	Brake/EPB	SAE Code: C0540 (Case 1 to 3) Output ECU: Skid control ECU (brake actuator assembly)

MONITOR DESCRIPTION

C0540 (Case 1 and 2):

When the pressure valve is at a certain value for a certain amount of time, the skid control ECU (brake actuator assembly) illuminates the MIL and stores this DTC.

C0540 (Case 3 and 4):

If the self-diagnosis function detects a pressure sensor internal malfunction, the skid control ECU (brake actuator assembly) illuminates the MIL and stores this DTC.

C0540 (Case 5 and 6):

If the self-diagnosis function detects a pressure sensor internal malfunction for a certain amount of time, the skid control ECU (brake actuator assembly) illuminates the MIL and stores this DTC.

C0541:

When the stop light switch assembly is off and the offset value of the master cylinder pressure is a certain value or more, the skid control ECU (brake actuator assembly) illuminates the MIL and stores this DTC.

MONITOR STRATEGY

Related DTCs	C0540 (Case 1): Pressure sensor SENT internal failure monitor (out of range high) C0540 (Case 2): Pressure sensor SENT internal failure monitor (out of range low) C0540 (Case 3): Pressure sensor SENT internal failure monitor (sensor internal) C0540 (Case 4): Pressure sensor SENT protocol monitor C0540 (Case 5): Pressure sensor SENT line monitor (high) C0540 (Case 6): Pressure sensor SENT line monitor (low) C0541: Pressure sensor offset monitoring
Required Sensors/Components(Main)	Skid control ECU (brake actuator assembly)
Required Sensors/Components(Related)	Skid control ECU (brake actuator assembly) Stop light switch assembly
Frequency of Operation	Continuous
Duration	-: C0541 0.1 seconds: C0540 (Case 3, 4, 5 and 6) 2 seconds: C0540 (Case 1 and 2)
MIL Operation	2 driving cycles
Sequence of Operation	None

TYPICAL ENABLING CONDITIONS

Monitor runs whenever the following DTCs are not stored	TMC's intellectual property
Other conditions belong to TMC's intellectual property	-

TYPICAL MALFUNCTION THRESHOLDS

TMC's intellectual property

COMPONENT OPERATING RANGE

TMC's intellectual property

CONFIRMATION DRIVING PATTERN

NOTICE:

When performing the normal judgment procedure, make sure that the driver door is closed and is not opened at any time during the procedure.

HINT:

After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.
When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.

Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
Turn the ignition switch off.
Turn the ignition switch to ON (READY) and turn the GTS on.
Wait for 5 seconds or more. [*]
HINT:

[*]: Normal judgment procedure.

The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.
Enter the following menus: Chassis / Brake/EPB* / Utility / All Readiness.
*: Electric Parking Brake System
Check the DTC judgment result.
HINT:
- If the judgment result shows NORMAL, the system is normal.
- If the judgment result shows ABNORMAL, the system has a malfunction.
- If the judgment result shows INCOMPLETE, perform driving pattern again.

PROCEDURE

1.	REPLACE BRAKE ACTUATOR ASSEMBLY

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