brake fluid TOYOTA AVENSIS 2005 Service Repair Manual

010B9±11
± INTRODUCTIONTERMS
01±37
AVENSIS REPAIR MANUAL (RM1018E)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
Approx.Approximately
ASSYAssembly
A/T, ATMAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
CANController Area Network
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current

022KS±01
± PREPARATIONBRAKE
02±33
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE
PREPARATION
SST
09023±00100Union Nut Wrench 10 mmBRAKE FLUID
BRAKE MASTER CYLINDER
SUB±ASSY
FRONT BRAKE
REAR BRAKE
BRAKE BOOSTER ASSY(LHD)
BRAKE BOOSTER ASSY(RHD)
BRAKE ACTUATOR ASSY(W/ VSC)
BRAKE ACTUATOR ASSY(W/O VSC)
09023±38400Union Nut Wrench 14mmBRAKE FLUID
BRAKE MASTER CYLINDER
SUB±ASSY
FRONT BRAKE
REAR BRAKE
BRAKE BOOSTER ASSY(LHD)
BRAKE BOOSTER ASSY(RHD)
BRAKE ACTUATOR ASSY(W/ VSC)
09214±76011Crankshaft Pulley ReplacerSKID CONTROL SENSOR
09520±00031Rear Axle Shaft PullerSKID CONTROL SENSOR
(09520±00040)ShockerSKID CONTROL SENSOR
09521±00020Drive Shaft Boot Clamping ToolSKID CONTROL SENSOR
09550±60010Differential Side Bearing
ReplacerFRONT BRAKE
(09710±06051)ReplacerREAR BRAKE
09950±00020Bearing RemoverSKID CONTROL SENSOR
Recomended Tools
09042±00010Torx Socket T30STEERING SENSOR

02±34
± PREPARATIONBRAKE
AVENSIS REPAIR MANUAL (RM1018E)
Equipment
Micrometer
Dial indicator w/ magnetic base
Brake drum gauge
Slide calipers
Torque wrench
Lubricant
ItemCapacityClassification
Brake fluid±SAE J1704 or FMVSS No. 116 DOT4

022KZ±01
± PREPARATIONCLUTCH
02±43
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH
PREPARATION
SST
09023±00100Union Nut Wrench 10 mmCLUTCH ACCUMULATOR
ASSY(1CD±FTV)
CLUTCH RELEASE CYLINDER
ASSY(MTM)
CLUTCH MASTER CYLINDER
ASSY(MTM)
09301±00220Clutch Guide ToolCLUTCH UNIT(MTM)
09333±00013Universal Joint Bearing Remover
& ReplacerCLUTCH UNIT(MTM)
Recomended Tools
09040±00011Hexagon Wrench SetCLUTCH PEDAL SUB±ASSY(MTM)
Equipment
Torque wrench
Vernier calipers
Dial indicator with magnetic base
Vernier calipers
Lubricant
ItemCapacityClassification
Brake fluid±SAE J1704 or FMVSS No.116 DOT 4

030KC±06
03±40
± SERVICE SPECIFICATIONSDRIVE SHAFT / PROPELLER SHAFT / AXLE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Front wheel set nut1031,05076
Rear wheel set nut1031,05076
Manual transaxle oil drain plug C50/C250:
E354/E357:39
49400
50029
36
Lower ball joint assy front x Suspension arm sub±assy lower No.18990866
Tie rod end sub±assy x Steering knuckle4950036
Flexible hose and speed sensor front x Shock absorber assy front1919414
Speed sensor front x Steering knuckle8.08271 in.
lbf
Front stabilizer link assy x Shock absorber assy front7475555
Front axle hub nut2162,200159
Disc brake dust cover front x Steering knuckle8.38573 in.
lbf
Lower ball joint assy front x Steering knuckle1031,05076
Front axle assy x Shock absorber assy front2202,243162
Front disc brake caliper assy x Steering knuckle1021,04075
Automatic transaxle fluid drain plug4950036
Drive shaft bearing case x Bearing bracket6465047
Rear axle hub & bearing assy x Rear axle carrier sub±assy5657141
Rear axle carrier sub±assy x Back plate assy1401,428103
Rear axle carrier sub±assy x Skid control sensor wire5.05144 in.
lbf
Rear disk brake caliper assy x Rear axle carrier sub±assy4747534
Rear axle carrier sub±assy x Upper control arm assy7475555
Rear axle carrier sub±assy x Lower control arm assy ball joint side:
member side:60
105612
1,07144
77
Rear axle carrier sub±assy x Rear suspension arm assy ball joint side:
member side:105
741,071
75577
55

05±314
±
DIAGNOSTICS SFI SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E) 


\f  
*
1
CHK ENG
 
 \b
P0555
(05±459)Brake Booster Pressure Sensor
Circuit

Open or short in brake booster pressure sensor circuit

Brake booster pressure sensor

Vacuum hose

ECM

P0556
(05±462)Brake Booster Pressure Sensor
Circuit Range/Performance

Vacuum hose (between the brake booster and intake manifold,
the brake booster and brake booster pressure sensor, and the
intake manifold and manifold absolute pressure sensor)

Open or short in brake booster pressure sensor circuit

Brake booster pressure sensor

Manifold absolute pressure sensor

Brake booster

Open or short in stop light switch circuit

Stop light switch

ECM

P0557
(05±459)Brake Booster Pressure Sensor
Circuit Low Input
Same as DTC No. P0555
P0558
(05±459)Brake Booster Pressure Sensor
Circuit High Input
Same as DTC No. P0555
P0560
(05±467)System Voltage
Open in back±up power source circuit

ECM
P0571
(05±1711)Brake Switch ºAº Circuit
Cruise control system

P0604
(05±470)Internal Control Module Random
Access Memory (RAM) Error
P0606
(05±470)ECM/PCM Processor
ECM
P0607
(05±470)Control Module Performance
P0617
(05±471)Starter Relay Circuit High

Short in park/neutral position switch (A/T)

Park/neutral position switch (A/T)

Ignition switch

ECM

P0657
(05±470)Actuator Supply Voltage Circuit /
Open
ECM
P0705 *4
(05±474)
Transmission Range Sensor Cir-
cuit Malfunction (PRNDL Input)
Short in park/neutral position switch circuit

Park/neutral position switch

ECM

P0710 *4
(05±941)
Transmission Fluid Temperature
Sensor ºAº circuit
Electronic controlled automatic transmission (ECT)
P0711 *3,4
(05±943)
Transmission Fluid Temperature
Sensor ºAº Performance
Electronic controlled automatic transmission (ECT)
P0712 *4
(05±941)
Transmission Fluid Temperature
Sensor ºAº Circuit Low Input
Electronic controlled automatic transmission (ECT)
P0713 *4
(05±941)
Transmission Fluid Temperature
Sensor ºAº Circuit High Input
Electronic controlled automatic transmission (ECT)
P0717 *4
(05±945)
Input/Turbine Speed Sensor ºAº
Circuit No Signal
Electronic controlled automatic transmission (ECT)
P0724 *4
(05±947)Brake Switch ºBº Circuit High

Short in stop light switch signal circuit

Stop light switch

ECM

P0741 *3,4
(05±948)
Torque Converter Clutch Circuit
Performance or Stuck Off
Electronic controlled automatic transmission (ECT)
P0743 *4
(05±951)
Torque Converter Clutch Circuit
Electrical
Electronic controlled automatic transmission (ECT)

0577Y±02
F45094
ABS Warning LightBRAKE Warning
Light
VSC Warning Light SLIP Indicator Light
TRC OFF Indicator
Light
C52361
DLC3 Tc
CG
05±756
±
DIAGNOSTICS ABS WITH EBD & BA & TRC & VSC SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PRE±CHECK
1.DIAGNOSIS SYSTEM
(a)Check the warning lights. (1)Release the parking brake lever.
(2)When the ignition switch is turned ON, check thatthe ABS warning light, Brake warning light, VSC
warning light, TRC OFF indicator light and SLIP in-
dicator light come on for approx. 3 seconds.
HINT:

When the parking brake is applied or brake fluid level is
low, the Brake warning light comes on.

If the ECU stores DTC, the ABS warning light , VSC warn-
ing light and TRC OFF indicator light come on.

If the indicator check result is not normal, proceed to trou-
bleshooting for the light circuit.
Trouble AreaSee page
ABS warning light circuit05±827
Brake warning light circuit05±840
VSC warning light circuit05±831
TRC OFF indicator light circuit05±844
SLIP indicator light circuit05±848
(b) Without using hand±held tester: Check the DTC.
(1) Using SST, connect terminal Tc and CG of theDLC3.
SST 09843±18040
(2) Turn the ignition switch ON.
(3) Read the DTC from the ABS warning light or VSC warning light on the combination meter.
HINT:

If no code appears, inspect the diagnostic circuit, ABS
warning light circuit or VSC warning light circuit.
Trouble AreaSee page
Tc terminal circuit05±852
ABS warning light circuit05±827
VSC warning light circuit05±831

05±744
± DIAGNOSTICSABS WITH EBD SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE WARNING LIGHT CIRCUIT
CIRCUIT DESCRIPTION
The Brake warning light comes on when the brake fluid is insufficient, the parking brake is applied or the EBD
is defective.
0577X±04

05±746
±
DIAGNOSTICS ABS WITH EBD SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION PROCEDURE
1RECONFIRM DTC
(a)Check the DTC (See page 05±699). OK:
Normal code
NGREPAIR CIRCUIT INDICATED BY OUTPUTCODE
OK
2INSPECT PARKING BRAKE SWITCH CIRCUIT
(a)Check for an open or short circuit in the parking brake switch circuit (See page 01±32). NGREPAIR OR REPLACE PARKING BRAKESWITCH CIRCUIT
OK
3INSPECT BRAKE FLUID LEVEL WARNING SWITCH CIRCUIT
(a)Check the brake fluid level in reservoir.
(b)Check for an open or shot circuit in brake fluid level warning switch ci\
rcuit (See page 01±32). NG REPAIR OR REPLACE BRAKE FLUID LEVELWARNING SWITCH CIRCUIT
OK
4 INSPECT VACUUM WARNING SWITCH CIRCUIT
(a) Check for an open or short circuit in harness and connector between the vacuum warning switch and skid control ECU (See page 01±32).
NG REPAIR OR REPLACE HARNESS ORCONNECTOR
OK
5 INSPECT COMBINATION METER ASSEMBLY(BRAKE WARNING LIGHT CIRCUIT)
(a)Check for an open or short circuit in the combination meter (See page 01±32). NG REPAIR OR REPLACE COMBINATION METERASSEMBLY
OK

±
DIAGNOSTICS ABS WITH EBD & BA & TRC & VSC SYSTEM
05±813
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION PROCEDURE
HINT:
Start the inspection from step 1 if you are using the hand±held tester and\
start from step 2 if you are not using
the hand±held tester.
1READ VALUE OF MASTER CYLINDER PRESSURE SENSOR
(a)Select the DATALIST mode on the hand±held tester.
(b)Check that the brake fluid pressure value of the No.1 master cylinder pressur\
e sensor and No.2 master
cylinder pressure sensor displayed on the hand±held tester changes wh\
en depressing the brake ped-
al.
OK:
Brake fluid pressure value is changing.
OKGo to step 4
NG
2INSPECT STOP LAMP SWITCH ASSY
(a)Check that the stop light comes on when the brake pedal is depressed and goes\
off when the brake pedal is released.
NGREPAIR OR REPLACE HARNESS ORCONNECTOR
OK
3CHECK HARNESS AND CONNECTOR(MASTER CYLINDER PRESSUR SENSOR ± SKID CONTROL ECU)
(a)Check for an open or short circuit in harness and connector between terminal \
of the master cylinder
pressure sensor and skid control ECU (See page 01±32).
NG REPAIR OR REPLACE HARNESS ORCONNECTOR
OK