Toyota Avalon (XX50): Excessive Brake Pedal Travel (No Fluid Leaks and No Air in System). Fail-safe Chart. Freeze Frame Data

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Brake / Brake Control / Dynamic Control Systems / Electronically Controlled Brake System(for Gasoline Model) / Excessive Brake Pedal Travel (No Fluid Leaks and No Air in System). Fail-safe Chart. Freeze Frame Data

Excessive Brake Pedal Travel (No Fluid Leaks and No Air in System)

CAUTION / NOTICE / HINT

NOTICE:

When replacing the skid control ECU (brake actuator assembly), perform system variant learning and acceleration sensor zero point calibration.

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PROCEDURE

1.

PRE-INSPECTION

(a) Brake pedal inspection

(1) Perform a visual inspection and operate the brake pedal to check for any malfunctions.

(2) Check the brake pedal height, brake pedal free play and brake pedal reserve distance.

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HINT:

If the brake pedal height is not within specification, confirm that there are no other malfunctions before adjusting the brake pedal height.

(b) Brake inspection

(1) Check that the disc brake pads of each wheel are installed correctly.

(2) Check that the bleeder plug and union bolt is not loose, and that there are no damaged gaskets or brake fluid leaks, for each wheel cylinder.

(c) Brake fluid leaks and air in brake line inspection

(1) Check and take a note of the fluid level in the brake master cylinder reservoir assembly.

(2) Repeatedly depress the brake pedal and confirm that the brake pedal feels normal (no air in the system, etc.).

(3) Check if the brake fluid level in the brake master cylinder reservoir assembly has changed.

(4) If the brake fluid level has decreased, check for leaks due to damaged brake lines or hoses, loose union nuts, damaged brake master cylinder sub-assembly seals, etc.

(d) Bleeding air from brake system

(1) Bleed air from the brake lines and brake actuator assembly.

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NEXT

2.

PERFORM ACTIVE TEST USING TECHSTREAM (ABS MOTOR RELAY)

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(c) Enter the following menus: Chassis / ABS/VSC/TRAC/EPB / Active Test.

Chassis > ABS/VSC/TRAC/EPB > Active Test

Tester Display

Measurement Item

Control Range

Diagnostic Note

Motor Relay

ABS motor relay

Relay OFF/ON

Operating sound of motor can be heard

Chassis > ABS/VSC/TRAC/EPB > Active Test

Tester Display

Motor Relay

(d) Fully depress and hold the brake pedal.

HINT:

Make sure that the brake pedal has travelled excessively before holding it depressed.

(e) Operate the ABS motor relay using the Active Test and check if the brake pedal height changes when the pump motor is operating.

OK:

The brake pedal height does not change (the brake pedal travel remains excessive).

NG

REPLACE BRAKE ACTUATOR ASSEMBLY

OK

3.

CHECK BRAKE MASTER CYLINDER SUB-ASSEMBLY

(a) Check that there are no brake fluid leaks and no indications of a malfunction in the brake master cylinder sub-assembly.

OK:

There are no brake fluid leaks and no indications of a malfunction in the brake master cylinder sub-assembly.

NG

REPLACE BRAKE MASTER CYLINDER SUB-ASSEMBLY

OK

4.

INSPECT BRAKE BOOSTER ASSEMBLY

(a) Inspect operation of the brake booster assembly.

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OK:

The brake booster assembly is normal.

OK

USE SIMULATION METHOD TO CHECK

NG

REPLACE BRAKE BOOSTER ASSEMBLY

Fail-safe Chart

FAIL-SAFE CHART

FAIL-SAFE OPERATION

  • If there is a problem with sensor signals or actuator systems, the skid control ECU prohibits power supply to the brake actuator assembly and informs the ECM of a VSC system malfunction.

    The brake actuator assembly turns off the solenoids and the ECM stops its VSC control according to signals from the skid control ECU. The vehicle will operate in a manner similar to a vehicle that is not equipped with ABS, TRAC, secondary collision brake, VSC and brake hold systems.

    ABS control will be prohibited, but EBD control will continue to the extent that EBD control is possible. If EBD control is impossible, the brake system warning light (red indicator) will come on to warn the driver.

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  • If a VSC system component malfunctions before VSC control begins, VSC control will be prohibited. If a system component malfunctions during VSC control, the system will gradually stop performing control so as not to trigger a sudden change in vehicle operation.

    If it is impossible for control to continue, the warning light comes on to inform the driver of system control termination.

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  • If the skid control ECU (brake actuator assembly) detects that a system related to the airbag system or the engine control system is malfunctioning, it will prohibit operation of the secondary collision brake in order to prevent further malfunctions and to protect the systems.
  • When a malfunction occurs in the VSC system or electric parking brake system, brake hold control prohibits brake hold operation to prevent incorrect operation and protect the system.
ABS, EBD and BA System

Item

Operation

Malfunction in the ABS.

ABS, BA, TRAC and VSC control prohibited.

Brake hold control prohibited.

Malfunction in the BA system.

ABS, BA, TRAC and VSC control prohibited.

Brake hold control prohibited.

Malfunction in the EBD system.

ABS, EBD, BA, TRAC and VSC control prohibited.

Brake hold control prohibited.

TRAC and VSC System

Item

Operation

Malfunction in the engine control system (TRAC and VSC systems).

Before control: Disables control.

During control: Uses only the brakes to perform control.

Malfunction in the brake control system (VSC system).

Before control: Disables control.

During control: Uses only the engine to perform control.

Malfunction in the brake control system (TRAC system).

Before control: Disables control.

During control: Disables control (by gradually ending control).

Secondary Collision Brake System

Item

Operation

Malfunction in the airbag system (secondary collision brake system).

Before control: Disables control.

During control: Uses only the brakes to perform control.

Malfunction in the engine control system (secondary collision brake system).

Before control: Disables control.

During control: Uses only the brakes to perform control.

Freeze Frame Data

FREEZE FRAME DATA

FREEZE FRAME DATA

(a) Whenever an ABS DTC is detected, the skid control ECU (brake actuator assembly) stores the current vehicle (ECU or sensor) state as Freeze Frame Data.

(b) The skid control ECU (brake actuator assembly) stores the number of times (maximum: 31) the engine switch has been turned from off to on (IG) since the last time the ABS was activated.

HINT:

  • If the vehicle is stopped or driven at a low speed (7 km/h (4.3 mph) or less), or if a DTC is detected, the skid control ECU (brake actuator assembly) will stop counting the number.
  • Freeze Frame Data at the time the ABS operates:

    The skid control ECU (brake actuator assembly) stores and updates data whenever the ABS operates.

    When the ECU stores data at the time a DTC is detected, the data stored during ABS operation is cleared.

  • Freeze Frame Data at the time a DTC is detected:

    When the skid control ECU (brake actuator assembly) stores data at the time a DTC is detected, no updates will be performed until the data is cleared.

CHECK FREEZE FRAME DATA

(a) Turn the engine switch off.

(b) Connect the Techstream to the DLC3.

(c) Turn the engine switch on (IG).

(d) Turn the Techstream on.

(e) Enter the following menus: Chassis / ABS/VSC/TRAC/EPB / Trouble Codes.

Chassis > ABS/VSC/TRAC/EPB > Trouble Codes

(f) Select a DTC to display its Freeze Frame Data.

Chassis > ABS/VSC/TRAC/EPB

Tester Display

Measurement Item

Range

Normal Condition

Diagnostic Note

Elapsed Time after Freeze Trigger

Elapsed time after freeze trigger

Min.: 0 msec, Max.: 510 msec

-

-

Number of IG ON

Number of times engine switch turned on (IG) after Freeze Frame Data stored

0 to 31

-

-

Stop Light SW

Stop light switch assembly

ON or OFF

ON: Brake pedal depressed

OFF: Brake pedal released

-

Parking Brake SW

Parking brake switch assembly

ON or OFF

ON: Parking brake applied

OFF: Parking brake released

-

Gear Position

Gear position information

P/N, R, 1st-10th, Fail or Not R

Actual gear position

-

Shift Lever Position

Shift lever position information

P/N, R, D/M, 1st-6th/B or Fail

Actual shift lever position

-

Operated System

Operated system status

Non, ABS, VSC, TRAC, BA, HAB, Fail, PBA, PB, HA-CTRL, TSC, SCB, Sys

Actual operated system

Non: No operation is activated.

ABS: ABS is activated.

VSC: VSC is activated.

TRAC: TRAC is activated.

BA: BA is activated.

HAB: HAB is activated.

Fail: Fail-safe mode is activated.

PBA: PBA is activated.

PB: PB is activated.

HA-CTRL: Hill-start assist control is activated.

TSC: Trailer sway control activated*

SCB: Secondary collision brake is activated.

Sys: System prohibit is activated.

HINT:

*: Not supported

Master Cylinder Sensor

Master cylinder pressure sensor reading

Min.: 0.00 V, Max.: 5.00 V

Brake pedal released: 0.20 to 0.40 V

Reading increases when brake pedal is depressed

M/C Sensor Grade

Master cylinder pressure sensor change

Min.: -30 MPa/s, Max.: 225 MPa/s

Brake pedal released or pedal held at constant position: 0 MPa/s

When brake pedal is being operated: Changes in proportion with the pedal movement speed

Yaw Rate Sensor

Yaw rate sensor

Min.: -128°/s, Max.: 127°/s

Vehicle stopped: 0°/s

Turning right: -128 to 0°/s

Turning left: 0 to 127°/s

-

Lateral G

Lateral G

Min.: -25.10 m/s2, Max.: 24.90 m/s2

-

During turning: Changes in proportion with lateral acceleration

Forward and Rearward G

Forward and backward G

Min.: - 25.10 m/s2, Max.: 24.90 m/s2

-

During acceleration/deceleration: Changes in proportion with acceleration

FR Wheel Speed

Front wheel speed sensor RH reading

Min.: 0 km/h (0 mph), Max.: 326.4 km/h (203 mph)

Vehicle stopped: 0 km/h (0 mph)

When driving at constant speed: No large fluctuations

FL Wheel Speed

Front wheel speed sensor LH reading

Min.: 0 km/h (0 mph), Max.: 326.4 km/h (203 mph)

Vehicle stopped: 0 km/h (0 mph)

When driving at constant speed: No large fluctuations

RR Wheel Speed

Rear wheel speed sensor RH reading

Min.: 0 km/h (0 mph), Max.: 326.4 km/h (203 mph)

Vehicle stopped: 0 km/h (0 mph)

When driving at constant speed: No large fluctuations

RL Wheel Speed

Rear wheel speed sensor LH reading

Min.: 0 km/h (0 mph), Max.: 326.4 km/h (203 mph)

Vehicle stopped: 0 km/h (0 mph)

When driving at constant speed: No large fluctuations

Vehicle Speed

Maximum wheel speed sensor reading

Min.: 0 km/h (0 mph), Max.: 326.4 km/h (203 mph)

Vehicle stopped: 0 km/h (0 mph)

When driving at constant speed: No large fluctuations

Vehicle Speed Grade

Vehicle speed grade

Min.: -25.10 m/s2, Max.: 24.90 m/s2

Vehicle stopped: 0 m/s2

During driving: Changes in proportion with vehicle acceleration/deceleration

Real Engine Torque

Actual engine torque

Min.: -1024 Nm, Max.: 1023 Nm

-

-

Accelerator Opening Angle %

Percentage of accelerator pedal opening angle

Min.: 0.0%, Max.: 127.5%

The accelerator pedal released: 0.0%

During accelerator pedal operation: Changes in proportion with the pedal movement

Inspection Mode

Inspection mode

Other or Inspect

Other: Normal mode

Inspect: Inspection mode

-

Steering Angle Sensor

Steering angle sensor

Min.: - 3276.8°, Max.: 3276.7°

Left turn: Increase

Right turn: Decrease

-

TRAC/VSC Off Mode

TRAC/VSC off mode

Normal, TRC OFF, VSC Expert Mode, VSC OFF

Normal: Normal mode

TRC OFF: TRAC off mode

VSC Expert Mode: VSC expert mode

VSC OFF: VSC off mode

-

Brake Hold Ready

Brake hold control permission status

OFF or ON

ON: Brake hold control permitted

OFF: Brake hold control not permitted

-

Brake Hold Control Mode

Brake hold control mode

OFF, ON, Release or EPB

OFF: Brake hold control is not operating

ON: Brake hold control is operating

Release: Brake hold control is released

EPB: Parking brake is engaged during brake hold control

HINT:

EPB stands for electric parking brake.

CLEAR FREEZE FRAME DATA

NOTICE:

Clearing the DTCs will also clear the Freeze Frame Data.

(a) Turn the engine switch off.

(b) Connect the Techstream to the DLC3.

(c) Turn the engine switch on (IG).

(d) Clear the DTCs and Freeze Frame Data.

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Chassis > ABS/VSC/TRAC/EPB > Clear DTCs

Diagnosis System. Diagnostic Trouble Code Chart. Dtc Check / Clear

How To Proceed With Troubleshooting. Parts Location. Precaution

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Toyota Avalon (XX50) 2019-2022 Service & Repair Manual

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