master cylinder TOYOTA AVALON 2001 Service Owner's Manual
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Page 506 of 1897
BR14Z-01
F09707
F09708
F09709
R00699
BR-4
- BRAKEBRAKE FLUID
1403 Author: Date:
2001 AVALON (RM808U)
BRAKE FLUID
BLEEDING
HINT:
If any work is done on the brake system or if air in the brake lines
is suspected, bleed the air from the system.
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Check the fluid level in the reservoir after bleeding each wheel.
Add fluid, if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3
2. BLEED MASTER CYLINDER
HINT:
If the master cylinder has been disassembled or if the reservoir
becomes empty, bleed the air from the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
SST 09023-00100
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outlet plugs with your fingers, and release
the brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
3. CONNECT VINYL TUBE TO BRAKE CALIPER BLEED-
ER PLUG
Insert other end of the tube in a half-full container of brake fluid.
NOTICE:
Bleed air of the rear brake first. If front brake is bled first,
rear brake air cannot be bled.
4. BLEED BRAKE LINE
(a) Slowly depress the brake pedal several times.
Page 507 of 1897
F10182
SST
F07901
2 1
(-)(+)
- BRAKEBRAKE FLUID
BR-5
1404 Author: Date:
2001 AVALON (RM808U)
(b) While an assistant depresses the pedal, loosen the
bleeder plug until fluid starts to run out. Then tighten the
bleeder plug.
(c) Repeat this procedure until there are no more air bubbles
in the fluid.
Bleeder plug tightening torque:
8.3 N´m (85 kgf´cm, 74 in.´lbf)
5. REPEAT PROCEDURE FOR EACH WHEEL
6. w/ VSC:
BLEED PRECHARGE PUMP
CAUTION:
When repairing the brake master cylinder or precharge
pump, bleed the precharge pump of the air.
(a) Install the SST to the reservoir.
SST 09992-00242, 09992-00350
(b) Using SST, apply pressure to the reservoir.
Pressure: 98.1 kpa (1.0 kgf/cm
2, 14.2 psi)
(c) Disconnect the precharge pump connector.
(d) Connect ML+ (2) terminal to the battery positive (+) and
ML- (1) terminal to the battery negative (-), and activate
the precharge pump about 20 seconds.
(e) Remove the SST from the reservoir.
(f) Connect the vinyl tube to the front brake caliper RH, and
loosen the bleeder plug.
(g) Activate the precharge pump again until there are no
more air bubbles in the fluid.
Bleeder plug tightening torque:
8.3 N´m (85 kgf´cm, 74 in.´lbf)
(h) Connect the precharge pump connector.
7. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3
Page 532 of 1897
BR159-01
F09741
Air Cleaner Cover With Air Cleaner Hose
Level Warning Switch Connector
Master Cylinder
Precharge Pump Precharge Pump Assembly
Master Cylinder Pressrue Sensor
3-way
Precharge Pump Bracket
N´m (kgf´cm, ft´lbf) : Specified torque
Non-reusable partCushion
15 (155, 11)
Holder
13 (130, 9)
19 (195, 14)
19 (195, 14)
13 (130, 9)8.0 (82, 71in.´lbf)
Washer CushionCollar
20 (200, 15)
15 (155, 11)
O-Ring
Spacer
81 (830, 60)
BR-56
- BRAKEPRECHARGE PUMP
1455 Author: Date:
2001 AVALON (RM808U)
PRECHARGE PUMP
COMPONENTS
Page 534 of 1897
BR15A-01
F09742
F09743
SST
F09744
F09745
- BRAKEPRECHARGE PUMP
BR-57
1456 Author: Date:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE AIR CLEANER CASE WITH AIR CLEANER
HOSE
2. REMOVE MASTER CYLINDER (See page BR-15)
3. DISCONNECT PRECHARGE PUMP CONNECTOR
4. REMOVE PRECHARGE PUMP ASSEMBLY
(a) Remove the 3 bolts and precharge pump assembly.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
(b) Using SST, disconnect the 2 brake lines from the prechar-
ge pump.
SST 09751-3601 1
Torque:
10 mm nut: 15 N´m (155 kgf´cm, 11 ft´lbf)
12 mm nut: 20 N´m (200 kgf´cm, 15 ft´lbf)
5. REMOVE PRECHARGE PUMP
(a) Remove the 2 nuts, 2 bolts and precharge pump from the
pump bracket.
Torque:
Nut: 13 N´m (130 kgf´cm, 9 ft´lbf)
Bolt: 8.0 N´m (82 kgf´cm, 71 in.´lbf)
(b) Remove the 2 holders, 2 collars, 2 washers and 4 cush-
ions.
6. REMOVE MASTER CYLINDER PRESSURE SENSOR
(a) Place the precharge pump in a vise with a cloth shown in
the illustration on the left.
(b) Using 30 mm deeper socket wrench, and remove the
master cylinder pressure sensor, O-ring and spacer.
Torque: 81 N´m (830 kgf´cm, 60 ft´lbf)
Page 547 of 1897
BR0KG-05
BR-2
- BRAKETROUBLESHOOTING
1401 Author: Date:
2001 AVALON (RM808U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Lower pedal or spongy pedal
5. Fluid leaks for brake system
6. Air in brake system
7. Piston seals (Worn or damaged)
8. Master cylinder (Faulty)
9. Booster push rod (Out of adjustment)DI-249
DI-346
BR-4
BR-28
BR-37
BR-13
BR-24
Brake drag
1. Brake pedal freeplay (Minimal)
2. Parking brake pedal travel (Out of adjustment)
3. Parking brake wire (Sticking)
4. Rear brake shoe clearance (Out of adjustment)
5. Pad (Cracked or distorted)
6. Piston (Stuck)
7. Piston (Frozen)
8. Tension or return spring (Faulty)
9. Booster push rod (Out of adjustment)
10.Vacuum leaks for booster system
11. Master cylinder (Faulty)BR-6
BR-9
-
BR-46
BR-25
BR-34
BR-28
BR-37
BR-28
BR-37
BR-43
BR-24
BR-22
BR-13
Brake pull
1. Piston (Stuck)
2. Pad (Oily)
3. Piston (Frozen)
4. Disc (Scored)
5. Pad (Cracked or distorted)BR-28
BR-37
BR-25
BR-34
BR-28
BR-37
BR-28
BR-37
BR-25
BR-34
Hard pedal but brake inefficient
1. Fluid leaks for brake system
2. Air in brake system
3. Piston (Stuck)
4. Pad (Cracked or distorted)
5. Pad (Oily)
6. Pad (Glazed)
7. Disc (Scored)
8. Booster push rod (Out of adjustment)
9. Vacuum leaks for booster systemDI-249
DI-346
BR-4
BR-28
BR-37
BR-25
BR-34
BR-25
BR-34
BR-25
BR-34
BR-28
BR-37
BR-24
BR-22
Page 672 of 1897
F09814
J/B No. 3
15
3B 15
3AABS & BA & TRAC
& VSC ECU
40
A20
LBL Driver Side J/B
Engine Room J/B
M6
Multi
DisplayIC1 Translate
ECU
L-B 25
T5 11
T5
16
T5R-W
7
R-W
3
4
R-B LVL2LBL
BRL R-W
R-W
Level
Warning Switch12
1I 8
1H
R-W
12
BB J1
J/B
W-B
EDDriver Side J/B
GAUGE No. 1
W-B
W-B
J/B No. 4
10
1DR-B4
4D13
4F 4
2D4
2F
BRAKE
DI-290
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
446 Author: Date:
2001 AVALON (RM808U)
DTC C1202 / 44 Brake Fluid Level Warning Switch Cir-
cuit
CIRCUIT DESCRIPTION
The brake fluid level warning switch sends appropriate signals to the ECU when the brake fluid level is low-
ered.
HINT:
Depressing the parking brake pedal turns on the brake warning light, but this DTC No. C1202/44 is not out-
put.
DTC No.DTC Detecting ConditionTrouble Area
C1202 / 44
Fluid level in the brake master cylinder reservoir tank re-
mains low for 60 sec. or more. This means brake fluid
warning switch likes on.Brake fluid level
Brake fluid level warning switch
Brake fluid level warning switch circuit
WIRING DIAGRAM
DI6O3-01
Page 682 of 1897
F09812
M2 Master Cylinder
Pressure SensorABS & BA &
TRAC & VSC ECU
VCM
E2 PMC
123
VCM
PMC
E2IF3
A20 A20A2065
66
67 IF3 IF3
29 8
P-L
R-L
BR-YP-L
R-L
BR-Y DI-300
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
456 Author: Date:
2001 AVALON (RM808U)
DTCC1246 / 53Master Cylinder Pressure Sensor Circuit
CIRCUIT DESCRIPTION
DTC No.DTC Detecting ConditionTrouble Area
C1246 / 53
When any of the following 1. through 3. is detected:
1. The voltage of sensor signal is out of range (less than
0.25 V, more than 4.75 V).
2. The sensor supply voltage is out of range (above 5.6 V,
below 4.4 V).
3. The sensor signal offset value is out of range.
Master cylinder pressure sensor
Master cylinder pressure sensor circuit
WIRING DIAGRAM
DI6O7-02
Page 683 of 1897
F07902
PMCE2
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
DI-301
457 Author: Date:
2001 AVALON (RM808U)
INSPECTION PROCEDURE
HINT:
Start the inspection from step 1, in case of using the TOYOTA hand-held tester and start from step 2, in case
of not using the TOYOTA hand-held tester.
1 Check output value of the master cylinder pressure sensor.
PREPARATION:
(a) Connect the TOYOTA hand-held tester to the DLC3.
(b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON.
(c) Select the DATALIST mode on the TOYOTA hand-held tester.
CHECK:
Check that the brake fluid pressure value of the master cylinder pressure sensor displayed on the TOYOTA
hand-held tester is changing when depressing the brake pedal.
OK:
Brake fluid pressure value must be changing.
OK Go to step 4.
NG
2 Check master cylinder pressure sensor.
PREPARATION:
Install LSPV gauge to the front caliper bleeder plug portion, and
bleed the air from LSPV gauge.
SST 09709-29018
CHECK:
Start the engine and depress the brake pedal, then check the
relation between the fluid pressure and voltage of PMC and E2
terminals of the master cylinder pressure sensor with connector
still connected.
OK:
Front brake caliper fluid pressureVoltage
0 kPa (0 Kgf/cm2, 0 psi)0.44 - 0.76 V
5,883 kPa (60 kgf/cm2, 853 psi)1.34 - 1.66 V
11,768 kPa (120 kgf/cm2, 1,706 psi)2.24 - 2.56 V
HINT:
Voltage between terminals VCM and E2: 4.7 - 5.3 V
NG Replace master cylinder pressure sensor.
OK
Page 720 of 1897
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
DI-259
415 Author: Date:
2001 AVALON (RM808U)C1300 / 62
(DI-305)
Malfunction in ABS & BA & TRAC & VSC ECUABS & BA & TRAC & VSC ECU
Always ON
(DI-319)Malfunction in ABS & BA & TRAC & VSC ECU
Open circuit in ABS warning light circuitCharging system
ABS warning light circuit
*: As the DTC cannot be erased only by replacing parts, do either of the following operations.
(1) Clear DTC (See page DI-252).
(2) At a vehicle speed of 20 km/h (12 mph), drive the vehicle for 30 sec. or more.
DTC chart of VSC system:
DTC No.
(See Page)Detection ItemTrouble Area
C1225 / 25
(DI-273)Open or short circuit in brake actuator solenoid circuit (SMC1
circuit)Brake actuator
SMC1 circuit
C1226 / 26
(DI-273)Open or short circuit in brake actuator solenoid circuit (SMC2
circuit)Brake actuator
SMC2 circuit
C1227 / 27
(DI-273)Open or short circuit in brake actuator solenoid circuit (SRC1
circuit)Brake actuator
SRC1 circuit
C1228 / 28
(DI-273)Open or short circuit in brake actuator solenoid circuit (SRC2
circuit)Brake actuator
SRC2 circuit
C1301 / 42*Malfunction in communication with the translate ECU
Brake fluid level warning switch circuit
Translate ECU
Translate ECU circuit
ECM
ECM circuit
C0365 / 43
(DI-285)Malfunction in deceleration sensor (combined in yaw rate sen-
sor)Deceleration sensor
Deceleration sensor circuit
C1202 / 44
(DI-290)Brake fluid level low
Open circuit in brake fluid level warning switch circuitBrake fluid level
Brake fluid level warning switch
Brake fluid level warning switch circuit
C1350 / 51
(DI-306)Pump motor is locked
Open circuit in pump motor groundBrake actuator pump motor
Brake actuator pump motor circuit
C1351 / 52
(DI-308)VSC pump motor is locked
Open or short circuit in VSC pump motor circuitPrecharge pump motor
Precharge pump motor circuit
C1246 / 53
(DI-300)Malfunction in master cylinder pressure sensorMaster cylinder pressure sensor
Master cylinder pressure sensor circuit
C1208 / 54
(DI-292)Malfunction in steering angle sensorSteering angle sensor
Steering angle sensor circuit
C0371 / 55
(DI-287)Malfunction in yaw rate sensor circuitYaw rate sensor
Yaw rate sensor circuit
Always ON
(DI-322)Malfunction in ABS & BA & TRAC & VSC ECU
Open circuit in VSC warning light circuitCharging system
VSC warning light circuit
*: Troubleshoot according to the DTC chart of the translate ECU.
Page 723 of 1897
DI6NU-01
F07883
ABS Warning Light
VSC Warning Light
VSC OFF Indicator Light
SLIP Indicator Light
BRAKE Warning Light
DLC2Rear Speed Sensor
Sensor Rotor
Brake Actuator
ABS & BA & TRAC & VSC ECU
VSC OFF Switch Front Speed Sensor
DLC1
ABS Solenoid RelayABS Motor Relay
Room R/B No. 8 Engine
Precharge PumpMaster Cylinder
Pressure Sensor
Parking Brake Switch
Stop Light Switch
Translate ECU
Front Speed Sensor
Sensor Rotor
Sensor Rotor
Rear Speed Sensor
DLC3
Steering Angle Sensor
Yaw Rate Sensor
(Including Deceleration Sensor)
Active Lamp Relay
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
DI-261
417 Author: Date:
2001 AVALON (RM808U)
PARTS LOCATION