Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM1000000019H83
Model Year Start: 2019 Model: Avalon HV Prod Date Range: [04/2018 - 08/2021]
Title: BRAKE SYSTEM (OTHER): BRAKE BOOSTER (for HV Model): REMOVAL; 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during brake booster with master cylinder assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane Departure Alert System (w/ Steering Control)

2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM (for HV Model): INITIALIZATION

Pre-collision System

Intelligent Clearance Sonar System*

Lighting System (for HV Model with Cornering Light)

Memorize steering angle neutral point

Parking Assist Monitor System

2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM(for HV Model): INITIALIZATION

Panoramic View Monitor System

2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): INITIALIZATION

Replacement of brake booster with master cylinder assembly
  1. Bleed air
  2. Clear the data stored during previous linear solenoid valve offset learning, ABS holding solenoid valve learning, brake pedal stroke sensor assembly zero point calibration and system information memorization
  3. Perform linear solenoid valve offset learning, ABS holding solenoid valve learning, brake pedal stroke sensor assembly zero point calibration and system information memorization
  • DTCs are stored
  • ABS warning light illuminates
  • Brake warning light / yellow (minor malfunction) illuminates
  • Slip indicator light illuminates
  • VSC disabled or malfunctions

for Initialization 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for HV Model): INITIALIZATION

for Calibration: 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for HV Model): CALIBRATION

  1. Clear zero point calibration data
  2. Perform yaw rate and acceleration sensor zero point calibration

NOTICE:

While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch turns on. Therefore, when servicing the brake system components, do not operate the brake pedal or open/close the doors while the auxiliary battery is connected.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

2. PERFORM ACCUMULATOR PRESSURE ZERO DOWN

(a) Using the Techstream, perform the accumulator pressure zero down operation.

(1) Connect the Techstream to the DLC3 with the power switch off.

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

(3) Turn the Techstream on and enter the following menus: Chassis / ABS/VSC/TRAC / Utility / ECB (Electronically Controlled Brake system) Utility.

Chassis > ABS/VSC/TRAC > Utility

Tester Display

ECB Utility

(4) Select "Motor Invalid" on the "ECB (Electronically Controlled Brake system) Utility" screen.

(5) Perform "Motor Invalid" according to the display on the Techstream.

(6) Enter the following menus: Chassis / ABS/VSC/TRAC / Utility / ECB (Electronically Controlled Brake system) Utility.

Chassis > ABS/VSC/TRAC > Utility

Tester Display

ECB Utility

(7) Select "ECB (Electronically Controlled Brake system) Invalid" on the "ECB (Electronically Controlled Brake system) Utility" screen.

(8) Perform "ECB (Electronically Controlled Brake system) Invalid" according to the display on the Techstream.

(9) Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.

HINT:

A buzzer may sound due to low accumulator pressure. As this is not a malfunction, continue the procedure.

(10) Check that the brake pedal is firm.

NOTICE:

If the brake pedal is not firm or the pump motor continues to operate even after depressing the brake pedal 40 times or more, the accumulator pressure zero down operation is not complete.

(11) Turn the Techstream off and turn the power switch off.

(12) Disconnect the Techstream from the DLC3.

(13) Disconnect the cable from the negative (-) auxiliary battery terminal.

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL

(b) When the accumulator pressure zero down could not be performed using the Techstream.

NOTICE:

If DTCs are output, the accumulator pressure zero down operation may not be complete. In this case, perform the following procedure.

(1) With the power switch off, release the lock lever and disconnect the brake booster pump assembly connector as shown in the illustration.

Release the lock lever

Disconnect the connector

NOTICE:

Be careful not to allow any brake fluid to enter the connector.

(2) Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.

(3) Check that the brake pedal is firm.

NOTICE:

If the brake pedal is not firm or the pump motor continues to operate even after depressing the brake pedal 40 times or more, the accumulator pressure zero down operation is not complete.

(4) Disconnect the cable from the negative (-) auxiliary battery terminal.

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; MAINTENANCE: A25A-FXS AUXILIARY BATTERY: REMOVAL

3. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; WIPER / WASHER: FRONT WIPER MOTOR: REMOVAL

4. REMOVE FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

(a) Disconnect the connector.

(b) Disengage the 2 clamps and separate the wire harness.

(c) Remove the 6 bolts, 4 nuts and front center upper suspension brace sub-assembly.

5. DRAIN BRAKE FLUID

NOTICE:

If brake fluid leaks onto any painted surface, immediately wash it off.

6. DISCONNECT ENGINE ROOM MAIN WIRE

(a) Disconnect the connector from the brake booster with master cylinder assembly.

(b) Push the lock arm of the connector to disengage the lock and release the lock lever as shown in the illustration.

*a

Lock Lever

*b

Lock Arm

*c

Push

Release the lock lever

(c) Using a screwdriver, release the pre-lock and disconnect the connector from the brake booster with master cylinder assembly as shown in the illustration.

*a

Screwdriver Insertion Point

*b

Pre-lock

Disconnect the connector

NOTICE:

Be careful not to allow any brake fluid to enter the connector.

7. DISCONNECT NO. 1 BRAKE ACTUATOR HOSE

(a) Slide the clip and disconnect the No. 1 brake actuator hose from the brake booster with master cylinder assembly.

8. DISCONNECT BRAKE LINE

(a) Using a union nut wrench, disconnect the 3 brake lines from the brake booster with master cylinder assembly.

NOTICE:

  • Do not kink or damage the brake lines.
  • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

9. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

Click here 2019 - 2021 MY Avalon Avalon HV [04/2018 - 08/2021]; INTERIOR PANELS / TRIM: INSTRUMENT PANEL SAFETY PAD: REMOVAL+

10. REMOVE PUSH ROD PIN

(a) Remove the clip and push rod pin.

11. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

(a) Remove the 4 nuts and brake booster with master cylinder assembly.

NOTICE:

  • Do not kink or damage the brake lines.
  • Do not carry the brake booster with master cylinder assembly by the parts shown in the illustration.
  • Be careful not to allow any brake fluid to enter the connector.

*a

Skid Control ECU

*b

No. 1 Reservoir Hose

*c

Brake Master Cylinder Push Rod Clevis

*d

Boot

*e

Master Cylinder Reservoir Assembly

12. REMOVE BRAKE MASTER CYLINDER GASKET