TOYOTA AVALON 2001 Service Repair Manual

BR158-01
- BRAKEABS & VSC ACTUATOR
BR-55
1454 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-54).
HINT:

After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4).

Check for fluid leaks.

D07259DLC3
TOYOTA Hand-held TesterBR155-01
BR-52
- BRAKEABS & VSC ACTUATOR
1451 Author
: Date
:
2001 AVALON (RM808U)
ABS & VSC ACTUATOR
ON-VEHICLE INSPECTION
1. CONNECT TOYOTA HAND-HELD TESTER:
(a) Connect the TOYOTA hand-held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the TOYOTA hand-
held tester.
Please refer to the TOYOTA hand-held tester operator's
manual for further details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay ON, check the actuator motor opera-
tion noise.
(b) Turn the motor relay OFF.
(c) Depress the brake pedal and hold it for about 15 seconds.
Check that the brake pedal cannot be depressed.
(d) With the motor relay ON, check that the pedal does not
pulsate.
NOTICE:
Do not keep motor relay ON for more than 5 seconds con-
tinuously. When operating it continuously, set the interval
of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn ON the solenoid which is not described below.
(a) With the brake pedal depressed, perform the following
operations.
(b) Turn the SFRH and SFRR solenoid ON simultaneously,
and check that the pedal cannot be depressed.
NOTICE:
Do not keep solenoid ON for more than 10 seconds contin-
uously. When operating it continuously, set the interval of
more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid OFF simultaneously,
and check that the pedal can be depressed.
(d) Turn the motor relay ON, and check that the pedal re-
turns.
NOTICE:
Do not keep motor relay ON for more than 5 seconds con-
tinuously. When operating it continuously, set the interval
of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
As in the same procedure, check the solenoids of other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR
5. CLEAR DTC (See page DI-252)

BR157-01
F09736
F09737
BR-54
- BRAKEABS & VSC ACTUATOR
1453 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE AIR CLEANER ASSEMBLY
2. DISCONNECT ABS & VSC ACTUATOR CONNECTOR
3. DISCONNECT BRAKE LINES
Using SST, disconnect the 6 brake lines from the ABS & VSC
actuator.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
4. REMOVE ABS & VSC ACTUATOR ASSEMBLY
Remove the 3 bolts and ABS & VSC actuator assembly.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
5. REMOVE ABS & VSC ACTUATOR
(a) Remove the 2 nuts and ABS & VSC actuator from the
bracket.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(b) Remove the 2 holders and 3 cushions from the ABS &
VSC actuator.

BR0KX-04
F09719
Air Cleaner with Air Cleaner Hose
Vacuum Hose
Master Cylinder
Brake Booster AssemblyReturn Spring
Lower LH Instrument
Panel Insert
Lower No. 1 Instrument
Panel
No. 2 Heater to Register DuctCleviseClip Wave Washer
Gasket 2-way
w/ VSC:

15 (155, 11)
13 (130, 9)
13 (130, 9)
13 (130, 9)15 (155, 11)
19 (195, 14)
N´m (kgf´cm, ft´lbf) : Specified torque

Non-reusable part
19 (195, 14)
Precharge Pump Assembly
Level Warning Switch
Connetor
Pin
12 (260, 19)
BR-22
- BRAKEBRAKE BOOSTER ASSEMBLY
1421 Author
: Date
:
2001 AVALON (RM808U)
COMPONENTS

BR152-01
F05420
SST Master
Cylinder
F05422
SST
F05421
SST
BR-24
- BRAKEBRAKE BOOSTER ASSEMBLY
1423 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(d) Install the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Set the SST on the master cylinder, and lower the pin until
its tip slightly touches the piston.
SST 09737-0001 1
(b) Turn the SST upside down, and set it on the booster.
SST 09737-0001 1
(c) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(d) Using SST, adjust the booster push rod length until the
push rod lightly touches the pin head.
SST 09737-00020
3. w/ VSC:
INSTALL PRECHARGE PUMP ASSEMBLY (See page
BR-58)
4. INSTALL MASTER CYLINDER (See page BR-20)
5. CONNECT VACUUM HOSE TO BRAKE BOOSTER
6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR-4)
7. CHECK FOR LEAKS
8. CHECK AND ADJUST BRAKE PEDAL (See page
BR-6)
9. INSTALL NO. 2 HEATER TO REGISTER DUCT, LOWER
LH INSTRUMENT PANEL INSERT AND LOWER NO. 1
INSTRUMENT PANEL (See page BO-87)
10. DO OPERATIONAL CHECK (See page BR-21)

BR2237
BR0KW-04
BR2238
GOODNO GOOD
2nd3rd
1st
- BRAKEBRAKE BOOSTER ASSEMBLY
BR-21
1420 Author
: Date
:
2001 AVALON (RM808U)
BRAKE BOOSTER ASSEMBLY
ON-VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed.
If there is no change in the pedal reverse travel after holding the
pedal for 30 seconds, the booster is air tight.

BR0KY-05
F06431
- BRAKEBRAKE BOOSTER ASSEMBLY
BR-23
1422 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE AIR CLEANER COVER WITH AIR CLEANER
HOSE
2. REMOVE MASTER CYLINDER (See page BR-15)
3. w/ VSC:
REMOVE PRECHARGE PUMP ASSEMBLY (See page
BR-57)
4. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
5. REMOVE LOWER NO. 1 INSTRUMENT PANEL, LOW-
ER LH INSTRUMENT PANEL INSERT AND NO. 2
HEATER TO REGISTER DUCT (See page BO-87)
6. REMOVE BRAKE BOOSTER ASSEMBLY
(a) Remove the pedal return spring.
(b) Remove the clip and clevis pin.
(c) Remove the 4 nuts and clevis.
(d) Pull out the brake booster and gasket.

BR0KQ-04
F09712
3-way
2-wayMaster CylinderAir Cleaner Cover with
Air Cleaner Hose
Brake Booster
N´m (kgf´cm, ft´lbf) : Specified torquew/ VSC:
15 (155, 11)
13 (130, 9)
15 (155, 11)
13 (130, 9)
Level Warning Switch Connetor
- BRAKEBRAKE MASTER CYLINDER
BR-13
1412 Author
: Date
:
2001 AVALON (RM808U)
BRAKE MASTER CYLINDER
COMPONENTS

F09748
Cap
Strainer
Reservoir Reservoir Set Screw
Grommet
Cylinder Body

Gasket
Stopper BoltNo. 1 Piston and Spring
No. 2 Piston and SpringSnap Ring
Grommet w/o VSC:
Cap
Strainer
Reservoir
Grommet Reservoir Set Screw
Grommet
Cylinder Body Straight Pin

Non-reusable part
Lithium soap base giycol grease
w/ VSC:
1.7 (17.5, 15.2 in.´lbf)
10 (100, 7)
1.7 (17.5, 15.2 in.´lbf)
N´m (kgf´cm, ft´lbf) : Specified torque
O-Ring

O-Ring

No. 1 Piston and Spring
No. 2 Piston and SpringSnap Ring
BR-14
- BRAKEBRAKE MASTER CYLINDER
1413 Author
: Date
:
2001 AVALON (RM808U)

BR0KS-03
F09715
Soft Jows
F09716
Soft Jows
R12236
A BR-16
- BRAKEBRAKE MASTER CYLINDER
1415 Author
: Date
:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N´m (17.5 kgf´cm, 15.2 in.´lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. w/o VSC:
PLACE CYLINDER IN VISE
4. w/o VSC:
REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
5. w/o VSC:
REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the No. 1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:

If pulled out and install at an angle, there is a possibil-
ity that the cylinder bore could be damaged.

At the time of reassembly, be careful not to damage
the rubber lips on the pistons.
(c) Place a rag and 2 wooden blocks on the work table, and
lightly tap the cylinder flange against the block edges until
the No. 2 piston drops out of the cylinder.
HINT:
Make sure that the distance (A) from the rag to the top of the
blocks is at least 100 mm (3.94 in.).