Toyota Avalon (XX50): Open Circuit in IG1/IG2 Power Source Circuit (C1242). Stroke Sensor (C1247,C1392). Brake Booster Pump Motor on Time Abnormally Long (C1252,C1253)

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Brake / Brake Control / Dynamic Control Systems / Electronically Controlled Brake System(for Hv Model) / Open Circuit in IG1/IG2 Power Source Circuit (C1242). Stroke Sensor (C1247,C1392). Brake Booster Pump Motor on Time Abnormally Long (C1252,C1253)

Open Circuit in IG1/IG2 Power Source Circuit (C1242)

DESCRIPTION

Refer to DTC C1241.

Click here

DTC No.

Detection Item

INF Code

DTC Detection Condition

Trouble Area

MIL

Note

C1242

Open Circuit in IG1/IG2 Power Source Circuit

111

112
  • INF Code: 111
    • When the IG1 terminal voltage is less than 3.5 V, the IG2 terminal voltage is 9.5 V or more for 4 seconds or more.
  • INF Code: 112
    • When communication with the hybrid vehicle control ECU is normal or the vehicle speed is 10 km/h (6 mph) or more, and the IG1 terminal voltage is 9.5 V or more, the IG2 terminal voltage is less than 3.5 V for 4 seconds or more.
  • INF Code: 111
    • Open or short in IG1 circuit
    • Improperly connected connector, deformation or corrosion of terminals
    • Smart key system (IG start circuit)
    • Auxiliary battery
    • Hybrid control system (Charging circuit)
    • Skid control ECU (brake booster with master cylinder assembly)
  • INF Code: 112
    • Open or short in IG2 circuit
    • Improperly connected connector, deformation or corrosion of terminals
    • Smart key system (IG start circuit)
    • Auxiliary battery
    • Hybrid control system (Charging circuit)
    • Skid control ECU (brake booster with master cylinder assembly)

Comes on
  • INF Code 111: SAE Code C123B
  • INF Code 112: SAE Code C123E
  • Electronically controlled brake system DTC

MONITOR DESCRIPTION

  • During normal operation, the voltage at IG1 and IG2 change mutually; however, if the voltages do not change mutually such as when IG1 is on and IG2 is off or when IG1 is off and IG2 is on, the skid control ECU (brake booster with master cylinder assembly) judges that there is an open in the IG1 or IG2 circuit and illuminates the MIL and stores a DTC.

MONITOR STRATEGY

Related DTCs

C123B: IG1 circuit low

C123E: IG2 circuit low

Required Sensors/Components(Main)

Skid control ECU (brake booster with master cylinder assembly)

Required Sensors/Components(Related)

Speed sensor

Skid control ECU (brake booster with master cylinder assembly)

Frequency of Operation

Continuous

Duration

4 seconds

MIL Operation

Immediately

Sequence of Operation

None

TYPICAL ENABLING CONDITIONS

C123B

Monitor runs whenever the following DTCs are not stored

None

IG2 voltage

Higher than 9.5 V
C123E

Monitor runs whenever the following DTCs are not stored

None

Both of the following conditions are met

A and B

A. IG1 voltage

Higher than 9.5 V

B. Either of the following condition is met

-

Vehicle speed

Higher than 10 km/h (6 mph)

Communication status with hybrid control system

Valid

TYPICAL MALFUNCTION THRESHOLDS

C123B

IG1

Off
C123E

IG2

Off

COMPONENT OPERATING RANGE

C123B

Both of the following conditions are met

-

IG2 voltage

Higher than 9.5 V

IG1

On
C123E

Both of the following conditions are met

-

IG1 voltage

Higher than 9.5 V

IG2

On

CONFIRMATION DRIVING PATTERN

  1. Connect the Techstream to the DLC3.
  2. Turn the power switch on (IG).
  3. Turn the Techstream on.
  4. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
  5. Turn the power switch off.
  6. Turn the power switch on (READY).
  7. Turn the Techstream on.
  8. Drive the vehicle at 10 km/h (6 mph) or more for 4 seconds or more.
  9. Enter the following menus: Chassis / ABS/VSC/TRAC / Trouble Codes.
  10. Read the DTCs.

    HINT:

    • If a DTC is output, the system is malfunctioning.
    • If a DTC is not output, perform the following procedure.
  11. If the DTCs are not output, perform a universal trip and check for permanent DTCs.

    Click here

    HINT:

    • If a permanent DTC is output, the system is malfunctioning.
    • If no permanent DTCs are output, the system is normal.

WIRING DIAGRAM

Refer to DTC C1241.

Click here

CAUTION / NOTICE / HINT

NOTICE:

  • After replacing the skid control ECU (brake booster with master cylinder assembly), perform linear solenoid valve offset learning, ABS holding solenoid valve learning, yaw rate and acceleration sensor zero point calibration and system information memorization after performing "Reset Memory".

    Click here

  • Inspect the fuses for circuits related to this system before performing the following procedure.

PROCEDURE

1.

CHECK FREEZE FRAME DATA

(a) Check the INF code from the Freeze Frame Data stored when DTC (C1242) was stored.

Click here

Chassis > ABS/VSC/TRAC > Trouble Codes

Result

Proceed to

INF code 111 is output.

A

INF code 112 is output.

B
B

REPLACE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

A

2.

CHECK HARNESS AND CONNECTOR (IG1 AND IG2 TERMINAL)

(a) Turn the power switch off.

*a

Front view of wire harness connector

(to Skid Control ECU (Brake Booster with Master Cylinder Assembly))

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

OK:

The connector is securely connected.

(c) Disconnect the A35 skid control ECU (brake booster with master cylinder assembly) connector.

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

OK:

No deformation or corrosion.

(e) Turn the power switch on (IG).

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

Standard Voltage:

Tester Connection

Condition

Specified Condition

A35-23 (IG1) - Body ground

Power switch on (IG)

11 to 14 V

A35-9 (IG2) - Body ground

Power switch on (IG)

11 to 14 V

Result

Proceed to

11 to 14 V.

A

Below 11 V.

B
A

REPLACE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

B

REPAIR OR REPLACE HARNESS OR CONNECTOR (IG1 AND/OR IG2 CIRCUIT)

Stroke Sensor (C1247,C1392)

DESCRIPTION

The brake pedal stroke sensor assembly sends a signal about the pedal stroke to the skid control ECU (brake booster with master cylinder assembly).

DTC No.

Detection Item

INF Code

DTC Detection Condition

Trouble Area

MIL

Note

C1247

Stroke Sensor

211

212

213

214

215

216

217
  • INF Code: 211
    • The sensor supply voltage (VCSK) is 4.7 V or less, or 5.3 V or more for 0.2 seconds or more.
  • INF Code: 212
    • The sensor output voltage 1 (SKS1) is less than 0.3 V, or 4.7 V or more for 0.2 seconds or more.
  • INF Code: 213
    • The sensor output voltage 2 (SKS2) is less than 0.3 V, or 4.7 V or more for 0.2 seconds or more.
  • INF Code: 214
    • The difference between the current value and previous value of the sensor output voltage 1 (SKS1) is 8.5% or more for 0.2 seconds or more.
  • INF Code: 215
    • The difference between the current value and previous value of the sensor output voltage 2 (SKS2) is 8.5% or more for 0.2 seconds or more.
  • INF Code: 216
    • The difference in change between sensor output voltage 1 (SKS1) and sensor output voltage 2 (SKS2) is excessively large for 0.2 seconds or more.

      (The comparison value of SKS1 and SKS2 is invalid.)

  • INF Code: 217
    • Sensor data is invalid for 0.2 seconds or more.

      (The sensor data of SKS1 and SKS2 is invalid.)
  • INF Code: 211
    • Open or short in brake pedal stroke sensor assembly power supply circuit
    • Improperly connected connector, deformation or corrosion of terminals
    • Skid control ECU (brake booster with master cylinder assembly)
  • INF Code: 212, 213, 214, 215, 216, 217
    • Open or short in wire harness
    • Improperly connected connector, deformation or corrosion of terminals
    • Brake pedal stroke sensor assembly

Comes on
  • INF Code 211: SAE Code C0562
  • INF Code 212: SAE Code P057C and P057D
  • INF Code 213: SAE Code P05DD and P05DE
  • INF Code 214: SAE Code P057E
  • INF Code 215: SAE Code P05DF
  • INF Code 216: SAE Code P05E0
  • INF Code 217: SAE Code C124B
  • Electronically controlled brake system DTC

C1392

Zero Point Calibration of Stroke Sensor undone

1124

The brake pedal stroke sensor assembly zero point calibration is not performed.

(Normal brake pedal stroke sensor assembly zero point not memorized.)

Normal brake pedal stroke sensor assembly zero point not memorized.

(Linear solenoid valve offset learning is not performed or Test Mode is not performed or not complete.)

Only DTC C1392 (INF code 1124) is stored: Does not come on

SAE Code C1392 is stored: Comes on
  • INF Code 1124: SAE Code C1392
  • Electronically controlled brake system DTC

HINT:

During Test Mode, related DTCs are cleared (except SAE code).

MONITOR DESCRIPTION

C0562:
  • The skid control ECU (brake booster with master cylinder assembly) monitors the power supply voltage of the brake pedal stroke sensor assembly. When the brake pedal stroke sensor assembly power supply voltage is outside of the normal range, the skid control ECU (brake booster with master cylinder assembly) judges that the power supply is abnormal and illuminates the MIL and stores this DTC.
C124B:
  • When the following conditions are met, the skid control ECU (brake booster with master cylinder assembly) judges that the data from the brake pedal stroke sensor assembly is invalid and illuminates the MIL and stores this DTC.
    1. Brake pedal stroke sensor assembly related DTCs (C0562, P057D, P05DE, P057C, P05DD, P05E0, P057E and P05DF) are not stored.
    2. When related malfunction DTCs are not stored, the skid control ECU (brake booster with master cylinder assembly) continuously detects a brake pedal stroke sensor assembly malfunction.
SAE Code C1392:
  • After any of the following situations, if the zero point of the brake pedal stroke sensor 1 or brake pedal stroke sensor 2 has not been learned and the vehicle is being driven at a certain speed or more, the skid control ECU (brake booster with master cylinder assembly) judges that the zero point of the brake pedal stroke sensor is uncalibrated and illuminates the MIL and stores this DTC.
    1. The skid control ECU (brake booster with master cylinder assembly) has been replaced with a new one.
    2. After the brake actuator assembly, brake pedal stroke sensor assembly or brake pedal is removed and installed or replaced, the zero point is cleared.
P057C, P057D, P057E, P05DD, P05DE, P05DF and P05E0:
  • The skid control ECU (brake booster with master cylinder assembly) monitors the output value of the brake pedal stroke sensor assembly, and if the following conditions are detected, the skid control ECU (brake booster with master cylinder assembly) judges that the brake pedal stroke sensor assembly has a malfunction and illuminates the MIL and stores a DTC.
    1. The power supply voltage ratio of the brake pedal stroke sensor 1 and brake pedal stroke sensor 2 is outside the normal range.

      HINT:

      The power supply voltage ratio is the ratio of the voltage of SKS1 and VSK1 or SKS2 and VSK2.

    2. When the brake pedal is operated, the relationship between the value output by the brake pedal stroke sensor 1 and brake pedal stroke sensor 2 is outside the normal range.
    3. The difference between the current power supply voltage ratio and the previous power supply voltage ratio of the brake pedal stroke sensor 1 and brake pedal stroke sensor 2 exceeds a specific value (improbable sudden change repeats).

      HINT:

      The power supply voltage ratio is the ratio of the voltage of SKS1 and VSK1 or SKS2 and VSK2.

C1392 (INF Code 1124):
  • After any of the following situations, if the zero point of the brake pedal stroke sensor 1 or brake pedal stroke sensor 2 has not been learned, the skid control ECU (brake booster with master cylinder assembly) judges that the zero point of the brake pedal stroke sensor is uncalibrated and illuminates the ABS warning, brake warning / red (malfunction), brake warning / yellow (minor malfunction) and slip indicator lights, blinks* the brake hold operated indicator light and stores this DTC.
    1. The skid control ECU (brake booster with master cylinder assembly) has been replaced with a new one.
    2. After the brake actuator assembly, brake pedal stroke sensor assembly or brake pedal is removed and installed or replaced, the zero point is cleared.

      HINT:

      • *: The brake hold switch (electric parking brake switch assembly) is turned on under the following vehicle conditions.
        • Vehicle Conditions:
          1. The driver side door is closed.
          2. The driver side seat belt is fastened.
      • As the detection conditions slightly differ from SAE code C1392, the detection conditions for DTC C1392 (INF code 1124) is also provided.

MONITOR STRATEGY

HINT:

SAE code only.

Related DTCs

C0562: Brake pedal stroke sensor assembly voltage circuit/open

C124B: Brake pedal stroke sensor assembly invalid data

C1392: Brake pedal stroke sensor learning not complete

P057C: Brake pedal stroke sensor assembly open circuit

P057D: Brake pedal stroke sensor assembly circuit high

P057E: Brake pedal stroke sensor assembly intermittent/erratic

P05DD: Brake pedal stroke sensor assembly open circuit

P05DE: Brake pedal stroke sensor assembly circuit high

P05DF: Brake pedal stroke sensor assembly intermittent/erratic

P05E0: Brake pedal stroke sensor assembly "1"/"2" correlation

Required Sensors/Components(Main)

Brake pedal stroke sensor assembly

Skid control ECU (brake booster with master cylinder assembly)

Required Sensors/Components(Related)

Skid control ECU (brake booster with master cylinder assembly)

Brake pedal stroke sensor assembly

Speed sensor

Frequency of Operation

Continuous

Duration

-: C1392

0.2 seconds: C0562, C124B, P057C, P057D, P057E, P05DD, P05DE, P05DF and P05E0

MIL Operation

Immediately

Sequence of Operation

None

TYPICAL ENABLING CONDITIONS

HINT:

SAE code only.

C0562

Monitor runs whenever the following DTCs are not stored

None

Brake system voltage 1 (VM1)

Higher than 6.92 V
C124B

Monitor runs whenever the following DTCs are not stored

C0562 (Brake pedal stroke sensor assembly voltage circuit/open)

P057C, P05DD (Brake pedal stroke sensor assembly open circuit)

P057D, P05DE (Brake pedal stroke sensor assembly circuit high)

P057E, P05DF (Brake pedal stroke sensor assembly intermittent/erratic)

P05E0 (Brake pedal stroke sensor assembly "1"/"2" correlation)

All of the following conditions are met

-

Brake system voltage 1 (VM1)

Higher than 6.92 V

Serial communication with high side IC

Valid

Brake pedal stroke sensor assembly fail (C0562, P057C, P057D, P057E, P05DD, P05DE, P05DF, P05E0)

Not detected
C1392

Monitor runs whenever the following DTCs are not stored

None

Vehicle speed

40 km/h (25 mph) or more
P057C, P057D, P057E, P05DD, P05DE and P05DF

Monitor runs whenever the following DTCs are not stored

None

Brake pedal stroke sensor assembly power supply

4.74 V or more, and 5.23 V or less
P05E0

Monitor runs whenever the following DTCs are not stored

C0562 (Brake pedal stroke sensor assembly voltage circuit/open)

C124B (Brake pedal stroke sensor assembly invalid data)

P057C, P05DD (Brake pedal stroke sensor assembly open circuit)

P057D, P05DE (Brake pedal stroke sensor assembly circuit high)

P057E, P05DF (Brake pedal stroke sensor assembly intermittent/erratic)

Both of the following conditions are met

-

Brake system voltage 1 (VM1)

Higher than 6.92 V

Brake pedal stroke sensor assembly fail (C0562, C124B, P057C, P057D, P057E, P05DD, P05DE, P05DF)

Not detected

TYPICAL MALFUNCTION THRESHOLDS

HINT:

SAE code only.

C0562

Brake pedal stroke sensor assembly power supply

Less than 4.74 V, or higher than 5.23 V
C124B

Brake pedal stroke sensor assembly state

Invalid
C1392

Either of the following conditions is met

-

Brake pedal stroke sensor 1 zero point calibration value

Not stored

Brake pedal stroke sensor 2 zero point calibration value

Not stored
P057C and P05DD

Power supply voltage ratio of SKS and VSK

Less than 0.06

HINT:

The power supply voltage ratio is the ratio of the voltage of SKS1 and VSK1 or SKS2 and VSK2.

P057D and P05DE

Power supply voltage ratio of SKS and VSK

Higher than 0.94

HINT:

The power supply voltage ratio is the ratio of the voltage of SKS1 and VSK1 or SKS2 and VSK2.

P057E and P05DF

Difference between the current power supply voltage ratio and the previous power supply voltage ratio of SKS and VSK

Higher than 8.5%

HINT:

The power supply voltage ratio is the ratio of the voltage of SKS1 and VSK1 or SKS2 and VSK2.

P05E0

Brake pedal stroke sensor assembly correlation state

Invalid

COMPONENT OPERATING RANGE

HINT:

SAE code only.

C0562

Both of the following conditions are met

-

Brake system voltage 1 (VM1)

Higher than 6.92 V

Brake pedal stroke sensor assembly power supply

4.74 V or more, and 5.23 V or less
C124B

Both of the following conditions are met

-

Brake system voltage 1 (VM1)

Higher than 6.92 V

Brake pedal stroke sensor assembly state

Valid
C1392

Both of the following conditions are met

-

Brake pedal stroke sensor 1 zero point calibration value

Stored

Brake pedal stroke sensor 2 zero point calibration value

Stored
P057C, P05DD, P057D and P05DE

Both of the following conditions are met

-

Brake pedal stroke sensor assembly power supply

4.74 V or more, and 5.23 V or less

Power supply voltage ratio of SKS and VSK

0.06 or more, and 0.94 or less

HINT:

The power supply voltage ratio is the ratio of the voltage of SKS1 and VSK1 or SKS2 and VSK2.

P057E and P05DF

Both of the following conditions are met

-

Brake pedal stroke sensor assembly power supply

4.74 V or more, and 5.23 V or less

Difference between the current power supply voltage ratio and the previous power supply voltage ratio of SKS and VSK

8.5% or less

HINT:

The power supply voltage ratio is the ratio of the voltage of SKS1 and VSK1 or SKS2 and VSK2.

P05E0

Both of the following conditions are met

-

Brake system voltage 1 (VM1)

Higher than 6.92 V

Brake pedal stroke sensor assembly on experience (low/mid/high)

On

CONFIRMATION DRIVING PATTERN

  1. Connect the Techstream to the DLC3.
  2. Turn the power switch on (IG).
  3. Turn the Techstream on.
  4. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
  5. Turn the power switch off.
  6. Turn the power switch on (READY).
  7. Turn the Techstream on.
  8. Fully depress the brake pedal.
  9. Drive the vehicle at a speed of 40 km/h (25 mph) or more for 1 minute.

    HINT:

    Only DTC C1392 is stored when the vehicle speed reaches 40 km/h (25 mph).

  10. Enter the following menus: Chassis / ABS/VSC/TRAC / Trouble Codes.
  11. Read the DTCs.

    HINT:

    • If a DTC is output, the system is malfunctioning.
    • If a DTC is not output, perform the following procedure.
  12. If the DTCs are not output, perform a universal trip and check for permanent DTCs.

    Click here

    HINT:

    • If a permanent DTC is output, the system is malfunctioning.
    • If no permanent DTCs are output, the system is normal.

WIRING DIAGRAM

CAUTION / NOTICE / HINT

NOTICE:

After replacing the skid control ECU (brake booster with master cylinder assembly) or brake pedal stroke sensor assembly, perform linear solenoid valve offset learning, ABS holding solenoid valve learning, yaw rate and acceleration sensor zero point calibration and system information memorization after performing "Reset Memory".

Click here

HINT:

Check the condition of each related circuit connector before troubleshooting.

Click here

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) Clear the DTCs.

Click here

Chassis > ABS/VSC/TRAC > Clear DTCs

(b) Turn the power switch off.

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

(d) Check if the same DTC is output.

Click here

Chassis > ABS/VSC/TRAC > Trouble Codes

Result

Proceed to

DTC C1247 is output.

A

DTC C1392 is output.

B
B

GO TO STEP 7

A

3.

CHECK FREEZE FRAME DATA

(a) Check the INF code from the Freeze Frame Data stored when DTC (C1247) was stored.

Click here

Chassis > ABS/VSC/TRAC > Trouble Codes

Result

Proceed to

INF code 211 is output.

A

INF code 212, 213, 214, 215, 216 or 217 is output.

B
B

GO TO STEP 6

A

4.

CHECK HARNESS AND CONNECTOR (BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY - BRAKE PEDAL STROKE SENSOR ASSEMBLY)

(a) Turn the power 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 A35 skid control ECU (brake booster with master cylinder assembly) connector.

(d) Disconnect the A34 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

A35-13 (SKG1) - A34-5 (SKG)

Always

Below 1 Ω

A35-13 (SKG1) or A34-5 (SKG) - Body ground

Always

10 kΩ or higher

A35-21 (VSK2) - A34-2 (VSK2)

Always

Below 1 Ω

A35-21 (VSK2) or A34-2 (VSK2) - Body ground

Always

10 kΩ or higher

A35-25 (VSK1) - A34-4 (VCSK)

Always

Below 1 Ω

A35-25 (VSK1) or A34-4 (VCSK) - Body ground

Always

10 kΩ or higher

A35-33 (SKG2) - A34-3 (SKG2)

Always

Below 1 Ω

A35-33 (SKG2) or A34-3 (SKG2) - Body ground

Always

10 kΩ or higher
NG

REPAIR OR REPLACE HARNESS OR CONNECTOR
OK

5.

INSPECT BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY (SENSOR OUTPUT)

(a) Reconnect the A35 skid control ECU (brake booster with master cylinder assembly) connector.

*a

Front view of wire harness connector

(to Brake Pedal Stroke Sensor Assembly)

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

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

Standard Voltage:

Tester Connection

Condition

Specified Condition

A34-4 (VCSK) - A34-5 (SKG)

Power switch on (IG)

4.84 to 5.16 V

A34-2 (VSK2) - A34-3 (SKG2)

Power switch on (IG)

4.84 to 5.16 V
OK

REPLACE BRAKE PEDAL STROKE SENSOR ASSEMBLY

NG

REPLACE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

6.

CHECK HARNESS AND CONNECTOR (BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY - BRAKE PEDAL STROKE SENSOR ASSEMBLY)

(a) Turn the power 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 A35 skid control ECU (brake booster with master cylinder assembly) connector.

(d) Disconnect the A34 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

A35-17 (SKS1) - A34-6 (SKS1)

Always

Below 1 Ω

A35-17 (SKS1) or A34-6 (SKS1) - Body ground

Always

10 kΩ or higher

A35-19 (SKS2) - A34-1 (SKS2)

Always

Below 1 Ω

A35-19 (SKS2) or A34-1 (SKS2) - Body ground

Always

10 kΩ or higher
OK

REPLACE BRAKE PEDAL STROKE SENSOR ASSEMBLY

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

7.

PERFORM BRAKE PEDAL STROKE SENSOR ASSEMBLY ZERO POINT CALIBRATION

(a) Perform brake pedal stroke sensor assembly zero point calibration.

Click here

NOTICE:

Make sure to perform linear solenoid valve offset learning, ABS holding solenoid valve learning, brake pedal stroke sensor assembly zero point calibration and system information memorization after performing "Reset Memory" as the data stored during linear solenoid valve offset learning, ABS holding solenoid valve learning, brake pedal stroke sensor assembly zero point calibration and system information memorization is cleared.

Chassis > ABS/VSC/TRAC > Utility

Tester Display

Reset Memory
Chassis > ABS/VSC/TRAC > Utility

Tester Display

ECB Utility
NEXT

8.

RECONFIRM DTC

(a) Clear the DTCs.

Click here

Chassis > ABS/VSC/TRAC > Clear DTCs

(b) Turn the power switch off.

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

(d) Check if the same DTC is output.

Click here

Chassis > ABS/VSC/TRAC > Trouble Codes

Result

Proceed to

DTC C1392 is output.

A

DTCs are not output.

B

DTCs other than C1392 are output.

C
B

END
C

REPAIR CIRCUITS INDICATED BY OUTPUT DTCS

A

9.

INSPECT BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY (SENSOR OUTPUT)

(a) Turn the power 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) Disconnect the A34 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 power switch on (IG).

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

Standard Voltage:

Tester Connection

Condition

Specified Condition

A34-4 (VCSK) - A34-5 (SKG)

Power switch on (IG)

4.84 to 5.16 V

A34-2 (VSK2) - A34-3 (SKG2)

Power switch on (IG)

4.84 to 5.16 V
OK

REPLACE BRAKE PEDAL STROKE SENSOR ASSEMBLY

NG

REPLACE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

Brake Booster Pump Motor on Time Abnormally Long (C1252,C1253)

DESCRIPTION

The skid control ECU (brake booster with master cylinder assembly) detects decreases in the accumulator pressure according to the data from the accumulator pressure sensor, and then starts and stops the pump motor by operating the motor relay.

DTC No.

Detection Item

INF Code

DTC Detection Condition

Trouble Area

MIL

Note

C1252

Brake Booster Pump Motor on Time Abnormally Long

311

The pump motor is operating continuously for 178 seconds or more. (When the relay is malfunctioning for 98 seconds or more.)
  • Short in pump motor circuit or pump motor monitor circuit
  • Motor relay stuck
  • Accumulator pressure sensor malfunction
  • Skid control ECU (brake booster with master cylinder assembly)

Comes on
  • INF Code 311: SAE Code C0594
  • Electronically controlled brake system DTC

C1253

Pump Motor Relay

321

322

327

328
  • INF Code: 321, 327, 328
    • An open is detected in the motor relay drive circuit for 0.2 seconds or more.
  • INF Code: 322
    • A short is detected in the motor relay drive circuit for 2 seconds or more.
  • INF Code: 321, 327, 328
    • Open in pump motor circuit or pump motor monitor circuit
    • Skid control ECU (brake booster with master cylinder assembly)
  • INF Code: 322
    • Short in pump motor circuit or pump motor monitor circuit
    • Skid control ECU (brake booster with master cylinder assembly)

Comes on

(When only SAE code C121D or SAE code C121E is stored)
  • INF Code 321: SAE Code C121D
  • INF Code 322: SAE Code C121E
  • Electronically controlled brake system DTC

MONITOR DESCRIPTION

The skid control ECU (brake booster with master cylinder assembly) monitors the voltage of the pump motor.

When the pump motor relay is instructed to be on and the voltage of the pump motor is within the range of an open circuit malfunction (voltage value is practically equal to that when off), or when the pump motor is instructed to be off and the voltage of the pump motor is within the range of a short circuit malfunction (voltage value is practically equal to that when on), an open circuit or short circuit is judged respectively and the MIL is illuminated and stores a DTC.

Furthermore, when the voltage of the pump motor is practically equal to that when on for a long period of time, the skid control ECU (brake booster with master cylinder assembly) judges that the pump motor is operating for an abnormally long time and illuminates the MIL and stores a DTC.

MONITOR STRATEGY

Related DTCs

C0594: Pump motor performance

C121D: Pump motor open circuit

C121E: Pump motor circuit high

Required Sensors/Components(Main)

Brake booster pump assembly

Required Sensors/Components(Related)

Skid control ECU (brake booster with master cylinder assembly)

Brake booster pump assembly

Brake actuator (brake booster with master cylinder assembly)

Frequency of Operation

Continuous

Duration

0.2 seconds: C121D

2 seconds: C121E

98 seconds: C0594 (Case 1)

178 seconds: C0594 (Case 2)

MIL Operation

Immediately

Sequence of Operation

None

TYPICAL ENABLING CONDITIONS

C0594 (Case 1)

Monitor runs whenever the following DTCs are not stored

None

Both of the following conditions are met

A and B

A. Serial communication with high side IC

Valid

B. One of the following conditions is met

a, b or c

a. Pump motor circuit fail (C121D)

Detected

b. Pump motor circuit fail (C121E)

Detected

c. Both of the following conditions are met

-

Accumulator pressure sensor

Valid

Accumulator pressure

Higher than 19.88 MPa (202.7 kgf/cm2, 2884 psi)
C0594 (Case 2)

Monitor runs whenever the following DTCs are not stored

None

Serial communication with high side IC

Valid
C121D

Monitor runs whenever the following DTCs are not stored

None

Both of the following conditions are met

A and B

A. Serial communication with high side IC

Valid

B. Either of the following conditions is met

a or b

a. Command to pump motor relay

On

b. Both of the following conditions are met

-

Command to pump motor relay from hardware

On

Serial communication with low side IC

Valid
C121E

Monitor runs whenever the following DTCs are not stored

None

All of the following conditions are met

-

Serial communication with high side IC

Valid

Serial communication with low side IC

Valid

Command to pump motor relay

Off

Command to pump motor relay from hardware

Off

TYPICAL MALFUNCTION THRESHOLDS

C0594 (Case 1), C0594 (Case 2) and C121E

Pump motor voltage

Higher than 6 V
C121D

Pump motor voltage

Less than 6 V

COMPONENT OPERATING RANGE

C0594

Both of the following conditions are met

-

Prohibit pump motor operating from microcomputer

Off

Pump motor voltage

Less than 6 V
C121D

All of the following conditions are met

A, B and C

A. Serial communication with high side IC

Valid

B. Either of the following conditions is met

a or b

a. Command to pump motor relay

On

b. Both of the following conditions are met

-

Command to pump motor relay from hardware

On

Serial communication with low side IC

Valid

C. Pump motor voltage

Higher than 6 V
C121E

Both of the following conditions are met

-

Serial communication with high side IC

Valid

Pump motor voltage

Less than 6 V

CONFIRMATION DRIVING PATTERN

  1. Connect the Techstream to the DLC3.
  2. Turn the power switch on (IG).
  3. Turn the Techstream on.
  4. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
  5. Turn the power switch off.
  6. Turn the power switch on (IG).
  7. Turn the Techstream on.
  8. Depress the brake pedal several times until the pump motor operates.
  9. Wait 3 minutes.
  10. Enter the following menus: Chassis / ABS/VSC/TRAC / Trouble Codes.
  11. Read the DTCs.

    HINT:

    • If a DTC is output, the system is malfunctioning.
    • If a DTC is not output, perform the following procedure.
  12. If the DTCs are not output, perform a universal trip and check for permanent DTCs.

    Click here

    HINT:

    • If a permanent DTC is output, the system is malfunctioning.
    • If no permanent DTCs are output, the system is normal.

WIRING DIAGRAM

CAUTION / NOTICE / HINT

NOTICE:

  • After replacing the skid control ECU (brake booster with master cylinder assembly), perform linear solenoid valve offset learning, ABS holding solenoid valve learning, yaw rate and acceleration sensor zero point calibration and system information memorization after performing "Reset Memory".

    Click here

  • Inspect the fuses for circuits related to this system before performing the following procedure.

PROCEDURE

1.

CHECK DTC

(a) Check the DTCs that are output.

Click here

Chassis > ABS/VSC/TRAC > Trouble Codes

Result

Proceed to

DTCs C1252 and/or C1253 are output.

A

DTCs C1241 and/or C1242 are output with DTCs C1252 and/or C1253.

B
B

REPAIR CIRCUITS INDICATED BY OUTPUT DTCS

A

2.

READ VALUE USING TECHSTREAM (MOTOR RELAY 1 AND MOTOR RELAY 2)

(a) Select the Data List on the Techstream.

Click here

Chassis > ABS/VSC/TRAC > Data List

Tester Display

Measurement Item

Range

Normal Condition

Diagnostic Note

ECB Motor Relay

Motor relay 1 operation request

ON or OFF

ON: Relay on

OFF: Relay off

ECB: Electronically Controlled Brake System

ECB Motor Relay2

Motor relay 2 operation request

ON or OFF

ON: Relay on

OFF: Relay off

ECB: Electronically Controlled Brake System
Chassis > ABS/VSC/TRAC > Data List

Tester Display

ECB Motor Relay

ECB Motor Relay2

(b) Depress the brake pedal several times and check the operation status of the motor relay 1 and motor relay 2.

HINT:

Depressing the brake pedal several times drops the accumulator pressure and operates the pump motor.

Result

Proceed to

The motor relay 1 and motor relay 2 in the Data List turns on or off by depressing the brake pedal several times.

A

The status of motor relay 1 and motor relay 2 in the Data List does not change even after depressing the brake pedal several times.

B
B

GO TO STEP 8

A

3.

INSPECT BRAKE BOOSTER PUMP ASSEMBLY

(a) Turn the power switch off.

*a

Component without harness connected

(Brake Booster Pump Assembly)

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

OK:

The connector is securely connected.

(c) Disconnect the A40 brake booster pump assembly connector.

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

OK:

No deformation or corrosion.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

2 (BM1) - 4 (GND1)

Always

10 Ω or less

1 (BM2) - 3 (GND2)

Always

10 Ω or less

2 (BM1) - 1 (BM2)

Always

Below 1 Ω

4 (GND1) - 3 (GND2)

Always

Below 1 Ω
NG

REPLACE BRAKE BOOSTER PUMP ASSEMBLY

OK

4.

CHECK HARNESS AND CONNECTOR (GND TERMINAL)

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

A40-4 (GND1) - Body ground

Always

Below 1 Ω

A40-3 (GND2) - Body ground

Always

Below 1 Ω

*a

Front view of wire harness connector

(to Brake Booster Pump Assembly)
NG

REPAIR OR REPLACE HARNESS OR CONNECTOR (GND CIRCUIT)
OK

5.

READ VALUE USING TECHSTREAM (ACCUMULATOR PRESSURE)

(a) Reconnect the A40 brake booster pump assembly connector.

(b) Disconnect the A34 brake pedal stroke sensor assembly connector.

(c) Select the Data List on the Techstream.

Click here

Chassis > ABS/VSC/TRAC > Data List

Tester Display

Measurement Item

Range

Normal Condition

Diagnostic Note

MT Voltage Value

MT voltage value

Min.: 0.00 V, Max.: 20.00 V

Pump motor off: 0.00 V

Pump motor on: 12.00 V

-

Accumulator Pressure

Accumulator pressure output value

Min.: 0.00 MPa, Max.: 24.48 MPa

15.00 to 21.00 MPa

(Pressure stable and pump motor stopped)

When brake fluid is stored in the accumulator: Accumulator pressure changes in accordance with volume of fluid stored in the accumulator
Chassis > ABS/VSC/TRAC > Data List

Tester Display

MT Voltage Value

Accumulator Pressure

(d) Depress the brake pedal several times to operate the pump motor, then wait until it stops.

(e) After the pump motor stops, wait for 30 seconds, then check the drop in the accumulator pressure sensor output value and the state of the pump motor.

HINT:

  • This inspection checks whether an accumulator pressure sensor malfunction, internal brake actuator (brake booster with master cylinder assembly) leak or prolonged operation due to detection of low pressure caused by accumulator deterioration, caused the DTC to be stored.
  • If the brake fluid level in the brake master cylinder reservoir assembly (brake booster with master cylinder assembly) drops, an external brake fluid leak is suspected.

Result

Proceed to

The drop in the accumulator pressure sensor output value is less than 2.50 MPa 30 seconds after the pump motor stops, and the pump motor does not operate within 30 seconds after the pump motor stops.

A

The drop in the accumulator pressure sensor output value is 2.50 MPa or more 30 seconds after the pump motor stops, or the pump motor operates within 30 seconds after the pump motor stops.

B
B

GO TO STEP 7

A

6.

RECONFIRM DTC

(a) Turn the power switch off.

(b) Reconnect the A34 brake pedal stroke sensor assembly connector.

(c) Clear the DTCs.

Click here

Chassis > ABS/VSC/TRAC > Clear DTCs

(d) Turn the power switch off.

(e) Turn the power switch on (IG).

(f) Check if the same DTC is output.

Click here

Chassis > ABS/VSC/TRAC > Trouble Codes

Result

Proceed to

DTCs C1252 and C1253 are not output.

A

DTCs C1252 and/or C1253 are output.

B
A

USE SIMULATION METHOD TO CHECK

B

REPLACE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

7.

READ VALUE USING TECHSTREAM (SERVO PRESSURE)

(a) Turn the power switch off.

(b) Reconnect the A34 brake pedal stroke sensor assembly connector.

(c) Select the Active Test on the Techstream.

Click here

Chassis > ABS/VSC/TRAC > Active Test

Tester Display

Measurement Item

Control Range

Diagnostic Note

ECB Solenoid (SLR)

Linear solenoid reduction valve (SLR)

Solenoid ON/OFF

ECB: Electronically Controlled Brake System
Chassis > ABS/VSC/TRAC > Data List

Tester Display

Measurement Item

Range

Normal Condition

Diagnostic Note

Servo Pressure

Pressure value of servo

Min.: 0.00 MPa, Max.: 24.48 MPa

Brake pedal released: 0.00 to 2.10 MPa

Brake pedal is being depressed: Changes in proportion to the depression force of the brake pedal
Chassis > ABS/VSC/TRAC > Active Test

Active Test Display

ECB Solenoid (SLR)

Data List Display

Servo Pressure

(d) Perform the Active Test and operate the linear solenoid (SLR) in the brake actuator (brake booster with master cylinder assembly).

(e) Check that the servo pressure output value does not increase when performing the Active Test.

OK:

The servo pressure output value does not increase when performing the Active Test.

HINT:

If the servo pressure output value increases, an internal brake fluid leak in the brake actuator (brake booster with master cylinder assembly) is suspected.

Result

Proceed to

The servo pressure output value increases.

A

The servo pressure output value does not increase.

B
A

REPLACE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

B

REPLACE BRAKE BOOSTER PUMP ASSEMBLY

8.

CHECK HARNESS AND CONNECTOR (MRI TERMINAL)

(a) Turn the power switch off.

*a

Front view of wire harness connector

(to Skid Control ECU (Brake Booster with Master Cylinder Assembly))

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

OK:

The connector is securely connected.

(c) Disconnect the A35 skid control ECU (brake booster with master cylinder assembly) connector.

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

OK:

No deformation or corrosion.

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

Standard Voltage:

Tester Connection

Condition

Specified Condition

A35-2 (MRI1) - Body ground

Always

11 to 14 V

A35-28 (MRI2) - Body ground

Always

11 to 14 V
NG

REPAIR OR REPLACE HARNESS OR CONNECTOR (MRI CIRCUIT)
OK

9.

CHECK HARNESS AND CONNECTOR (BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY - BRAKE BOOSTER PUMP ASSEMBLY)

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

OK:

The connector is securely connected.

(b) Disconnect the A40 brake booster pump assembly connector.

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

OK:

No deformation or corrosion.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

A35-1 (MRO1) - A40-2 (BM1)

Always

Below 1 Ω

A35-1 (MRO1) or A40-2 (BM1) - Body ground

Always

10 kΩ or higher

A35-27 (MRO2) - A40-1 (BM2)

Always

Below 1 Ω

A35-27 (MRO2) or A40-1 (BM2) - Body ground

Always

10 kΩ or higher
OK

REPLACE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

Deceleration Sensor (C1232,C1243,C1245). Yaw Rate Sensor discrimination (C1240). Low or High Power Supply Voltage (C1241)

Accumulator Low Pressure (C1256)

See More:

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Toyota Avalon (XX50) 2019-2022 Service & Repair Manual

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