Toyota Avalon (XX50): Brake Booster Pump(for Hv Model)

Components

COMPONENTS

ILLUSTRATION

*1	FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY	-	-
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque

ILLUSTRATION

ILLUSTRATION

*1	ACCUMULATOR TO BRAKE MASTER CYLINDER TUBE	*2	BRAKE BOOSTER PUMP ASSEMBLY
*3	NO. 2 BRAKE ACTUATOR HOSE	*4	BRAKE ACTUATOR CASE COLLAR
*5	BRAKE BOOSTER PUMP BUSHING	-	-
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)	*	For use with a union nut wrench

ILLUSTRATION

Disposal

DISPOSAL

PROCEDURE

1. DISPOSE OF BRAKE BOOSTER PUMP ASSEMBLY

(a) Remove the accumulator from the brake booster pump assembly.

(b) Secure the accumulator in a vise.

(c) Using a hacksaw, make a cut in the side of the accumulator within location (A) to release the high-pressure gas.

• Wear protective glasses.
• Small pieces of metal may fly out when cutting into the accumulator. Put a cloth over the hacksaw when cutting the accumulator. Cut the accumulator slowly so that the gas will be released gradually.

HINT:

Nitrogen gas, which is colorless, odorless and harmless, will be discharged.

Inspection

INSPECTION

PROCEDURE

1. INSPECT BRAKE BOOSTER PUMP ASSEMBLY

(a) 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

*a Component without harness connected (Brake Booster Pump Assembly)

Installation

INSTALLATION

PROCEDURE

1. INSTALL NO. 2 BRAKE ACTUATOR HOSE

(a) Install the No. 2 brake actuator hose to the brake booster pump assembly and slide the clip to secure it.

*a	Identification Mark
	Front of the vehicle

NOTICE:

• Make sure to connect the No. 2 brake actuator hose with its identification mark facing the front of the vehicle.
• Install the clip within the range shown in the illustration.

2. INSTALL BRAKE BOOSTER PUMP ASSEMBLY

(a) Install the 2 brake booster pump collars and 2 brake booster pump bushings to the brake booster pump assembly as shown in the illustration. HINT: Perform this procedure only when replacement of the brake booster pump collars or brake booster pump bushings is necessary.

*1 Brake Booster Pump Collar *2 Brake Booster Pump Bushing

(b) Install the brake booster pump assembly, brake booster pump bushing and brake actuator case collar to the brake actuator bracket assembly as shown in the illustration.

*1	Brake Booster Pump Collar	*2	Brake Booster Pump Bushing
*a	Union	*b	Connector
*c	Wire Harness	*d	Stud
	Install in this Direction	-	-

NOTICE:

• Be careful not to allow brake fluid to enter the connector.
• Do not apply excessive force to the brake lines.
• When installing the brake booster pump assembly to the brake actuator bracket assembly, confirm that the 2 brake booster pump bushings and 2 brake booster pump collars are installed to the brake booster pump assembly.
• Do not drop the brake booster pump assembly when carrying it.
• If installing a new brake booster pump assembly, do not remove the hole plugs before connecting the brake lines because the brake booster pump assembly is filled with brake fluid.
• Do not carry the brake booster pump assembly by the parts shown in the illustration.

(c) Install the nut.

Torque:

6.5 N·m {66 kgf·cm, 58 in·lbf}

(d) Engage the claw and clamp to install the brake booster pump assembly wire harness to the brake actuator bracket assembly. NOTICE: Engage the claw and clamp in the order shown in the illustration.

(e) Connect the connector to the brake booster pump assembly and lock the lock lever as shown in the illustration.

	Connect the connector
	Lock the lock lever

NOTICE:

• Make sure that the connector is locked securely.
• Make sure that the connector can be connected smoothly.
• Do not allow water, oil or dirt to enter the connector.

3. CONNECT ACCUMULATOR TO BRAKE MASTER CYLINDER TUBE

(a) Using a union nut wrench, connect the accumulator to brake master cylinder tube to the brake booster pump assembly. Torque: Specified tightening torque : 15.2 N·m {155 kgf·cm, 11 ft·lbf} NOTICE: Do not kink or damage the accumulator to brake master cylinder tube. Do not allow the accumulator to brake master cylinder tube to twist or interfere with other parts or the vehicle body during tightening. Do not allow any foreign matter such as dirt or dust to enter the accumulator to brake master cylinder tube from the connecting parts. HINT: Calculate the torque wrench reading when changing the fulcrum length of the torque wrench. Click here When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

*a Torque Wrench Fulcrum Length *b Union Nut Wrench

4. CONNECT NO. 2 BRAKE ACTUATOR HOSE

(a) Connect the No. 2 brake actuator hose to the No. 1 brake actuator tube and slide the clip to secure it.

*a	Identification Mark
	Front of the vehicle

NOTICE:

• When connecting the No. 2 brake actuator hose, face the identification mark up.
• Install the clip within the range shown in the illustration.

5. BLEED NO. 1 BRAKE ACTUATOR TUBE

Click here

6. FILL RESERVOIR WITH BRAKE FLUID

7. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

Click here

8. BLEED BRAKE SYSTEM

Click here

9. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

Click here

10. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

Click here

11. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Click here

Removal

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 pump assembly removal/installation are shown below.

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

2. PERFORM ACCUMULATOR PRESSURE ZERO DOWN

Click here

3. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Click here

4. REMOVE FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

Click here

5. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

Click here

6. DRAIN BRAKE FLUID

NOTICE:

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

7. DISCONNECT NO. 2 BRAKE ACTUATOR HOSE

(a) Slide the clip and disconnect the No. 2 brake actuator hose from the No. 1 brake actuator tube.

8. DISCONNECT ACCUMULATOR TO BRAKE MASTER CYLINDER TUBE

(a) Using a union nut wrench, disconnect the accumulator to brake master cylinder tube from the brake booster pump assembly. NOTICE: Do not kink or damage the accumulator to brake master cylinder tube. Do not allow any foreign matter such as dirt or dust to enter the accumulator to brake master cylinder tube from the connecting parts.

9. REMOVE BRAKE BOOSTER PUMP ASSEMBLY

(a) Release the lock lever and disconnect the connector from the brake booster pump assembly 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.

(b) Disengage the claw and clamp to separate the brake booster pump assembly wire harness from the brake actuator bracket assembly.

(c) Remove the nut from the brake booster pump assembly.

(d) Remove the brake booster pump assembly, brake booster pump bushing and brake actuator case collar from the brake actuator bracket assembly as shown in the illustration.

NOTICE:

• Do not apply excessive force to the brake lines.
• Do not carry the brake booster pump assembly by the parts shown in the illustration.
• Do not drop the brake booster pump assembly when carrying it.
• Be careful not to allow brake fluid to enter the connector.

*a	Union
*b	Connector
*c	Wire Harness
*d	Stud
	Remove in this Direction

(e) Remove the 2 brake booster pump collars and 2 brake booster pump bushings from the brake booster pump assembly. HINT: Perform this procedure only when replacement of the brake booster pump collars or brake booster pump bushings is necessary.

10. REMOVE NO. 2 BRAKE ACTUATOR HOSE

(a) Slide the clip and remove the No. 2 brake actuator hose from the brake booster pump assembly.